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ABB Advant AC500 Manual

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Contents
............................................................................................................................................ 1-4
Operating and ambient conditions ............................................................................................................ 1-4
Creepage distances and clearances ....................................................................................................... 1-5
Insulation test voltages, routine test, according to EN 61131-2 ............................................................... 1-5
Power supply units ................................................................................................................................... 1-5
Electromagnetic compatibility .................................................................................................................. 1-6
Mechanical data ....................................................................................................................................... 1-7
Mounting and disassembling the Terminal Bases and the couplers
Assembly on DIN rail ............................................................................................................................... 1-8
Assembly with screws ............................................................................................................................ 1-13
Assembly on DIN rail ............................................................................................................................. 1-14
Assembly with screws ............................................................................................................................ 1-17
Insertion / Replacement of the Lithium battery ..................................................................
Insertion of the SD Memory Card ........................................................................................
Terminals at the Terminal Units (I/O, FBP) ............................................................................................ 1-26
Connection of wires at the spring terminals ........................................................................................... 1-27
Bad wiring on power supply terminals .................................................................................................... 1-31
Bad wiring on I/O terminals..................................................................................................................... 1-31
..................................................................................................................................................... 1-32
General .................................................................................................................................................. 1-32
____________________________________________________________________________________________________________
V2
AC500 Hardware
..................................................................................................................... 1-18
......................................................................................................... 1-21
............................................................................................................................. 1-25
.......................................................................................................................... 1-29
................................................................................................... 1-31
........................................................................ 1-4
1-1
System data
...................................... 1-8
................................ 1-14
.. 1-31
AC500 / Issued: 05.2007
1-22
1-24
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Summary of Contents for ABB Advant AC500

  • Page 1: Table Of Contents

    Contents System data and system construction ................ 1-4 System data ............................1-4 Operating and ambient conditions ......................1-4 Creepage distances and clearances ....................... 1-5 Insulation test voltages, routine test, according to EN 61131-2 ............... 1-5 Power supply units ........................... 1-5 Electromagnetic compatibility ........................
  • Page 2 Wiring..............................1-32 Number of user data, bus cycle time and data security ................. 1-32 Replacement of modules on the I/O bus ....................1-33 Serial interfaces of the CPU Terminal Bases ................1-33 Interface standard ........................... 1-33 Technical data............................1-33 Serial interface COM1 ..........................
  • Page 3 Ethernet ..............................1-50 Wiring..............................1-50 Bus line ............................... 1-50 Cable length restrictions ........................1-50 ARCNET ..............................1-51 The ARCNET system (Attached Resource Computer Network) ............1-51 ARCNET bus topology..........................1-51 The networking possibilities of Linear ARCNET ................1-51 Linear ARCNET, expanded by active distribution units (Active Hubs) ..........1-52 Wiring..............................

  • Page 4: System Data And System Construction

    AC500 System data and system construction The product family Advant Controller 500 control system is designed according to EN 61131-2 IEC 61131-2 standards. Data, different from IEC 61131, are caused by the higher requirements of Maritime Services. System data Operating and ambient conditions Voltages, according to EN 61131-2 24 V DC process and supply...

  • Page 5: Creepage Distances And Clearances

    Creepage distances and clearances The creepage distances and clearances meet the overvoltage category II, pollution degree 2. Insulation test voltages, routine test, according to EN 61131-2 230 V circuits against other circuitry 2500 V surge 1.2/50 µs 120 V circuits against other circuitry 1500 V surge 1.2/50 µs 120 V to 240 V circuits against other circuitry...

  • Page 6: Electromagnetic Compatibility

    Electromagnetic compatibility Immunity against electrostatic discharge (ESD) according to EN 61000-4-2, zone B, criterion B - electrostatic voltage in case of air discharge 8 kV - electrostatic voltage in case of contact 4 kV, in a closed switch-gear cabinet 6 kV ¹) discharge ESD with communication connectors In order to prevent operating malfunctions, it is...

  • Page 7: Mechanical Data

    Mechanical data Wiring method / terminals Mounting horizontal Degree of protection IP 20 Housing according to UL 94 Vibration resistance acc. to EN 61131-2 all three axes 2 Hz...15 Hz, continuous 3.5 mm 15 Hz...150 Hz, continuous 1 g (4 g in preparation) Vibration resistance with SD Memory Card 15 Hz...150 Hz, continuous 1 g inserted...

  • Page 8: Assembly On Din Rail

    Mounting and disassembling the Terminal Bases, the CPUs and the couplers Assembly on DIN rail Step 1: Mount DIN rail 7.5 mm or 15 mm Step 2: Mount Terminal Base (TB521, TB521, TB541) Figure: Assembly of the Terminal Base (TB511, TB521 or TB541) The Terminal Base is put on the DIN rail above and then snapped-in below.
  • Page 9 Step 3: Mount I/O Terminal Unit (TU515, TU516, TU531 or TU532) Figure: Assembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532) The I/O Terminal Unit is snapped into the DIN rail in the same way as the Terminal Base. Once secured to the DIN rail, slide the I/O unit to the left until it fully locks into place creating a solid mechanical and electrical connection.
  • Page 10 - PS501 as of version V1.2 - CPUs as of firmware V1.2.0 Figure: Disassembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532) A screwdriver is inserted in the indicated place to separate the Terminal Units. Step 4: Mount the CPU PM581 Figure: Assembly of the CPU Press the CPU into the Terminal Base until it locks in place.
  • Page 11 The disassembly is carried out in a reversed order. Figure: Disassembly of the CPU Disassembly: Press above and below, then remove the CPU. Step 5: Mount the coupler (communication module) Figure: Assembly of a coupler The coupler is first inserted below, then clicked-in above. ____________________________________________________________________________________________________________ AC500 Hardware 1-11...
  • Page 12 The disassembly is carried out in a reversed order. Figure: Disassembly of a coupler Disassembly: Press above (and below), then swing out the coupler and remove it. The following figure shows a Terminal Base with a CPU and two couplers inserted. CM572 CM577 PM581...

  • Page 13: Assembly With Screws

    Assembly with screws If the Terminal Base should be mounted with screws, Wall Mounting Accessories TA526 must be inserted at the rear side first. These plastic parts prevent bending of the Terminal Base while screwing on. TB511 needs one TA526, TB521 and TB541 need two TA526. Rear view Holes for wall mounting Rear view...

  • Page 14: Mounting And Disassembling The Terminal Units And The I/O Modules

    Mounting and disassembling the Terminal Units and the I/O modules Assembly on DIN rail Step 1: Mount DIN rail 7.5 mm or 15 mm Step 2: Mount FBP Terminal Unit (TU505 or TU506) Figure: Assembly of the FBP Terminal Unit (TU505 or TU506) The FBP Terminal Unit is put on the DIN rail above and then snapped-in below.
  • Page 15 Step 3: Mount I/O Terminal Unit (TU515, TU516, TU531 or TU532) Figure: Assembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532) The I/O Terminal Unit is installed on the DIN rail in the same way as the FBP Terminal Unit. Once secured on the DIN rail, slide the I/O unit to the left until it fully locks into place creating a solid mechanical and electrical connection.
  • Page 16 Figure: Disassembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532) A screwdriver is inserted in the indicated place to separate the Terminal Units. Step 4: Mount the modules DC532 Figure: Assembly of the modules Press the electronic module into the Terminal Unit until it locks in place. ____________________________________________________________________________________________________________ AC500 Hardware 1-16...

  • Page 17: Assembly With Screws

    The disassembly is carried out in a reversed order. Figure: Disassembly of the modules Disassembly: Press obove and below, then remove the module. Assembly with screws If the Terminal Unit should be mounted with screws, a Wall Mounting Accessory TA526 must be inserted at the rear side first.

  • Page 18: Mechanical Dimensions

    By wall mounting, the Terminal Unit is earthed through the screws. It is necessary that • the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-plated) • the mounting plate is earthed • the screws have a good electrical contact to the mounting plate Mechanical dimensions AC500 4.9 (0.19) 40.3...
  • Page 19 84.5 (3.33) 77 (3.03) 75 (2.95) 13 (0.51) 62 (2.44) DIN rail 15 mm DIN rail 7.5 mm (1.10) Dimensions: 135 mm View on the left side (5.31) inches Figure: Terminal Base with coupler, view from the left side 57.7 (2.27) DC505 67.5 (2.66)
  • Page 20 84.5 (3.33) 77 (3.03) 75 (2.95) 21 (0.83) 54 (2.13) DIN rail 15 mm DIN rail 7.5 mm Dimensions: 135 mm (1.10) (5.31) inches View on the left side View on the right side Figure: Dimensions of the S500 Terminal Units (view from the left and the right side) ____________________________________________________________________________________________________________ AC500 Hardware 1-20...

  • Page 21: Switch-Gear Cabinet Assembly

    Switch-gear cabinet assembly Basically, it is recommended to mount the modules on an earthed mounting plate, independent of the mounting location. CM572 CM577 PM581 DC532 DC532 DIN rail, earthed Mounting plate, earthed Cable duct 20 mm minimum distance between the modules and the cable duct DC505 DC532 DC532...

  • Page 22: Insertion / Replacement Of The Lithium Battery

    Important: Horizontal mounting is highly recommended. Vertical mounting is possible, however, derating consideration should be made to avoid problems with poor air circulation and the potential for excessive temperatures (see also the AC500 system data, operating and ambient conditions, for reduction of ambient temperature).
  • Page 23 Insertion of the battery: 1. Open the battery compartment by inserting a fingernail in the small locking mechanism, press it down and slip down the door. The door is attached to the front face of the CPU and cannot be removed.

  • Page 24: Insertion Of The Sd Memory Card

    The CPU uses a standard file system. This allows standard card readers to read the MC502 SD Memory Cards. Attention: The use of memory cards other than the MC502 SD Memory Card is prohibited. ABB is not responsible nor liable for consequences resulting from the use of unapproved memory cards.

  • Page 25: Connection System

    Connection system Terminals for power supply and the COM1 interface (CPU Terminal Base AC500) COM1 Figure: Terminals for power supply and the COM1 interface (CPU Terminal Base AC500) Terminal type: Screw-type terminal Number of cores per terminal Conductor type Cross section solid 0.08 mm²...

  • Page 26: Terminals At The Terminal Units (I/O, Fbp)

    Terminals at the Terminal Units (I/O, FBP) Figure: Terminals at the Terminal Units (I/O, FBP) Terminal type: Screw-type terminal Number of cores per terminal Conductor type Cross section solid 0.08 mm² to 2.5 mm² flexible 0.08 mm² to 2.5 mm² 1 with wire end ferrule flexible 0.25 mm²...

  • Page 27: Connection Of Wires At The Spring Terminals

    Connection of wires at the spring terminals Connect the wire to the spring terminal Opening Opening for screw- conductor driver Screwdriver Terminal Screwdriver open inserted Terminal Screwdriver closed Spring Figure: Connect the wire to the spring terminal (steps 1 to 3) Figure: Connect the wire to the spring terminal (steps 4 to 7) ____________________________________________________________________________________________________________ AC500 Hardware...
  • Page 28 Side view (open terminal drawn for illustration) The top view shows the openings for wire and screwdriver 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 While erecting the screwdriver, insert it until the stop (requires a little strength) Screwdriver inserted, terminal open Strip the wire for 7 mm (and put on wire end ferrule)

  • Page 29: Mechanical Encoding

    Terminal with wire connected 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 While erecting the screwdriver, insert it until the stop (requires a little strength), terminal is now open Remove wire from the open terminal Remove the screwdriver...
  • Page 30 The following figure shows the possible codings. Mechanical codings Positions 1 - 18 TB511-ETH TB511-ARCNET TU505 TU507-RT-ETH TU515 TB521-ETH TB521-ARCNET TU506 TU508-RT-ETH TU516 TB541-ETH TB541-ARCNET for FBP for CPUs for CPUs Interface Modules Real-Time I/O Modules with Ethernet with ARCNET e.g.

  • Page 31: General Wiring Recommendations

    General wiring recommendations Bad wiring on power supply terminals Attention: The product should be installed by trained people who have the knowledge of wiring electronic devices. In case of bad wiring, although the modules are protected against various errors (reverse polarity, short circuit, etc.), some problems could always happen: - On the CPU Terminal Base, the terminals L+ and M are doubled.

  • Page 32: I/O-Bus

    I/O-Bus General The synchronized serial I/O-Bus connects the I/O expansion modules with the AC500 CPU or with the S500 FBP Interface Module. The I/O-Bus provides the following signals: • Supply voltage of 3.3 V DC for feeding the electronic interface components •...

  • Page 33: Replacement Of Modules On The I/O Bus

    Replacement of modules on the I/O bus The I/O-Bus is not designed for plugging and unplugging modules while in operation. If a module is plugged or replaced while the bus is in operation, the following consequences are possible • reset of the station or of the CPU •...
  • Page 34 The serial interface COM1 is connected via a removable 9-pole terminal block. It is configurable for RS- 232 or RS-485 and can be used for • an online access (RS-232 programming interface for PC/Control Builder) • a free protocol (communication via the COMSND and COMREC function blocks) •...

  • Page 35: Cs31 System Bus

    Ohms Ohms Slave at the Master within Slave within Slave at the bus line end, the bus line, the bus line bus line end, bus termination pull-up and bus termination 120 Ohms pull-down 120 Ohms activated Figure: RS-485 bus with the master within the bus line The following photo shows a wiring example "master within the bus line".

  • Page 36: Wiring

    With connecting the terminals 1-2 and 3-4, a pull-up and a pull-down resistor can be activated (see chapter "Serial interface COM1” for details). Wiring Bus line 2 cores, twisted, with common shield Construction Conductor cross section > 0.22 mm² (24 AWG) - recommendation 0.5 mm²...
  • Page 37 Master within the bus line, COM1 pull-up and CS31 bus master pull-down e.g. PM581 activated Ohms Ohms CS31 system bus CS31 CS31 slave slave direct earthing with clip Figure: Bus topology for a CS31 system bus at COM1 (bus master within the bus line) COM1 Ohms WRONG!

  • Page 38: Earthing

    Earthing In order to avoid disturbance, the cable shields must be earthed directly. Case a: Multiple switch-gear cabinets: If it can be guaranteed that no potential differences can occur between the switch-gear cabinets by means of current-carrying metal connections (earthing bars, steel constructions etc.), the direct earthing is chosen.

  • Page 39: Number Of User Data, Bus Cycle Time And Data Security

    Case b: Multiple switch-gear cabinets: If potential differences can occur between the switch-gear cabinets, the capacitive earthing method is chosen in order to avoid circulating currents on the cable shields. Cabinet 1 COM1 CS31 system bus CS31 slave direct CS31 bus master Ohms e.g.

  • Page 40: Serial Interface Com2

    Serial interface COM2 of the CPU Terminal Bases The serial interface COM2 is connected via a 9-pole SUB-D plug. It is configurable for RS-232 or RS- 485 and can be used for • an online access (RS-232 programming interface for PC/Control Builder) •...
  • Page 41 If the master is located within the bus line, it does not need a terminating resistor. The pull-up and the pull-down resistors, however, are necessary (see the following drawing). Ohms RxD/TxD-N Ohms Ohms RxD/TxD-P Ohms Slave at the Master within Slave within Slave at the bus line end,...

  • Page 42: Fieldbusplug / Fbp

    FieldBusPlug / FBP Wiring For example, refer to description of the PROFIBUS DP FBP, documentation 2CDC 192 001 D010x.PDF Bus topology For example, refer to description of the PROFIBUS DP FBP, documentation 2CDC 192 001 D010x.PDF ____________________________________________________________________________________________________________ AC500 Hardware 1-42 System data AC500 / Issued: 05.2007...

  • Page 43: Modbus

    Modbus General ® The Modbus protocol is used all over the world. The MODICON Modbus RTU protocol is integrated in the AC500 CPUs. Numerous automation devices, such as PLC installations, displays, variable-frequency inverters or ® monitoring systems, for instance, have a Modbus RTU interface by default or as an option and can therefore communicate with the AC500 CPUs without any problems via the serial interfaces COM1 and COM2 (RS-232 or RS-485).

  • Page 44: Profibus

    PROFIBUS ISO/OSI model At the moment, PROFIBUS DP is the Field bus most frequently used worldwide for industrial applications. It is standardized under IEC 61158 together with other field bus protocols. The definition of the PROFIBUS is based on the experience concerning data transmission collected during long years.

  • Page 45: Typical Field Bus Topologies

    Typical Field Bus Topologies Party Line Trunc Party Line with branch and drop The PROFIBUS DP realized with PDP21 or PDP22 represents a real Party Line topology that supports high baud rates up to 12 Mbit/s best possible. Branches and Drops cause reflexions Ring which results in a dramatic reduction of the max.

  • Page 46: Overview Of Transferred Data

    Overview of transferred data Device Control System Example of a slave with PROFIBUS FieldBusPlug Data exchange on the PROFIBUS Group Type / example * Direction Comment DI = digital input read Cyclic data Monitored signals (inputs) exchange AI = analog input read Commands (outputs) DO=digital output...
  • Page 47 Diagnosis The diagnosis telegram provides detailed information if there is any problem, particularly in the process. A trip caused by overload of a motor is an example. Diagnosis data are automatically read by the PROFIBUS DP master if it gets a general fault info within a monitoring telegram. Complete diagnosis telegram: PROFIBUS DP PROFIBUS DP with PDP21, PDP22...
  • Page 48 DP-V1 offers reading and writing single parameters. The possibility to read single parameters is an important advantage: If e.g. during commissioning the "Set current" for a motor is modified locally by the electrician, then the control system must be able to read this value to back it up into its data base.

  • Page 49: Wiring

    Wiring Bus line Type twisted wires (2 cores, shielded) 135...165 Ω Characteristic impedance Cable capacitance < 30 pF/m ≥ 0.64 mm Diameter of the cores (copper) ≥ 0.34 mm² Conductor cross section of the cores ≤ 55 Ω /km Wire resistance per core ≤...

  • Page 50: Ethernet

    Ethernet Wiring Bus line Parameter 100Base-TX [100 MHz] Attenuation [dB/100 m] 23.2 NEXT [dB/100 m] ACR [dB/100 m] Return Loss [db/100 m] Characteristic impedance [ Ω ] Category Class D or higher Cable length restrictions For the maximum possible cable lengths within an Ethernet network various factors have to be taken into account.

  • Page 51: Arcnet

    ARCNET The ARCNET system (Attached Resource Computer Network) • ARCNET is a system for data transmission in local networks. • The ARCNET protocol is based on the Token Passing principle. • By passing an identifier (token) from station to station it is guaranteed, that only one station can start a data transmission (transmission without collision).

  • Page 52: Linear Arcnet, Expanded By Active Distribution Units (Active Hubs)

    Linear ARCNET, expanded by active distribution units (Active Hubs) Active Hubs amplify the arriving signals. So they stabilize the network configuration and allow especially for high distances. The Active Hub decouples the station connectors from each other. Therefore, the entire network does not fail when one of the connections fails. The maximum length of the network is 6 km.

  • Page 53: Wiring

    Wiring Bus cable: Cable RG 62 A/U: e.g. Lapp Kabel, Stuttgart Telephone: 0711/7838-0 Plugs for bus cable: BNC plugs 75 Ω : Order No. B-9005 BNC T plug 75 Ω : OrderNo. B-9083 BNC termination 93 Ω : Order No. B-9093 Rufenach Vertriebs-GmbH, Heidelberg Telephon: +49 6221/8443-0 Telefax: +49 6221/8443-99...

  • Page 54: General Considerations For Emc-Conforming Assembly And Construction

    General considerations for EMC-conforming assembly and construction Electric and electronical devices have to work correctly on site. This is also valid when electro-magnetic influences affect them in defined and/or expected strength. The devices themselves must not emit electro-magnetic noises. Advant Controller components are developed and constructed so that they have a very high noise immunity.

  • Page 55: Cable Shields

    Cable shields • Only use shielded data cables. The shield should be earthed at both ends. Make sure that no parasitic currents can flow through the cable shields. This can be done by installing current-carrying equipotential bondings. • A cable shield only earthed at one end can only protect from capacitively coupled interference and low-frequency disturbances (50 Hz hum).

  • Page 56: Equipotential Bonding

    Equipotential bonding • Install sufficiently dimensioned equipotential bondings, if potential differences are present or have to be expected in your application between different parts of the installation. • The impedance of a equipotential bonding must be equal or lower than 10 % of the shield impedance of the shielded signal cables between the same points.

  • Page 57: Power Consumption Of An Entire Station

    Power consumption of an entire station The power consumption of a complete station consists of the sum of all individual consumptions. An AC500 CPU cluster has • a power consumption of the CPU itself over the terminals L+ and M of the Terminal Base. After conversion of the voltage, also the I/O-Bus for the attached I/O modules is supplied then.
  • Page 58 Calculation of the total current consumption In the following example, the aC500 control system consists of - the CPU PM581-ETH - the 4 communication modules CM572-DP (1x), CM575-DN (1x), CM577-ETH (1x), CM578-CN (1x) - the 7 expansion modules DC522 (1x), DC523 (1x), DC532 (1x), AX521 (1x), AX522 (1x), AI523 (1x), AO523 (1x) - as well as the required Terminal Bases and Terminal Units Remark: Because of the high total current consumption of the digital I/O modules (from UP = 24 DC),...
  • Page 59 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 the example shown above: I/O-Bus LOADx CPU part...
  • Page 60 ____________________________________________________________________________________________________________ AC500 Hardware 1-60 System data AC500 / Issued: 05.2007...

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