Product Introduction

Model Interpretation

• 1SAP: ABB S500 I/O series prefix

• 2603: Motion module (2×encoder, 2×PWM)

• 0001: Standard hardware revision

• CD522: Commercial type; “C” = control, “D” = drive, “5” = AC500 compatible, “22” = 2 encoder + 2 PWM channels

Technical Parameters

• Encoder Inputs: 2 channels, supports incremental (A/B/Z) and absolute encoders; 5/24 VDC, 2‑wire; max 1 MHz count frequency

• PWM Outputs: 2 channels, 24 VDC, 0.5 A per channel; adjustable frequency (0–100 kHz) and duty cycle (0–100%)

• Digital I/O: 6×sensor DI (5/24 VDC), 10×standard DI (24 VDC), 10×DO (24 VDC/0.5 A)

• Power: 24 V DC ±10%, ≤5 W

• Isolation: 1500 V AC between field and backplane

• Operating Temperature: -25°C to +60°C

• Storage Temperature: -40°C to +70°C

• Protection: IP20

• Dimensions (W×H×D): 142 mm × 35 mm × 123 mm

• Weight: 0.2 kg

• Mounting: 35 mm DIN rail

Interface & Communication

• Field Wiring: Screw terminals for encoder, PWM, and digital I/O; channel‑labeled for easy connection

• System Bus: Direct AC500 backplane connection for high‑speed motion data exchange

• Protocols: PROFIBUS DP, CANopen, Modbus RTU via PLC communication ports

• LED Indicators: PWR (green), RUN (yellow), channel status (yellow), fault (red)

Core Functions

• High‑Speed Position Measurement: 2 encoder channels deliver accurate position/speed feedback for closed‑loop control

• Precision PWM Control: 2 PWM outputs drive motors, valves, and actuators with adjustable frequency and duty cycle

• Integrated Digital I/O: 16 DI/10 DO simplify connection to sensors and actuators, reducing external modules

• Motion Diagnostics: Detects encoder errors, PWM overload, and I/O faults; logs to PLC for quick troubleshooting

Application Scenarios

• Motion Control: Servo/stepper motor control in packaging, machine tools, and material handling

• Process Automation: PWM‑controlled valves, dampers, and actuators in HVAC, water treatment, and chemical industries

• Factory Automation: Conveyor speed control, rotary axis positioning, and synchronous motion applications

Operation & Maintenance

• Installation: DIN rail mount; 20 mm clearance for cooling; avoid dust, moisture, and corrosive environments

• Wiring: Shielded cables for encoder/PWM signals; separate from power cables; torque terminals to 0.5–0.6 Nm

• Configuration: Use Automation Builder/CoDeSys to set encoder type, PWM parameters, and I/O mapping

• Maintenance: Periodic wiring checks; clean with dry cloth; update firmware as needed

• Troubleshooting: PWR off → check 24 V supply; RUN flashing → config error; channel alarm → sensor/wiring fault