CI500 interface modules serve as the foundation for building distributed I/O stations, offering flexible connectivity to various fieldbus systems. Fully compatible with S500 and S500-eCo I/O modules.

Benefits

AC500 interface modules connect fieldbus, serial, and distributed I/O systems – making your control system adaptable and integration-friendly. Perfect for tailoring I/O and communication to your specific setup.

Flexible connectivity and scalable integration

AC500 communication interface modules enable seamless networking for remote I/Os and distributed peripherals. With support for multiple protocols, they ensure future-ready automation across all system sizes.

Beyond communication, they offer onboard functions like fast counters and configurable I/O channels to boost application flexibility.

Supported protocols:

EtherCAT

PROFINET

PROFIBUS DP

CANopen

Modbus TCP

ABB CS31

S500 I/O modules

Modular I/O modules support a wide range of signal types. They are suitable for both centralized control and remote I/O expansion.

Flexible I/O integration for every application

With S500 I/O modules, you can easily adapt your system architecture to project needs – whether centralized, decentralized, or multifunctional. Mix and match connection types to build exactly what your automation solution requires:

Central

Via the local I/O bus of the CPU module

Connect up to 10 I/O modules directly to the CPU

Decentralized

Using fieldbus links between CPU and remote I/O

Each fieldbus slave can host up to 10 modules

Multifunctional

Some modules, like the AI531. handle up to 8 different analog signal types in one device

Related videos

Explore more in action – watch how our PLC solutions perform across real-world applications, expert tutorials, and product highlights.

S500 I/O modules Terminal units

ABB terminal units provide a reliable foundation for connecting I/O modules to the AC500 system. They simplify wiring, support fast module replacement, and offer flexible mounting options for various installation needs. Designed to ensure long-term stability in industrial environments.

TU56xx Terminal Units – The foundation of reliable field connectivity

Every great automation system starts with a solid connection.

TU56xx terminal units provide the essential hardware backbone for S500 I/O and CI5xx modules, ensuring secure, organized, and efficient wiring from field to controller.

Designed for quick installation and service-friendly access, these terminal units simplify commissioning, reduce downtime, and enhance overall system reliability.

With mechanical robustness and a layout optimized for industrial environments, TU56xx keeps your signals stable, your cabinet clean, and your automation running without interruptions.

Benefits

S500 terminal units provide the solid foundation for connecting I/O modules within the AC500 system. With flexible mounting options and tool-free wiring, they support fast installation, reliable signal transmission, and simplified maintenance.

AC500 Condition monitoring system CMS

CMS modules detect faults and wear before failure occurs. This supports predictive maintenance and reduces costly downtime.

Unlock smart diagnostics with FM502-CMS

Boost operational efficiency and machine reliability with the FM502-CMS module – your gateway to advanced condition monitoring on the AC500 PLC platform. Designed for fast protection and precise diagnostics, it supports both stand-alone and integrated CMS setups with ease.

Key Features of the FM502-CMS Module:

• Onboard analytics with support for up to 16 standard CMS sensors per module
• Function block library for advanced signal processing and customized calculations
• Automatic generation of compact WAV files synchronized with encoder signals
• Instant availability of input values in the CPU I/O image for fast protection, even without active measurements
• BenefitsThe CMS system tracks wear and faults in real time – enabling predictive maintenance and preventing costly downtime. It’s the ideal upgrade for smarter asset management.

AC500-eCo option modules

AC500-eCo option modules add communication and I/O flexibility to your PLC without affecting the system’s footprint. They allow easy customization to fit your specific application needs.

Smart expansion for AC500-eCo V3

Need more I/Os or communication ports?

With AC500-eCo V3 option boards, you can easily tailor your PLC setup – no extra space or wiring needed.

Highlights:

• Up to 3 option boards depending on CPU type
• Add digital or analog I/Os
• Serial communication via RS232, RS485, or CAN
• Real-time clock and KNX support
• Fast installation, no extra wiring
• BenefitsAC500-eCo option modules let you tailor your automation solution to match your connectivity and performance needs.

AC500-eCo Accessories

Practical accessories support fast installation and maintenance. They include wiring kits, memory options, and mounting tools tailored for the AC500-eCo platform.

Safety specifications are generally applicable to control system handling. Instructions and warnings related to a specific subject or operation of the product.

The following norms must be strictly observed:

 must strictly comply with the technical specifications and typical applications of the product system

 Personnel training: Only trained personnel shall install, operate, maintain or repair the product system. must

Provide guidance and explanation of the situation in danger areas to these personnel.

 Unauthorized changes: Changes or structural changes to the product system may not be made.

 Maintenance responsibility: Must ensure that the product system is used only under appropriate conditions and in full fitness for use.

 Working environment: The user must meet the specified environmental conditions:

Safety regulation

The following safety provisions of EN 50110-1 shall be fully complied with when handling product systems (maintenance) :

1 Disconnect completely.

2 Secure to prevent reconnection.

3 Verify that the installation is complete.

4 Ground and short-circuit the device.

Warning: Only qualified maintenance personnel can remove and insert the module. In order to ensure the personal safety of the operator, before each pulling out or inserting, you must

Disconnect the power supply and ensure that there is no voltage on all terminals at the back, and the product is effectively grounded with the ground screw at the back.

Automation Builder

ABB’s Automation Builder is an integrated software suite for efficiently programming and configuring PLCs, drives, HMIs, and motion control systems, streamlining industrial automation engineering from design to commissioning.

Your all-in-one automation platform

Automation Builder simplifies PLC and motion control engineering – with integrated tools, flexible programming, and full system transparency.

Unified environment for PLC, HMI, drive, and motion

Multi-language support (IEC 61131-3. etc.)

Scalable from small machines to complex systems

Reusable code blocks and libraries

Seamless integration with Panel Builder 600

Benefits

Automation Builder offers a powerful and unified engineering environment for PLCs, drives, HMIs, and motion control – ideal for efficient, scalable automation projects. It simplifies development and accelerates commissioning with integrated features.

AC500-S

AC500-S combines standard automation with certified functional safety, making it ideal for applications requiring SIL 3 / PL e compliance. It scales easily from basic safety requirements to complex safety architectures over PROFINET/PROFIsafe, offering flexibility and performance in a single, integrated platform.

Functional safety with AC500-S

When safety is critical, trust a system that’s built to protect. The AC500-S combines certified SIL 3 / PL e compliance with powerful control – ensuring people, machines, and processes are safeguarded in one integrated platform.

AC500-S CPUs

The three integrated AC500-S CPUs are certified for safety applications up to SIL 3 and PL e. With scalable safety capabilities, they support solutions ranging from basic safety needs to advanced safety features for applications such as autonomous machines.

Certified safety ‒ seamlessly integrated

The AC500-S Safety PLC and I/O modules deliver powerful and flexible functional safety for applications ranging from basic to complex. The system supports PROFINET/PROFIsafe communication across multi-host networks with high-speed data exchange. Flexible configuration, intuitive programming, and XC variants make it a perfect fit for demanding environments.

AC500-S S500 I/O modules

Safety I/O modules ensure secure signal processing. They are ideal for applications with emergency stops, guard monitoring, and zone control.

Certified protection you can rely on

All AC500-S I/O modules are certified to SIL3 and PL e standards – ensuring safe and compliant automation. Whether used centrally or remotely via PROFINET/PROFIsafe, they offer high performance and flexible integration.

• DI581-S: Up to 16 (SIL2) or 8 (SIL3) digital safety inputs, fully protected and designed for long cable runs.
• DX581-S: Combine digital safety in- and outputs in one module up to SIL3-certified channels.
• AI581-S: Four fast analog input module with 14-bit resolution and SIL3 support for current signals.
• TU582-S: Reliable spring-type terminal unit for clean, tool-free installation.

All modules are also available in XC versions – for extreme environmental conditions like vibration, cold, or humidity.

Benefits

S500-S Safety I/O modules ensure secure, real-time handling of safety-relevant signals – from emergency stops to zone control. They’re designed for speed, reliability, and full integration with AC500-S CPUs.