3ADR011074, 1, en - US, System - Manual - V3

SYSTEM MANUAL
PLC Automation
Automation Builder, programmable logic control-
lers, control panels
Automation Builder, AC500 V3, AC500-eCo V3, AC500-XC V3, AC500-S, CP600, CP600-eCo,
CP600-Pro
Table of contents
—
Table of contents
1 Preface............................................................................................................................................................. 4
1.1 Guidance through the documentations..................................................................................................... 4
1.2 Do I have AC500 V2 or AC500 V3?.......................................................................................................... 4
1.3 Regulations............................................................................................................................................... 5
1.4 Older revisions of this document............................................................................................................... 5
1.5 Use the "magic button" to display your current position in the table of contents....................................... 6
1.6 Structure of safety notices......................................................................................................................... 6
2 Safety instructions.......................................................................................................................................... 8
3 System overview........................................................................................................................................... 12
3.1 AC500 PLC product family...................................................................................................................... 12
3.2 AC500/S500 system structure................................................................................................................. 13
3.3 AC500-eCo/S500-eCo system structure................................................................................................. 14
3.4 AC500/S500: Short description hardware............................................................................................... 16
3.5 AC500-eCo/S500-eCo: Short description hardware............................................................................... 20
3.6 AC500-S.................................................................................................................................................. 21
3.7 CP600 control panels.............................................................................................................................. 22
3.8 Automation Builder: Short description engineering software................................................................... 22
4 Application planning..................................................................................................................................... 24
4.1 Processor module and I/O selection....................................................................................................... 24
4.2 Communication within the PLC............................................................................................................... 24
4.3 Power supply dimensioning..................................................................................................................... 26
4.3.1 Calculation of the total current consumption............................................................................ 26
4.3.2 Dimensioning of the fuses........................................................................................................ 28
4.4 Libraries and software............................................................................................................................. 29
5 Mechanical planning and installation.......................................................................................................... 30
5.1 Control cabinet assembly for AC500 (Standard)..................................................................................... 30
5.2 Control cabinet assembly for AC500-eCo............................................................................................... 32
5.3 Mounting and demounting - general information..................................................................................... 33
5.3.1 Optimized mounting of the option boards................................................................................ 34
5.4 Mounting and demounting the terminal base.......................................................................................... 35
5.5 Mounting and demounting the AC500 processor module....................................................................... 37
5.6 Mounting and demounting the terminal unit............................................................................................ 38
5.7 Mounting and demounting the communication module........................................................................... 39
5.8 Mounting and demounting the I/O module.............................................................................................. 41
5.9 Mounting and demounting the AC500-eCo processor module............................................................... 42
5.9.1 Mounting a processor module on a DIN rail............................................................................. 42
5.9.2 Demounting a processor module mounted on a DIN rail......................................................... 43
5.9.3 Mounting a processor module on a metal plate....................................................................... 44
5.9.4 Demounting a processor module mounted on a metal plate................................................... 45
5.9.5 Mounting of TA5301-CFA......................................................................................................... 46
5.10 Mounting and demounting the S500-eCo I/O module........................................................................... 46
5.11 Accessories for AC500 (Standard)........................................................................................................ 50
5.11.1 Inserting and removing a memory card.................................................................................. 51
5.12 Accessories for AC500-eCo.................................................................................................................. 52
5.12.1 Mounting and demounting the option boards......................................................................... 52
5.12.2 Mounting and demounting of the terminal blocks for onboard I/Os....................................... 54
5.12.3 Inserting and removing a memory card.................................................................................. 56
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Table of contents
5.13 Control panels CP600........................................................................................................................... 57

6 Wiring............................................................................................................................................................. 58
6.1 Grounding concept.................................................................................................................................. 58
6.2 EMC-conforming assembly and construction.......................................................................................... 59
6.2.1 General principles.................................................................................................................... 59
6.2.2 Cable routing............................................................................................................................ 60
6.2.3 Cable shields............................................................................................................................ 61
6.2.4 Control cabinet......................................................................................................................... 61
6.2.5 Reference potential.................................................................................................................. 62
6.2.6 Equipotential bonding............................................................................................................... 62
6.3 Connection and wiring............................................................................................................................. 63
6.3.1 AC500...................................................................................................................................... 64
6.3.2 AC500-eCo.............................................................................................................................. 71
6.3.3 Control panels CP600.............................................................................................................. 72
7 Configuration and programming................................................................................................................. 73
7.1 Cyber security......................................................................................................................................... 74
7.1.1 Defense in depth...................................................................................................................... 75
7.1.2 Secure operation...................................................................................................................... 76
7.1.3 Hardening................................................................................................................................. 79
7.1.4 Certificates factory default - no encryption............................................................................... 80
7.1.5 Open Ports and Services......................................................................................................... 83
8 Commissioning............................................................................................................................................. 84
9 Operation....................................................................................................................................................... 86
9.1 Status LEDs, display and control elements............................................................................................. 86
9.2 PLC firmware/application update............................................................................................................ 86
9.3 Control panel firmware/application update.............................................................................................. 87
9.4 Reset to factory settings.......................................................................................................................... 87
10 Troubleshooting............................................................................................................................................ 88
11 Maintenance................................................................................................................................................... 90
11.1 Replace an AC500 module.................................................................................................................... 90
11.2 Replace an I/O module with hot swap................................................................................................... 91
11.2.1 Preconditions for using hot swap........................................................................................... 91
11.2.2 Compatibility of hot swap....................................................................................................... 94
11.2.3 Hot swap behavior.................................................................................................................. 95
12 Decommissioning......................................................................................................................................... 96
13 Recycling....................................................................................................................................................... 97
14 Appendix........................................................................................................................................................ 98
14.1 Diagnosis messages via display of the processor module.................................................................... 98
14.1.1 Error severity E2: Severe errors............................................................................................. 99
14.1.2 Error severity E3: Minor errors............................................................................................. 100
14.1.3 Error severity E4: Warnings................................................................................................. 104
14.1.4 Error severity E11: Parameter errors................................................................................... 106
14.1.5 Diagnosis messages of communication modules or fieldbuses........................................... 108
14.2 PLC firmware/application update via memory card............................................................................. 108
14.2.1 Preparation of memory card................................................................................................. 108
14.2.2 Execution of update via memory card.................................................................................. 111
15 Glossary....................................................................................................................................................... 113
16 Index............................................................................................................................................................. 116
2023/03/03 3ADR011074, 1, en_US 3

Preface
Do I have AC500 V2 or AC500 V3?
—
1 Preface
1.1 Guidance through the documentations
Where to find information about:
● PLC system
– System description
Ä Chapter 3 “System overview” on page 12
– Getting started: First steps with the platform and create your first program
– Starter kit: Introduction into PLC programming using pre-installed kits, including creation
of control panel visualization
– Safety user manual for safety PLCs
● Devices
– Data sheets
– Installation instructions
– PLC hardware descriptions
– Safety user manual for safety PLCs
– Control panels
● Software and programming
– Engineering suite Automation Builder
– Programming examples for download
– Programming examples available in engineering suite: Open Automation Builder menu
“Help è Project examples”
– Application descriptions for specific features and use cases
– Release notes for the latest version of the engineering suite Automation Builder
1.2 Do I have AC500 V2 or AC500 V3?

This document describes AC500 V3 products.
We offer different ranges of the processor modules (V2, V3). You can easily find out which ones
are used in your system. Either have a look at your used modules or your configuration.
Fig. 1: Hardware: Processor modules
Written type on the module Example Range Relevant manual

Processor module type PM + PM595 V2 AC500 V2
3 digits
Processor module type PM + PM5670 V3 AC500 V3 (this manual)
4 digits
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Preface
Older revisions of this document
Fig. 2: Software: Configuration in engineering software Automation Builder
Written type in brackets Example Range Relevant manual

Processor module type PM + PM564 V2 AC500 V2
3 digits
Processor module type PM + PM5675 V3 AC500 V3 (this manual)
4 digits
1.3 Regulations
Planning and The planning and installation of the electrical system must be carried out in compliance with the
installation of applicable regulations and standards. Hazards due to malfunctions must be prevented by taking
the electrical appropriate measures.
system
The suitability of the products for the respective application is proven by declarations of con-
formity and certificates.
The PLC Automation catalog contains an overview of the available declarations of conformity
and certificates. These can be found in the table "Certifications" in the chapter "Additional
information" of the catalog.
Qualified per- Both the AC500 control system and other components in the vicinity are operated with dan-
sonnel gerous touch voltages. Touching live components can lead to serious health implications or
even death.
To avoid such risks and the occurrence of property damage, persons involved in the installation,
commissioning and maintenance must have relevant knowledge about:
● Automation technology
● Handling of hazardous voltages
● Application of relevant standards and regulations, accident prevention regulations and reg-
ulations on special environmental conditions (e.g., hazardous areas due to explosive sub-
stances, heavy soiling or corrosive influences).
1.4 Older revisions of this document

You can always find all revisions of our documents on our website.
System manual
2023/03/03 3ADR011074, 1, en_US 5

Preface
Structure of safety notices
Revisions Select any of the revisions

Latest revision Get a link to the latest revision
This revision Get a direct link to the selected revision
1.5 Use the "magic button" to display your current position in the table of con-
tents
Documentation is opened in a PDF reader. PDF readers often provide a button to syn-
chronize with the table of contents. Usually, you can find the "magic button" in the bookmarks
tab. For example, it looks like this: /
Select the "magic button".
ð Your current position will be highlighted in the bookmark tab.
1.6 Structure of safety notices

Throughout the documentation we use the following types of safety and information notices.
They make you aware of safety considerations or give advice on AC500 products usage.
1 Safety alert symbol indicates the danger.

2 Signal word classifies the danger.
3 Type and source of the risk are mentioned and possible consequences are described.
4 Measures to avoid these consequences (enumerations).
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Preface
Structure of safety notices
Signal words
DANGER!
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Ensure to take measures to prevent the described impending danger.
WARNING!
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
Ensure to take measures to prevent the described dangerous situation.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE!
NOTICE is used to address practices not related to physical injury but might
lead to property damage for example damage of the product.
NOTE provides additional information on the product, e.g., advices for configu-
ration or best practice scenarios.
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Safety instructions
—
2 Safety instructions
Relevant standards and regulations, accident prevention regulations and regulations on spe-
cial environmental conditions must be observed (e.g., hazardous areas due to explosive sub-
The devices must be handled and operated within the specified technical data and system data.
The devices contain no serviceable parts and must not be opened.
Removable covers must be closed during operation unless otherwise specified.
Any liability for the consequences of incorrect use or unauthorized repairs is rejected.
Qualified per- Both the AC500 control system and other components in the vicinity are operated with dan-
sonnel gerous touch voltages. Touching live components can lead to serious health implications or
even death.
To avoid such risks and the occurrence of property damage, persons involved in the installation,
commissioning and maintenance must have relevant knowledge about:
● Automation technology
● Handling of hazardous voltages
● Application of relevant standards and regulations, accident prevention regulations and reg-
ulations on special environmental conditions (e.g., hazardous areas due to explosive sub-
Functional The AC500-S safety user manual must be read and understood before using the safety configu-
safety ration and programming tools of Automation Builder/PS501 Control Builder Plus. Only qualified
personnel are permitted to work with AC500-S safety PLCs.
General infor- The examples and diagrams in this manual are included solely for illustrative purposes.
mation Because of the many variants and requirements associated with any particular installation, ABB
cannot assume responsibility or liability for actual use based on the examples and diagrams.
The PLC was developed according to the relevant standards. Any module-specific measures
are described in the individual descriptions of the modules.
PLC-specific
safety notices The product family AC500 control system is designed according to the EN
61131-2 and IEC 61131-2 standards. Any data that differs from IEC 61131-2,
is due to the higher requirements of Maritime Services. Other differences are
described in the technical data description of the devices.
NOTICE!
Avoidance of electrostatic charging
PLC devices and equipment are sensitive to electrostatic discharge, which can
cause internal damage and affect normal operation. Observe the following rules
when handling the system:
– Touch a grounded object to discharge potential static.
– Wear an approved grounding wrist strap.
– Do not touch connectors or pins on component boards.
– Do not touch circuit components inside the equipment.
– If available, use a static-safe workstation.
– When not in use, store the equipment in appropriate static-safe packaging.
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Safety instructions
NOTICE!
Use of suitable enclosure
The devices must be mounted in a control cabinet that ensures compliance with
the specified environmental conditions.
Cleaning instructions
Do not use cleaning agent for cleaning the device.
Use a damp cloth instead.
Connection plans and a user program must be created so that no dangerous situations can
occur during normal operation or failure.
The application must be tested to ensure that no dangerous situations can occur during opera-
tion.
Do not operate devices outside of the specified, technical data!

Trouble-free functioning cannot be ensured outside of the specified data.
NOTICE!
PLC damage due to missing grounding
– Make sure to ground the devices.
– The grounding (switch cabinet grounding) is supplied both by the mains
connection (or 24 V supply voltage) and via the DIN rail. The DIN rail
must be connected to ground before power is supplied to the device. The
grounding may be removed only if it is certain that no more power is being
supplied to the control system.
– In case of screw mounting, grounding must be ensured by the screws.
CAUTION!
Do not obstruct the ventilation for cooling!
The ventilation slots on the upper and lower sides of the devices must not be
covered.
CAUTION!
Run signal and power wiring separately!
Signal and supply lines (power cables) must be laid out so that no malfunctions
due to capacitive and inductive interference can occur (EMC).
WARNING!
Warning sign on the module!
This indicates that dangerous voltages may be present or that surfaces may
have dangerous temperatures.
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Safety instructions
WARNING!
Splaying of strands can cause hazards!
Avoid splayed strands when wiring terminals with stranded conductors.
– Ferrules can be used to prevent splaying.
WARNING!
Removal/Insertion under power
Removal or insertion under power is permissible only if all conditions for hot
swapping are fullfilled.
Ä Chapter 11.2 “Replace an I/O module with hot swap” on page 91
The devices are not designed for removal or insertion under power when the
conditions for hot swap do not apply. Because of unforeseeable consequences,
it is not allowed to plug in or unplug devices with the power being ON.
Make sure that all voltage sources (supply and process voltage) are switched
off before you
– connect or disconnect any signal or terminal block
– remove, mount or replace a module.
Disconnecting any powered devices while they are energized in a hazardous
location could result in an electric arc, which could create an ignition source
resulting in fire or explosion.
Prior to proceeding, make sure that power is been disconnected and that the
area has been thoroughly checked to ensure that flammable materials are not
present.
The devices must not be opened when in operation. The same applies to the
network interfaces.
Information on
batteries CAUTION!
Use only ABB approved lithium battery modules!
At the end of the battery’s lifetime, always replace it only with a genuine battery
module.
CAUTION!
Risk of explosion!
Do not open, re-charge or disassemble lithium batteries. Attempting to charge
lithium batteries will lead to overheating and can cause explosions.
Protect them from heat and fire and store them in a dry place.
Never short-circuit or operate lithium batteries with the polarities reversed. The
batteries are likely to overheat and explode. Avoid unintentional short circuiting
do not store batteries in metal containers and do not place them on metallic
surfaces. Escaping lithium is a health hazard.
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Safety instructions
Environment considerations
Recycle exhausted batteries. Dispose of batteries in an environmentally con-
scious manner in accordance with regulations issued by the local authorities.
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System overview
AC500 PLC product family
—
3 System overview
3.1 AC500 PLC product family
AC500 program- The AC500 (Standard), AC500-eCo, AC500-S and AC500-XC scalable PLC ranges provide
mable logic con- solutions for small, medium and high-end applications. Our AC500 platform offers different
trollers (PLCs) performance levels and is the ideal choice for high availability, extreme environments or safety
solutions. Our AC500 PLC platform offers interoperability and compatibility in hardware and
software from compact PLCs up to high-end and safety PLCs.
Due to the flexible combinations of AC500 devices and components, AC500 PLCs can be used
for controlling a wide variety of applications to fulfill your automation needs.
Features of AC500 PLCs

● Scalable and consistently expandable system
● Different performance classes of processor modules (CPUs) available
● Several fieldbusses available
● Parallel connection to several fieldbusses which can be combined arbitrarily
The AC500 product family consists of the product groups:

● AC500 (Standard):
AC500 standard PLCs offer a wide range of performance levels and scalability. The PLCs
are highly capable of communication and extension for flexible application.
● AC500-eCo:
AC500-eCo PLCs are cost-effective, high-performance compact PLCs that offer total inter-
operability with the core AC500 range and provide battery-free buffering of remanent data.
All I/O modules can be freely connected in a simple, stable and reliable manner.
● AC500-S:
AC500-S PLCs are designed for safety applications in factory, process or machine
automation.
● AC500-XC:
AC500 (Standard) and AC500-S provide devices with -XC extension as a product variant.
These variants operate according to their product group and can, in addition, be operated
under extreme conditions. AC500-XC PLCs can be used at high altitudes, extended oper-
ating temperature and in humid conditions. The devices also provids a high level of resist-
ance to vibration and corrosive gases. The AC500-XC series is consistent with standard
devices concerning the overall dimensions, the control function and the software compati-
bility.
The AC500 product family is characterized by functional modularity. As the complete AC500
product family shares the same hardware platform and programming software tool, the devices
of the AC500 product groups can be flexibly combined.
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System overview
AC500/S500 system structure
S500 devices represent the I/O modules of the product group AC500 (Standard), whereas
S500-eCo devices represent the I/O modules of the product group AC500-eCo. Both S500 and
S500-eCo devices can be flexibly combined with devices of the AC500 product family.
3.2 AC500/S500 system structure

The AC500 product family provides a variety of modules and pluggable components for
expanding the capabilities of the processor module with additional I/Os or other communication
protocols. Depending on the features and functions of the processor module (CPU) compatible
components can be added to a complete AC500 PLC system.
Centralized I/O
extension
01 Terminal base for processor module and 0 to 6 communication modules, with serial and
Ethernet interfaces
02 Communication module for, e.g., PROFIBUS, EtherCAT, and for support of safety solution
03 Processor module with integrated communication
04 I/O module, up to 10 I/O modules can be connected
05 Terminal unit for I/O modules, also for decentralized extension
2023/03/03 3ADR011074, 1, en_US 13

System overview
AC500-eCo/S500-eCo system structure
Decentralized
I/O extension
1 Terminal unit for communication interface modules

2 Communication interface module with up to 24 integrated I/Os
3 I/O bus
4 Terminal unit for I/O modules, with screw or spring connection
5 Terminal unit for hot swap of I/O modules to exchange of I/O modules while the system is
running
6 S500 I/O modules with up to 32 channels for analog and/or digital signals
7 Compact S500-eCo I/O modules with up to 16 channels for analog and/or digital signals
8 Removable terminal blocks
3.3 AC500-eCo/S500-eCo system structure

AC500-eCo/S500-eCo series is compatible with AC500/S500.
The compact AC500-eCo processor module can be used for small applications with the inte-
grated I/O channels.
The functionality of the processor modules can be extended with option boards, e.g., for addi-
tional I/O channels.
For larger applications, I/O modules can be connected centralized or decentralized.
14 3ADR011074, 1, en_US 2023/03/03

System overview
AC500-eCo/S500-eCo system structure
1 AC500-eCo processor module with option boards, different memory sizes, inputs and out-
puts available
2 S500-eCo I/O module, up to 10 I/O modules can be connected, also for decentralized
extension
3 Terminal blocks in different variants available
Centralized I/O Processor modules with an I/O bus interface on the right side can be expanded by up to 10 I/O
extension modules to increase the number of the I/O channels.
Fig. 3: I/O modules (S500-eCo) directly connected to an AC500-eCo processor module
Decentralized Up to 10 I/O modules can be connected remotely with the onboard Ethernet interface. Usually, a
I/O extension Modbus/TCP communication interface module or a processor module is used for the decentral-
ized I/O extension.
2023/03/03 3ADR011074, 1, en_US 15

System overview
AC500/S500: Short description hardware
Fig. 4: I/O modules (S500-eCo) connected to an AC500-eCo processor module via Modbus/TCP network, using a
Modbus/TCP communication interface module or a processor module as client.
3.4 AC500/S500: Short description hardware

Processor
modules
AC500 processor modules contain the CPU with the core component of the PLC. The CPU is
connected with the user memory, input and output module, communication port and other units
via the system bus and performs tasks by means of system programs preset in the system
memory. The CPU adopts the function preset by the application program to command the PLC
for operation.
It has the following functions:
● To receive user programs and data entered
● To diagnose work faults of the power supply and PLC circuit as well as syntax errors in
programming
● To receive the state or data of the site via the input interface and save it into the shadow
register or data register
● To read the user programs in the memory one by one and execute them after interpretation
● To updating the state of the associated flag bits and the contents of the shadow register
according to the execution results and providing output control using the output unit.
Processor modules are available in different performance classes. Only one processor module
is required for a valid system architecture.
There are different types of processor module available that differ in the features and functions
they provide, e.g. performance, LED display etc.
If required, processor modules are also available with an integrated Ethernet communication
module (TCP/IP).
Communication
modules
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System overview
AC500 communication modules are required for

● a connection to standard fieldbus systems and
● for integration into existing networks.
AC500 communication modules
● enable communication on different fieldbuses.
● are mounted on the left side of the processor module on the same terminal base.
● are directly powered via the internal communication module bus of the terminal base.
A separate voltage source is not required.
Terminal bases
The terminal base is needed for mounting and connecting the processor module and the
communication modules. The modules are plugged on the terminal base.
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System overview
On AC500-eCo processor modules and special AC500 (Standard) processor

modules the terminal base cannot be removed.
I/O modules
The I/O modules are the input/output unit which connects the PLC with the process. The PLC
can detect controlled object data via the input interface and the data is taken as the basis
for PLC control on the controlled object. In addition, the PLC sends processing results via the
output interface to the controlled object to execute the control.
External input equipment and output equipment needs various signal levels whereas the infor-
mation processed by the processor module in the PLC can only be the standard level. In
order to perform this conversion, the I/O interface generally uses optical isolation and filtering
to improve the interference immunity of the PLC. In addition, the I/O interface can generally
indicate the working state to facilitate maintenance.
The PLC provides multiple I/O interfaces for operation level and drive capability to users for
selection such as digital input, digital output, analog input, analog output, etc. I/O interfaces
of the PLC interpret the number of input/output signals as the number of PLC I/O points. The
number of I/O points is an important basis for PLC selection. If the system has insufficient I/O
points, it can be expanded via the I/O extension interface of the PLC.
The I/O modules for digital and/or analog inputs and outputs are available in different versions
and allow flexible use thanks to configurable channels.
The modules can be simply plugged onto a terminal unit for a centralized or decentralized I/O
extension via communication interface modules.
Terminal units
I/O modules and function modules are plugged on a terminal unit.

Terminal units enable simple prewiring without electronics and are available for 24 V DC and
120/230 V AC, optionally for spring or screw-type terminals.
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System overview
Communication
interface
modules
Communication interface modules are used to build decentralized I/O stations in decentralized
systems. They contain the fieldbus interface and a set of onboard I/O channels. Additional I/O
modules can be attached to build larger decentralized I/O stations. A communication interface
module is mounted on a terminal unit.
Function Function modules extend the PLC system to perform special task control. These modules often
modules provide independent components such as a CPU, system programs, memory and interfaces
connected with the PLC system bus.
Function modules are connected with the PLC via the I/O bus to exchange data and independ-
ently work under cooperative management of the PLC.
Memory In the PLC, the memory is mainly used for saving system programs, user programs and work
data. There are two types of memory:
● Volatile memory:
All saved data will be lost after power failure of the memory but the memory can provide
a high access rate and unlimited programming cycles. Common volatile memories mainly
include SRAM and DRAM (including common memories such as SDRAM).
● Nonvolatile memory:
All saved data will not be lost after power failure of the memory, but the memory is subject
to a low read-write rate and limited rewrite cycles. Common nonvolatile memories mainly
include NORflash, NANDflash, EEPROM, memory card, etc.
AC500 PLCs store all user programs in the nonvolatile memory to protect them from power
failure. The programs are exported to the volatile memory during operation of the PLC to ensure
high-speed and efficient operation. If user program debugging is finished, the programs can be
fixed in the nonvolatile memory when they need no change. The work data is subject to frequent
change and access during the PLC operation. It is saved in the volatile memory to meet the
requirements for random access.
The work data memory of the PLC has the memory area for input and output relay, auxiliary
relay, timer, counter and other logic devices. The state of these devices depends on initial
setting and operation of the user programs. Some data maintains its existing state by using
built-in supercapacitors or backup batteries in the event of a power failure. The memory area for
data saving in the event of a power failure is called the data retention area.
Power supply The PLC is equipped with a switching power supply for the internal supply. In comparison with
an ordinary power supply, the switching power supply has a higher stability and a higher noise
immunity.
Some modules include a stabilized power supply for the supply of external sensors.
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System overview
AC500-eCo/S500-eCo: Short description hardware
3.5 AC500-eCo/S500-eCo: Short description hardware

Processor
modules
AC500-eCo processor modules contains the CPU with the core microprocessor of the PLC. It is
integrated with power supply, onboard I/Os and communication interface.
Functions:
● To download user programs
● To run the CPU
● To execute user programs in loops
● To monitor program input and output devices.
Processor modules are available in different performance classes and provide different numbers
of onboard I/Os.
Only one processor module is required for a valid system architecture.
Option boards
AC500-eCo processor modules can be extended with option boards. Option boards provide
specific functionality. According to the processor module type, up to three option board slots
are available for extension. Each option board slot supports most existing types of option board
module. The option board modules provide the following functionality for processor module
extension:
● Serial interface RS232 (isolated) or RS485 (isolated or not isolated)
● Digital I/O channels extension (digital inputs, digital outputs, or mixed type)
● Analog I/O channels extension (analog inputs, analog outputs) for standard signal voltage or
current, but also temperature measurement with RTD/NTC or thermocouple sensors
● RTC real-time clock board for processor module PM5012 (other processor modules include
RTC functionality)
● Configuration address switch board for KNX protocol, for specific processor module
PM5072
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System overview
AC500-S
I/O modules
If the number of onboard I/Os provided on the processor module is insufficient for a certain use
case, the PLC can be expanded with I/O modules to meet the control requirements.
Memory In the PLC, the memory is mainly used for saving system programs, user programs and work
data. There are two types of memory:
● Volatile memory:
All saved data will be lost after power failure of the memory but the memory can provide
a high access rate and unlimited programming cycles. Common volatile memories mainly
include SRAM and DRAM (including common memories such as SDRAM).
● Nonvolatile memory:
All saved data will not be lost after power failure of the memory, but the memory is subject
to a low read-write rate and limited rewrite cycles. Common nonvolatile memories mainly
include NORflash, NANDflash, EEPROM, memory card, etc.
AC500 PLCs store all user programs in the nonvolatile memory to protect them from power
failure. The programs are exported to the volatile memory during PLC operation to ensure
high-speed and efficient operation. If user program debugging is finished, the programs can
be fixed in the nonvolatile memory when they need no change. The work data is subject to
frequent change and access during PLC operation. It is saved in the volatile memory to meet
the requirements for random access.
The work data memory of the PLC has the memory area for input and output relay, auxiliary
relay, timer, counter and other logic devices. The state of these devices depends on initial
setting and operation of the user programs. Some data maintains its existing state by using
built-in supercapacitors or backup batteries in the event of a power failure. The memory area for
data saving in the event of a power failure is called the data retention area.
Power supply The PLC is equipped with a switching power supply for the internal supply. In comparison with
an ordinary power supply, the switching power supply has a higher stability and a higher noise
immunity.
Some modules include a stabilized power supply for the supply of external sensors.
3.6 AC500-S
Functional The AC500-S safety user manual must be read and understood before using the safety configu-
safety ration and programming tools of Automation Builder/PS501 Control Builder Plus. Only qualified
personnel are permitted to work with AC500-S safety PLCs.
The AC500-S safety PLC includes the following safety-relevant hardware components.
● SM560-S/SM560-S-FD-1/SM560-S-FD-4
● DI581-S
2023/03/03 3ADR011074, 1, en_US 21

System overview
Automation Builder: Short description engineering software
● DX581-S
● AI581-S
● TU582-S
3.7 CP600 control panels
CP600 control The CP600-eCo, CP600 and CP600-Pro control panels offer a wide range of features and
panels platform functionalities for tailor-made visualization. Our CP600 platform offers different performance
levels including control panels for economic applications, robust standard operator panels, high
end multi-touch human machine interfaces (HMIs).
The easy to use engineering tool PB610 Panel Builder 600, part of Automation Builder, ensures
easy scalability on the CP600 platform.
● CP600-eCo: The economical CP600-eCo control panel, with screen sizes from 4.3” to 10.1”
widescreen, is aimed for standard functions and high usability for clear interaction with the
operation process.
● CP600: The robust CP600 HMI, with screen sizes from 7” to 15” provides up-to-date visual-
ization performance, versatile communication and representative design for machines and
systems.
● CP600-Pro: The CP600-Pro HMI, with screen sizes from 5” to 21.5” widescreen, comes
with high end visualization performance, multi-touch operation and versatile communication
options
Ä Further information on page 4
3.8 Automation Builder: Short description engineering software

Details about the Automation Builder license model, the features of the editions and the latest
license information
Configuration Configuration and programming of all AC500 control systems (processor modules) is done by
and program- using Automation Builder software.
ming
Features:
● Standardized programming according to IEC 61131-3, five programming languages (Struc-
tured Text (ST), Function Block Diagram (FBD), Instruction List (IL), Ladder Diagram (LD),
Sequential Function Chart (SFC)), Continuous Function Chart (CFC), debugging functions
for program test
● Online diagnosis
● Debugging functions for the program test: Single step, single cycle, breakpoint
● Offline simulation - simulate commands without PLC being connected
● Sampling trace - timing diagrams for process variables
● Recipe management and watch lists
● Visualization
● Configuration of the communication interface modules (for PROFINET, PROFIBUS,
EtherCAT, CANopen, Ethernet, Modbus)
● Programming - serial or via Ethernet networks
● Comprehensive libraries
22 3ADR011074, 1, en_US 2023/03/03

System overview
Automation Builder: Short description engineering software
● Export and import interfaces for devices, signals, applications, visualization, etc.
● Multi-user support and project compare
● Project scripting
Offline simula- IEC 61131-3 commands can be simulated without a PLC being connected, including the rele-
tion vant malfunctions. After the program test, the application can be downloaded to the control
system.
Sampling trace Timing diagrams for process variables and storage of data in a circular buffer with event trigger.
Recipe manage- Values of selected variables are displayed. Pre-defined values can be assigned to variables
ment and watch which can then be downloaded to the control system all at once ("Write recipe"). Actual values
lists from the control system can also be pre-assigned for reading into the Watch and Recipe
Manager, and stored in memory there ("Read recipe"). These functions are also helpful, for
example, for setting and entering control parameters.
Visualization Includes color change, moving elements, bitmaps, text display, allows input of setpoint values
and display of process variables read from the PLC, dynamic bar diagrams, alarm and event
management, function keys and ActiveX elements.
Programming The Ethernet interface of the processor modules is used to connect to the engineering software
for programming, debugging and diagnosis.
Engineering Provides access from the programming system to an external project database in which the
interface program source code of one or several automation projects is managed. Optionally, a version
control system can be used in order to ensure data consistency of the program code for several
different users and projects.
2023/03/03 3ADR011074, 1, en_US 23

Application planning
Communication within the PLC
—
4 Application planning
4.1 Processor module and I/O selection
How to select modules for your automation task: In our main catalog we offer a CPU selector
and several comparative tables to find the modules for your application.
Reference documentation for hardware
4.2 Communication within the PLC

The synchronized serial I/O bus is the I/O data bus for the I/O modules connected with the
processor modules or communication interface modules. Through this bus, I/O and diagnosis
data are transferred.
With its fast data transmission, the I/O bus obtains very low reaction times.
Up to 10 I/O terminal units (for one I/O module each) can be added to one terminal base or
to one AC500-eCo processor module. The I/O terminal units and the AC500-eCo I/O modules,
have a bus input at the left side and a bus output at the right side. Thus the length of the I/O bus
increases with the number of attached I/O modulesÄ Table 1 “Maximum number of I/O devices
which can be connected to the I/O bus” on page 25.
1 I/O bus connection

The connection of the I/O bus is performed automatically by telescoping the modules on the DIN
rail. The I/O bus provides the following signals:
● Supply voltage of 3.3 V DC for feeding the electronic interface components
● 3 data lines for the synchronized serial data exchange
● several control signals
NOTICE!
Except when using hot swap terminal units, the I/O bus is not designed for
pulling and plugging modules during operation. If a module is pulled or plugged
on a terminal unit that is not hot swap capable while the bus is running, the
following consequences are possible
– reset of the station or of the processor module
– system lockup
– damage of the module
24 3ADR011074, 1, en_US 2023/03/03

Communication within the PLC
WARNING!
Removal or insertion under power is permissible only if all conditions for hot
swapping are fullfilled.
Ä Chapter 11.2 “Replace an I/O module with hot swap” on page 91
The devices are not designed for removal or insertion under power when the
conditions for hot swap do not apply. Because of unforeseeable consequences,
it is not allowed to plug in or unplug devices with the power being ON.
off before you
Disconnecting any powered devices while they are energized in a hazardous
location could result in an electric arc, which could create an ignition source
resulting in fire or explosion.
Prior to proceeding, make sure that power is been disconnected and that the
area has been thoroughly checked to ensure that flammable materials are not
present.
network interfaces.
Table 1: Maximum number of I/O devices which can be connected to the I/O bus
Device Version Automation Version firmware Max. number of I/O
Builder devices
CANopen bus As of V2.1.0 All 0
modules CI581-CN
and CI582-CN
PROFINET bus As of V2.1.0 all 10
modules CI501-PNIO
and CI502-PNIO
EtherCAT com- As of V2.1.0 As of V2.0.x 10
munication inter-
face module CI511-
ETHCAT and
CI512-ETHCAT
Modbus communica- Independent from all 10
tion interface module Automation Builder
CI521 and CI522 version
Profibus (master and slave) and CM589-PNIO are available since version 2.5.0 of the
Automation Builder.
Table 2: General data of the I/O bus

Parameter Value
Supply voltage, signal level 3.3 V DC ± 10 %
Max. supply current On request
Type of the data interface Synchronized serial data exchange
Bus data transmission speed 1.8 Mb/s
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Power supply dimensioning > Calculation of the total current consumption
Parameter Value
Minimum bus cycle time 500 µs
This value is valid for all module combinations
(from 1 to 10 I/O modules)
Galvanic isolation I/O bus is galvanic connected to CPU and
communication interface logic ciruits. Galvanic
isolation of I/O bus is I/O module specific. See
each module specification for details.
Protection against electrostatic discharge TB5xx, TB56xx: with protection diodes,
(ESD)
no ESD discharge allowed on the port.
Table 3: Wiring (bus connection)

Parameter Value
Bus connection Left-side and right-side connection from
module to module via a 10-pole HE plug (male
at the left side, female at the right side)
Mechanical connection Established by the terminal units
Max. bus length 1m
4.3 Power supply dimensioning

The power consumption of a complete station consists of the sum of all individual consump-
tions.
The two supply voltages with 24 V DC are distinguished in the AC500 platform:
● Supply of the internal logic via terminals L+ and M on the CPU module, or an the AC500
terminal base for: CPU, communication mudule(s) and I/O bus.
● Supply of the process-side input/output circuits for analog signals and 24 V DC digital
signals via the ZP and UP terminals of the S500 terminal units.
The two supply voltages can be provided by the same power supply unit. The CPU and the
I/O modules should, however, be fused separately. Of course also separate power supplies are
possible.
4.3.1 Calculation of the total current consumption

Example In the example, the AC500 control system consists of the following devices:
● AC500 CPU with Ethernet interface
● 4 communication modules
● 7 I/O modules (digital and analog)
● As well as the required terminal bases and terminal units
26 3ADR011074, 1, en_US 2023/03/03

Power supply dimensioning > Calculation of the total current consumption
Because of the high total current consumption of the digital I/O modules (from
UP = 24 V DC), the supply is divided up into several electric circuits fused
separately.
The maximum permitted total current over the supply terminals of the I/O ter-
minal units is 8 A.
The total current can be calculated as follows:

ITotal = IL+ + IUP
with the assumptions
IL+ = ICPU + II/O bus + IC1 + IC2 + IC3 + IC4 (CPU + communication modules + I/O bus)
II/O bus = Number of expansion modules × Current consumption through the I/O bus per module
and
IUP = IUP1 + ILOAD1 + IUP2 + ILOAD2 + IUP3 + ILOAD3 + IUP4 + ILOAD4 + IUP5 + ILOAD5 + IUP6 + ILOAD6 + IUP7
+ ILOAD7
If one assumes that all outputs are switched on and are operated with their maximum permitted
load currents (under compliance with the maximum permitted currents at the supply terminals),
then the following values are the result for an example shown above:
2023/03/03 3ADR011074, 1, en_US 27

Power supply dimensioning > Dimensioning of the fuses
ICPU *) ICx *) II/O bus *) IUPx *) ILOADx *)

CPU/communication module part
CPU 0.110 A - - - -
C1 - 0.050 A - - -
C2 - 0.085 A - - -
C3 - 0.050 A - - -
C4 - 0.050 A - - -
I/O module part
Analog1 - - 0.002 A 0.150 A -
Analog2 - - 0.002 A 0.150 A 0.160 A
Analog3 - - 0.002 A 0.100 A 0.080 A
Analog4 - - 0.002 A 0.100 A 0.080 A
Digital1 - - 0.002 A 0.050 A 8.000 A
Digital2 - - 0.002 A 0.050 A 8.000 A
Digital3 - - 0.002 A 0.050 A 8.000 A
S columns 0.110 A 0.235 A 0.014 A 0.650 A 24.320 A
S IL+ ≈ 0.4 A S IUP ≈ 25 A
ITotal ≈ 25.4 A
*) All values in this column are exemplary values
4.3.2 Dimensioning of the fuses

To be able to select the fuses for the station correctly, both the current consumption and the
inrush currents (melting integral for the series-connected fuse) must be taken into consideration.
Fuse for S of the I L+ A IUPx A Recommended fuse

melting
integrals in Type Value
A²s
F1 CPU logic 1.000 » 0.4 - Quick 10 A
F2 Module Dig- 0.005 - 8.050 Quick 10 A
ital1
ital2
ital3
F5 Modules 0.130 - 0.820 Quick 10 A
Analog1 +
Analog2 +
Analog3 +
Analog4
28 3ADR011074, 1, en_US 2023/03/03

Libraries and software
4.4 Libraries and software

Additional libraries and software packages for specific use cases are available to reduce the
programming effort and implement quickly your application. In our main catalog we offer an
overview of the available libraries and software packages.
Reference documentation for the function blocks included in the libraries
2023/03/03 3ADR011074, 1, en_US 29

Mechanical planning and installation
Control cabinet assembly for AC500 (Standard)
—
5 Mechanical planning and installation
5.1 Control cabinet assembly for AC500 (Standard)
PLC enclosure
NOTICE!
PLC damage due to wrong enclosures
Due to their construction (degree of protection IP 20 according to EN 60529)
and their connection technology, the devices are suitable only for operation in
enclosed control cabinets.
To protect PLCs against:

● unauthorized access,
● dusting and pollution,
● moisture and wetness and
● mechanical damage,
control cabinet IP54 for common dry factory floor environment is suitable.
Maintain spacing from:

● enclosure walls
● wireways
● adjacent equipment
Allow a minimum of 20 mm clearance on all sides. This provides ventilation and galvanic
isolation.
It is recommended to mount the modules on an grounded mounting plate, or an grounded DIN
rail, independent of the mounting location.
30 3ADR011074, 1, en_US 2023/03/03

Control cabinet assembly for AC500 (Standard)
Fig. 5: Installation of AC500/S500 modules in a control cabinet

1 Cable duct
2 Distance from cable duct ≥20 mm
3 Mounting plate, grounded
NOTICE!
Horizontal mounting is highly recommended.
Vertical mounting is possible, however, derating consideration should be made
to avoid problems with poor air circulation and overheating.
2023/03/03 3ADR011074, 1, en_US 31

Control cabinet assembly for AC500-eCo
When vertically mounted, always place an end-stop terminal block on the

bottom and on the top of the modules to properly secure the modules.
With high vibration applications and horizontal mounting, we also recommend
to place end-stop terminals at the right and left side of the device to properly
secure the modules.
5.2 Control cabinet assembly for AC500-eCo
PLC enclosure To protect PLCs against:

● unauthorized access,
● dusting and pollution,
● moisture and wetness and
● mechanical damage,
control cabinet IP54 for common dry factory floor environment is suitable.
Maintain spacing from:

● enclosure walls
● cable ducts
● adjacent equipment
Allow a minimum of 20 mm clearance on all sides. This provides ventilation and galvanic
isolation.
It is recommended to mount the modules on an grounded mounting plate, or an grounded DIN
rail, independent of the mounting location.
32 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting - general information
Fig. 6: Installation of AC500-eCo V3 CPU/S500 modules in a control cabinet

1 Cable duct
2 Distance from cable duct ≥20 mm
3 Mounting plate, grounded
NOTICE!
Horizontal mounting is highly recommended.
Vertical mounting is possible, however, derating consideration should be made
to avoid problems with poor air circulation and overheating.
When vertically mounted, always place an end-stop terminal block on the

bottom and on the top of the modules to properly secure the modules.
With high vibration applications and horizontal mounting, we also recommend
to place end-stop terminals at the right and left side of the device to properly
secure the modules.
5.3 Mounting and demounting - general information

The control system is designed to be mounted to a well-grounded mounting surface such as a
metal panel. Additional grounding connections from the mounting tabs or DIN rail (if used), are
not required unless the mounting surface cannot be grounded.
During panel or DIN rail mounting of all devices, be sure that all debris (metal
chips, wire strands, etc.) is kept from falling into the controller. Debris that falls
into the controller could cause damage while the controller is energized.
2023/03/03 3ADR011074, 1, en_US 33

Mounting and demounting - general information > Optimized mounting of the option boards
All devices are grounded through the DIN rail to chassis ground. Use zinc
plated yellow-chromate steel DIN rail to assure proper grounding. The use of
other DIN rail materials (e.g. aluminium, plastic, etc.) that can corrode, oxidize,
or are poor conductors, can result in improper or intermittent grounding.
5.3.1 Optimized mounting of the option boards

The AC500-eCo processor modules have up to 3 slots for option boards.
The best thermal circulation is given on slot 3 (bottom slot), followed by slot 2 (middle slot) and
then slot 1 (top slot).
The best mounting position of the option board depends on its power dissipation.
Rules for optimized mounting of the option boards

– The greater the power dissipation of the option board, the lower the
mounting position should be selected.
– The TA5126-2AO-UI option board has the highest power dissipation
and must always be mounted at the lowest option board slot.
The optimized mounting position can be easily determined with the help of this
table.
Table 4: Power dissipation of the option boards

Power dissipation of Digital Analog Serial interface Accessory
the option boards
very small TA5141-RS232I(W) TA5130-KNXPB(W)
TA5142-RS485I(W) TA5131-RTC
TA5142-RS485(W)
small TA5105-4DOT(W) TA5123-2AI-RT(D/W)
medium TA5110-2DI2DO(T/W) TA5120-2AI-UI(W)
TA5101-4DI(W)
large TA5126-2AO-UI(W)
If the option boards to be mounted are in the same power dissipation level, then
the slots can be freely selected.
34 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting the terminal base
5.4 Mounting and demounting the terminal base

Mounting and
demounting on
DIN rail
1. Mount DIN rail 7.5 mm or 15 mm.
2. Mount the terminal base/function module terminal base:
ð The terminal base is put on the DIN rail above and then snapped-in below.
3. The demounting is carried out in a reversed order.
Mounting with If the terminal base should be mounted with screws, wall mounting accessories TA526 must be
screws inserted at the rear side first. These plastic parts prevent bending of the terminal base while
screwing on. TB560x and TB561x need one TA526, TB562x, TB564x and TB566x need two
TA526.
2023/03/03 3ADR011074, 1, en_US 35

Mounting and demounting the terminal base
Fig. 7: Terminal bases, Fastening with screws
Fig. 8: Function module terminal bases, Fastening with screws
By wall mounting, the terminal base is grounded through the screws. It is neces-
sary that
– the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-
plated)
– the mounting plate is grounded
– the screws have a good electrical contact to the mounting plate
Practical tip The following procedure allows you to use the mounted modules as a template for drilling holes
in the panel. Due to module mounting hole tolerance, it is important to follow these procedures:
1. On a clean work surface, mount no more than 3 modules (e.g. one terminal base and two
terminal units).
2. Using the mounted modules as a template, carefully mark the center of all module-
mounting holes on the panel.
3. Return the mounted modules to the clean work surface, including any previously mounted
modules.
4. Drill and tap the mounting holes for the screws (M4 or #8 recommended).
5. Place the modules back on the panel and check for proper hole alignment.
6. Attach the modules to the panel using the mounting screws.
If mounting more modules, mount only the last one of this group and put
the others aside. This reduces remounting time during drilling and tapping
of the next group.
7. Repeat the steps for all remaining modules.
36 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting the AC500 processor module
5.5 Mounting and demounting the AC500 processor module

1. After mounting the terminal base on the DIN rail, mount the processor module.
2. Press the processor module into the terminal base until it locks in place.
3. The demounting is carried out in a reversed order. Press above and below, then remove
the processor module.
2023/03/03 3ADR011074, 1, en_US 37

Mounting and demounting the terminal unit
5.6 Mounting and demounting the terminal unit

Mounting on
DIN rail
1. Mount DIN rail 7.5 mm or 15 mm.
2. Mount the terminal unit.
The terminal unit is snapped into the DIN rail in the same way as the Terminal Base.
Once secured to the DIN rail, slide the terminal unit to the left until it fully locks into place
creating a solid mechanical and connection.
When attaching the devices, make sure the bus connectors are securely
locked together to ensure proper connection. Max. 10 terminal units can
be attached.
3. Demounting: A screwdriver is inserted in the indicated place to separate the terminal units.
Mounting with If the terminal unit should be mounted with screws, wall mounting accessories TA526 must be
screws inserted at the rear side first. These plastic parts prevent bending of the Terminal Base while
screwing on.
38 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting the communication module
Fig. 9: Fastening with screws
By wall mounting, the terminal unit is grounded through the screws. It is neces-
sary that
– the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-
plated)
– the mounting plate is grounded
– the screws have a good electrical contact to the mounting plate
Practical tip The following procedure allows you to use the mounted modules as a template for drilling holes
in the panel. Due to module mounting hole tolerance, it is important to follow these procedures:
1. On a clean work surface, mount no more than 3 modules (e.g. one terminal base and two
terminal units).
2. Using the mounted modules as a template, carefully mark the center of all module-
mounting holes on the panel.
3. Return the mounted modules to the clean work surface, including any previously mounted
modules.
4. Drill and tap the mounting holes for the screws (M4 or #8 recommended).
5. Place the modules back on the panel and check for proper hole alignment.
6. Attach the modules to the panel using the mounting screws.
If mounting more modules, mount only the last one of this group and put
the others aside. This reduces remounting time during drilling and tapping
of the next group.
7. Repeat the steps for all remaining modules.
5.7 Mounting and demounting the communication module

Communication modules are mounted on the left side of the processor module on the same
terminal base. The connection is established automatically when mounting the communication
module.
2023/03/03 3ADR011074, 1, en_US 39

Mounting and demounting the communication module
NOTICE!
Risk of damaging the PLC modules!
Overvoltages and short circuits might damage the PLC modules.
– Make sure that all voltage sources (supply voltage and process supply
voltage) are switched off before you begin with operations on the system.
– Never connect any voltages or signals to reserved terminals (marked with
---). Reserved terminals may carry internal voltages.
After mounting the terminal base, mount the communication modules.

1. First insert the bottom nose of the communication module into the dedicated holes of the
terminal base. Then, rotate the communication module on the dedicated terminal base slot
until it is locked in place.
ð
NOTICE!
Risk of malfunctions!
Unused slots for communication modules are not protected against
accidental physical contact.
– Unused slots for communication modules must be covered with
dummy communication modules to achieve IP20 rating.
– I/O bus connectors must not be touched during operation.

Press above and below, then rotate the communication module and remove it.
40 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting the I/O module
5.8 Mounting and demounting the I/O module

After mounting the terminal unit, mount the I/O modules.
1. Press the I/O module into the terminal unit until it locks in place.

Press above and below, then remove the module.
2023/03/03 3ADR011074, 1, en_US 41

Mounting and demounting the AC500-eCo processor module > Mounting a processor module on a DIN rail
5.9 Mounting and demounting the AC500-eCo processor module

5.9.1 Mounting a processor module on a DIN rail
NOTICE!
Risk of function faults!
The processor module is grounded via DIN rail.
The DIN rail must be included into the grounding conception of the plant.
Mount the processor module at the top of the DIN rail, then snap it in below.
42 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting the AC500-eCo processor module > Demounting a processor module mounted on a DIN rail
5.9.2 Demounting a processor module mounted on a DIN rail

1. Remove I/O modules if connected.
2. While pressing down processor module pull it away from DIN rail.
2023/03/03 3ADR011074, 1, en_US 43

Mounting and demounting the AC500-eCo processor module > Mounting a processor module on a metal plate
5.9.3 Mounting a processor module on a metal plate
NOTICE!
Missing electrical contact by isolating screws or washers!
Use metal screws on the metal plate.
The metal plate must be included into the grounding concept of the plant.
Do NOT use insulating washers!
One TA543 wall mounting accessory is needed per processor module.
1. Snap in the TA543 at the back side of the processor module.
2. Fasten the processor module with two screws (diameter: 4 mm) to the metal plate.
44 3ADR011074, 1, en_US 2023/03/03

Mounting and demounting the AC500-eCo processor module > Demounting a processor module mounted on a metal plate
5.9.4 Demounting a processor module mounted on a metal plate

1. Remove I/O modules if connected.
2. Remove the 2 screws.
2023/03/03 3ADR011074, 1, en_US 45

Mounting and demounting the S500-eCo I/O module
5.9.5 Mounting of TA5301-CFA
1 TA5301-CFA cable fixing accessory

2 2 openings on the PM50x2 processor module
Insert the TA5301-CFA cable fixing accessory into the two openings on the PM50x2
processor module marked white in the figure.
5.10 Mounting and demounting the S500-eCo I/O module

S500-eCo I/O modules can be mounted either on a DIN rail or with screws on a metal plate.
Mounting I/O
modules on a NOTICE!
DIN rail
The S500-eCo I/O modules are grounded via the DIN rail.
The DIN rail must be included into the grounding concept of the plant.
Use only metal screws.
1. Mount I/O module at the top of the DIN rail, then snap it in below.
46 3ADR011074, 1, en_US 2023/03/03

2. Attach I/O module by hand to an other module. The serial I/O bus is connected automati-
cally.
Demounting I/O
modules
mounted on a
DIN rail
1. Remove I/O module by hand if connected.
2023/03/03 3ADR011074, 1, en_US 47

2. While pressing down I/O module pull it away from DIN rail.
Mounting I/O
modules on a NOTICE!
metal plate
Missing electrical contact by isolating screws or washers!
Use metal screws on the metal plate.
The metal plate must be included into the grounding concept of the plant.
Do NOT use insulating washers!
One TA566 wall mounting accessory is needed per S500-eCo I/O module.
1. Snap in the TA566 at the back side of the I/O module.
48 3ADR011074, 1, en_US 2023/03/03

2. Attach the I/O module by hand to an other module. The serial I/O bus is connected
automatically.
3. Fasten the I/O module with two screws (diameter: 4 mm) to the metal plate.
2023/03/03 3ADR011074, 1, en_US 49

Accessories for AC500 (Standard)
Demounting I/O
modules
mounted on a
metal plate
1. Remove the 2 screws.
2. Remove the I/O module from the connected module by hand.
5.11 Accessories for AC500 (Standard)

This section only describes accessories that are frequently used for system assembly, connec-
tion and construction.
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Accessories for AC500 (Standard) > Inserting and removing a memory card
5.11.1 Inserting and removing a memory card
NOTICE!
Removal of the memory card
Do not remove the memory card during access.
Otherwise the memory card and/or files on it might get corrupted and/or normal
PLC operation might be disturbed.
1 Memory card
2 Micro memory card
3 Micro memory card adapter
4 Memory card slot
Insert the memory card into the memory card slot of the processor module until locked.
1 MC502 or MC5141 memory card

2 MC5102 micro memory card
3 Micro memory card adapter
4 Memory card slot
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Accessories for AC500-eCo > Mounting and demounting the option boards
To remove the memory card, push on the memory card until it moves forward. By this, the
memory card is unlocked and can be removed.
5.12 Accessories for AC500-eCo

This section only describes accessories that are frequently used for system assembly, connec-
tion and construction.
5.12.1 Mounting and demounting the option boards

5.12.1.1 Optimized mounting of the option boards
The AC500-eCo processor modules have up to 3 slots for option boards.
The best thermal circulation is given on slot 3 (bottom slot), followed by slot 2 (middle slot) and
then slot 1 (top slot).
The best mounting position of the option board depends on its power dissipation.
Rules for optimized mounting of the option boards

– The greater the power dissipation of the option board, the lower the
mounting position should be selected.
– The TA5126-2AO-UI option board has the highest power dissipation
and must always be mounted at the lowest option board slot.
The optimized mounting position can be easily determined with the help of this
table.
Table 5: Power dissipation of the option boards

Power dissipation of Digital Analog Serial interface Accessory
the option boards
very small TA5141-RS232I(W) TA5130-KNXPB(W)
TA5142-RS485I(W) TA5131-RTC
TA5142-RS485(W)
small TA5105-4DOT(W) TA5123-2AI-RT(D/W)
medium TA5110-2DI2DO(T/W) TA5120-2AI-UI(W)
TA5101-4DI(W)
large TA5126-2AO-UI(W)
If the option boards to be mounted are in the same power dissipation level, then
the slots can be freely selected.
5.12.1.2 Inserting the option board

After mounting the PM50x2 processor module on the DIN rail, mount the option board.
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Accessories for AC500-eCo > Mounting and demounting the option boards
Press the option board TA51xx (or TA5300-CVR) into the slot of the processor module
PM50x2 until it locks in place.
The option board must click into the slot of the processor module.
5.12.1.3 Removing the option board
1. Push the option board on the side to release the lock.

2. At the same time, pull the option board out of the slot.
CAUTION!
Risk of injury and damaging the product!
Always plug in the option board slot cover when the option board is not inserted.
If the option board slot cover is lost, please order the replacement TA5300-CVR
(1SAP187500R0001).
Never power up the CPU with uncovered option board slot, otherwise it may
cause serious injury and/or damage the product.
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Accessories for AC500-eCo > Mounting and demounting of the terminal blocks for onboard I/Os
5.12.2 Mounting and demounting of the terminal blocks for onboard I/Os
Intended pur- Removable terminal blocks are used for power supply and for I/O connectors on AC500-eCo V3
pose processor modules PM50x2.
For option boards there are different removable terminal blocks in spring version.
For the AC500-eCo V3 Basic CPUs a 3-pin terminal block for power supply and a 13-pin
terminal block for I/O connectors are used.
For the AC500-eCo V3 Standard CPUs and Pro CPUs a 3-pin terminal block for power supply,
a 13-pin terminal block and a 12-pin terminal block for I/O connectors are used.
For all CPUs there is a screw and a spring variant available.
Basic CPU Standard and Pro CPUs

Spring terminal Screw terminal Spring terminal Screw terminal
TA5211-TSPF-B TA5211-TSCL-B TA5212-TSPF TA5212-TSCL
Various removable spring terminal blocks are available for option boards.
The following spare parts are available (depending on the number of pins).
Spring terminals
TA5220-SPF5 TA5220-SPF6 TA5220-SPF7 TA5220-SPF8
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Accessories for AC500-eCo > Mounting and demounting of the terminal blocks for onboard I/Os
CAUTION!
Improper installation and maintenance may result in injury and can damage the
product!
– Installation and maintenance have to be performed according to the
technical rules, codes and relevant standards, e.g. EN 60204-1.
– Read product documentation carefully before wiring. Improper wiring or
wrong terminal block from other devices can damage the product!
– Only by qualified personnel.
CAUTION!
Risk of injury and damaging the module when using unapproved terminal
blocks!
Only use terminal blocks approved by ABB to avoid injury and damage to the
module.
Terminal block set for PM50x2

Processor modules PM50x2 CPU are not delivered with terminal blocks.
Screw terminal block set:
– TA5211-TSCL-B (1SAP187400R0001) for PM5012-x-ETH
– TA5212-TSCL (1SAP187400R0004) for PM5032-x-ETH, PM5052-x-ETH,
PM5072-T-2ETH(W)
Spring terminal block set:
– TA5211-TSPF-B (1SAP187400R0002) for PM5012-x-ETH
– TA5212-TSPF (1SAP187400R0005) for PM5032-x-ETH, PM5052-x-ETH,
PM5072-T-2ETH(W)
Assembly
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Accessories for AC500-eCo > Inserting and removing a memory card
Disassembly
5.12.3 Inserting and removing a memory card
NOTICE!
Removal of the memory card
Do not remove the memory card during access.
Otherwise the memory card and/or files on it might get corrupted and/or normal
PLC operation might be disturbed.
AC500-eCo V3
1 Micro memory card slot cover

2 Micro memory card
3 Micro memory card slot
1. Open the micro memory card slot cover by turning it upwards.
2. Carefully insert the micro memory card into the micro memory card slot as far as it will go.
Observe orientation of card.
3. Close the micro memory card slot cover by turning it downwards.
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Control panels CP600
AC500-eCo V3
1 Micro memory card slot cover

2 Micro memory card
3 Micro memory card slot
1. Open the micro memory card slot cover by turning it upwards.
2. Micro memory card can be removed from the micro memory card slot by gripping and
pulling with two fingers.
3. Close the micro memory card slot cover by turning it downwards.
5.13 Control panels CP600

Refer to the installation instructions delivered with each control panel and to the operating
instructions.
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Wiring
Grounding concept
—
6 Wiring
6.1 Grounding concept
NOTICE!
PLC damage due to missing grounding
– Make sure to ground the devices.
– The grounding (switch cabinet grounding) is supplied both by the mains
connection (or 24 V supply voltage) and via the DIN rail. The DIN rail
must be connected to ground before power is supplied to the device. The
grounding may be removed only if it is certain that no more power is being
supplied to the control system.
– In case of screw mounting, grounding must be ensured by the screws.
Block diagram:
Digital I/O
modules
I/O Terminal Unit TU515/TU516 I/O-Bus
DC532/DI524
I/O-Bus
DIN
rail Digital
I/O interface
UP CH-ERRx
1M Power
supply
I/Os
1M ZP ZP
ZP UP Inputs/outputs
0V +24V
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Wiring
EMC-conforming assembly and construction > General principles
Block diagram:
Analog I/O
modules
I/O Terminal Unit TU515/TU516 I/O-Bus
AX522
Analog I/O interface
I/O-Bus
DIN
rail
UP CH-ERRx Inputs Outputs
Power
1M
supply + – + – + – + –
PTC PTC
1M
ZP UP I+ I– I+ I– O+ O– O+ O–
0V +24V
6.2 EMC-conforming assembly and construction

6.2.1 General principles
General consid- Electric and electronical devices have to work correctly on site. This is also valid when electro-
erations magnetic influences affect them in defined and/or expected strength. The devices themselves
must not emit electro-magnetic noises.
Advant controller components have a very high noise immunity.
When the wiring and grounding instructions are met, an error-free operation is given.
High electro-magnetic noises of nearby mounted applications must be taken in consideration
during the planning phase.
An EMC compatible earthing concept will also guarantee an error-free operation here.
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Wiring
EMC-conforming assembly and construction > Cable routing
There are three important principles to be especially considered:

– Keep all connections as short as possible (in particular the grounding con-
ductors)
– Use large conductor cross sections (in particular for the grounding conduc-
tors)
– Create low-impedance, i.e. good and large-sized contacts (in particular for
the grounding conductors)
Pay attention to the following:

– Use vibration-resistant connections
– Clean metallic contact areas
– Use solid plug and screw-type connections
– Use earth cable shields with clips on a well-grounded metallic surface
– Do not use aluminium parts
– Do not use sheath wires
– Do not use toothed lock washers under screw connections
Fig. 10: Assembly: wrong
Fig. 11: Assembly: correct

Make a connection between the DIN rails and PE (Protective Earth). For this, use an grounding
wire with a minimum conductor cross section of 10 mm².
The wire is connected to the DIN rail with an M6 screw.
A large-area contact of the DIN rail with the metallic mounting plate improves the EMC behavior
significantly, as the disturbances can be discharged more effective.
6.2.2 Cable routing

● Route cables meeting the standards.
● Sort the cables into cable groups:
– Power current cables
– Power supply cables
– Signal cables
– Data cables
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Wiring
EMC-conforming assembly and construction > Control cabinet
● Route signal cables and data cables separately from the power cables.
– Separate cable ducts or cable bundles.
– The distance should be 20 cm or greater.
● Lay signal and data cables close to earthed surfaces.
6.2.3 Cable shields

● Use only shielded data cables. The shield should be grounded at both ends.
A cable shield only grounded at one end can only protect from capacitively coupled interfer-
ence and low-frequency disturbances (50 Hz hum).
● Avoid parasitic currents flowing through the cable shields.
This can be done by installing current-carrying equipotential bondings.
● Use only cables with braided shields.
Foil shields are not robust enough, cannot be contacted well and have poor HF properties.
● Use only metallic or [metal]-plated plugs for shielded data cables.
● Use only shielded cables for analog signals.
For small signals ground the shield only at one end.
● Ground the cable shield directly with a clip when entering the control cabinet.
Do not cut the shield until the cable reaches the module connected.
The connection between the PE bar and the shield bar must have a low impe-
dance.
6.2.4 Control cabinet
Installation of configurations in shielded cabinet can be required in shipping

applications. Follow specific instructions in the applicable type approval certifi-
cate.
Available certifi- 1. Open landing page of the product e.g. DO526

cates can be
found in the 2. In the middle of the page, click on [Downloads].
internet ð A two-column window opens on the page with all available documents.
3. In the left column of the downloads page click on [Certificate].
ð All available certificates are listed in the right column.
In the list of certificates, the maritime certificates can be identified by the title. The title consists
of the abbreviation of the maritime classification society followed by the words: Type Approval
Certificate. E.g. "DNV Type Approval Certificate: ...".
Connections The connections between the control cabinet, the mounting plates, the PE bar and the shield
bar must have a low impedance.
Grounding Ground the control cabinet doors with short and highly flexible conductors.
Control cabinet Only use lighting with interference suppression.

lighting
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Wiring
EMC-conforming assembly and construction > Equipotential bonding
For supplying Use the mains socket which is located inside the control cabinet.
the PC
Ä Chapter 5.1 “Control cabinet assembly for AC500 (Standard)” on page 30
6.2.5 Reference potential

● Provide a uniform reference potential in the entire installation and ground all electrical
appliances if possible.
● Route your grounding conductors in a star configuration so that no ground loops can occur.
6.2.6 Equipotential bonding

The Installation of equipotential bondings are necessary if there are present or expected poten-
tial differences between parts of your application.
– The impedance of equipotential bonding must be equal or lower than 10 %

of the shield impedance of the shielded signal cables between the same
points.
– The conductor cross section of a equipotential bonding must be 16 mm² to
withstand the maximum possible compensating current.
– Equipotential bondings and shielded signal cables should be laid close to
each other.
– Equipotential bondings must be connected to PE with low impedance.
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Wiring
Connection and wiring
Fig. 12: AC500, equipotential bonding

1 Cabinet 1
2 Cabinet 2
3 Power supply for the CPU
4 Fuse for the CPU power
5 Power supply for the I/Os
6 Fuse for the I/O power
7 For fuses for the contacts of the relay outputs
8 0V rail
9 Grounding of the 0V rail
10 Cabinet grounding
11 Equipotential bonding between the cabinets min. 16 mm2
12 Cable shields grounding
13 Fieldbus connection (e.g. Ethernet)
6.3 Connection and wiring

This chapter provides general information about the platform.
Specific information about the connections of the modules and the wiring is available in the
installation instructions.
● Installation instructions of AC500 PLC product family
● Installation instructions of CP600 control panels
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Wiring
Connection and wiring > AC500
NOTICE!
Attention:
The devices should be installed by experts who are trained in wiring electronic
devices. In case of bad wiring, the following problems could occur:
– On the terminal base, the terminals L+ and M are doubled. If the power
supply is badly connected, a short circuit could happen and lead to a
destruction of the power supply or its fuse. If no suitable fuse exists, the
terminal base itself might be destroyed.
– The terminal bases and all electronic modules and terminal units are pro-
tected against reverse polarity.
– All necessary measures should be carried out to avoid damages to modules
and wiring. Notice the wiring plans and connection examples.
NOTICE!
All I/O channels (digital and analog) are protected against reverse polarity,
reverse supply, short circuit and temporary overvoltage up to 30 V DC.
NOTICE!
Attention:
Due to possible loss of communcation, the communication cables should be
fixed with cable duct or bracket or clamp during application.
6.3.1 AC500
6.3.1.1 Power supply for AC500 system
The system is powered by two different power circuits:
● The power supply for the processor module is provided through the terminals L+/M.
● The power supply for the I/O modules is provided through the terminals UP/ZP.
The power supply for the processor module is galvanic isolated from the power supply for the
I/O modules.
As soon as the power supply for the processor module is present, the processor module starts.
The power supply of the processor module and the I/O modules should be powered on the
same time, otherwise the processor module will not switch to run mode after startup.
When during operation the power supply falls below the minimum process and supply voltage
for more than 10 ms, the processor module switches to safe mode. A restart of the processor
module only occurs by switching the power supply off and on again.
If an I/O module is disconnected during operation from the power supply while the processor
module is still powered, the processor module will continue its normal operation on all other
powered peripherals (other I/O modules, communication modules and communication inter-
faces), but freezes the input image. After recovery of the power supply of the affected I/O
module it will continue normal operation and inputs and outputs will be updated.
As power supply for the AC500 system, the ABB power supplies series CP can be used.
6.3.1.2 Power supply for processor modules

The supply voltage of 24 V DC is connected to a removable 5-pin terminal block. L+/M exist
twice. It is therefore possible to feed e.g. external sensors (up to 8 A max. with 1.5 mm2
conductor) via these terminals.
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Wiring
Pin assignment Pin Assignment Label Function Description

L+ +24 V DC Positive pin of the
power supply voltage
L+ +24 V DC Positive pin of the
M 0V Negative pin of the
Terminal block Terminal block
removed inserted M 0V Negative pin of the
FE Functional earth
6.3.1.3 Connection of wires at the spring terminals

Connection
Opening Opening for

for screw-
conductor driver b
Screwdriver
Terminal Screwdriver
b open inserted
Terminal
closed Screwdriver
Spring
a a
1 2 3
Fig. 13: Connect the wire to the spring terminal (steps 1 ... 3)
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Wiring
4 5 6 7
Fig. 14: Connect the wire to the spring terminal (steps 4 ... 7)
1. Side view (open terminal drawn for illustration)
2. The top view shows the openings for wire and screwdriver
3. Insert screwdriver (2.5 x 0.4 to 3.5 x 0.5 mm) at an angle, screwdriver must be at least 15
mm free of insulation at the tip
4. While erecting the screwdriver, insert it until the stop (requires a little strength)
5. Screwdriver inserted - terminal open
6. Strip the wire for 7 mm (and put on wire-end ferrule)
7. Insert wire into the open terminal
8. Done
Disconnection
Screwdriver
Screwdriver
1 2 3
Fig. 15: Disconnect wire from the spring terminal (steps 1 ... 3)
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Wiring
Conductor
Screwdriver
4 5 6
Fig. 16: Disconnect wire from the spring terminal (steps 4 ... 6)
1. Terminal with wire connected
2. Insert screwdriver (2.5 x 0.4 ... 3.5 x 0.5 mm) at an angle, screwdriver must be at least 15
mm free of insulation at the tip
3. While erecting the screwdriver, insert it until the stop (requires a little strength) - terminal is
now open
4. Remove wire from the open terminal
5. Done
6.3.1.4 Terminals for CANopen communication modules
Fig. 17: Combicon, 5-pole, female, removable plug with spring terminals
Fig. 18: Combicon, 5-pole, female, removable plug with spring terminals
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Wiring
Terminal type: Number of cores Conductor type Cross section Stripped conductor
Spring terminal per terminal end
1 solid 0.2 mm² ... 2.5 mm² 10 mm
1 flexible 0.2 mm² ... 2.5 mm² 10 mm
1 with wire-end fer- flexible 0.25 mm² ... 2.5 mm² 10 mm
rule (without plastic
sleeve)
1 with wire-end fer- flexible 0.25 mm² ... 2.5 mm² 10 mm
rule (with plastic
sleeve)
6.3.1.5 Ethernet connection details
Ethernet is also used for PROFINET, EtherCAT and Modbus TCP connection.
6.3.1.5.1 Ethernet interface

Pin assignment Interface Pin Signal Description
1 TxD+ Transmit data +
2 TxD- Transmit data -
3 RxD+ Receive data +
4 NU Not used
5 NU Not used
6 RxD- Receive data -
7 NU Not used
8 NU Not used
Shield Cable shield Functional earth
6.3.1.5.2 Wiring
Cable length For the maximum possible cable lengths within an Ethernet network, various factors have to
restrictions be taken into account. Twisted pair cables (TP cables) are used as transmission medium for
10 Mbit/s Ethernet (10Base-T) as well as for 100 Mbit/s (Fast) Ethernet (100Base-TX). For a
transmission rate of 10 Mbit/s, cables of at least category 3 (IEA/TIA 568-A-5 Cat3) or class C
(according to European standards) are allowed. For fast Ethernet with a transmission rate of
100 Mbit/s, cables of category 5 (Cat5) or class D or higher have to be used. The maximum
length of a segment, which is the maximum distance between two network components, is
restricted to 100 m due to the electric properties of the cable.
Furthermore, the length restriction for one collision domain has to be observed. A collision
domain is the area within a network which can be affected by a possibly occurring collision
(i.e. the area the collision can propagate over). This, however, only applies if the components
operate in half-duplex mode since the CSMA/CD access method is only used in this mode. If
the components operate in full-duplex mode, no collisions can occur. Reliable operation of the
collision detection method is important, which means that it has to be able to detect possible
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Wiring
collisions even for the smallest possible frame size of 64 bytes (512 bits). But this is only
guaranteed if the first bit of the frame arrives at the most distant subscriber within the collision
domain before the last bit has left the transmitting station. Furthermore, the collision must
be able to propagate to both directions at the same time. Therefore, the maximum distance
between two ends must not be longer than the distance corresponding to the half signal propa-
gation time of 512 bits. Thus, the resulting maximum possible length of the collision domain is
2000 m for a transmission rate of 10 Mbit/s and 200 m for 100 Mbit/s. In addition, the bit delay
times caused by the passed network components also have to be considered.
Table 6: Specified cable properties of the respective cable types per 100 m:
Parameter 10Base-T [10 MHz] 100Base-TX [100 MHz]
Attenuation [dB/100m] 10.7 23.2
NEXT [dB/100m] 23 24
ACR [dB/100m] N/A 4
Return loss [dB/100m] 18 10
Wave impedance [Ohms] 100 100
Category 3 or higher 5
Class C or higher D or higher
TP cable The TP cable has eight wires arranged in four pairs of twisted wires. Different color codes
exist for the coding of the wires, the coding according to EIA/TIA 568, version 1, being the one
most commonly used. In this code, the individual pairs are coded with blue, orange, green and
brown color. One wire of a pair is unicolored and the corresponding second wire is striped,
the respective color alternating with white. For shielded cables, a distinction is made between
cables that have one single shield around all pairs of wires and cables that have an additional
individual shield for each pair of wires. The following table shows the different color coding
systems for TP cables:
Table 7: Color coding of TP cables:

Pairs EIA/TIA 568 EIA/TIA 568 DIN 47100 IEC 189.2
Version 1 Version 2
Pair 1 white/ blue green red white brown white blue
blue
Pair 2 white/ orange black yellow green yellow white orange
orange
Pair 3 white/ green blue orange grey pink white green
green
Pair 4 white/ brown brown slate blue red white brown
brown
Two general variants are distinguished for the pin assignment of the normally used RJ45
connectors: EIA/TIA 568 version A and version B. The wiring according to EIA/TIA 568 version
B is the one most commonly used.
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Wiring
Pair 2 Pair 3
Pair 3 Pair 1 Pair 4 Pair 2 Pair 1 Pair 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
T3 R3 T2 R1 T1 R2 T4 R4 T3 R3 T2 R1 T1 R2 T4 R4
T568A T568B
Fig. 19: Pin assignment of RJ45 sockets
6.3.1.5.3 Cable types

Crossover cable
Particular use
Crossover cables are needed only for a direct Ethernet connection without
crossover functionality. In particular for AC500 modules in product life cycle
phase "Classic".
Crossover cables are for a direct Ethernet connection of two terminal devices as the simplest
variant of a network. From transmission lines of the first station to the reception lines of the
second station.
12345678 12345678
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Fig. 20: Wiring of a crossover cable
Straight-through For networks with more than two subscribers, hubs or switches have to be used additionally for
cable distribution. These active devices already have the crossover functionality implemented which
allows a direct connection of the terminal devices using straight-through cables.
12345678 12345678
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Fig. 21: Wiring of a straight-through cable
CAUTION!
Risk of communication faults!
When using inappropriate cables, malfunctions in communication may occur.
Only use network cables of the categories 5 (Cat 5, Cat 5e, Cat 6 or Cat 7) or
higher within PROFINET networks.
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Wiring
Connection and wiring > AC500-eCo
6.3.2 AC500-eCo
6.3.2.1 Power supply
The processor modules PM50x2 can be connected to the 24 V DC supply voltage via a remov-
able 3-pin spring terminal block or a 3-pin screw terminal block.
Table 8: Removable terminal block for the supply voltage 24 V DC

3-pin spring terminal block 3-pin screw terminal block
The terminal block is available as a set for AC500-eCo V3 processor modules.
Basic CPU (PM5012) Standard CPUs (PM5032, PM5052) and

Pro CPUs (PM5072)
Spring type Screw type Spring type Screw type
TA5211-TSPF-B TA5211-TSCL-B TA5212-TSPF TA5212-TSCL
Pin assignment Pin Assignment Pin Label Function Description

1 FE Functional earth
2 L+ +24 V DC Positive pin of the
3 M 0V Negative pin of the
Terminal block
inserted
NOTICE!
Risk of damaging the PLC due to improper voltage levels!
– Never exceed the maximum tolerance values for process and supply vol-
tages.
– Never fall below the minimum tolerance values for process and supply
voltages.
Observe the system data and the technical data of the used module.
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Wiring
Connection and wiring > Control panels CP600
6.3.2.2 Ethernet
Ethernet is also used for Modbus TCP connection.
6.3.2.2.1 Ethernet interface

The Ethernet interface is carried out via a RJ45 jack. The pin assignment of the Ethernet
interface:
Interface Pin Description

1 Tx+ Transmit Data +
2 Tx- Transmit Data -
3 Rx+ Receive data +
4 NC Not connected
5 NC Not connected
6 Rx- Receive data -
7 NC Not connected
8 NC Not connected
Shield Cable shield Functional earth
6.3.3 Control panels CP600

Refer to the installation instructions delivered with each control panel and to the operating
instructions.
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Configuration and programming
—
7 Configuration and programming
New to AC500? We recommend to use the step-by-step instructions in the Getting started document to install
the engineering suite and to configure and program your first project.
Advanced Detailed information is available in the installation and licensing document.

installation of
engineering
suite
Programming All information about the configuration and the programming are available in the software
for PLC system manual (contained in PLC Automation manual).
Activating soft- Detailed information is available in the installation and licensing document.
ware licenses
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Cyber security
7.1 Cyber security

Cyber security This product is designed to be connected to and to communicate information and data via a
disclaimer network interface. It is your sole responsibility to provide and continuously ensure a secure con-
nection between the product and your network or any other network (as the case may be). You
shall establish and maintain any appropriate measures (such as but not limited to the installation
of firewalls, application of authentication measures, encryption of data, installation of anti-virus
programs, etc.) to protect the product, the network, its system and the interface against any kind
of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data
or information. ABB Ltd and its affiliates are not liable for damages and/or losses related to such
security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data
or information.
Although ABB provides functionality testing on the products and updates that we release,
you should institute your own testing program for any product updates or other major system
updates (to include but not limited to code changes, configuration file changes, third party
software updates or patches, hardware exchanges, etc.) to ensure that the security measures
that you have implemented have not been compromised and system functionality in your envi-
ronment is as expected. This also applies to the operating system. Security measures (such
as but not limited to the installation of latest patches, installation of firewalls, application of
authentication measures, installation of anti-virus programs, etc.) are in your responsibility. You
have to be aware that operating systems provide a considerable number of open ports that
should be monitored carefully for any threats.
It has to be considered that online connections to any devices are not secured. It is your
responsibility to assure that connections are established to the correct device (and e.g. not to an
unknown device pretending to be a known device type). Furthermore you have to take care that
confidential data exchanged with the PLC is either compiled or encrypted.
Security related Security details for industrial automation is provided on ABB website in a whitepaper.
deployment
guidelines for
industrial
automation
Signed firmware The firmware update files for the AC500 V3 PLC are digitally signed releases by ABB. During
updates the update process, these signatures are validated by a hardware security component in the
PLC. This way, the AC500 V3 PLC will only update with valid, authentic firmware, signed by
ABB.
Open ports and As part of the ABB security concept the AC500 V3 PLC comes with minimal services opened by
services default. Only the services needed for initial setup and programming are open before any user
application is downloaded.
Only used services/ports should be enabled (e.g. to enable the functionality of

an FTPS server).
Encrypted and An application can be encrypted and signed in order to protect a running application in an
signed applica- AC500 V3 PLC and to protect a configured project. How to set-up the user management, the
tions communication and the boot application in order to prevent unauthorized access is explained in
the application note AC500 V3 - Encrypt and sign your application.
Secure commu- Whenever possible, use an encrypted communication between AC500 V3 devices and third
nication party devices, such as HMI devices. This is necessary to protect passwords and other data.
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Cyber security > Defense in depth
Secure shell The AC500 V3 PLC contains a secure shell service to access core logging data in case of
access for ABB problems which need a deeper analysis. This service is inactive by default, which means that no
service one can access this privileged shell in the normal operating state.
To activate this service, local access to the PLC is necessary and activation is only valid until
the next power cycle of the PLC. Once activated, the service run on TCP port 22. Each PLC
also protects the secure shell access by an individual password.
Frequently For more information around cyber security please see our AC500 cyber security FAQ.
asked questions
7.1.1 Defense in depth

The defense in depth approach implements multi-layer IT security measures. Each layer pro-
vides its special security measures. All deployed security mechanisms in the system must be
updated regularly. It is also important to follow the system vendor’s recommendations on how
to configure and use these mechanisms. As a basis, the components must include security
functions such as:
● Virus protection
● Firewall protection
● Strong and regularly changed passwords
● User management
● Using VPN tunnels for connections between networks
Additional security components such as routers and switches with integrated firewalls should
be available. A defined user and rights concept managing access to the controllers and their
networks is mandatory. Finally, the manufacturer of the components should be able to quickly
discover weaknesses and provide patches.
Only used services/ports should be enabled (e.g. to enable the functionality of

an FTPS server).
References: CODESYS Security Whitepaper
Security zones IT resources vary in the extent to which they can be trusted. A common security architecture is
therefore based on a layered approach that uses zones of trust to provide increasing levels of
security according to increasing security needs. Less-trusted zones contain more-trusted zones
and connections between the zones are only possible through secure interconnections such as
firewallsFig. 22. All resources in the same zone must have the same minimum level of trust. The
inner layers, where communication interaction needs to flow freely between nodes, must have
the highest level of trust. This is the approach described in the IEC 62443 series of standards.
Firewalls, gateways, and proxies are used to control network traffic between zones of different
security levels, and to filter out any undesirable or dangerous material. Traffic that is allowed to
pass between zones should be limited to what is absolutely necessary because each type of
service call or information exchange translates into a possible route that an intruder may be able
to exploit. Different types of services represent different risks. Internet access, incoming e-mail
and instant messaging, for example, represent very high risks.
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Cyber security > Secure operation
Fig. 22: Security zones

Fig. 22 shows three safety zones, but the number of zones is not necessarily decisive, there can
also be more or less - depending on the safety requirement. The use of multiple zones allows
access between zones of different trust levels to be controlled to protect a trusted resource from
attack by a less trusted one.
High-security zones should be kept small and independent. They need to be physically pro-
tected, i.e. physical access to computers, network equipment and network cables must be
limited by physical means to authorized persons only. A high-security zone should obviously not
depend on resources in a less secure zone for its security. Therefore, it should form its own
domain that is administered from the inside, and not depend on, e.g., a domain controller in a
less secure network.
Even if a network zone is regarded as trusted, an attack is still possible: by a user or compro-
mised resource that is inside the trusted zone, or by an outside user or resource that succeeds
to penetrate the secure interconnection. Trust therefore depends also upon the types of meas-
ures taken to detect and prevent compromise of resources and violation of the security policy.
References: Security for industrial automation and control systems
7.1.2 Secure operation

The controller must be located in a protected environment in order to avoid accidental or
intended access to the controller or the application.
A protected environment can be:
● Locked control cabinets without connection from outside
● No direct internet connection
● Use firewalls and VPN to separate different networks
● Separate different production areas with different access controls
To increase security, physical access protection measures such as fences, turnstiles, cameras
or card readers can be added.
Follow these rules for the protected environment:
● Keep the trusted network as small as possible and independent from other networks.
● Protect the cross-communication of controllers and the communication between controllers
and field devices via standard communication protocols (fieldbus systems) using appro-
priate measures.
● Protect such networks from unauthorized physical access.
● Use fieldbus systems only in protected environments. They are not protected by additional
measures, such as encryption. Open physical or data access to fieldbus systems and their
components is a serious security risk.
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● Physically protect all equipment, i.e., ensure that physical access to computers, network
equipment and cables, controllers, I/O systems, power supplies, etc., is limited to authorized
persons
● When connecting a trusted network zone to outer networks, make sure that all connections
are through properly configured secure interconnections only, such as a firewall or a system
of firewalls, which is configured for “deny by default”, i.e., blocks everything except traffic
that is explicitly needed to fulfill operational requirements.
● Allow only authorized users to log on to the system, and enforce strong passwords that are
changed regularly.
● Continuously maintain the definitions of authorized users, user groups, and access rights,
to properly reflect the current authorities and responsibilities of all individuals at all times.
Users should not have more privileges than they need to do their job.
● Do not use the system for e-mail, instant messaging, or internet browsing. Use separate
computers and networks for these functions if they are needed.
● Do not allow installation of any unauthorized software in the system.
● Restrict temporary connection of portable computers, USB memory sticks and other remov-
able data carriers. Computers that can be physically accessed by regular users should have
ports for removable data carriers disabled.
● If portable computers need to be connected, e.g., for service or maintenance purposes, they
should be carefully scanned for viruses immediately before connection.
● All CDs, DVDs, USB memory sticks and other removable data carriers, and files with
software or software updates, should also be checked for viruses before being introduced
into the trusted zone.
● Continuously monitor the system for intrusion attempts.
● Define and maintain plans for incident response, including how to recover from potential
disasters.
● Regularly review the organization as well as technical systems and installations with respect
to compliance with security policies, procedures and practices.
A protected local control cabinet could look like in figure 23, page 77. This network is not
connected to any external network. Security is primarily a matter of physically protecting the
automation system and preventing unauthorized users from accessing the system and from
connecting or installing unauthorized hardware and software.
Fig. 23: Isolated automation system

Servers and workplaces that are not directly involved in the control and monitoring of the
process should preferably be connected to a subnet that is separated from the automation
system network by means of a router/firewall. This makes it possible to better control the
network load and to limit access to certain servers on the automation system network. Note that
servers and workplaces on this subnet are part of the trusted zone and thus need to be subject
to the same security precautions as the nodes on the automation system network.
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Fig. 24: Plant information network connected to an automation system

For the purposes of process control security, a general-purpose information system (IS) network
should not be considered a trusted network, not the least since such networks are normally
further connected to the Internet or other external networks. The IS network is therefore a
different lower-security zone, and it should be separated from the automation system by means
of a firewall. The IS and automation system networks should form separate domains.
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Cyber security > Hardening
Fig. 25: Automation system and IS network
7.1.3 Hardening
System hardening means to eliminate as many security risks as possible. Hardening your
system is an important step to protect your personal data and information. This process intends
to eliminate attacks by patching vulnerabilities and turning off inessential services. Hardening a
system involves several steps to form layers of protection.
Commissioning phase
● Protect the hardware from unauthorized access
● Be sure the hardware is based on a secure environment
● Disable unused software and services (network ports)
● Install firewalls
● Disallow file sharing among programs
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Cyber security > Certificates factory default - no encryption
● Install virus and spyware protection

● Use containers or virtual machines
● Create strong passwords by applying a strong password policy
● Create and keep backups
● Use encryption when possible
● Disable weak encryption algorithms
● Separate data and programs
● Enable and use disk quotas
● Strong logical access control
● Adjust default settings, especially passwords
Verification phase
● Verification of antivirus - Check antivirus is active and updated
● Verification of the identification - Check that test and unauthorized accounts are removed
● Verification of intrusion detection systems - Check malicious traffic is blocked
● Verification of audit logging - Check audit log is enabled
● You can use the checklist out of the cyber security white paper
Operation phase
● Keep software up-to-date, especially by applying security patches
● Keep antivirus up and running
● Keep antivirus definitions up-to-date
● Delete unused user accounts
● Lock an active session whenever it is unattended, e.g., lock the screen of the PC or of the
control panel (HMI)
Decommissioning phase
● Delete all credentials stored in the device like certificates and user data Ä Chapter 12
“Decommissioning” on page 96.
References: Hardening in Wikipedia (2021)
7.1.4 Certificates factory default - no encryption

As of Automation Builder Release 2.6.0, the encryption of the AC500 communication policy
is set to “No encryption” by default. The reason for that is that the PLC clock defaults to
01/01/1970 when shipped from the factory, any pre-installed certificate would already be expired
when the user attempts to connect.
Preliminary
work
Connection of the PLC to the Automation Builder and Internet access.
The PLC must be equipped with a battery to keep the date in case of power off.
The PLC must be set to the current date and time.
1. If necessary reboot the PLC.
2. Connect the PLC to the Automation Builder again.
Create an CA- The basis for an official trusted signed certificate is the creation of a Certificate Signing
signed certifi- Request.
cate
As an example, the creation of a certificate for a FTP server is described.
80 3ADR011074, 1, en_US 2023/03/03

1. Double-click to the PLC main node and select the “PLC Shell” tab. Command line input is
on the bottom. Find the index number for the FTP server and type [cert-getapplist] in the
below command line.
2. Type [cert-createcsr <index number> encoding=Base64] in the command line e.g. here:
[cert-createcsr 1 encoding=Base64] and press [ENTER].
For some users it may be necessary to swap “Base64” for “ASN1” if the
user's PKI needs this format.
3. Change to the “Log” tab.

4. Click the refresh button.
ð Wait until the log entry of CSR file created pops up.
5. Change to the “Files” tab.

6. Click the refresh button.
7. Open the “cert” folder in the PLC.
8. Open the “export” folder.
9. Copy the certificate request file [1_IoDrvFTPServer.csr] to any folder on your PC.
10. This file, here [1_IoDrvFTPServer.csr] must then be signed by your Public Key Infrastruc-
ture (PKI).
The signing process itself is outside the scope of this documentation. There are sufficient
sources on the internet for building your own PKI (e.g. PKI tutorial) - or get in touch with your IT
department.
Integrate a cer- After the signed certificate comes back from the PKI and is stored on the PC, it has to be
tificate imported into the controller.
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Be sure to import into the “Own Certificates” folder.
1. Change to the “Security Screen”.

2. Select tab “Devices”, the folder “Own Certificates” and press the import button.
3. Select the certificate ([1_IoDrvFTPServer.cer]) to be imported in the opening file manager.

4. Press the “Open” button.
ð The new certificate will be shown as “IoDrvFTPServer” in the information column. The
previous self-signed certificate will lose its name and is therefore not valid anymore.
DON’T delete any of the installed certificates.
5. Check the validation and “Issued by” of the new certificate by activating the top PLC
branch.
6. Download and reboot the PLC (repower or use “PLC Shell” and command [reboot].)
We recommend changing the communication policy accordingly so that only

encrypted connections are allowed.
Encrypted and An application can be encrypted and signed in order to protect a running application in an
signed applica- AC500 V3 PLC and to protect a configured project. How to set-up the user management, the
tions communication and the boot application in order to prevent unauthorized access is explained in
the application note AC500 V3 - Encrypt and sign your application.
Enforced As of Automation Builder 2.6.0 there is also the possibility to activate the “Enforced signing”
signing mode in the “Change Runtime Security Policy”. Then the controller accepts ONLY signed
downloads.
“Tab Communication Settings è Device è Change Runtime Security Policy... è Code Signing
è New policy è Enforced signing”
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Cyber security > Open Ports and Services
White Paper - More information about certificates and cyber security can be found in the white paper AC500
AC500 cyber cyber security.
security
7.1.5 Open Ports and Services

Overview of minimum cyber security requirements for open ports and services settings.
Port Protocol Description

1217 TCP CODESYS Gateway V3
22350 TCP/UDP CodeMeter License Server
(runtime) – license
22352 HTTP CodeMeter License Server
(runtime) – WebAdmin
22353 HTTPS CodeMeter License Server
(runtime) – WebAdmin
11040 HTTP Python editor server
2023/03/03 3ADR011074, 1, en_US 83

Commissioning
—
8 Commissioning
Commissioning Preconditions:
the PLC
● All PLC modules are installed and wired according to the configuration in Automation
Builder.
● The PLC is connected to the power supply.
● The application and the necessary licenses are available.
WARNING!
Risk of injury or damage to equipment
To avoid endangering persons or equipment, check before commissioning:
– Mechanical and electrical installation
– Electrical safety of the installation
– Safety functions
1. Switch on the power supply.

ð The green PWR LED goes on.
ð Processor modules with display: Wait until the processor module displays “Update”.
2. Install the firmware and the application on the processor module.

Installing the firmware and the application on a very new processor module is the same
process than updating a firmware and an application on a CPU.
Ä Chapter 9.2 “PLC firmware/application update” on page 86
ð The PLC starts with the new firmware and the new application.
WARNING!
Risk of injury or damage to equipment
To avoid endangering persons or equipment, a functional test of the applica-
tion must be performed before the final commissioning of the system.
Commissioning Preconditions:
the control
● The control panel is installed and wired.
panel
● The control panel is connected to the power supply.
● The project file and the necessary licenses are available.
1. Start the control panel.
2. Set the IP address of the control panel.
3. Download the project file to the control panel.
4. Connect the PLC and the control panel with an Ethernet cable.
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Commissioning
Commis- Step-by-step instructions using the example of the AC500-eCo starter kit with a control panel
sioning included
example
The PLC has an integrated diagnosis system to output diagnosis messages, e.g., parameter
setting is wrong or battery low. A diagnosis message is indicated by ERR LED = on.
Ä Chapter 10 “Troubleshooting” on page 88
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Operation
PLC firmware/application update
—
9 Operation
The common operating mode is called run mode.
Table 9: Run mode

LED Display Description
PWR LED = on Power supply is present. PLC is in run
mode.
RUN LED = on
ERR LED = off
If the PLC is connected to the power supply, but does not operate, it is in stop mode. In stop
mode, the processor module does not control the system.
Table 10: Stop mode

LED Display Description
PWR LED = on E.g., after the download of an applica-
tion, after a firmware update, an error
RUN LED = off occured or the PLC was stopped by the
ERR LED = off/on user, etc.
The PLC has an integrated diagnosis system to output diagnosis messages, e.g., parameter
setting is wrong or battery low. A diagnosis message is indicated by ERR LED = on.
9.1 Status LEDs, display and control elements

Depending on the device type, various operating elements provided on the front panel can be
used to control the devices of the PLC system and/or to change the operating mode.
Operating elements:
● Status LEDs:
Indicates the availability of devices and components such as communication modules,
communication interface modules or function modules. Functionality and diagnosis of the
status LEDs depends on the specific module and is described in the device description of
the appropriate module. Possible status: on/off/blinking
● I/O LEDs:
Displays the status of the inputs and outputs.
● Display:
Available for some processor modules. It can be used for simple configurations and for
reading out diagnosis information.
● Function keys and switches:
Allows to change the current operating modes/status manually.
9.2 PLC firmware/application update

During runtime it might be necessary to update the firmware of the modules, e.g., for security
reasons.
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Operation
Reset to factory settings
Updating the firmware and the application on a processor module is the same process than
installing a firmware and an application on a very new processor module.
The installation can be performed either via the engineering suite Automation Builder (recom-
mended, for details refer to the software manual) or via memory card Ä Chapter 14.2 “PLC
firmware/application update via memory card” on page 108.
Fig. 26: The “Version information” tab of a device in Automation Builder
9.3 Control panel firmware/application update

The system components can be updated via Panel Builder software or via USB flash drive.
Refer to the Panel Builder manual for a detailed description.
9.4 Reset to factory settings

PLC
PLC is in STOP mode.
1. Press and hold (> 5 sec) [RUN].
ð RUN LED = ON.
“Reset” is displayed.
2. Press [OK] to reset+ the PLC.
Control panel The factory restore of a control panel is described in the Panel Builder manual.
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Troubleshooting
—
10 Troubleshooting
Diagnosis messages are shown in the engineering suite Automation Builder. The diagnosis
information can be accessed in the IEC application and can be forwarded to, e.g., a web server
or a control panel.
Some diagnosis messages need to be acknowledged by the user (alarms+), others do not
require acknowledgment (events+). The diagnosis system stores alarms and events in a diag-
nosis history.
Diagnosis messages include the severity of an error. Error severity can be used for defining
system behavior, e.g., activating the error LED or stop the PLC.
Diagnosis messages can also be read out from the display of the PLC.
Possible mal-
functions
Fault description Cause Remedy

A processor module, a com- Terminal bases and terminal Check the given design scheme of your con-
munication module or an I/O units have a mechanical trol cabinet.
module can not be plugged encoding. The encoding makes
Get in touch with the planner of the design
on the corresponding terminal it impossible to insert a module
scheme.
base or terminal unit. to the wrong place to prevent
dangerous voltages or destroyed Check the possible combinations in the PLC
modules. Automation catalog.
The module does not respond Module is not connected to the Check power supply.
and is not available for online power supply. Or module is not
Replace the module or HMI.
connection. functional any more.
I/O module on a hot swap ter- I/O module is not plugged or As soon as the correct and operational I/O
minal unit does not respond damaged. module is plugged on the terminal unit, the
and is not available for online module is configured and ready to start.
connection.
After hot swap of a (remote) Wrong I/O module type plugged. Plug the correct I/O module type.
I/O module, the system The type must be the same as of
and/or I/O module does not the replaced module.
start.
The display of the control Control panel is not connected Check power supply.
panel is black. to the power supply. Or control
Replace the control panel.
panel is not functional any more.
ERR LED of the processor A fatal system error occured. Contact ABB technical support
module flashes fast. The dis-
play shows “AC500”.
ERR LED of the processor Installation or update of firm- Restart the device. Perform the installation or
module flashes. RUN LED is ware, boot project or application update again.
off. The display shows “FAIL”. failed.
Ä Chapter 9.2 “PLC firmware/application
update” on page 86
ERR LED is on. PLC with event+ or unacknowl- ● Use Automation Builder, IEC application
edged alarm+. or other external access available in your
project, e.g., a control panel, to read
out and acknowledge the diagnosis mes-
sages.
In Automation Builder, double-click on a
device and select the “Diagnosis” tab to
access the diagnosis messages.
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Troubleshooting
Fault description Cause Remedy

ERR LED is on. PLC with event+ or unacknowl- Or:
edged alarm+. ● Read out the diagnosis data on the display
of the processor module.
The display of the pro- PLC runs in demo mode You can buy the missing license or extend the
cessor module shows “Demo” because at least one feature demo license via Automation Builder. The PLC
for 5 min at every license is missing. The demo will not switch back to run mode until a new
license check. (For processor license is valid for 10 days PLC license is activated or the licensed features
modules without display only in run. After this time, PLC will go are removed from the PLC application.
visible when logged in with to stop mode.
Automation Builder.)
Every 10 min, the display of PLC runs in grace mode You need to buy or activate the missing. We
the processor module shows because at least one feature recommend to use the Automation Builder for
“Grace” for 5 min. license which has been available activation. After the PLC is in stop mode, it
disappeared. If the grace time will not switch back to run mode until a new
expires, PLC will go to stop license is activated or the licensed features
mode. are removed from the PLC application.
The CPU displays “noConn” No communication between CPU Check the application for loops and operations
(no connection). and display is possible due do they need time. For example file handling.
very high CPU load (e.g., end- Wait for response from other device who will
less loop in user program and block the execution from other code.
not activated task watchdog).
If a problem persists, contact ABB technical support.
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Maintenance
Replace an AC500 module
—
11 Maintenance
Interval Maintenance work
After 3 years of utilisation or as soon as pos- Replace battery of the CPU.
sible after the PLC diagnosis message "low
Refer to the hardware manual.
battery warning"
Regularly or when the faceplate of the control Keep the faceplate of the control panel clean.
panel is dusty.
Refer to the panel's operating instruction.
11.1 Replace an AC500 module
CAUTION!
Improper installation and maintenance may result in injury and can damage the
product!
– Installation and maintenance have to be performed according to the
technical rules, codes and relevant standards, e.g. EN 60204-1.
– Only by qualified personnel.
WARNING!
The devices are not designed for removal or insertion under power. Because of
unforeseeable consequences, it is not allowed to plug or unplug devices with
the power being ON.
off before you
Disconnecting any powered devices while energized in a hazardous location
could result in an electric arc, which could create a flammable ignition resulting
in fire or explosion.
Make sure that power is removed and that the area has been thoroughly
checked to ensure that flammable materials are not present prior to proceeding.
network interfaces.
All modules of the AC500 range are maintenance free. Spare parts are not available and repair
is not allowed. If a module is not functional any more, you have to replace the whole module.
When an I/O module is installed on a hot swap terminal unit, it is possible to replace it with the
same type during runtime.
1. Disconnect the power supply.

2. For processor modules, insert the memory card into the new module.
3. For communciation modules, adjust the position of the rotary switches on the new module.
4. For terminal units and terminal bases, disconnect the connectors from the old module.
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Maintenance
Replace an I/O module with hot swap > Preconditions for using hot swap
5. Demount the module to be replaced as described in the installation instructions.

6. Mount the new module as described in the installation instructions.
7. For terminal units and terminal bases, connect the connectors.
8. Reconnect the power supply.
ð System boots up again.
9. If necessary, update module firmware Ä Chapter 9.2 “PLC firmware/application update”
on page 86.
If a processor module is replaced, you must install the firmware, the application, the
licenses and the certificates on the new processor module.
If a problem persists, contact ABB technical support.
11.2 Replace an I/O module with hot swap
Hot swap
System requirements for hot swapping of I/O modules:
– Types of terminal units that support hot swapping of I/O modules have the
appendix TU5xx-H.
– I/O modules as of index F0.
The following I/O bus masters support hot swapping of attached I/O modules:
– Communication interface modules CI5xx as of index F0.
– Processor modules PM56xx-2ETH with firmware version as of V3.2.0.
NOTICE!
Risk of damage to I/O modules!
Hot swapping is only allowed for I/O modules.
Processor modules and communication interface modules must not be removed
or inserted during operation.
Conditions for hot swapping

– Digital outputs are not under load.
– Input/output voltages above safety extra low voltage/
protective extra low voltages (SELV/PELV) are switched off.
– Modules are completely plugged on the terminal unit with both snap fit
engaged before switching on loads or input/output voltage.
11.2.1 Preconditions for using hot swap

Hot swap
WARNING!
Risk of explosion or fire in hazardous environments during hot swapping!
Hot swap must not be performed in flammable environments to avoid
life-threatening injury and property damage resulting from fire or explosion.
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Maintenance
WARNING!
Electric shock due to negligent behavior during hot swapping!
To avoid electric shock
– make sure the following conditions apply:
– Digital outputs are not under load.
– Input/output voltages above safety extra low voltage/
protective extra low voltage (SELV/PELV) are switched off.
– Modules are fully interlocked with the terminal unit with both snap-fits
engaged before switching on loads or input/output voltage.
– Never touch exposed contacts (dangerous voltages).
– Stay away from electrical contacts to avoid arc discharge.
– Do not operate a mechanical installation improperly.
NOTICE!
Hot swapping is only allowed for I/O modules.
Processor modules and communication interface modules must not be removed
or inserted during operation.
H = Hot swap
Hot swap
System requirements for hot swapping of I/O modules:
– Types of terminal units that support hot swapping of I/O modules have the
appendix TU5xx-H.
– I/O modules as of index F0.
The following I/O bus masters support hot swapping of attached I/O modules:
– Communication interface modules CI5xx as of index F0.
– Processor modules PM56xx-2ETH with firmware version as of V3.2.0.
Hot swap is not supported by AC500-eCo V3 CPU!
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Maintenance
The index of the module is in the right corner of the label.
NOTICE!
Modules with index below F0 can be damaged when inserted or removed from
the terminal unit in a powered system.
NOTICE!
Do not perform hot swapping if any I/O module with firmware version lower than
3.0.14 is part of the I/O configuration.
For min. required device index see table below.
Device Min. required device index for I/O module as of

FW Version 3.0.14
AC522(-XC) F0
AI523 (-XC) D2
AI531 D4
AI531-XC D2
AI561 B2
AI562 B2
AI563 B3
AO523 (-XC) D2
AO561 B2
AX521 (-XC) D2
AX522 (-XC) D2
AX561 B2
CD522 (-XC) D1
DA501 (-XC) D2
DA502 (-XC) F0
DC522 (-XC) D2
DC523 (-XC) D2
DC532 (-XC) D2
DC562 A2
DI524 (-XC) D2
DI561 B2
DI562 B2
DI571 B2
DI572 A1
2023/03/03 3ADR011074, 1, en_US 93

Maintenance
Replace an I/O module with hot swap > Compatibility of hot swap
Device Min. required device index for I/O module as of

FW Version 3.0.14
DO524 (-XC) A3
DO526 A2
DO526-XC A0
DO561 B2
DO562 A2
DO571 B3
DO572 B2
DO573 A1
DX522 (-XC) D2
DX531 D2
DX561 B2
DX571 B3
FM562 A1
11.2.2 Compatibility of hot swap
Hot swap is not supported by AC500-eCo V3 CPU!
Central I/O on V3 CPU

I/O module on TU5xx-H connected to I/O bus AC500 V3 CPU types:
master
PM56xx-2ETH
Required version of I/O bus master Firmware as of V3.2.0
Fieldbus master when used as remote I/O with -
AC500 V3
When used as remote I/O on third party -
controller (PLC or DCS)
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Maintenance
Replace an I/O module with hot swap > Hot swap behavior
11.2.3 Hot swap behavior

Hot swap behavior Central I/O on V3 CPU
Start-up behavior with unplugged or damaged System and I/O modules attached to the CPU
I/O module on hot swap terminal unit TU5xx-H are starting (except unplugged or damaged
module when plugged on hot swap terminal
unit).
As soon as the correct and operational I/O
module is plugged on the terminal unit, the
module is configured and ready to start.
No specific setting needed.
Start-up behavior with wrong I/O module type System and I/O modules are not starting
on any terminal unit
Diagnosis of presence of hot swap terminal Diagnosis using PLC browser command "io-
unit bus desc" in Automation Builder V3.
The PLC browser then provides an overview
of the modules on the I/O bus including the
position of hot swap terminal units in the
I/O bus.
In the application program this
can be detected with a func-
tion block "IoModuleHotSwapInfo"
(Library: AC500_Io/Function Blocks/I/O-Bus).
One instance of function block is needed per
terminal unit on the I/O bus. The function
block provides five outputs delivering infor-
mation about slut number, hot swap capa-
bility and plugged/unplugged state of the I/O
module
Diagnosis while hot swap module is pulled or If module is pulled then diagnosis Err 9480
module (mounted on hot swap terminal unit) "Module removed from Hot Swap Terminal
has stopped working Unit" is generated
Diagnosis after plugging the I/O module on Diagnosis Err 9480 is automatically
the hot swap terminal unit acknowledged
2023/03/03 3ADR011074, 1, en_US 95

Decommissioning
—
12 Decommissioning
1. Delete the runtime licenses.
2. Delete certificates available on the CPU.
3. Delete applications.
4. Delete applications from memory card, if available.
5. If available, remove memory card and battery from CPU.
6. Delete all user accounts and user data.
7. Demount and dispose the hardware modules.
Ä Chapter 13 “Recycling” on page 97
If you can not access the data stored in the CPU, e.g., because the CPU is not
functional any more, then physically destroy the device.
This ensures that the credentials that are stored in the device, can not be
misused.
96 3ADR011074, 1, en_US 2023/03/03

Recycling
—
13 Recycling
Disposal and recycling information
This symbol on the product (and on its packaging) is in accordance with the
European Union's Waste Electrical and Electronic Equipment (WEEE) Directive.
The symbol indicates that this product must be recycled/disposed of separately
from other household waste.
It is the end user’s responsibility to dispose of this product by taking it to a
designated WEEE collection facility for the proper collection and recycling of the
waste equipment.
The separate collection and recycling of waste equipment will help to conserve
natural resources and protect human health and the environment.
For more information about recycling, please contact your local environmental
office, an electrical/electronic waste disposal company or the store where you
purchased the product.
2023/03/03 3ADR011074, 1, en_US 97

Appendix
Diagnosis messages via display of the processor module
—
14 Appendix
14.1 Diagnosis messages via display of the processor module
We recommend to read out the diagnosis messages within the engineering suite Automation
Builder or with the IEC application.
If the processor module has a display, you can access the diagnosis system via the display and
the buttons.
Fig. 27: Example "battery is empty or missing"

Err 1 Total number of active diagnosis messages, here: 1
E4 bat Error severity, here: 4, and location of error, here: battery
Id 1 In the list of all errors, the position of the error, here: first error message
8, d1-d4 Error code, here: 8, and system information to identify the error with the help of the
diagnosis lists Ä E2 Ä E3 Ä E4 Ä E11
98 3ADR011074, 1, en_US 2023/03/03

Appendix
Diagnosis messages via display of the processor module > Error severity E2: Severe errors
The display of the processor module does not show any communication
modules or fieldbus diagnosis. To view these diagnosis messages use
Automation Builder or IEC application.
This is valid for:
– all external communication modules incl. safety processor module,
CM574-RS, FM502-CMS
– CANopen on onboard CAN interface
– fieldbuses on Ethernet interfaces ETH1/ETH2 like PROFINET IO controller,
EtherCAT master, etc.
14.1.1 Error severity E2: Severe errors

Table 11: Error severity E2: Severe errors
Error Location Error d1 d2 d3 d4 Description Remedy
severity code
E2 iob 2 14 0 0 0 Resource failure

(I/O bus)
E2 iob 3 14 0 0 0 Timeout
(I/O bus)
E2 CPU 11 0 0 0 0 Type scaling on PLC
startup failed
E2 FLd 12 19 0 0..n 0..n Flash memory is
(flash- temporary protected
disk) (read only, panic
mode)
E2 iob 17 14 0 0 0 Error setting I/O bus
(I/O bus) master parameter
E2 diS 23 21 0 0 0 Wrong version of
(display) display firmware
E2 CPU 27 0 2 0 0 Failed to set param-
eter "Reboot at pow-
erfail"
E2 CPU 29 0 0 0 0 Combination of
plugged option
boards is invalid
E2 CPU 49 0 0 0 0 Restore failed
E2 iob 8482 Module 0 - 0 Timeout, while initi-
(I/O bus) number alizing
E2 iob 9249 Module 0 - 0 Timeout while
(I/O bus) number waiting for Reset
E2 iob 9258 Module 0 - 0 Breakdown, commu-
(I/O bus) number nication lost
E2 iob 16129 0 0 0 0 Severe error, see
(I/O bus) log
E2 iob 16130 0 0 0 0 Fatal error, see log
(I/O bus)
E2 iob 16194 0 0 0 0 Fatal error, not run-
(I/O bus) ning any more
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Appendix
Diagnosis messages via display of the processor module > Error severity E3: Minor errors
14.1.2 Error severity E3: Minor errors

Table 12: Error severity E3: Minor errors
severity code
E3 iob 3 Module 1 Channel 0 Discrepancy time Check dis-

(I/O bus) number number expired crepancy
time value,
channel
wiring and
sensor.
E3 FLd 10 19 5 0...n 0 Medium has almost
(flash- used its complete
disk) spare capacity or is
already dead, action
required
E3 iob 12 Module 1 Channel 0 Test pulse error Check
(I/O bus) number number wiring and
sensor
E3 iob 13 Module 1 Channel 0 Test pulse cross-talk Check
(I/O bus) number number error wiring and
sensor. If
this error
persists,
replace I/O
module.
Contact
ABB tech-
nical sup-
port.
E3 iob 18 Module 1 Channel 0 Test error
(I/O bus) number number
E3 diS 22 21 0 0 0 Error at initialization
(display) of display
E3 iob 25 Module 1 Channel 0 Stuck-at error Check I/O
(I/O bus) number number module
wiring.
Restart I/O
module, if
needed. If
this error
persists,
replace I/O
module.
E3 iob 28 Module 1 Channel 0 Cross-talk error Check I/O
wiring.
Restart I/O
module, if
needed. If
this error
persists,
replace I/O
module.
E3 CPU 44 0 7 0 0 Loading boot project
failed due to failing
load of retain data
100 3ADR011074, 1, en_US 2023/03/03

Appendix

severity code

failed due to mis-
match of retain data
failed due to insuf-
ficient license for
application
failed due to unspe-
cified reason
E3 CPU 48 0 0 0 0 Backup failed
E3 FLd 54 19 5 0 0 Root partition has
(flash- 1% or less free
disk) space left
E3 iob 311 Module 1 Channel 0 Value difference too Adjust toler-
(I/O bus) number number high ance
window for
channels.
Check
channel
wiring and
sensor con-
figuration.
E3 iob 524 Module 1 Channel 0 Stuck-at error
E3 iob 525 Module 1 Channel 0 Readback error Check I/O
wiring.
Restart I/O
module, if
needed. If
this error
persists,
replace I/O
module.
E3 iob 530 Module 1 Channel 0 Cross-talk error Check I/O
wiring.
Restart I/O
module, if
needed. If
this error
persists,
replace I/O
module.
E3 iob 555 Module 1 Channel 0 Internal error
2023/03/03 3ADR011074, 1, en_US 101

Appendix

severity code
E3 iob 8480 Module 0 - 0 Not supported pro-

(I/O bus) number tocol variant
E3 iob 8707 Module 0 - 0 PROFIsafe
(I/O bus) number watchdog timed out
E3 iob 8708 Module 0 - 0 Overvoltage
(I/O bus) number
E3 iob 8711 Module 0 - 0 Undervoltage
(I/O bus) number
E3 iob 8722 Module 0 - 0 Internal error
(I/O bus) number
E3 iob 8723 Module 0 - 0 Checksum error has
(I/O bus) number occured in iParame-
ters
E3 iob 8724 Module 0 - 0 PROFIsafe commu-
(I/O bus) number nication error
E3 iob 8732 Module 0 - 0 Internal error
(I/O bus) number
E3 iob 8747 Module 0 - 0 Internal runtime error
(I/O bus) number
E3 iob 8961 Module 0 - 0 Wrong parameter
(I/O bus) number value, check config-
uration
E3 iob 8979 Module 0 - 0 Checksum error has
(I/O bus) number occured in iPara-
meter or F-Parame-
ters
E3 iob 8986 Module 0 - 0 Invalid configuration Check
(I/O bus) number modules
and param-
eterization
E3 iob 8988 Module 0 - 0 F-Parameter config- Check I/O
(I/O bus) number uration and address module F-
switch value do not Parameter
match. configura-
tion and
module
address
switch
value.
E3 iob 16131 Module 0 - 0 Timeout Replace I/O
(I/O bus) number module
E3 iob 16137 Module 0 - 0 Overflow diagnosis Restart
(I/O bus) number buffer
E3 iob 16138 Module 0 - 0 Non-safety I/O: Check ter-
(I/O bus) number Voltage overflow on minals/
outputs (above UP3 process
level), voltage
Safety I/O: Process
voltage too high
102 3ADR011074, 1, en_US 2023/03/03

Appendix

severity code
E3 iob 16139 Module 0 - 0 Process voltage UP Check

(I/O bus) number or UP3 too low process
voltage
E3 iob 16146 Module 0 - 0 Plausibility check Check con-
(I/O bus) number failed (iParameter) figuration
E3 iob 16147 Module 0 - 0 Checksum error Non-safety
(I/O bus) number I/O: Replace
I/O module
Safety I/O:
Check
safety con-
figuration
and CRCs
for I- and F-
Parameters.
E3 iob 16148 Module 0 - 0 PROFIsafe commu- Restart I/O
(I/O bus) number nication error module. If
this error
persists,
contact ABB
technical
support.
E3 iob 16153 Module 0 - 0 PROFIsafe Restart I/O
(I/O bus) number watchdog timed out module. If
this error
persists,
increase
PROFIsafe
watchdog
time.
E3 iob 16154 Module 0 - 0 Parameter error Check con-
(I/O bus) number figuration.
E3 iob 16156 Module 0 - 0 F-Parameter config- Check I/O
(I/O bus) number uration and address module F-
switch value do not Parameter
match. configura-
tion and
module
address
switch
value.
E3 iob 16164 Module 0 - 0 Internal data inter- Replace I/O
(I/O bus) number change failure module
E3 iob 16168 Module 0 - 0 Different hard-/firm- Replace I/O
(I/O bus) number ware versions in the module
module
E3 iob 16171 Module 0 - 0 Internal error Replace I/O
(I/O bus) number module
E3 iob 16175 Module 0 - 0 Sensor voltage too
(I/O bus) number low
E3 iob 16128 0 0 0 0 Failed Max Wait Run
(I/O bus)
2023/03/03 3ADR011074, 1, en_US 103

Appendix
Diagnosis messages via display of the processor module > Error severity E4: Warnings
14.1.3 Error severity E4: Warnings

Table 13: Error severity E4: Warnings
severity code
E4 bAt 8 22 0 0 0 Empty or missing

(battery)
E4 FLd 9 19 5 0...n 0 Medium has used
(flash- 80 % of its spare
disk) capacity
E4 FLd 53 19 5 0 0 Root partition has
(flash- 15% or less free
disk) space left
E4 iob 257 Module 1 Channel 0 Wrong measure-
(I/O bus) number number ment, false tempera-
ture at the compen-
sation channel
E4 iob 258 Module 1 Channel 0 AI531: wrong meas-
(I/O bus) number number urement, potential
difference is too
high;
CD522: PWM duty
cycle out of duty
area
E4 iob 260 Module 1 Channel 0 Measurement over- Check
(I/O bus) number number flow channel
wiring and
sensor
power
supply.
E4 iob 263 Module 1 Channel 0 Measurement under- Check
(I/O bus) number number flow at analog input channel
wiring and
sensor
power
supply.
E4 iob 266 Module 1 Channel 0 Short circuit and cut
(I/O bus) number number wire or "out of range"
E4 iob 267 Module 1 Channel 0 Output/process
(I/O bus) number number voltage to small/low.
E4 iob 303 Module 1 Channel 0 Short circuit at the Check
(I/O bus) number number analog input channel
wiring
E4 iob 304 Module 1 Channel 0 Analog value over-
(I/O bus) number number flow or broken wire
at an analog input.
E4 iob 530 Module 1 Channel 0 Internal fuse at 0 V
(I/O bus) number number is defect. 0 V
not connected with
GND.
E4 iob 559 Module 1 Channel 0 Short circuit at the Check
(I/O bus) number number digital output channel
wiring
104 3ADR011074, 1, en_US 2023/03/03

Appendix
Diagnosis messages via display of the processor module > Error severity E4: Warnings

severity code
E4 iob 772 Module 1 Channel 0 Measurement over- Check

(I/O bus) number number flow at an analog channel
output wiring
E4 iob 775 Module 1 Channel 0 Measurement under- Check
(I/O bus) number number flow at analog output channel
wiring
E4 iob 796 Module 1 0 0 Different configura-
(I/O bus) number tion
E4 iob 8482 Module 0 - 0 Timeout while
(I/O bus) number waiting for ready
status
E4 iob 8483 Module 0 - 0 Timeout during
(I/O bus) number parameterization
E4 iob 9480 Module 0 - 0 I/O module removed Plug I/O
(I/O bus) number from hot swap ter- module,
minal unit or defec- replace I/O
tive module on hot module
swap terminal unit.
E4 iob 9480 Module 0 0 0 Module removed
(I/O bus) number from hot swap ter-
minal unit
E4 iob 9500 Module 0 - 0 Wrong I/O module Remove
(I/O bus) number replugged on hot wrong I/O
swap terminal unit module and
plug pro-
jected I/O
module
E4 iob 9514 Module 0 - 0 No communication Replace I/O
(I/O bus) number with I/O module on module
hot swap terminal
unit
E4 iob 9526 Module 0 - 0 I/O module does not Power off
(I/O bus) number support hot swap system and
replace I/O
module
E4 iob 9526 Module 0 0 0 Module on hot swap
(I/O bus) number terminal unit does
not support hot swap
functionality
E4 iob 9736 Module 0 - 0 Hot swap terminal
(I/O bus) number unit required, but not
found
E4 iob 9764 Module 0 0 0 Defective hot swap
(I/O bus) number terminal unit
E4 iob 9770 Module 0 - 0 No communication Restart, if
(I/O bus) number with hot swap ter- error per-
minal unit sists replace
terminal unit
2023/03/03 3ADR011074, 1, en_US 105

Appendix
Diagnosis messages via display of the processor module > Error severity E11: Parameter errors

severity code
E4 iob 16172 Module 0 - 0 Has not passed fac-

(I/O bus) number tory test
E4 iob 16173 Module 0 - 0 No process voltage Check
(I/O bus) number UP or UP3 process
voltage
14.1.4 Error severity E11: Parameter errors

Table 14: Error severity E11: Parameter errors
severity code
E11 CPU 18 0 2 0 0 At least one param-

eter not found
E11 CPU 19 0 2 0 0 Unable to read at
least one parameter
value
E11 CPU 20 0 2 0 1 (too Invalid value of
big) or parameter "LED"
2 (too
small)
big) or parameter "Battery"
2 (too
small)
big) or parameter "Diag-
nosis, stop on error
2 (too class"
small)
big) or parameter "Diag-
nosis, add Plc name
2 (too to node name"
small)
big) or parameter "Reboot
at powerfail"
2 (too
small)
E11 CPU 28 0 2 0 1 (too Value of parameter
big) or "Missed Cycle Task
behaviour" is not in
2 (too
range
small)
big) or "Priority Scheme" is
not in range
2 (too
small)
106 3ADR011074, 1, en_US 2023/03/03

Appendix
Diagnosis messages via display of the processor module > Error severity E11: Parameter errors

severity code

big) or "Reboot on E2" is
not in range
2 (too
small)
big) or parameter "Enable
diagnosis history"
2 (too
small)
E11 CPU 51 0 2 0 1 (too Invalid value
big) or of parameter "Max-
imum number of
2 (too entries in diagnosis
small) history"
E11 CPU 52 0 2 0 1 (too Invalid value
big) or of parameter "Max-
imum size of
2 (too extended diagnosis
small) data in diagnosis
history"
E11 iob 16133 Module 0 0 0 Output data size
(I/O bus) number mismatch
E11 iob 16134 Module 0 0 0 Input data size mis-
(I/O bus) number match
E11 iob 16145 0 0 0 0 Error setting I/O bus
(I/O bus) master parameter
E11 iob 16146 0 0 0 0 Failed to start the
(I/O bus) parameterization of
modules
E11 iob 16147 Module 0 0 0 Failed setting
(I/O bus) number parameters
E11 iob 16149 Module 0 0 0 No module data
(I/O bus) number
E11 iob 16246 0 0 0 0 Failed to start the
(I/O bus) parameterization of
modules
E11 iob 16247 1..20 0 0 0 Failed setting
(I/O bus) parameters
E11 iob 16248 Module 0 0 0 Failed setting
(I/O bus) number expected module
E11 iob 16254 Module 0 0 0 Size of parameters
(I/O bus) number expected by module
differs from size pro-
vided by configura-
tion
E11 iob 16158 Module 0 0 0 Type of present
(I/O bus) number module does not
match configuration
2023/03/03 3ADR011074, 1, en_US 107

Appendix
PLC firmware/application update via memory card > Preparation of memory card

severity code
E11 - 16159 0 0 - 0 Configured number

of modules differs
from found ones
E11 - 16160 0 0 - 0 At least one module
failed during configu-
ration
14.1.5 Diagnosis messages of communication modules or fieldbuses

Table 15: Diagnosis messages of communication modules or fieldbuses
Error severity Location Description
E‒ CMx (communication To view these diagnosis messages use Automation Builder or IEC
module) application.
x = slot number
Ex CAn (CAN interface)
Ex Et1 or Et2 (Ethernet
ETH1 or ETH2)
14.2 PLC firmware/application update via memory card

14.2.1 Preparation of memory card
Firmware packages can be downloaded from ABB website or exported from Automation Builder.
In Automation Builder, you can choose if you want to export the firmware only or, in addition, the
boot project as well. If the boot project does not exist yet, it will be created automatically.
The memory card will contain the firmware of the PLC, the firmware of the communication
modules, the application, the visualizations and all related objects (like text lists).
108 3ADR011074, 1, en_US 2023/03/03

Appendix
Fig. 28: Example

1. Right-click “Application” in the device tree.
2. Select “Export è Boot project and firmware” or “Export è Firmware”.
3. Choose a location for the export folder.
Select [Make New Folder] and type in "MEMORY CARD".
4. Select [OK] to add the folder.
2023/03/03 3ADR011074, 1, en_US 109

Appendix
5. Select folder “MEMORY CARD”.
ð The "MEMORY CARD" structure has been created and the firmware and application
have been exported.
The created "MEMORY CARD" folder does not contain user data,
remanent data, config data, safety PLC power dip data and safety
PLC password.
Add this data if required by the used application.
6. Copy all subfolders and files of the "MEMORY CARD" folder to a memory card.
The copy process can be performed with the Automation Builder software with the
memory card inserted in the processor module or with the PC with a suitable memory
card slot.
Copy process 1. Insert memory card into the processor module.

with Automation
2. Connect the PC to the processor module with an Ethernet cable.
Builder software
3. In Automation Builder, log-in to the processor module.
4. Double-click on the processor module in the device tree and select “Files”.
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Appendix
PLC firmware/application update via memory card > Execution of update via memory card
5. On the right side, select and open the folder “sdcard”.

6. On the left side, select all the subfolders and files of the MEMORY CARD folder, but not
the folder itself.
7. Copy all selected subfolders and files from the left side to the memory card by clicking
to the right side.
Copy process 1. Insert the memory card into the PC.

on the PC
2. Mark all subfolders and files of the "MEMORY CARD" folder, but not the "MEMORY
CARD" folder itself, and copy them.
3. Select the memory card and paste the copied subfolders and files.
14.2.2 Execution of update via memory card

Boot project Precondition: Prepared memory card with boot project and firmware Ä Chapter 14.2.1
and firmware “Preparation of memory card” on page 108.
update
1. Switch off the device.
2. Insert the memory card.
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Appendix
PLC firmware/application update via memory card > Execution of update via memory card
3. Switch on the device.

ð The alternate flashing of the RUN and the ERR LED indicates the running update
process.
At the end of the update process a reboot is executed and the boot project and system
firmware is started for the finishing of the update process.
If RUN LED blinks (ERR LED is off), the update was successful and the display shows
“done”.
If ERR LED blinks (RUN LED is off), the update failed and the display shows “FAIL”.
The text file “SDCARD.RDY” includes the results of the different updates. If the update
fails, the file contains the reasons for the abort. Based on this, further steps can be
taken to fix the problem.
5. Remove the memory card.
ð The system starts with the new boot project and firmware.
Firmware Precondition: Prepared memory card with boot project and firmware Ä Chapter 14.2.1
update “Preparation of memory card” on page 108.
2. Insert the memory card.
ð The alternate flashing of the RUN and the ERR LED indicates the running update
process.
At the end of the update process a reboot is executed and the system firmware is
started for the finishing of the update process.
If RUN LED blinks (ERR LED is off), the update was successful and the display shows
done.
If ERR LED blinks (RUN LED is off), the update failed and the display shows FAIL.
The text file “SDCARD.RDY” includes the results of the different updates. If the update
fails, the file contains the reasons for the abort. Based on this, further steps can be
taken to fix the problem.
5. Remove the memory card.
ð The system starts with the new firmware.
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Glossary
—
15 Glossary
AC500 Standard PLCs
AC500-eCo Compact PLCs
AC500-S Safety PLCs
AC500-S IEC 61131-3 editor, integrated in engineering suite Automation Builder
Program-
ming Tool
AC500-S- Safety PLCs suitable for extreme environmental conditions
XC
AC500 V2 Range of AC500 and AC500-eCo CPUs
AC500 V3 Range of AC500 and AC500-eCo CPUs
AC500-XC Standard PLCs suitable for extreme environmental conditions
Alarm Diagnosis message which must be acknowledged by the user. The alarm will continue
to be displayed even if the issue has been resolved in the meantime until it is acknowl-
edged.
Automation Engineering suite for configuration and programming of all PLCs
Builder
Cold start Note: The AC500-eCo V3 does not use a battery for buffering the operand areas speci-
fied below, hence the “cold start” mode does not exist in this product.
● A cold start is performed by switching power OFF/ON if no battery is connected.
● All RAM memory modules are checked and erased.
● If no user program is stored in the Flash EPROM, the default values (as set on
delivery) are applied to the interfaces.
● If there is a user program stored in the Flash EPROM, it is loaded into RAM.
● The default operating modes set by the PLC configuration are applied.
CP600 Control panels for application visualizations
Data buf- ● Data buffering, i.e., maintaining data after power ON/OFF, is only possible, if a battery
fering is connected for AC500 CPU and the buffering will take place in FLASH with AC500-
eCo V3 CPU. The following data can be buffered completely or in parts:
– Data in the addressable flag area (%M area)
– RETAIN variable
– PERSISTENT variable (number is limited, no structured variables)
– PERSISTENT area (%R area)
● In order to buffer particular data, the data must be excluded from the initialization
process.
Download ● Download means loading the complete user program into the PLC's RAM. This
process is started by selecting the menu item "Online/Download" in the programming
system or after confirming a corresponding system message when switching to online
mode (menu item "Online/Login").
● Execution of the user program is stopped.
● In order to store the user program to the Flash memory, the menu item "Online/Create
boot project" must be called after downloading the program.
● Variables are set to their initialization values according to the initialization table.
● RETAIN variables can have wrong values as they can be allocated to other memory
addresses in the new project!
● A download is forced by the following:
– changed PLC configuration
– changed task configuration
– changed library management
– changed compile-specific settings (segment sizes)
– execution of the commands "Project/Clean all" and "Project/Rebuild All".
2023/03/03 3ADR011074, 1, en_US 113

Glossary
Event Diagnosis message which does not require acknowledgement. The event describes the
current status of the device. The event disappears once the issue has been resolved.
HMI Human machine interface
Online ● After a project has changed, only these changes are compiled when pressing the
change key <F11> or calling the menu item "Project/Build". The changed program parts are
marked with a blue arrow in the block list.
● The term Online Change means loading the changes made in the user program into
the PLC's RAM using the programming system (after confirming a corresponding
system message when switching to online mode, menu item "Online/Login").
● Execution of the user program is not stopped. After downloading the program
changes, the program is re-organized. During re-organization, no further online
change command is allowed. The storage of the user program to the Flash memory
using the command "Online/Create boot project" cannot be initiated until re-organiza-
tion is completed.
● Online Change is not possible after:
– changes in the PLC configuration
– changes in the task configuration
– changes in the library management
– changed compile-specific settings (segment sizes)
– performing the commands "Project/Clean all" and "Project/Rebuild All".
Panel Engineering tool for control panels, integrated in engineering suite Automation Builder
Builder
PB610
Reset ● Performs a START -> STOP process.
● Preparation for program restart, i.e., the variables (VAR) (exception: RETAIN varia-
bles) are set to their initialization values.
● Reset is performed using the menu item "Online/Reset" in the programming system
or pressing the function key RUN for ≥ 5 s in STOP mode.
Reset ● Performs a START -> STOP process.
(cold) ● Preparation for program restart, i.e., the variables (VAR) (also RETAIN variables) are
set to their initialization values.
● Reset (cold) is performed using the menu item "Online/Reset (cold)" in the program-
ming system.
Reset ● Resets the controller to its original state (deletion of Flash, SRAM (%M, area, %R
(original) area, RETAIN, RETAIN PERSISTENT), Communication Module configurations and
user program!).
● Reset (original) is performed using the menu item "Online/Reset (original)" in the
programming system.
RUN -> ● RUN -> STOP means pressing the RUN function key on the PLC while the PLC is in
STOP run mode (AC500 PLC display "run", AC500-eCo PLC "RUN LED" is ON).
● If a user program is loaded into RAM, execution is stopped.
● All outputs are set to FALSE or 0.
● Variables keep their current values, i.e., they are not initialized.
● The AC500 PLC display changes from "run" to "StoP", AC500-eCo "RUN LED"
changes from ON to OFF.
START -> ● START -> STOP means stopping the execution of the user program in the PLC's
STOP RAM using the menu item "Online/Stop" in the programming system.
● All outputs are set to FALSE or 0.
● Variables keep their current values, i.e., they are not initialized.
● The AC500 PLC display changes from "run" to "StoP".
114 3ADR011074, 1, en_US 2023/03/03

Glossary
STOP -> ● STOP -> RUN means short pressing the RUN function key on the PLC while the PLC
RUN is in STOP mode (AC500 PLC display "StoP", AC500-eCo "RUN LED" is ON). "RUN
LED" is OFF of the toggle switch of an AC500-eCo CPU.
● If a user program is loaded into RAM, execution is continued, i.e., variables will not be
● The AC500 PLC display changes from "StoP" to "run", AC500-eCo "RUN LED"
changes from OFF to ON.
STOP -> ● STOP -> START means continuing the execution of the user program in the PLC's
START RAM using the menu item "Online/Start" in the programming system.
● If a user program is loaded into RAM, execution is continued, i.e., variables will not be
● The AC500 PLC display changes from "StoP" to "run", AC500-eCo PLC "RUN LED"
changes from OFF to ON.
Warm start ● A warm start is performed by switching power OFF/ON with a battery connected.
● All RAM memory modules are checked and erased except of the buffered operand
areas and the RETAIN variables.
● If there is a user program stored in the Flash EPROM, it is loaded into RAM.
● The default operating modes set by the PLC configuration are applied.
2023/03/03 3ADR011074, 1, en_US 115

Index
—
16 Index
A C
AB (Automation Builder) central I/O extension . . . . . . . . . . . . . . . . . . . . 13, 15
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 centralized I/O expansion . . . . . . . . . . . . . . . . . 13, 15
AC500 centralized I/O extension . . . . . . . . . . . . . . . . . . . . 13
connection and wiring . . . . . . . . . . . . . . . . . . . . 64 centralized IO extension . . . . . . . . . . . . . . . . . . . . . 15
control cabinet assembly . . . . . . . . . . . . . . . . . . 30 CI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
system structure . . . . . . . . . . . . . . . . . . . . . . . . 13 communication module
AC500 V2/AC500 V3 . . . . . . . . . . . . . . . . . . . . . . . . 4 mounting and demounting . . . . . . . . . . . . . . . . . 39
AC500-eCo configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
connection and wiring . . . . . . . . . . . . . . . . . . . . 71 connection and wiring
control cabinet assembly . . . . . . . . . . . . . . . . . . 32 AC500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 AC500-eCo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
mounting and demounting the option boards . . . 52 control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
system structure . . . . . . . . . . . . . . . . . . . . . . . . 14 control cabinet assembly . . . . . . . . . . . . . . . . . 30, 32
AC500-Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
accessories control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 control panels CP600 . . . . . . . . . . . . . . . . . . . . 57, 72
AC500-eCo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AI581-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mounting and demounting . . . . . . . . . . . . . . . . . 39
application update CP600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 57, 72
control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 CPU
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 108 mounting and demounting . . . . . . . . . . . . . . 37, 42
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 CPU selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 cyber security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
communication module . . . . . . . . . . . . . . . . . . . 39 cyber security requirements . . . . . . . . . . . . . . . . . . 83
CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 42
D
FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
data security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
function module terminal base . . . . . . . . . . . . . . 35
decentral I/O extension . . . . . . . . . . . . . . . . . . 14, 15
I/O modules . . . . . . . . . . . . . . . . . . . . . . . . . 41, 46
decentralized I/O expansion . . . . . . . . . . . . . . . 14, 15
option boards (AC500-eCo) . . . . . . . . . . . . . . . 52
decentralized I/O extension . . . . . . . . . . . . . . . . . . 14
processor module . . . . . . . . . . . . . . . . . . . . 37, 42
decentralized IO extension . . . . . . . . . . . . . . . . 14, 15
TA5301-CFA . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 96
terminal base . . . . . . . . . . . . . . . . . . . . . . . . . . 35
demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
terminal block for onboard I/O (AC500-eCo) . . . 54
CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
terminal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
communication module . . . . . . . . . . . . . . . . . . . 39
assembly and disassembly . . . . . . . . . . . . . . . . . . 33
FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Automation Builder
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
I/O modules . . . . . . . . . . . . . . . . . . . . . . . . . 41, 46
B option boards (AC500-eCo) . . . . . . . . . . . . . . . 52
block diagrams processor module . . . . . . . . . . . . . . . . . . . . 37, 42
grounding concept . . . . . . . . . . . . . . . . . . . . . . . 58
116 3ADR011074, 1, en_US 2023/03/03

Index
terminal base . . . . . . . . . . . . . . . . . . . . . . . . . . 35 G
terminal block for onboard I/O (AC500-eCo) . . . 54 grounding concept
terminal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 58
demounting a processor module
on DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
H
on metal plate . . . . . . . . . . . . . . . . . . . . . . . . . . 45 hardware protection . . . . . . . . . . . . . . . . . . . . . . . . 79
description HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 hot swap behaviour . . . . . . . . . . . . . . . . . . . . . . . . 95
S500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 human machine interface . . . . . . . . . . . . . . . . . . . . 22
DI581-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 I
diagnosis messages list . . . . . . . . . . . . . . . . . . . . . 98 I/O module
Differentiation AC500 V2/AC500 V3 . . . . . . . . . . . . . 4 mounting and demounting . . . . . . . . . . . . . . 41, 46
disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 i/o selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
input/output module
communication module . . . . . . . . . . . . . . . . . . . 39 mounting and demounting . . . . . . . . . . . . . . 41, 46
CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 42
io modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
IO modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
IT security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
I/O modules . . . . . . . . . . . . . . . . . . . . . . . . . 41, 46
option boards (AC500-eCo) . . . . . . . . . . . . . . . 52 L
processor module . . . . . . . . . . . . . . . . . . . . 37, 42 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
terminal base . . . . . . . . . . . . . . . . . . . . . . . . . . 35
M
terminal block for onboard I/O (AC500-eCo) . . . 54
MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51, 56
terminal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
mechanical installation . . . . . . . . . . . . . . . . . . . . . . 30
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
mechanical planning . . . . . . . . . . . . . . . . . . . . . . . 30
DX581-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
mechanical planning and installation . . . . . . . . . . . 30
E memory card . . . . . . . . . . . . . . . . . . . . . . 51, 56, 108
earthing concept mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 58 CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
elimination of security risks . . . . . . . . . . . . . . . . . . 79 communication module . . . . . . . . . . . . . . . . . . . 39
EMC-conforming mounting and construction . . . . . 59 FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
engineering software . . . . . . . . . . . . . . . . . . . . . . . 22 function module terminal base . . . . . . . . . . . . . . 35
error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 I/O modules . . . . . . . . . . . . . . . . . . . . . . . . . 41, 46
option boards (AC500-eCo) . . . . . . . . . . . . . . . 52
F processor module . . . . . . . . . . . . . . . . . . . . 37, 42
factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 TA5301-CFA . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
FAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
firewall protection . . . . . . . . . . . . . . . . . . . . . . . . . . 75 terminal base . . . . . . . . . . . . . . . . . . . . . . . . . . 35
firmware update terminal block for onboard I/O (AC500-eCo) . . . 54
control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 terminal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 108 TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mounting a processor module
function module terminal base on DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
mounting and demounting . . . . . . . . . . . . . . 35, 38 on metal plate . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2023/03/03 3ADR011074, 1, en_US 117

Index
O SM560-S-FD-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
older versions of this document . . . . . . . . . . . . . . . . 5 SM560-S-FD-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
open ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
open ports and service . . . . . . . . . . . . . . . . . . . . . . 83 state LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
output/input module status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
mounting and demounting . . . . . . . . . . . . . . 41, 46 status LEDs, display and control elements . . . . . . . 86
overview of product family . . . . . . . . . . . . . . . . . . . 12 synchronization with table of contents . . . . . . . . . . . 6
system protection . . . . . . . . . . . . . . . . . . . . . . . . . . 75
P system structure
Panel Builder 600 . . . . . . . . . . . . . . . . . . . . . . . . . . 87 AC500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PB610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 AC500-eCo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 S500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PLCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 S500-eCo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 20
processor module T
mounting and demounting . . . . . . . . . . . 37, 42, 54 TA5211-TSCL-B . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
processor module selection . . . . . . . . . . . . . . . . . . 24 TA5211-TSPF-B . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
processor modules . . . . . . . . . . . . . . . . . . . . . . . . . 16 TA5212-TSCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
programmable logic controllers . . . . . . . . . . . . . . . 12 TA5212-TSPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 TA5220-SPF5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
protected environment . . . . . . . . . . . . . . . . . . . . . . 76 TA5220-SPF6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TA5220-SPF7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
R TA5220-SPF8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 TB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
replace a module . . . . . . . . . . . . . . . . . . . . . . . . . . 90 terminal base
replacement of a module . . . . . . . . . . . . . . . . . . . . 90 mounting and demounting . . . . . . . . . . . . . . 35, 38
replacement of an I/O module with hot swap . . . . . 91 terminal block for onboard I/O (AC500-eCo)
reset to factory settings . . . . . . . . . . . . . . . . . . . . . 87 mounting and demounting . . . . . . . . . . . . . . . . . 54
total current consumption . . . . . . . . . . . . . . . . . . . . 26
S
TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S500
TU582-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
system structure . . . . . . . . . . . . . . . . . . . . . . . . 13 U
S500-eCo update
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 boot project . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
system structure . . . . . . . . . . . . . . . . . . . . . . . . 14 firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SD card . . . . . . . . . . . . . . . . . . . . . . . . . . 51, 56, 108 V
SD memory card . . . . . . . . . . . . . . . . . . . 51, 56, 108 V2/V3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
secure operation . . . . . . . . . . . . . . . . . . . . . . . . . . 76 virus protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 74
security notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
serial I/O bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SM560-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
118 3ADR011074, 1, en_US 2023/03/03

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Telephone: +49 (0)6221 701 1444
E-mail: plc.support@de.abb.com
3ADR011074, 1, en_US
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SYSTEM MANUAL

2 3ADR011074, 1, en_US 2023/03/03

5.13 Control panels CP600........................................................................................................................... 57

2023/03/03 3ADR011074, 1, en_US 3

1.2 Do I have AC500 V2 or AC500 V3?

Fig. 1: Hardware: Processor modules

Written type on the module Example Range Relevant manual

4 3ADR011074, 1, en_US 2023/03/03

Fig. 2: Software: Configuration in engineering software Automation Builder

Written type in brackets Example Range Relevant manual

1.4 Older revisions of this document

2023/03/03 3ADR011074, 1, en_US 5

Revisions Select any of the revisions

1.6 Structure of safety notices

1 Safety alert symbol indicates the danger.

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Do not operate devices outside of the specified, technical data!

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Ä Chapter 11.2 “Replace an I/O module with hot swap” on page 91

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Features of AC500 PLCs

The AC500 product family consists of the product groups:

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3.2 AC500/S500 system structure

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1 Terminal unit for communication interface modules

3.3 AC500-eCo/S500-eCo system structure

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Fig. 3: I/O modules (S500-eCo) directly connected to an AC500-eCo processor module

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3.4 AC500/S500: Short description hardware

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AC500 communication modules are required for

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On AC500-eCo processor modules and special AC500 (Standard) processor

I/O modules and function modules are plugged on a terminal unit.

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3.5 AC500-eCo/S500-eCo: Short description hardware

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3.7 CP600 control panels

3.8 Automation Builder: Short description engineering software

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Reference documentation for hardware

4.2 Communication within the PLC

1 I/O bus connection

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Ä Chapter 11.2 “Replace an I/O module with hot swap” on page 91

Table 2: General data of the I/O bus

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Table 3: Wiring (bus connection)

4.3 Power supply dimensioning

4.3.1 Calculation of the total current consumption

ICPU ) ICx ) II/O bus ) IUPx ) ILOADx *)