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  3. AC500 Series
AC500 Series

ABB AC500 Series Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
AC500 Product Family
—
Table of contents
1 AC522............................................................................................................................................................... 9
1.1 Assembly................................................................................................................................................. 10
1.2 Disassembly............................................................................................................................................ 11
1.3 Dimensions.............................................................................................................................................. 11
1.4 Connection.............................................................................................................................................. 12
1.4.1 Process Supply Voltage........................................................................................................... 13
1.4.2 Inputs/Outputs.......................................................................................................................... 13
1.5 Cleaning.................................................................................................................................................. 14
1.6 Certification............................................................................................................................................. 14
1.7 Recycling................................................................................................................................................. 14
2 AI523............................................................................................................................................................... 15
2.1 Assembly................................................................................................................................................. 18
2.2 Disassembly............................................................................................................................................ 19
2.3 Dimensions.............................................................................................................................................. 19
2.4 Connection.............................................................................................................................................. 20
2.4.1 Process Supply Voltage........................................................................................................... 21
2.4.2 Inputs....................................................................................................................................... 21
2.5 Cleaning.................................................................................................................................................. 22
2.6 Certification............................................................................................................................................. 22
2.7 Recycling................................................................................................................................................. 22
3 AI531............................................................................................................................................................... 23
3.1 Assembly................................................................................................................................................. 26
3.2 Disassembly............................................................................................................................................ 27
3.3 Dimensions.............................................................................................................................................. 27
3.4 Connection.............................................................................................................................................. 28
3.4.1 Process Supply Voltage........................................................................................................... 29
3.4.2 Inputs....................................................................................................................................... 29
3.5 Cleaning.................................................................................................................................................. 30
3.6 Certification............................................................................................................................................. 30
3.7 Recycling................................................................................................................................................. 31
4 AI581-S........................................................................................................................................................... 32
4.1 Assembly................................................................................................................................................. 33
4.2 Disassembly............................................................................................................................................ 34
4.3 Dimensions.............................................................................................................................................. 34
4.4 Connection.............................................................................................................................................. 35
4.4.1 Process Supply Voltage........................................................................................................... 36
4.4.2 Inputs....................................................................................................................................... 36
4.5 Cleaning.................................................................................................................................................. 37
4.6 Certification............................................................................................................................................. 37
4.7 Recycling................................................................................................................................................. 37
5 AO523............................................................................................................................................................. 38
5.1 Assembly................................................................................................................................................. 41
5.2 Disassembly............................................................................................................................................ 42
5.3 Dimensions.............................................................................................................................................. 42
5.4 Connection.............................................................................................................................................. 43
5.4.1 Process Supply Voltage........................................................................................................... 44
5.4.2 Outputs..................................................................................................................................... 44
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5.5 Cleaning.................................................................................................................................................. 45
5.6 Certification............................................................................................................................................. 45
5.7 Recycling................................................................................................................................................. 45
6 AX521............................................................................................................................................................. 46
6.1 Assembly................................................................................................................................................. 49
6.2 Disassembly............................................................................................................................................ 50
6.3 Dimensions.............................................................................................................................................. 50
6.4 Connection.............................................................................................................................................. 51
6.4.1 Process Supply Voltage........................................................................................................... 52
6.4.2 Inputs....................................................................................................................................... 52
6.4.3 Outputs..................................................................................................................................... 52
6.5 Cleaning.................................................................................................................................................. 53
6.6 Certification............................................................................................................................................. 53
6.7 Recycling................................................................................................................................................. 53
7 AX522............................................................................................................................................................. 54
7.1 Assembly................................................................................................................................................. 57
7.2 Disassembly............................................................................................................................................ 58
7.3 Dimensions.............................................................................................................................................. 58
7.4 Connection.............................................................................................................................................. 59
7.4.1 Process Supply Voltage........................................................................................................... 60
7.4.2 Inputs....................................................................................................................................... 60
7.4.3 Outputs..................................................................................................................................... 60
7.5 Cleaning.................................................................................................................................................. 61
7.6 Certification............................................................................................................................................. 61
7.7 Recycling................................................................................................................................................. 61
8 CD522............................................................................................................................................................. 62
8.1 Assembly................................................................................................................................................. 63
8.2 Disassembly............................................................................................................................................ 64
8.3 Dimensions.............................................................................................................................................. 64
8.4 Connection.............................................................................................................................................. 65
8.4.1 Process Supply Voltage........................................................................................................... 66
8.4.2 Inputs....................................................................................................................................... 66
8.4.3 Inputs/Outputs.......................................................................................................................... 67
8.4.4 Outputs..................................................................................................................................... 67
8.5 Cleaning.................................................................................................................................................. 68
8.6 Certification............................................................................................................................................. 68
8.7 Recycling................................................................................................................................................. 69
9 CI541-DP......................................................................................................................................................... 70
9.1 Assembly................................................................................................................................................. 73
9.2 Disassembly............................................................................................................................................ 74
9.3 Dimensions.............................................................................................................................................. 74
9.4 Connection.............................................................................................................................................. 75
9.4.1 Process Supply Voltage........................................................................................................... 76
9.4.2 Inputs/Outputs.......................................................................................................................... 76
9.5 Cleaning.................................................................................................................................................. 77
9.6 Certification............................................................................................................................................. 77
9.7 Recycling................................................................................................................................................. 78
10 CI542-DP......................................................................................................................................................... 79
10.1 Assembly............................................................................................................................................... 82
10.2 Disassembly.......................................................................................................................................... 83
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10.3 Dimensions............................................................................................................................................ 83
10.4 Connection............................................................................................................................................ 84
10.4.1 Process Supply Voltage......................................................................................................... 85
10.4.2 Inputs/Outputs........................................................................................................................ 85
10.5 Cleaning................................................................................................................................................ 86
10.6 Certification........................................................................................................................................... 86
10.7 Recycling............................................................................................................................................... 86
11 CI5x1............................................................................................................................................................... 87
11.1 Assembly............................................................................................................................................... 91
11.2 Disassembly.......................................................................................................................................... 92
11.3 Dimensions............................................................................................................................................ 92
11.4 Connection............................................................................................................................................ 93
11.4.1 Process Supply Voltage......................................................................................................... 94
11.4.2 Inputs/Outputs........................................................................................................................ 94
11.5 Cleaning................................................................................................................................................ 95
11.6 Certification............................................................................................................................................ 95
11.7 Recycling............................................................................................................................................... 96
12 CI5x2............................................................................................................................................................... 97
12.1 Assembly............................................................................................................................................. 101
12.2 Disassembly........................................................................................................................................ 102
12.3 Dimensions.......................................................................................................................................... 102
12.4 Connection.......................................................................................................................................... 103
12.4.1 Process Supply Voltage....................................................................................................... 104
12.4.2 Inputs/Outputs...................................................................................................................... 104
12.5 Cleaning.............................................................................................................................................. 105
12.6 Certification......................................................................................................................................... 105
12.7 Recycling............................................................................................................................................. 105
13 CM582-DP..................................................................................................................................................... 106
13.1 Assembly............................................................................................................................................. 107
13.2 Disassembly........................................................................................................................................ 107
13.3 Dimensions.......................................................................................................................................... 108
13.4 Connection.......................................................................................................................................... 109
13.4.1 Interface for PROFIBUS....................................................................................................... 110
13.5 Cleaning.............................................................................................................................................. 110
13.6 Certification.......................................................................................................................................... 110
13.7 Recycling............................................................................................................................................. 111
14 CM589-PNIO(-4)........................................................................................................................................... 112
14.1 Assembly............................................................................................................................................. 113
14.2 Disassembly........................................................................................................................................ 113
14.3 Dimensions.......................................................................................................................................... 114
14.4 Connection.......................................................................................................................................... 115
14.4.1 Ethernet Network Interface................................................................................................... 116
14.5 Cleaning.............................................................................................................................................. 116
14.6 Certification.......................................................................................................................................... 116
14.7 Recycling............................................................................................................................................. 117
15 DA501........................................................................................................................................................... 118
15.1 Assembly............................................................................................................................................. 121
15.2 Disassembly........................................................................................................................................ 122
15.3 Dimensions.......................................................................................................................................... 122
15.4 Connection.......................................................................................................................................... 123
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15.4.1 Process Supply Voltage....................................................................................................... 124
15.4.2 Inputs/Outputs...................................................................................................................... 124
15.5 Cleaning.............................................................................................................................................. 125
15.6 Certification......................................................................................................................................... 125
15.7 Recycling............................................................................................................................................. 126
16 DA502........................................................................................................................................................... 127
16.1 Assembly............................................................................................................................................. 128
16.2 Disassembly........................................................................................................................................ 129
16.3 Dimensions.......................................................................................................................................... 129
16.4 Connection.......................................................................................................................................... 130
16.4.1 Process Supply Voltage....................................................................................................... 131
16.4.2 Inputs/Outputs...................................................................................................................... 131
16.5 Cleaning.............................................................................................................................................. 132
16.6 Recycling............................................................................................................................................. 132
17 DC522........................................................................................................................................................... 133
17.1 Assembly............................................................................................................................................. 136
17.2 Disassembly........................................................................................................................................ 137
17.3 Dimensions.......................................................................................................................................... 137
17.4 Connection.......................................................................................................................................... 138
17.4.1 Process Supply Voltage....................................................................................................... 139
17.4.2 Inputs/Outputs...................................................................................................................... 139
17.5 Cleaning.............................................................................................................................................. 139
17.6 Certification......................................................................................................................................... 140
17.7 Recycling............................................................................................................................................. 140
18 DC523........................................................................................................................................................... 141
18.1 Assembly............................................................................................................................................. 144
18.2 Disassembly........................................................................................................................................ 145
18.3 Dimensions.......................................................................................................................................... 145
18.4 Connection.......................................................................................................................................... 146
18.4.1 Process Supply Voltage....................................................................................................... 147
18.4.2 Inputs/Outputs...................................................................................................................... 147
18.5 Cleaning.............................................................................................................................................. 147
18.6 Certification......................................................................................................................................... 148
18.7 Recycling............................................................................................................................................. 148
19 DC532........................................................................................................................................................... 149
19.1 Assembly............................................................................................................................................. 152
19.2 Disassembly........................................................................................................................................ 153
19.3 Dimensions.......................................................................................................................................... 153
19.4 Connection.......................................................................................................................................... 154
19.4.1 Process Supply Voltage....................................................................................................... 155
19.4.2 Inputs................................................................................................................................... 155
19.4.3 Inputs/Outputs...................................................................................................................... 155
19.5 Cleaning.............................................................................................................................................. 156
19.6 Certification......................................................................................................................................... 156
19.7 Recycling............................................................................................................................................. 156
20 DI524............................................................................................................................................................. 157
20.1 Assembly............................................................................................................................................. 160
20.2 Disassembly........................................................................................................................................ 161
20.3 Dimensions.......................................................................................................................................... 161
20.4 Connection.......................................................................................................................................... 162
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20.4.1 Process Supply Voltage....................................................................................................... 163
20.4.2 Inputs................................................................................................................................... 163
20.5 Cleaning.............................................................................................................................................. 163
20.6 Certification......................................................................................................................................... 164
20.7 Recycling............................................................................................................................................. 164
21 DI581-S......................................................................................................................................................... 165
21.1 Assembly............................................................................................................................................. 166
21.2 Disassembly........................................................................................................................................ 167
21.3 Dimensions.......................................................................................................................................... 167
21.4 Connection.......................................................................................................................................... 168
21.4.1 Process Supply Voltage....................................................................................................... 169
21.4.2 Inputs................................................................................................................................... 169
21.5 Cleaning.............................................................................................................................................. 170
21.6 Certification......................................................................................................................................... 170
21.7 Recycling............................................................................................................................................. 170
22 DO524........................................................................................................................................................... 171
22.1 Assembly............................................................................................................................................. 174
22.2 Disassembly........................................................................................................................................ 175
22.3 Dimensions.......................................................................................................................................... 175
22.4 Connection.......................................................................................................................................... 176
22.4.1 Process Supply Voltage....................................................................................................... 177
22.4.2 Outputs................................................................................................................................. 177
22.5 Cleaning.............................................................................................................................................. 177
22.6 Certification......................................................................................................................................... 177
22.7 Recycling............................................................................................................................................. 178
23 DO526........................................................................................................................................................... 179
23.1 Assembly............................................................................................................................................. 182
23.2 Disassembly........................................................................................................................................ 183
23.3 Dimensions.......................................................................................................................................... 183
23.4 Connection.......................................................................................................................................... 184
23.4.1 Process Supply Voltage....................................................................................................... 185
23.4.2 Outputs................................................................................................................................. 185
23.5 Cleaning.............................................................................................................................................. 185
23.6 Certification......................................................................................................................................... 186
23.7 Recycling............................................................................................................................................. 186
24 DX522........................................................................................................................................................... 187
24.1 Assembly............................................................................................................................................. 190
24.2 Disassembly........................................................................................................................................ 191
24.3 Dimensions.......................................................................................................................................... 191
24.4 Connection.......................................................................................................................................... 192
24.4.1 Process Supply Voltage....................................................................................................... 193
24.4.2 Inputs................................................................................................................................... 193
24.4.3 Outputs................................................................................................................................. 193
24.5 Cleaning.............................................................................................................................................. 194
24.6 Certification......................................................................................................................................... 194
24.7 Recycling............................................................................................................................................. 194
25 DX531........................................................................................................................................................... 195
25.1 Assembly............................................................................................................................................. 198
25.2 Disassembly........................................................................................................................................ 199
25.3 Dimensions.......................................................................................................................................... 199
Table of contents
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25.4 Connection.......................................................................................................................................... 200
25.4.1 Process Supply Voltage....................................................................................................... 201
25.4.2 Inputs................................................................................................................................... 201
25.4.3 Outputs................................................................................................................................. 201
25.5 Cleaning.............................................................................................................................................. 202
25.6 Certification......................................................................................................................................... 202
25.7 Recycling............................................................................................................................................. 202
26 DX581-S........................................................................................................................................................ 203
26.1 Assembly............................................................................................................................................. 204
26.2 Disassembly........................................................................................................................................ 205
26.3 Dimensions.......................................................................................................................................... 205
26.4 Connection.......................................................................................................................................... 206
26.4.1 Process Supply Voltage....................................................................................................... 207
26.4.2 Inputs/Outputs...................................................................................................................... 207
26.5 Cleaning.............................................................................................................................................. 208
26.6 Certification......................................................................................................................................... 208
26.7 Recycling............................................................................................................................................. 209
27 PD501-4CH................................................................................................................................................... 210
27.1 Assembly............................................................................................................................................. 211
27.2 Disassembly........................................................................................................................................ 212
27.3 Dimensions.......................................................................................................................................... 212
27.4 Connection.......................................................................................................................................... 213
27.4.1 Process Supply Voltage....................................................................................................... 214
27.4.2 Inputs/Outputs...................................................................................................................... 214
27.5 Cleaning.............................................................................................................................................. 214
27.6 Certification......................................................................................................................................... 215
27.7 Recycling............................................................................................................................................. 215
28 PM595........................................................................................................................................................... 216
28.1 Assembly............................................................................................................................................. 217
28.2 Disassembly........................................................................................................................................ 217
28.3 Dimensions.......................................................................................................................................... 218
28.4 Connection.......................................................................................................................................... 219
28.4.1 Power Supply....................................................................................................................... 220
28.4.2 Serial Interface COM1.......................................................................................................... 220
28.4.3 Serial Interface COM2.......................................................................................................... 220
28.4.4 Ethernet Network Interface.................................................................................................. 221
28.5 Cleaning.............................................................................................................................................. 221
28.6 Certification......................................................................................................................................... 222
28.7 Recycling............................................................................................................................................. 222
29 PM56xx-2ETH............................................................................................................................................... 223
29.1 Assembly............................................................................................................................................. 224
29.2 Disassembly........................................................................................................................................ 225
29.3 Dimensions.......................................................................................................................................... 225
29.4 Connection.......................................................................................................................................... 226
29.5 Cleaning.............................................................................................................................................. 227
29.6 Recycling............................................................................................................................................. 227
30 PM5xx (-y).................................................................................................................................................... 228
30.1 Assembly............................................................................................................................................. 230
30.2 Disassembly........................................................................................................................................ 231
30.3 Dimensions.......................................................................................................................................... 231
Table of contents
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30.4 Connection.......................................................................................................................................... 232
30.5 Cleaning.............................................................................................................................................. 232
30.6 Certification......................................................................................................................................... 233
30.7 Recycling............................................................................................................................................. 233
31 TB56xx-2ETH............................................................................................................................................... 234
31.1 Assembly............................................................................................................................................. 235
31.2 Disassembly........................................................................................................................................ 235
31.3 Assembly with Screws......................................................................................................................... 236
31.4 Dimensions.......................................................................................................................................... 236
31.5 Connection.......................................................................................................................................... 237
31.5.1 CAN Interface....................................................................................................................... 237
31.5.2 Power Supply....................................................................................................................... 238
31.5.3 Serial Interface COM1.......................................................................................................... 239
31.5.4 Ethernet Network Interface.................................................................................................. 239
31.6 Cleaning.............................................................................................................................................. 240
31.7 Recycling............................................................................................................................................. 240
32 TB51x-TB54x................................................................................................................................................ 241
32.1 Assembly............................................................................................................................................. 242
32.2 Disassembly........................................................................................................................................ 242
32.3 Assembly with Screws......................................................................................................................... 243
32.4 Dimensions.......................................................................................................................................... 243
32.5 Connection.......................................................................................................................................... 244
32.5.1 Power Supply....................................................................................................................... 245
32.5.2 Serial Interface COM1.......................................................................................................... 245
32.5.3 Serial Interface COM2.......................................................................................................... 245
32.5.4 ARCNET Network Interface................................................................................................. 246
32.5.5 Ethernet Network Interface.................................................................................................. 246
32.5.6 Fieldbus-neutral Interface.................................................................................................... 247
32.6 Cleaning.............................................................................................................................................. 247
32.7 Certification......................................................................................................................................... 247
32.8 Recycling............................................................................................................................................. 248
33 TU582-S........................................................................................................................................................ 249
33.1 Assembly............................................................................................................................................. 250
33.2 Disassembly........................................................................................................................................ 250
33.3 Assembly with Screws......................................................................................................................... 251
33.4 Dimensions.......................................................................................................................................... 251
33.5 Connection.......................................................................................................................................... 252
33.6 Cleaning.............................................................................................................................................. 253
33.7 Recycling............................................................................................................................................. 253
34 TU5xx............................................................................................................................................................ 254
34.1 Assembly............................................................................................................................................. 257
34.2 Disassembly........................................................................................................................................ 258
34.3 Assembly with Screws......................................................................................................................... 258
34.4 Dimensions.......................................................................................................................................... 259
34.5 Connection.......................................................................................................................................... 260
34.6 Cleaning.............................................................................................................................................. 260
34.7 Certification......................................................................................................................................... 261
34.8 Recycling............................................................................................................................................. 261
Table of contents
2019/11/153ADR024117M02xx, 11, en_US8
—
1 AC522
● AC522
CAUTION!
Risk of injury and damaging the product!
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 skilled electricians.
AC522
2019/11/15 3ADR024117M02xx, 11, en_US 9
1.1 Assembly
AC522
Assembly
2019/11/153ADR024117M02xx, 11, en_US10
1.2 Disassembly
1.3 Dimensions
The dimensions are in mm and in brackets in inch.
AC522
Dimensions
2019/11/15 3ADR024117M02xx, 11, en_US 11
1.4 Connection
1 I/O bus
2 Allocation between terminal number and signal name
3 8 yellow LEDs to display the signal states C0 - C7
4 1 green LED to display the state of the process supply voltage UP
5 1 red LED to display errors
6 Label
7 Terminal unit TU515/TU516
All I/O channels (digital and analog) are protected against reverse polarity,
reverse supply and continuous overvoltage up to 30 VDC.
AC522
Connection
2019/11/153ADR024117M02xx, 11, en_US12
1.4.1 Process Supply Voltage
CAUTION!
The process supply voltage must be included in the earthing concept (e. g.
earthing of the minus pole).
1.4.2 Inputs/Outputs
Fig. 1: Example for connection input
Examples
AC522
Connection > Inputs/Outputs
2019/11/15 3ADR024117M02xx, 11, en_US 13
Fig. 2: Example for connection output
1.5 Cleaning
Cleaning instruction
Do not use cleaning agent for cleaning the device.
Use a damp cloth instead.
1.6 Certification
1.7 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.
AC522
Recycling
2019/11/153ADR024117M02xx, 11, en_US14
—
2 AI523
● AI523
● AI523-XC
CAUTION!
Risk of injury and damaging the product!
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 skilled electricians.
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.
Hot Swap
AI523
2019/11/15 3ADR024117M02xx, 11, en_US 15
WARNING!
Electric shock due to wrongdoing during hot swapping!
To avoid electric shock
– follow these 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.
– Never touch exposed contacts (dangerous voltages).
– Stay away from electrical contacts to avoid a skipping arc.
– Do not operate improperly mechanical installation.
H = Hot swap
Hot swap
System requirements for hot swapping of I/O modules:
– Hot-swappable terminal units have the appendix TU5xx-H.
– I/O modules as of index F0.
– Communication interface modules CI5xx as of index F0.
The index of the module is in the right corner of the label.
NOTICE!
Risk of damage to I/O modules!
Modules with index below F0 can be damaged when inserted or removed from
the terminal unit in a powered system.
AI523
2019/11/153ADR024117M02xx, 11, en_US16
NOTICE!
Risk of damage to I/O modules!
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.
Hot swapping is only allowed for I/O modules.
Processor modules and communication interface modules must not be removed
or inserted during operation.
Device Min. required device index for I/O module as of
FW Version 3.0.14
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
DC522 (-XC) D2
DC523 (-XC) D2
DC532 (-XC) D2
DC561 B2
DC562 A2
DI524 (-XC) D2
DI561 B2
DI562 B2
DI571 B2
DI572 A1
DO524 (-XC) A3
DO526 A2
DO526-XC A0
DO561 B2
DO562 A2
DO571 B3
AI523
2019/11/15 3ADR024117M02xx, 11, en_US 17
Device Min. required device index for I/O module as of
FW Version 3.0.14
DO572 B2
DO573 A1
DX522 (-XC) D2
DX531 D2
DX561 B2
DX571 B3
FM562 A1
2.1 Assembly
AI523
Assembly
2019/11/153ADR024117M02xx, 11, en_US18
2.2 Disassembly
2.3 Dimensions
The dimensions are in mm and in brackets in inch.
AI523
Dimensions
2019/11/15 3ADR024117M02xx, 11, en_US 19
2.4 Connection
1 I/O bus
2 Allocation between terminal number and signal name
3 16 yellow LEDs to display the signal states at the analog inputs (I0 - I15)
4 1 green LED to display the state of the process supply voltage UP
5 2 red LEDs to display errors
6 Label
7 Terminal unit
Sign for XC version
All I/O channels (digital and analog) are protected against reverse polarity,
reverse supply and continuous overvoltage up to 30 VDC.
AI523
Connection
2019/11/153ADR024117M02xx, 11, en_US20
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