Safety instructions

Industrial environment The products have been designed for use in an industrial environment in com pliance with the 2014/30/EU directive.

Relevant standards and regulations, accident prevention regulations and regulations on special environmental conditions must be observed (e.g. hazardous areas due to explosive substances, heavy soiling or corrosive influences). The devices must be handled and operated within the specified technical data and system data. The devices contain no serviceable parts and must not be opened. Removable covers must be closed during operation unless otherwise specified. If the equipment is used in a manner not specified by ABB, the protection provided by the equip ment may be compromised. Any liability for the consequences of incorrect use or unauthorized repairs is rejected.

Qualified per sonnel

Both the AC500 control system and other components in the vicinity are operated with dan gerous touch voltages. Touching live components can lead to serious health implications or even death.

To avoid such risks and the occurrence of property damage, persons involved in the installation, commissioning and maintenance must have relevant knowledge about the following:

● Automation technology 

● Handling of hazardous voltages 

● Application of relevant standards and regulations (e.g. EN 60204-1), accident prevention regulations and regulations on special environmental conditions (e.g., hazardous areas due to explosive substances, heavy soiling or corrosive influences)

Functional safety

The AC500-S safety user manual must be read and understood before using the safety configu ration and programming tools of Automation Builder/PS501 Control Builder Plus. Only qualified personnel are permitted to work with AC500-S safety PLCs.

General infor mation

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variants and requirements associated with any particular installation, ABB cannot assume responsibility or liability for actual use based on the examples and diagrams. The PLC was developed according to the relevant standards. Any module-specific measures are described in the individual descriptions of the modules.

PLC-specific safety notices

The product family AC500 control system is designed according to the EN 61131-2 and IEC 61131-2 standards. Any data that differs from IEC 61131-2, is due to the higher requirements of Maritime Services. Other differences are described in the technical data description of the devices.

NOTICE!

Avoidance of electrostatic charging

PLC devices and equipment are sensitive to electrostatic discharge, which can cause internal damage and affect normal operation.

Observe the following rules when handling the system:– Touch a grounded object to discharge potential static.

– Wear an approved grounding wrist strap.

– Do not touch connectors or pins on component boards.

– Do not touch circuit components inside the equipment.

– If available, use a static-safe workstation.

– When not in use, store the equipment in appropriate static-safe packaging.

NOTICE!

The devices must be mounted in a control cabinet that ensures compliance with the specified environmental conditions.

Cleaning instructions

Do not use cleaning agent for cleaning the device. Use a damp cloth instead.

Connection plans and a user program must be created so that no dangerous situations can occur during normal operation or failure. The application must be tested to ensure that no dangerous situations can occur during opera tion.

Do not operate devices outside of the specified, technical data! Trouble-free functioning cannot be ensured outside of the specified data.

NOTICE

PLC damage due to missing grounding

– Make sure to ground the devices.

– The grounding (switch cabinet grounding) is supplied both by the mains connection (or 24 V supply voltage) and via the DIN rail. The DIN rail must be connected to ground before power is supplied to the device. The grounding may be removed only if it is certain that no more power is being supplied to the control system.

– In case of screw mounting, use metal screws for grounding.

CAUTION!

Do not obstruct the ventilation for cooling! The ventilation slots on the upper and lower sides of the devices must not be covered.

CAUTION! Run signal and power wiring separately! Signal and supply lines (power cables) must be laid out so that no malfunctions due to capacitive and inductive interference can occur (EMC).

WARNING! Warning sign on the module! This indicates that dangerous voltages may be present or that surfaces may have dangerous temperatures.

WARNING! Splaying of strands can cause hazards! Avoid splayed strands when wiring terminals with stranded conductors.– Ferrules can be used to prevent splaying.

WARNING! Removal/Insertion under power Removal or insertion under power is permissible only if all conditions for hot swapping are fullfilled. Ä “Conditions for hot swap” on page 5 The devices are not designed for removal or insertion under power when the conditions for hot swap do not apply. Because of unforeseeable consequences, it is not allowed to plug in or unplug devices with the power being ON. Make sure that all voltage sources (supply and process voltage) are switched off before doing any of the following actions:– Connect or disconnect any signal or terminal block.– Remove, mount or replace a module. Disconnecting any powered devices while they are energized in a hazardous location could result in an electric arc, which could create an ignition source resulting in fire or explosion. Prior to proceeding, make sure that power is been disconnected and that the area has been thoroughly checked to ensure that flammable materials or ignit able concentrations are not present. The devices must not be opened when in operation. The same applies to the network interfaces.

NOTICE! Except when using hot swap terminal units, the I/O bus is not designed for pulling and plugging modules during operation. If a module is pulled or plugged on a terminal unit that is not hot swap capable while the bus is running, the following consequences are possible.

– Reset of the station or of the processor module.

– System lockup.– Damage of the module.

NOTICE! Risk of device damage!– I/O modules with a device index above F0 can be hot-swapped. When I/O modules below F0 are inserted or removed from the terminal unit in a powered system the I/O modules can be damaged. Before hot swapping a device, check the device index and ensure that the modules meet the requirements.

– Terminal units that support hot swapping of I/O modules have the appendix TU5xx-H.

– Hot swap is not supported by AC500-eCo CPU! The following I/O bus masters support hot swapping of attached I/O modules:

– Communication interface modules CI5xx as of index F0.

– Processor module PM585-ETH with firmware version as of V2.8.1.

– Processor modules PM56xx-2ETH with firmware version as of V3.2.0.

NOTICE! Risk of damage to I/O modules! Hot swapping is only allowed for I/O modules. Processor modules and communication interface modules must not be removed or inserted during operation.

Conditions for hot swapping–Digital outputs are not under load.

–Input/output voltages above safety extra low voltage/ protective extra low voltages (SELV/PELV) are switched off.–Modules are completely plugged on the terminal unit with both snap fit engaged before switching on loads or input/output voltage.

CAUTION! Use only ABB approved lithium battery modules! At the end of the battery’s lifetime, always replace it only with a genuine battery module.

CAUTION! Risk of explosion! Do not open, re-charge or disassemble primary lithium battery. Attempting to charge primary lithium battery will lead to overheating and can cause explo sions. Protect them from heat and fire and store them in a dry place. Never short-circuit or operate primary lithium battery with the polarities reversed. The primary lithium battery are likely to overheat and explode. Avoid unintentional short circuiting do not store primary lithium batteries in metal con tainers and do not place them on metallic surfaces. Escaping lithium is a health hazard.

Environment considerations Recycle exhausted batteries. Dispose of batteries in an environmentally con scious manner in accordance with regulations issued by the local authorities.