The Compact Product Suite: An Introduction To The AC500 PLC Family

ABB Control Technologies, Partner Webinar Series, Feb 25, 2015
The Compact Product Suite

An Introduction to the AC500 PLC Family
© ABB
February 26, 2015 Slide 1
Presenting Today: An Introduction to AC500 PLC Family
Feb 25, 2015 9:00 – 10:00 AM CET
Wangelis Porikis Gero Lustig

Product Manager AC500 PLC Family Product Manager Compact Product Suite
AC500, AC500-eCo, AC500-S and AC500-XC scalable PLC ranges provide solutions for small,
middle and high-end applications.
Get to know essentials in this webinar about
architecture, key features and benefits, markets, promotional material
© ABB
ABB Essential Automation
Compact Product Suite
Products for Process Automation

 Essential HMI Suite
 Essential Controller Suite
 Essential Connect Suite
 Essential Recorder Suite
 Essential Safety Suite
© ABB
Our Mission: Sustainable Products Business
Creating a more independent product line
One fits all

approach eA xA eA xA
Past Future
 
Extended Essential
Automation Automation
© ABB
Gray Hardware
Ready to deliver product business
 More flexibility to adapt to product

business
 Price
 Delivery lead time
 Technology
 Will include more products

 We will see new additions „born gray“
© ABB
Broadening our portfolio
AC500 PLC will be offered also via ABB’s
Division Process Automation
© ABB
PG PLC & Automation
Product Portfolio
AC500 (HA) Water/Pumping, Buildings/HVAC, Material

PLC High Availability Handling, High Speed Machines,
AC500 - XC Harsh environment Industries - Marine,

PLC Water, Wind, Solar, Material Handling
AC500 - eCo General Industry and Machinery -

PLC Solar, HVAC, Pumping, Compact Machines
AC500 - S Factory Automation - Material Handling,

Safety PLC Cranes, Hoist, Winches and Robotic Cells
CP600 All Industries and Automation

HMI and control solution markets
Automation Builder Engineering SW & Library Packages for all

& Library Packages Automation Industries & Control Solutions
©
© ABB
ABB Group
February
February 26,
26, 2015
2015 | Slide 7 Slide 7
Process Industries
Typical automation landscape
Main Process control by

DCS technology PLC
PLC for discrete applications PLC for fast
(e.g. motion) or PLC
Package units, motion and
processes
discrete by Hybrid/ PLC
low scale automation PLC
technology Package PLC
DCS Unit
DCS
DCS
PLC
DCS
Package
DCS
Unit
PLC
Package PLC
Unit
PLC
Package
Small DCS for Unit Large DCS for
DCS utility processes/ DCS processes
tankfarm etc
© ABB
Water treatment - Example
800xA/ Freelance for DCS, AC500 for Satellites
Freelance for central control
Using AC500 PLC for

satellites, remote locations.
Full operation through
Freelance DigiVis or
Compact HMI possible
Recent projects:
Holland: Water treatment
Freelance replacing
Emerson DeltaV to be
company standard
Oman: Water distribution

with 800xA and AC500Eco
© ABB
Process OEMs
Skids, Package Units
 Water treatment
 Boiler
 Mixer
 Industrial Heating
 Power units
 Dosing
 etc
© ABB
Wangelis Porikis, IMS/webinar, 2015-02-25
PG Machinery Controls and Automation

Discovering AC500 Introduction
© ABB
Discovering AC500 Introduction
 Introducing Discrete Automation and Motion
division
 ABB Programmable Logic Control (PLC) milestones
 AC500
 System architecture
 Key features and associated benefits
 Industries on which the AC500 is focused
 Sales and promotional tools available
© ABB
How are we organized?
© ABB
Discovering AC500 Marketing Introduction
© ABB
Business Unit Discrete Automation and Motion
Division Business Unit Product Group
 Drives and Controls  Machinery Controls and Automation

 Power Conversion  Low Power AC Drives
 Motors and Generators  High Power Drives
 Robotics  Low Power Inverters
 Service
 Revenues $9.4 billion (2013)

 Total employees 29,290 (2013)
 Sales in more than > 100 countries
 Manufacturing sites > 70
© ABB
AC500 Product Family
© ABB
Discovering AC500 Marketing Introduction - Milestones of ABB’s PLC
2013 Automation Builder Software

Programming Suite for DM Solutions
2013 Safety PLC SIL3 (AC500-S)
2011 eXtreme Condition PLC (XC)

2009 Compact Cost Effective Scalable PLC (eCo)
2008 Webserver Capability for Platform

2005 First Scalable PLC Platform (AC500)
1992 Safety PLC
1991 The First Distributed PLC (CS31)
1988 DOS Based PLC Programming
1975 Software PLC Introduction
1971 Hardwired Programmable Logic Control (PLC) System
© ABB
Discovering AC500 Marketing Introduction - Our Product Offering
© ABB
Discovering AC500 Marketing Introduction - AC500-eCo
 Flexible
 Fast
 Robust
 SD card
 Configurable I/Os
 Automatic addressing I/Os
One  Onboard serial and ETH
common
engineering
 Onboard I/Os
platform  Onboard web server
Automation
Builder
© ABB
Discovering AC500 Marketing Introduction - AC500
 Scalable
 Flexible
 Fast
 Robust
 Fieldbus independent
 Integrated display
One  SD card
common
engineering
 Configurable I/Os
platform  Automatic addressing I/Os
Automation  Pre-wiring
Builder
 Motion interfaces
© ABB
Discovering AC500 Marketing Introduction - AC500 eXtreme Condition
 Vibration (4 g)
 Temp range (-40 to +70 °C)
 Humidity (up to 95% humidity)
 Salt mist
 Corrosive gases
 Corrosive environments
One  High altitude (4.000 m above sea)
common
engineering
platform
Automation
Builder
© ABB
Discovering AC500 Marketing Introduction - AC500-S Safety PLC
 Totally integrated in AC500 platform
 Safety and non-safety in one eng. tool
 LD, FBD and ST (Structured Text)
 XC (eXtreme Condition) versions
 Trigonometric functions
 TUV SIL3 certified
One  Connectivity via PROFIsafe
common
engineering
platform
Automation
Builder
© ABB
Discovering AC500 Marketing Introduction - CP600 Control Panels
 Highly visible display
 Aluminum frame
 Brilliant screen colors
 Modern graphic elements
 Printer functions
 Eng. SW integrated (Automation Builder)
One  Remote internet access
common
engineering
platform
Automation
Builder
© ABB
AC500 – The Architecture
© ABB
Discovering AC500 Marketing Introduction - The Architecture
1
5
1. AC500 CPU (PM-XXX)
3 2. Communication module (CM-XXX)
2 3. Terminal base for PM and CM

4. S500 I/O modules
5. Terminal unit for I/O modules
© ABB
 AC500 CPU PMXXX
 Different CPUs with selection for user program, data memory, processing speed
 2 internal serial interfaces, RS232 / RS485 configurable
 Display and 8 function keys for diagnosis and status
 Centrally expandable with up to 10 I/O modules, 320 I/Os (S500 and/or S500-eCo
modules allowed)
 Simultaneous operation of up to 4 external communication modules in any desired

combination
 Optional SD card for data storage and program backup
 Integrated 4 GB high density mass storage non rotating on flash disk (PM592)
 Ethernet version provides web server and IEC 60870-5-104 remote control protocol
© ABB
 Communication Modules CMXXX for
fieldbus connection
 Simultaneous operation of up to 4
external communication modules in
any desired combination
 PROFIBUS DP, Ethernet, Modbus
TCP, EtherCAT, CANopen or
PROFINET IO Device, ABB CS31
© ABB
 Terminal base TBXXX
 Same for all AC500 CPU types
 For mounting and connection of the

CPU and communication modules
 1 to 4 plug-in communication modules
 I/O interface for direct connection of

up to 10 expansion modules
 Fieldbus-neutral FieldBusPlug-Slave
interface
 Connection COM1: 9-pole pluggable

terminal
 Connection COM2: 9-pole Sub-D

(socket)
© ABB
 S500 analog I/O modules
 For central and decentralized extension
 Power supply over I/O bus connection, galvanic isolation per module
 Input channels single configurable for current or voltage signals or as digital inputs
 Output channels single configurable for current and voltage signals
 Resolution 12 bits plus sign or 15 bits plus sign (AI531)
 All channels protected against reverse polarity / supply, short circuit and continuous
overvoltage up to 30 V DC
 Signal value indication by LED brightness
 Diagnosis LEDs on module
 Configurable module monitoring and diagnosis by the CPU and configurable
substitute value for first output at communication fault
 Mounting: TU515 or TU516
© ABB
 S500 digital I/O modules
 For central and decentralized extension
 Power supply over I/O-Bus connection, galvanic isolation per module
 Channels single configurable as input or output
 All channels protected against reverse polarity / supply, short circuit and continuous
overvoltage up to 30 V DC
 Digital inputs 24 V DC or 120/230 V AC
 Configurable input delay: 0.1 ms, 1 ms, 8 ms, 32 ms, default: 8 ms
 Digital outputs: transistor 24 V DC, 0.5 A or relays
 Fast counter with 10 operation modes, type related
 Diagnosis LEDs on module
 Configurable module monitoring, diagnosis by the CPU and configurable substitute
values for outputs at communication fault
 Mounting: TU515 or TU516 for 24 V DC, TU531 or TU532 for 230 V AC
© ABB
 Multi functional approach 8 type of
signals in 1 module
 Configurable I/O modules
(thermocouple, voltage, current,
PT100, PT1000, Ni100, Ni1000)
 All channels protected against reverse
polarity / supply, short circuit and
AI/O-Thermocoupler continuous overvoltage up to 30 V DC
AI/O-Voltage
 Swap in without tools
DI/O-Logic
AX521  Configurable via software (one

programming tool)
 Continuous diagnosis by monitoring
the I/O with the programming software
© ABB
 S500 fast counter for digital I/O modules
 10 operation modes related to module type

 Up to 2 digital inputs and 1 output (if existing) used
 Signal frequency up to 50 kHz

 Function blocks for programming available, library included and automatically loaded into the project
after configuration
 S500 encoder and PWM module CD522
 2 independent encoder / counter inputs with up to 12 different modes
 Hardware interface with 24 V DC, 5 V DC, differential RS422 signal, 1 Vpp sinus signal
 1 x 32 bits counter, 2 x 16 bits counter, relative position encoder, absolute encoder (connection with
SSI interface), time / frequency measurement, frequency input up to 300 kHz, two 5 V DC power
supplies for sensors
 Two independent PWM or pulse outputs with push pull driver
 Dedicated I/O for counting specific function (TOUCH, SET, RESET…)
 8 configurable digital I/Os available as standard I/Os
© ABB
 Communication interface modules CIXXX-
YY – the fieldbus connectivity
 Decentralized I/Os
 Eg, EtherCAT = CI512-ETHCAT
 PROFIBUS DP, Ethernet, Modbus TCP,
EtherCAT, CANopen or PROFINET IO
device, ABB CS31 global features
 Space saving compact housing for DIN rail
or wall mounting, height and depth is the
same with existing S500 modules
 I/O-Bus connection can connect up to 10
modules
© ABB
Discovering AC500 Marketing Introduction - Configuration Example
Central expansion
 Terminal base
Eg, PROFINET
expansion
 Terminal units
 S500-eCo I/O module
 CPU
Decentralized
 S500 I/O modules
 Communication modules
 Communication interface module
© ABB
Discovering AC500 Marketing Introduction - Configuration Example
© ABB
Discovering AC500 Marketing Introduction - Next Generation CPU
Instructions in  Multi processor system with large amount of
1 µs memory optimized for demanding machinery
1800
1600
and motion automation control
1400
1200  Involving complexities eg, precision
1000
800 coordinated motion > 64 axes, intensive
600
400
mathematic computation like advanced
200 kinematic applications
0
Bit Word Floating
point
 4 Ethernet ports built in, 2 with software
configurable protocol (PROFINET/EtherCAT)
Memory MB
20  Multiple backup and data storage capabilities
15  Hardware without fan

10  Integrated safety (with SM560-S)
5
0
Work Data
© ABB
Discovering AC500 Marketing Introduction - Engineering Productivity
 Programming
 Automation Builder – one engineering tool
 AC500 and AC500-eCo PLC can be programmed using

IEC61131-3 languages: FBD, ST, LD, IL, SFC
 Additional CFC, C and C++
 Shared engineering
 Multi user operation (check in/check out)
 Reuse of projects by drag and drop
 Libraries available – motion, drives, solar, water
 Shortest learning curve
© ABB
AC500 Key Features and Associated Benefits
© ABB
Discovering AC500 Marketing Introduction - Key Features and Benefits
 Fast, best in class
Recently launched from competition AC500 offerings
CPU 1513 CPU 1516- CPU 1518- ABB ABB ABB
Features
-1 PN 3 PN/DP 4 PN/DP PM583-ETH PM592-ETH PM595-4ETH-F
Work memory for

300 kB 1 MB 3 MB 1 MB 4 MB 16 MB
program, integrated
5.6 MB, 16 MB
Work memory for data,
1.5 MB 5 MB 10 MB 1 MB 1.5 MB saved 3 MB saved
integrated
4 GB flash disk 4 GB flash disk
Bit
0.04 µs 0.01 µs 0.001 µs 0.05 µs 0.002 µs 0.0006 µs
operations
Comm
and Word
executi 0.048 µs 0.012 µs 0.002 µs 0.06 µs 0.004 µs 0.001 µs
operations
on
times Floating-
point 0.256 µs 0.064 µs 0.006 µs 0.5 µs 0.004 µs 0.001 µs
operations
© ABB
 Scalable and flexible
 CPUs exchangeable
 Fieldbus independent
 Up to 4 fieldbus connection in
different combination
 All modules can be used on any

CPU concept
 SD Card slot for fast updates, data

archiving, project duplication and
project backup
 Configurable and automatic

addressing I/Os
 Pre-wiring
© ABB
 Reliable and safe
 Extended environmental operating
conditions:
 Operating temperature from

-40 °C … up to +70 °C
 Freezing climate, high humidity
 High altitude up to 4000 m

(620 hPa)
 Corrosive gases (G3, 3C2), salt

mist, dust and dirt
 Large vibration ranges and

extended EMC requirements
 Integrated safety
© ABB
 Easy to install and maintain
 Less components needed:
 Same modules and two terminal units for centralized and decentralized I/Os
 Multifunctional approach, a few modules cover a broad range of requirements.
 Built in fast counter
 Every module can be used in the AC500 product family
 Mechanical coded module to avoid the damage of “wrong” usage

 I/O channel per software configurable means fast diagnosis of firmware, software and
configuration
 No access to cabinet needed, no post it maintenance
 Multiple fieldbus opportunity, helps our customers to react quickly, flexibly and
economically on new requirements
© ABB
One Advanced services
common Packages and solutions
engineering
platform Common engineering environment
Automation PLC Drives HMI Safety Motors Motion Robots MPT 3rd party
Control products
Builder
Open connectivity and communication
© ABB
 Automation Builder
 One engineering tool - helps you to
save time, effort and money
 One project for all (PLC, HMI, drives,

robots) - helps to increase quality and
reduces software maintenance costs
 Shorter time to market, all necessary

engineering tools in one environment
 Library for drives, motion, solar and

water
© ABB
AC500 Focused Markets and Industries
© ABB
Discovering AC500 Marketing Introduction - Markets
 AC500 in solar
 Concentrating Solar Power (CSP) and Photovoltaic (PV) and Concentrated
photovoltaics (CPV)
 Applications:
 Solar library for tracker control, string monitoring, data logging function, web
server, FTP server, SNTP protocol, multi online change tool
© ABB
 AC500 in water
 Drinking water production, municipal waste water treatment, industrial water
treatment, water transportation and distribution
 Focus on pumping applications like level control applications and boost

control applications (transfer liquid from source to destination, circulate liquid
around a system and boost the pressure)
© ABB
 AC500 in wind
 Applications:
 Turbine control, turbine monitoring, SCADA interface, web interface, remote
control, battery charging and monitoring, generator monitoring
(temperatures), pitch and yaw control, power-management for off-grid
applications like transmission tower or weather station
© ABB
 AC500 in cranes
 Applications:
 Slew control, stability control (counter weight / tipping load), operating zone
control, anti-collision detection
 Mining hoist, tunnel hoist, industrial hoist
© ABB
 AC500 in infrastructure (tunnels, airports, buildings)

 Applications:
 Remote data access with telecontrol protocol IEC60870-5-104 with
redundancy of control lines
 Data logging, remote access, remote control stations
 Separate networks eg, Modbus TCP and email transmission (SMTP)

© ABB
 AC500 in factory automation

 Applications:
 Motion control: single and multi axis movements, move position absolute /
relative, move velocity, homing
 Machine builder: feed, forming and filling, sealing and cutting, picking,
packing and palletizing
© ABB
Sales and Promotional Tools Available
© ABB
Discovering AC500 Marketing Introduction - Sales and Promotional Tools
 See CT Partner Portal for Authorized Value Provider
http://www.abb.com/partnerportal/us/9AAF500002.aspx
 WWW.ABB.COM/PLC
 Sales collateral
 Brochures available on request
 Starter kits available on request
 PowerPoint presentations
 Catalog (internet and pdf version) available on request
 Videos on YouTube, search for “ABB PLC” or “ABB AC500”
© ABB
Discovering AC500 Marketing Introduction - Questions
© ABB

The Compact Product Suite: An Introduction To The AC500 PLC Family

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ABB Control Technologies, Partner Webinar Series, Feb 25, 2015

The Compact Product Suite

Wangelis Porikis Gero Lustig

Products for Process Automation

One fits all

 More flexibility to adapt to product

 Delivery lead time

 Will include more products

AC500 (HA) Water/Pumping, Buildings/HVAC, Material

AC500 - XC Harsh environment Industries - Marine,

AC500 - eCo General Industry and Machinery -

AC500 - S Factory Automation - Material Handling,

CP600 All Industries and Automation

Automation Builder Engineering SW & Library Packages for all

Main Process control by

Freelance for central control

Using AC500 PLC for

Oman: Water distribution

PG Machinery Controls and Automation

 Key features and associated benefits

 Industries on which the AC500 is focused

 Sales and promotional tools available

Division Business Unit Product Group

 Drives and Controls  Machinery Controls and Automation

 Revenues $9.4 billion (2013)

2013 Automation Builder Software

2011 eXtreme Condition PLC (XC)

2008 Webserver Capability for Platform

1992 Safety PLC

1991 The First Distributed PLC (CS31)

1988 DOS Based PLC Programming

1975 Software PLC Introduction

1971 Hardwired Programmable Logic Control (PLC) System

2 3. Terminal base for PM and CM

 2 internal serial interfaces, RS232 / RS485 configurable

 Display and 8 function keys for diagnosis and status

 Simultaneous operation of up to 4 external communication modules in any desired

 Optional SD card for data storage and program backup

 For mounting and connection of the

 1 to 4 plug-in communication modules

 I/O interface for direct connection of

 Connection COM1: 9-pole pluggable

 Connection COM2: 9-pole Sub-D

AX521  Configurable via software (one

 10 operation modes related to module type

 Signal frequency up to 50 kHz

15  Hardware without fan

 AC500 and AC500-eCo PLC can be programmed using

 Additional CFC, C and C++

 Multi user operation (check in/check out)

 Reuse of projects by drag and drop

 Libraries available – motion, drives, solar, water

 Shortest learning curve

Work memory for

 All modules can be used on any

 SD Card slot for fast updates, data

 Configurable and automatic

 Operating temperature from

 Freezing climate, high humidity

 High altitude up to 4000 m

 Corrosive gases (G3, 3C2), salt

 Large vibration ranges and

 Multifunctional approach, a few modules cover a broad range of requirements.