ABB Product Group PLC

ABB Programmable Logic Control

AC500 Presentation
3ADR025066N020

© ABB
27 May 2014 | Slide 1
AC500, your PLC from ABB Supervision Solutions
Automation Offer

HMI range – 4.3” to 15”

Software Suite
Automation Builder is ABB's

new engineering

productivity suite

Software Libraries

PLC hardware

Solar Water Motion

© ABB
27 May 2014 | Slide 2
AC500 family, your PLCs from ABB
AC500 CPU range

CPU Range Range Suggested Applications

Compatible platform interchangeable modules

Stand alone OEM machines, remote monitoring systems,
HVAC systems, . Cost-effective small PLC offering total inter-
AC500-eCo operability with the core AC500 range integrated with

Single programming software

onboard Ethernet and I/Os.

World-class operations
Robot cells, printing machines, marine vessels, building
automations, cranes, water & waste water, plastic machines,
AC500 high speed & precision machines, string monitoring systems
which demand high performance extended expandability.
Water & waste water, solar, wind, construction machineries,
cranes, chemical treatment plants, tunnels, rails. Applications
AC500-XC which requires Extreme Conditions operability e.g. vibration,
hazardous gases, high altitudes, rainy condition.
For any critical applications which could not afford downtime.
A very cost effective solution which is based on the AC500
AC500-HA platform, allows warm standby with standard hardware via
ABB proprietary CS31 bus system.
Functional safety application such as crane, robot cells, wind
which requires (TÜV cerified up to SIL3 (IEC62061) and PL e
AC500-S
(ISO13849)).

© ABB
27 May 2014 | Slide 3
AC500 family, your PLCs from ABB
AC500 CPU rangePerformance

Ethernet enabled

Fieldbus enabled
Stand-alone

PM591-ETH,
PM590-ETH PM592-ETH

New

SM560-S
PM583-ETH

PM573-ETH
AC500

PM554-ETH
PM564-ETH PM556-ETH New

PM554
PM564
AC500 -eCo

128kB 512kB 1MB 2MB > 4 MB Versatility

© ABB
27 May 2014 | Slide 4
AC500, your PLC from ABB
Product benefit

High performance PLC for

demanding applications
 Full featured high performance
PLC

 Program processing time and

program memory provides the
performance your application
needs

 Configurable I/O for easy

integration of various motion
control applications

 Possibility to configure analog

inputs as digital inputs supports
customized solutions

 High functionality with

integrated onboard digital and
analogue I/O

© ABB
27 May 2014 | Slide 5
AC500, your PLC from ABB
Product benefit

Comprehensive communication options save time and

money
 Integrated Ethernet interface can provide multiple communication
possibilities
 Up to ten serial ports for remote IO, communication and
programming / 9 Ethernet ports
 Easy network configuration based on the widely-used CoDeSys
programming software
© ABB
27 May 2014 | Slide 6
AC500, your PLC from ABB
Product benefit
Protecting your investment
 Programming software based on
international standard IEC 61131-3
 Complete range of S500 I/O can be
connected
 Supports decentralized I/O
 Flexible to meet different customers
requirements
Profibus  Safety offer SIL3
Easy to learn and higher
compatibility saves you engineering
time and effort
 Single programming tool for entire AC500
family, based on CoDeSys
 Existing AC500 libraries are compatible
and readily available for use

© ABB
27 May 2014 | Slide 7
AC500, your PLC from ABB
Product benefit
Easy to program
 Five programming languages available for
each purpose
 Program Drive, HMI and PLC in Same
project
 Extensive Function Block libraries, or
create your own for re-use
 Powerful simulation and visualization
feature
Easy to maintain
Ethernet

Profibus  Download of user program with SD card

 eXtreme Condition Versions available

© ABB
27 May 2014 | Slide 8
AC500, your PLC from ABB
Product benefit
eXtreme Conditions
 Extreme Temperature ( - 40 to + 70
Degrees C)
 High Humidity (95%)
 Vibration Immune (4g RMS random and
2g sinusoidal @ 500Hz)
 Extended EMC immunity - surges and
bursts
 Extended immunity to HAZ gasses and
Salt mist
 High altitude operation – 4000m

© ABB
27 May 2014 | Slide 9
AC500-XC
Intended environments for use – overview
 Extreme Environments
 High vibration
 Corrosive environments
 Hot ambient temperature
 High humidity
 High altitude
 Freezing climates
© ABB
 Extreme Industry Applications
 Marine
 Onshore and offshore
 Solar
 PV power plants
 Thermal solar power plants
 Wind
 Turbines and wind parks
 Infrastructure
 Tunnels and bridges, locks
 Water Waste Water
 Treatment plants, industrial
water, pumping
AC500, your PLC from ABB
Product Features
In summary
 A CPU integrating onboard Ethernet and
Web server for Visualization

 Back plane not required

 Up to 10 Direct I/O modules connected to

any CPUs

 320 Local & 32,000 Remote IO

 Dual Processor, (High Availability)

solution

 Single Integrated programming and

configuration tool for AC500, AC500-eCo,
AC500-S PLCs, Drives, Motion, Robotics
and HMI panels

© ABB
27 May 2014 | Slide 11
ABB’s PLC & Automation
How S500 IO fits together with Eco-CPUs

© ABB
ABB’s PLC & Automation
How S500 IO fits together with CPUs or CI

© ABB
AC500, your PLC from ABB
Operating, display and connection elements of AC500
1 Terminal base:
 Easy snap-on of CPU and optional communication module
 CPU performance upgrade is convenient and fast
 Pre-wiring of CPU Connections

Communication module – Optional for Masters

1 2  Up to 4 modules in numerous combinations to
communicate with PLCopen, PROFINET, Profibus DP,
2
Modbus and Modbus TCP, CANopen, EtherCAT, etc.

3 FieldBusPlug connector – built-in for Slaves

 Slaves for Profibus DP, CANopen, DeviceNet

4 4 Onboard Ethernet (optional)

 Programming via PC
5
 Internet protocols (WEB server, FTP, e-mail, time sync,
6 UDP and more)
 IEC 60870-5-104 (Sub station automation protocol)
3

5 COM1 (spring terminal, RS232/RS485)

 Programming via PC CS31 bus (master)
 ASCII protocol
 Modbus-RTU (master or slave)

6 COM2 (Sub-D9, RS232/RS485)

 Programming via PC
 ASCII protocol
 Modbus-RTU (master or slave)
© ABB
27 May 2014 | Slide 14
AC500-eCo, your PLC from ABB
Technical data AC500-eCo CPU
PM554- PM554-T- PM564-R- PM564-T- PM564-R- PM564-R-
CPU-Feature PM554-T PM554-R PM564-T PM564-R
R-AC ETH AC ETH ETH ETH-AC
100-240 100-240 V 100-240 V
Power supply 24 V DC 24 V DC 24 V DC
V AC AC AC
Binary inputs 8 Digital Inputs, 6 Digital Outputs 6 Digital Inputs, 6 Digital Outputs, 2 Analogue Inputs, 1 Analogue Outputs

Transistor outputs 6 - 6 - 6 -

Relay outputs - 8 - 6 - 6
User Program
128k
memory
User data memory 14 kB, 2kB saved
Cycle time for 1
Binary 0.08 µs, Word 0.1 µs, Floating 1.2 µs
instruction (minimum)
Max. centralized inputs/outputs

Binary inputs 320 + 8 onboard

Binary outputs 240 + 6 onboard

Analog inputs 160 + 2 onboard

Analog outputs 160 + 1 onboard

Onboard communication

Com 1 RS485, Sub-D connection, Programming, Modbus, ASCII, CS31

Com 2 (option) RS485, Sub-D connection, Programming, Modbus, ASCII

Ethernet - √ - √

© ABB
27 May 2014 | Slide 15
AC500, your PLC from ABB
Technical data AC500 CPUs

CPU-Feature PM556 Eco PM573-ETH PM582 PM583-ETH PM590-ETH PM591-ETH PM592-ETH

Power supply 24 V DC

User program
512 kB 512 kB 512 kB 1024 kB 2048 kB 4096 kB 4096 kB
memory
User data 130 kB, 512 kB, 416 kB, 288 kB 1024 kB, 288 kB 3072 kB, 5632 kB, 5632 kB,
memory 2 kB saved 288 kB saved saved saved 1536 kB saved 1536 kB saved 1536 kB saved

SD card Slot Yes

Real-Time Clock Yes

Data buffering Battery

Processing time per instruction

Binary 0.06 µs 0.05 µs 0.002 µs

Word 0.09 µs 0.06 µs 0.004 µs

Floating-point 0.7 µs 0.5 µs 0.004 µs

© ABB
27 May 2014 | Slide 16
AC500 your Automation Solution from ABB
Packaging AC500 PLC & HMIs with ACS Drives

Profibus

© ABB
27 May 2014 | Slide 23
AC500-eCo, your PLC from ABB
Architecture Example 1

Modbus
master

Modbus on AC500-eCo COM2 (option)

Modbus Slave

ABB CS31
Master
CS31 on AC500-eCo COM1

S500 I/O S500 I/O

CS31-Interface + I/O CS31-Interface + I/O

© ABB
27 May 2014 | Slide 25
AC500-eCo, your PLC from ABB
Architecture Example 2

Modbus
master

Modbus on AC500-eCo COM1

Modbus Slave

Modbus Master

Modbus on AC500-eCo COM2 (option)

Modbus
HMI
slave

© ABB
27 May 2014 | Slide 26
AC500-eCo, your PLC from ABB
Architecture Example 4

PC with
Modbus PS501
HMI
master Control
Builder Plus

Programming, UDP or MODBUS

TCP on Ethernet

CS31 master Modbus Master

CS31 on AC500-eCo COM1 Modbus on AC500-eCo COM2 (option)

S500 I/O CS31-interface + I/O Modbus slave HMI

© ABB
27 May 2014 | Slide 28
Automation
AC500-eCo, your PLC from ABB
One programming tool for the whole AC500 family

Easy and standardized programming

 The programming tool PS501 for all CPU performance classes of the
scalable AC500 control unit
 Standardized programming in accordance with IEC 61131-3 based on
CoDeSys.
 Configuration of the entire system complete with fieldbuses and interfaces
Various functionality and features within one programming tool
 Extensive module library
 Extensive diagnostic functions, like alarm functions, integrated visualization
and open software interfaces
 OPC multi-access for several OPC servers
 Web server functionality (All Ethernet CPU’s)
 A integrated visualization WEB HMI makes it easy for the the operation of a
small application
 Different languages

© ABB
27 May 2014 | Slide 29
AC500 flexible architecture
Connecting productivity with possibilities
CoDeSys
Programming DigiVis 500 DigiVis 500
Station

Industrial Ethernet (Optionally Ring Redundancy)

CP400
AC500 PLC AC500 PLC
HMI AC500 HA

Remote ACS800
System
HMI
S500
Remote I/O Motor
AC500-
eCo Switchgear
Machine Push Panel
Buttons

ACS800
Flow UMC
UMC
Meter

MCB
Temp
Sensor Field
Devices Robot
Soft Starter
Motor Actuator
Motor
ACSM HA Remote I/Os
Certifications Bus Connections 1

© ABB
Software Strategy in Discrete Automation and Motion
What is Automation Builder?
Advanced Services
Packages and Solutions

Common Engineering Environment

Motors &
Transmissions

Open Connectivity and Communication

© ABB Group
April 2013 | Slide 32
AC500, your PLC from ABB
Information portal

www.abb.com/PLC

© ABB
AC500, your PLC from ABB
Application Examples
AC500 steam-to-water heater, UK

AC500-eCo foam mixer, Germany

AC500 data center, South Africa

AC500 refrigeration plant, Italy

AC500-eCo Mine Winders and Hoists, South Africa

AC500-eCo anti-dust machine, Sweden

AC500-eCo industrial kiln application, China

AC500 shaftless printing press, USA

AC500 in Steel Plant - Jordan

AC500/AC500-eCo control of gear boxes and torque multipliers, Brazil

AC500 and AC500-eCo Clean Rooms HVAC for Semiconductors Plant, Czech Republic

AC500 and DCS800 DC drives Helicopter Testing Facility, Australia

AC500 and AC500-eCo motion application printing machine Wuxi Zhongxin, China

AC500 in wind applications - CSR wind turbines, China (wind brochure)

AC500 Safal Steel, South Africa

AC500 in wind applications - Norvento, Spain (wind brochure)

AC500 Nanpu Water Reuse Treatment Plant, Beijing Greentech, China

AC500 Qianfeng Waste Water Treatment Plant, Shanghai Xinhua Group, China

AC500 Solar Application, South Africa, Largest in Africa, 75MW, Northern Cape

AC500 Boiler control, South Africa

© ABB

AC500 Pump station control, South Africa

Engineered for Purpose
Wind
Success story
CSR wind turbines – 86 GW in China

© ABB
© ABB
ABB PLC’s safety is integrated and
seamless

© ABB