ABB AC500 PM564-RP-ETH-AC 1SAP121100R0071 PLC Modules

Technical Dossier

Product Details And Specifications

ABB AC500 Series: Comprehensive Module Range and Technical Overview

The ABB AC500 is a scalable modular PLC platform deployed across global heavy industry sectors including petrochemical refineries, nuclear power auxiliary systems, offshore platforms, pulp and paper mills, and water treatment infrastructure. Its distributed I/O architecture, deterministic scan cycle performance, and IEC 61131-3 compliance make it a standard-bearer in process automation and discrete manufacturing. The AC500 family spans entry-level compact controllers to high-availability redundant CPU configurations, supporting installations from single-machine control to plant-wide SCADA integration. The PM564-RP-ETH-AC (order code 1SAP121100R0071) is a mid-range CPU module within this platform, featuring onboard Ethernet, RS-485, and SD card interfaces, with a program memory of 1 MB and support for up to 512 I/O points.

The Evolution of AC500 Architecture

The AC500 platform was introduced by ABB in the early 2000s as a successor to the CS31 and Advant Controller 31 (AC31) families. The first generation (AC500 V1.x) established the modular backplane concept using the S500 I/O bus, with CPU modules such as the PM571 and PM581 providing foundational processing capability. The second generation introduced the PM5xx series with enhanced memory, faster cycle times, and integrated Ethernet ports, eliminating the need for separate communication adapters for standard TCP/IP connectivity.

The PM564 sub-family specifically targets mid-complexity applications requiring redundant communication paths. The "-RP" suffix denotes the onboard RS-485 port for serial fieldbus connectivity (Modbus RTU, CS31), while "-ETH" confirms the integrated 10/100 Mbps Ethernet port. Compatibility across generations is maintained through the S500 I/O bus standard, allowing PM5xx CPUs to drive legacy S500 I/O modules without hardware modification. The AC500-S (Safety) and AC500-XC (Extreme Condition) variants extend the platform into SIL 3 / PLe safety applications and harsh-environment deployments respectively. As of 2024, the AC500 V3 firmware generation is current production, while V1 and early V2 hardware remains in active field service requiring long-term spare parts support.

AC500 Full Catalog & Functionalities (SKU List)

CPU Modules

• PM554-TP-ETH 1SAP110200R0271: Entry CPU, 256KB RAM, onboard Ethernet, 2 serial ports.
• PM556-TP-ETH 1SAP130000R0271: Mid-entry CPU, 512KB RAM, Ethernet, SD card slot.
• PM564-RP-ETH-AC 1SAP121100R0071: Mid-range CPU, 1MB RAM, RS-485 + Ethernet, AC power supply input.
• PM564-TP-ETH 1SAP121100R0271: Mid-range CPU, 1MB RAM, dual Ethernet ports, DC supply variant.
• PM566-ETH 1SAP130100R0271: Upper-mid CPU, 2MB RAM, Ethernet, extended I/O capacity.
• PM571-ETH 1SAP130200R0271: High-performance CPU, 4MB RAM, dual Ethernet, 2048 I/O points.
• PM581-ETH 1SAP140100R0271: Advanced CPU, 8MB RAM, dual Ethernet, motion control ready.
• PM591-ETH 1SAP140200R0271: Top-tier CPU, 16MB RAM, redundancy-capable, high-speed task execution.
• PM592-ETH 1SAP140300R0271: Redundant CPU module for hot-standby configurations in critical process plants.

Digital Input Modules (DI)

• DI524 1SAP240000R0001: 16x 24VDC digital inputs, S500 bus, standard density.
• DI572 1SAP231100R0001: 32x 24VDC digital inputs, high-density I/O expansion module.
• DI581-S 1SAP281000R0001: 16x safety digital inputs, SIL 2 / PLd rated, AC500-S compatible.

Digital Output Modules (DO)

• DO524 1SAP244000R0001: 16x 24VDC 0.5A digital outputs, S500 bus, transistor type.
• DO572 1SAP235100R0001: 32x 24VDC digital outputs, high-density, short-circuit protected.

Analog Input/Output Modules (AI/AO)

• AI523 1SAP250100R0001: 8x analog inputs, 0–10V / 4–20mA, 12-bit resolution.
• AO523 1SAP250400R0001: 4x analog outputs, 0–10V / 4–20mA, 12-bit resolution.

Communication Adapters

• CI502-PNIO 1SAP221000R0001: PROFINET IO adapter for S500 I/O stations, device role.
• CI504-PNIO 1SAP221100R0001: PROFINET IO controller/device adapter, dual-port switch.
• CI541-DP 1SAP220000R0001: PROFIBUS DP master/slave adapter for distributed I/O expansion.
• CI590-CS31-HA 1SAP221200R0001: CS31 high-availability bus adapter for legacy CS31 I/O integration.

Power Supply Modules

• PS501-PROC-1 1SAP120600R0001: 24VDC system power supply for AC500 CPU rack, 3A output.
• PS560-ME-1 1SAP120700R0001: 24VDC power supply module, 10A, for large I/O configurations.

Sourcing Hard-to-Find & Obsolete AC500 Parts

DriveKNMS maintains a dedicated inventory program for AC500 modules across all hardware generations, including V1-era CPUs (PM571, PM581 original variants) and first-generation S500 I/O modules that have reached end-of-production status with ABB. For facilities operating legacy AC500 installations where a full platform migration is not economically viable, DriveKNMS provides:

• Verified surplus stock of discontinued CPU and I/O modules with full traceability documentation.
• Cross-reference matching between obsolete order codes and current or equivalent replacement part numbers.
• Long-lead procurement support for modules with 12–26 week factory lead times.
• Emergency same-day dispatch for in-stock critical spares to minimize unplanned downtime.

All sourced modules are accompanied by inspection records and, where applicable, original manufacturer packaging and date codes. DriveKNMS does not supply uncertified or remarked components.

Quality Control for the AC500 Range

AC500 CPU modules such as the PM564-RP-ETH-AC incorporate multi-layer PCB backplane interfaces and proprietary S500 bus communication logic that require protocol-level verification beyond standard power-on testing. DriveKNMS applies the following test procedures to all AC500 modules prior to dispatch:

• Backplane Bus Integrity Test: S500 bus signal continuity and timing verification using a reference I/O station to confirm correct data frame exchange.
• Ethernet Port Validation: Link negotiation, ping response, and Modbus TCP / EtherNet/IP frame handling confirmed at 10/100 Mbps.
• RS-485 Serial Port Test: Modbus RTU master/slave transaction verification at 9600–115200 baud.
• Memory Integrity Check: RAM and flash memory sector read/write cycle test to confirm absence of bit-level degradation.
• Firmware Version Logging: Current firmware revision recorded and reported with each unit; downgrade/upgrade compatibility noted per ABB release matrix.
• Thermal Cycling: Modules subjected to operational temperature range cycling (0°C to +60°C) to screen latent solder joint failures.