ABB AC500 Modules: PM564-RP-ETH-AC

Technical Dossier

Product Details And Specifications

ABB AC500 Series Technical Notes

The ABB AC500 is a scalable, modular programmable logic controller platform deployed across heavy industry worldwide — including petrochemical refineries, nuclear auxiliary systems, steel rolling mills, water treatment infrastructure, and offshore oil & gas platforms. Its distributed I/O architecture, deterministic scan cycle, and IEC 61131-3 compliance have made it a de facto standard in process automation projects requiring long service life and multi-vendor integration.

The AC500 platform spans three hardware generations (AC500 V1, AC500 V2, and AC500-eCo), each maintaining backward compatibility at the software level while introducing enhanced CPU performance, expanded communication stacks, and improved environmental ratings. Installed base estimates exceed 500,000 units globally, making long-term spare parts availability a critical operational concern for plant maintenance teams.

The Evolution of AC500 Architecture

The AC500 platform was introduced by ABB in the mid-2000s as a successor to the CS31 and Advant series controllers. The original V1 generation established the S500 I/O bus standard and the TB5xx terminal base ecosystem. Key architectural milestones include:

• AC500 V1 (2006–2012): PM554, PM556, PM564 CPUs with onboard Ethernet and serial ports. S500 I/O modules introduced standardized 8/16-channel DI/DO/AI/AO cards. Limited to 512 I/O points per station.
• AC500 V2 (2012–2020): Refreshed PM5xx-2ETH CPUs with dual Ethernet ports, PROFINET IO controller/device capability, and expanded memory. Introduced the TB5xx-2ETH terminal base family. Backward-compatible with V1 I/O modules.
• AC500-eCo (2014–present): Cost-optimized sub-range targeting smaller machine applications. PM5072-ETH and PM5082-ETH CPUs with integrated I/O. Not compatible with S500 expansion modules.
• AC500 V3 / AC500-S (Safety, 2018–present): SIL 2/3 certified safety CPUs (PM5650-2ETH-AC) for functional safety applications. Integrated with ABB Ability platform for IIoT connectivity.

Compatibility note: V1 terminal bases (TB5xx without -2ETH suffix) are not compatible with V2 CPUs. Procurement teams must verify terminal base generation when sourcing replacement CPUs to avoid field installation failures.

AC500 Full Catalog & Functionalities (SKU List)

The following SKUs represent the core AC500 module range. Each entry reflects verified product functionality within the AC500 ecosystem.

CPU / Controller Modules

• PM554-T-ETH: Entry-level CPU, 256KB program memory, 1x Ethernet, 1x RS-485, 512 I/O max
• PM556-T-ETH: Mid-range CPU, 512KB memory, Modbus TCP/RTU, CANopen master support
• PM564-RP-ETH-AC: High-performance CPU, 1MB program memory, dual RS-232/485, Ethernet, AC power input — the subject SKU of this page
• PM564-T-ETH: Equivalent to PM564-RP-ETH-AC with DC power supply input variant
• PM566-ETH: Advanced CPU with extended I/O capacity, PROFIBUS DP master, 2MB memory
• PM572-ETH: High-end CPU, 4MB memory, redundancy-ready, supports up to 2048 I/O points
• PM581-ETH: Top-tier V1 CPU with 8MB memory, hot-standby redundancy support
• PM591-ETH: V2 generation flagship CPU, dual Ethernet, PROFINET IO controller, 16MB memory
• PM5650-2ETH-AC: AC500-S safety CPU, SIL 2/3 certified, TÜV Rheinland approved

Digital Input (DI) Modules

• DI524: 16-channel 24VDC digital input, S500 bus, standard density
• DI572: 32-channel 24VDC digital input, high-density, S500 bus compatible
• DI581-S: 8-channel safety digital input, SIL 2 rated, for AC500-S systems

Digital Output (DO) Modules

• DO524: 16-channel 24VDC/0.5A transistor output, S500 bus
• DO572: 32-channel digital output, high-density, S500 bus
• DO581-S: 8-channel safety digital output, SIL 2, for AC500-S systems

Analog Input/Output (AI/AO) Modules

• AI523: 8-channel analog input, 0–10V / 4–20mA, 12-bit resolution
• AO523: 4-channel analog output, 0–10V / 4–20mA, 12-bit resolution

Communication & Fieldbus Modules

• CM572-DP: PROFIBUS DP master/slave communication module, S500 bus
• CM574-RS: RS-232/RS-485 serial communication expansion module
• CM577-ETH: Additional Ethernet port expansion for V1 CPUs
• CM589-PNIO: PROFINET IO device adapter for legacy AC500 V1 CPUs

Quality Control for the AC500 Range

AC500 modules — particularly CPU units with onboard Ethernet PHY chips and S500 backplane bus controllers — require specialized test procedures beyond basic power-on verification. DriveKNMS applies the following protocol to all AC500 units prior to dispatch:

• Backplane bus integrity test: Module seated in live AC500 rack; S500 bus communication verified via Automation Builder diagnostic scan
• CPU memory validation: Full program memory read/write cycle executed; flash memory sector health confirmed
• Ethernet port test: Link negotiation, ping response, and Modbus TCP transaction verified on all RJ45 ports
• Serial port test: RS-232 and RS-485 loopback test at 9600 and 115200 baud
• Firmware version check: Firmware version recorded and disclosed to buyer; downgrade/upgrade advisory provided if required
• Visual and mechanical inspection: Capacitor condition, connector pin integrity, conformal coating status, and label authenticity reviewed