ABB AC500 PM564-TP-ETH 1SAP121100R0071 CPU Module

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 heavy industrial sectors including petrochemical refineries, nuclear power auxiliary systems, offshore oil & gas platforms, pulp and paper mills, and large-scale water treatment infrastructure. Its distributed I/O architecture and deterministic real-time execution make it a reference-class controller in process automation environments where mean-time-between-failure (MTBF) requirements exceed 100,000 hours. The AC500 family spans entry-level compact CPUs to high-availability redundant configurations, supporting IEC 61131-3 programming languages and fieldbus protocols including PROFIBUS, PROFINET, EtherNet/IP, Modbus TCP, and CANopen. Installed base globally exceeds several hundred thousand units, with active deployments in facilities operated by major energy, chemical, and infrastructure companies across Europe, Asia-Pacific, and the Americas.

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) established the modular CPU + terminal unit (TU) concept, where CPUs mount onto dedicated terminal units that provide field wiring connectivity and bus interface. This mechanical separation allows CPU replacement without rewiring — a critical maintainability feature in live plant environments.

The second generation introduced the S500 I/O expansion modules with enhanced diagnostics and the PM5xx CPU range, covering performance tiers from PM510 (entry) through PM591 (high-end). Communication was extended with dedicated CM (Communication Module) adapters for PROFIBUS DP, DeviceNet, and CANopen. The PM564-TP-ETH (1SAP121100R0071) represents the mid-range tier of this generation, integrating dual Ethernet ports natively on the CPU for PROFINET and Modbus TCP without requiring an external CM module.

The third generation (AC500 V3, introduced circa 2018–2020) brought the PM5650, PM5670, and PM5690 CPUs with increased memory, faster cycle times, and IEC 62443 cybersecurity compliance. Legacy AC500 V1/V2 I/O modules (S500 series) retain backward compatibility with V3 CPUs via the same TB (Terminal Base) mechanical interface, protecting existing field wiring investments. For plants running PM564-TP-ETH units, migration paths to PM5650 or PM5670 are documented in ABB migration guide 2CDC135025M0201.

AC500 Full Catalog & Functionalities (SKU List)

CPU Modules

• PM510 / 1SAP110100R0270: Entry-level CPU, 256 KB program memory, single Ethernet port, compact applications.
• PM531 / 1SAP130100R0270: Mid-entry CPU, 512 KB program memory, RS-232/RS-485, no onboard Ethernet.
• PM554-T / 1SAP110300R0271: Mid-range CPU with onboard PROFIBUS DP master, 1 MB program memory.
• PM564-TP-ETH / 1SAP121100R0071: Mid-high CPU, dual Ethernet (PROFINET + Modbus TCP), 4 MB program memory, SD card slot, USB programming port.
• PM573-ETH / 1SAP130300R0278: High-performance CPU, 8 MB program memory, dual Ethernet, extended I/O capacity up to 512 DI/DO.
• PM591 / 1SAP140100R0270: Top-tier V2 CPU, 16 MB program memory, redundancy-capable, high-speed task execution <1 ms.
• PM5650-2ETH / 1SAP450100R0001: AC500 V3 mid-range CPU, dual Ethernet, IEC 62443 security, 8 MB user memory.
• PM5670-2ETH / 1SAP460100R0001: AC500 V3 high-performance CPU, 16 MB user memory, extended diagnostics.
• PM5690-2ETH / 1SAP470100R0001: AC500 V3 top-tier CPU, 32 MB user memory, redundancy support.

Digital I/O Modules (S500 Series)

• DC532 / 1SAP220200R0001: 16 DI (24 VDC), 8 DO (transistor), standard density digital I/O.
• DC552 / 1SAP240200R0001: 16 DI / 16 DO (relay), mixed digital I/O for relay-switched outputs.
• DI524 / 1SAP210500R0001: 32-channel digital input module, 24 VDC, high-density.
• DO526 / 1SAP220600R0001: 16-channel digital output, 24 VDC transistor, 0.5 A per channel.

Analog I/O Modules (S500 Series)

• AI523 / 1SAP250100R0001: 8-channel analog input, 0–10 V / 0–20 mA / 4–20 mA, 12-bit resolution.
• AO523 / 1SAP250200R0001: 4-channel analog output, 0–10 V / 4–20 mA, 12-bit resolution.
• AI531 / 1SAP250500R0001: 8-channel analog input with HART pass-through capability.

Communication Modules

• CM572-DP / 1SAP170010R0001: PROFIBUS DP master/slave communication module for AC500 CPUs without onboard PROFIBUS.
• CM575-DN / 1SAP170100R0001: DeviceNet master communication module.
• CM589-PNIO / 1SAP170900R0001: PROFINET IO controller module for CPUs without native PROFINET.

Power Supply Modules

• PS501-PROG / 1SAP190100R0001: AC500 programming and configuration software (Automation Builder), not a hardware module — listed for completeness of the ecosystem.
• CP600 HMI Panel / 1SAP500900R0001: Operator panel series integrated with AC500 via Ethernet, 7-inch to 15-inch variants.

Sourcing Hard-to-Find & Obsolete AC500 Parts

The AC500 V1 and early V2 CPU modules — including the PM510, PM531, PM554-T, and PM564-TP-ETH — have entered the mature/end-of-active-production phase. ABB's official last-order dates for several V2 SKUs have passed, shifting procurement responsibility to the secondary market and authorized spare parts distributors. DriveKNMS maintains a dedicated inventory buffer for AC500 V2 CPUs and S500 I/O modules, sourced through verified OEM-surplus and controlled decommissioning channels.

For the PM564-TP-ETH (1SAP121100R0071) specifically, DriveKNMS provides: (1) unit-level availability from tested surplus stock; (2) cross-reference validation against the terminal unit TU516-ETH (1SAP214000R0001) to ensure mechanical and electrical compatibility; (3) firmware version documentation to match the replacement unit to the existing project's Automation Builder version requirements. Plants operating on extended maintenance contracts beyond ABB's standard support window can engage DriveKNMS for multi-year supply agreements covering both CPU and associated I/O modules.

Quality Control for the AC500 Range

AC500 CPU modules present specific test challenges due to their integrated dual-Ethernet PHY, SD card controller, and backplane communication bus (internal S-Bus). DriveKNMS applies the following test protocol to all AC500 CPU units prior to dispatch:

• Power-on and boot sequence verification: Unit is powered via the correct TU (Terminal Unit) with 24 VDC supply; boot LED sequence is logged against ABB diagnostic codes.
• Ethernet port continuity and link negotiation: Both ETH1 and ETH2 ports are tested for 10/100 Mbps auto-negotiation and physical layer integrity using a network analyzer.
• Automation Builder connectivity test: CPU is connected via USB programming port; Automation Builder establishes online connection, reads firmware version, and confirms project download capability.
• S-Bus backplane communication test: A reference S500 I/O module (DC532) is mounted on the terminal unit; the CPU is verified to enumerate and communicate with the I/O module over the internal S-Bus.
• SD card slot functional test: A formatted SD card is inserted; the CPU is verified to read/write configuration data correctly.
• Thermal stress cycle: Unit operates under load for a minimum of 2 hours at ambient temperature before final inspection and packaging.

All units are shipped with a test report, firmware version label, and ESD-protective packaging compliant with IEC 61340-5-1.