The recorded condition monitoring data can be

stored in the CPU flash disk before communica

tion or directly analyzed. Higher level indicators

can be calculated and communicated to a local or

remote HMI or database system.

Predictive performance for your process or machines

• Easy and cost saving integration of condition

monitoring into the AC500 platform.

• Early detection of mechanical damages.

• Fast protection from spontaneous failures.

• Even complex C-code analytics can be used

locally for meaningful own performance

indicators.

• Leads to optimized planning of maintenance

instead of fixed, scheduled service and

spontaneous repair.

• No additional system or fixed software for

diagnostics and visualization needed.

• Easy storage of the data, locally (4GB) or in

remote servers and databases.

• Ideally suited also for retrofit of older equip

ment, as it can make use of mechanical reserves

of still valuable equipment.

Controller integrated or stand-alone condition

monitoring

The AC500 condition monitoring module FM502

is a natural part of the AC500 platform and

Automation Builder engineering suite, and can be

used in different condition monitoring concepts,

stand-alone or control integrated.

Due to the easy programming in PLC languages,

it is usable for a variety of use cases and is espe

cially suitable for plant, line and machine builders

as easy extension of their offering.

If controller integrated

• it enables at very reasonable cost

• the best prediction horizon as it can measure

online, when best measurement quality is given

without scheduling production interruptions

• while continuously protecting the application in

real time e.g. with the same or other sensor(s).

• Further inputs can be used as fast data logger

e.g. precisely documenting process quality.

Therefore it is not only able to continually check

the mechanical components but also gives fast

protection for spontaneous and large failures

even while measuring. The condition monitoring

mode creates a database internally or externally

for predictive maintenance. Automatic and user

assisted responses can be enabled to prevent

costly consequences including total failures.

As many as 16 vibration sensors + 2 encoder

counters can be connected.

Integrated documentation

For engineering, the function blocks for AC500

include the user documentation. The faceplates

provide multi-language support for the text ele

ments and allow adaptation of the color codes of

the elements to the preferences of the application.

Availability

The Process Control Objects Library (PCO) for

AC500 V2 is available in Automation Builder as of

version 2.2.3. The Automation Builder installation

also contains the required OPC server. The corre

sponding 800xA PLC Object Library for 800xA or

Compact HMI can be ordered via the 800xA 6.0.3

add-on features list.

Communication between System 800xA and

AC500 PLC

Communication between the AC500 function

blocks and the objects in System 800xA uses the

PLC Connect option of System 800xA and the

AC500 OPC Server.

Simplified engineering

The Process Control Objects (PCO) library for

AC500 V2 contains a function block for each

object. The control task is engineered with the

AC500 engineering tool Automation Builder.

The communication between the objects in Sys

tem 800xA and the function blocks in AC500 is

configured with Bulk Data Manager, which is part

of the System 800xA Engineering toolset. A li

brary with ready-made symbols and faceplates

for the objects is available for System 800xA engineering.

Integration of AC500 PLC into System 800xA

The AC500 PLC hardware can be used for certain

process control functions while the operator

benefits from user experience in System 800xA.

Proven libraries are provided for System 800xA

and AC500. This allows programming control

tasks in the AC500 PLC while System 800xA is the

operator interface. For large distributed projects,

many AC500 PLCs can be connected to a System 800xA node.

Process Control objects

Twelve objects are available which cover the

following functionalities:

• Digital and analog setpoints

• Analog measurement with threshold alarm functions

• Valve control

• Motor control with or without variable speed drives

• Proportional integral controller

The Modbus masters can access the process data

of the I/O stations in two different ways:

• Fixed mode: each I/O module in the station

uses a separate register address range, which

requires separate Modbus read/write opera

tions for the modules in the station.

• The dynamic mode allows to pack the data of all

I/O modules in the station in one data structure

that can be exchanged in one single read/write operation.

ABB provides a configurator in the Automation

Builder tool, which allows the configuration of

Modbus TCP I/O stations with the communica

tion interfaces CI521-MODTCP or CI522-MODTCP

in the same style as the AC500 configuration. For

larger applications a Bulk Data Manager tool can

be used. The configuration can be stored in the

communication interface, which allows using

the configured station with any PLC or PC that

supports Modbus TCP. This e.g. allows the use

directly on other controllers or monitoring

systems as e.g. ABB Ability™ Data Center Auto

mation or external systems.

S500 remote I/O with Modbus TCP

ABB provides a configurator in the Automation

Builder tool, which allows the configuration of

Modbus TCP I/O stations with the communica

tion interfaces CI521-MODTCP or CI522-MODTCP

in the same style as the AC500 configuration. For

larger applications a Bulk Data Manager tool can

be used. The configuration can be stored in the

communication interface, which allows using

the configured station with any PLC or PC that

supports Modbus TCP. This e.g. allows the use

directly on other controllers or monitoring

systems as e.g. ABB Ability™ Data Center Auto

mation or external systems.

Thanks to the Modbus feature that allows

several masters to exchange data with the same

slave, it is possible to use the I/O station as

shared devices with up to 10 PLC CPUs.

AC500-eCo CPU as S500 remote I/O

When the AC500-eCo compact CPU is used as

remote I/O, it can be programmed with  Automa

tion Builder for local intelligence while communi

cating via the open protocols Modbus TCP or

Modbus RTU with a CPU that will then be the

master of this intelligent remote I/O station. The

AC500-eCo CPU can be expanded by I/O modules

from the S500 and S500-eCo range.

The electronic configuration files that are

provided by ABB for different fieldbus systems

make it easy to configure the S500 remote I/O

station in your engineering tool. The files such as

GSD and GSDML are available for download at

www.abb.com/plc. For Modbus TCP remote I/O

stations a dedicated configurator is included in

Automation Builder and for larger applications a

Bulk Data Manager tool can be used.

Easy engineering

The electronic configuration files that are

provided by ABB for different fieldbus systems

make it easy to configure the S500 remote I/O

station in your engineering tool. The files such as

GSD and GSDML are available for download at

www.abb.com/plc. For Modbus TCP remote I/O

stations a dedicated configurator is included in

Automation Builder and for larger applications a

Bulk Data Manager tool can be used.

The availability of different fieldbus communi

cation interfaces makes it easy to use S500 I/O

modules as remote I/O for nearly any PLC and

PC. The S500 remote I/O station consists of a

communication interface and I/O modules. The

smallest configuration can be just the communi

cation interface with the onboard I/O channels.

S500 remote I/O

The availability of different fieldbus communi

cation interfaces makes it easy to use S500 I/O

modules as remote I/O for nearly any PLC and

PC. The S500 remote I/O station consists of a

communication interface and I/O modules. The

smallest configuration can be just the communi

cation interface with the onboard I/O channels.

Communication interfaces are available for the

following fieldbuses:

• PROFIBUS

• PROFINET/PROFIsafe

• EtherCAT

• Modbus TCP

• CANopen

• ABB CS31 System Bus

The files such as

GSD and GSDML are available for download at

www.abb.com/plc. For Modbus TCP remote I/O

stations a dedicated configurator is included in

Automation Builder and for larger applications a

Bulk Data Manager tool can be used.