3BHB030310R0001 GVC736CE101
3BHB030310R0001 GVC736CE101
3BHB030310R0001 GVC736CE101
3BHB030310R0001 GVC736CE101
3BHB030310R0001 GVC736CE101

ABB 1SAP220700R0001 CI502 | 16-Channel DeviceNet I/O Adapter for AC500 PLC

  • Model: 1SAP220700R0001 CI502
  • Alt. P/N: N/A
  • Series: AC500 Series
  • Type: Communication Interface Module
  • Key Feature: 16-channel (8 digital inputs, 8 digital outputs) DeviceNet I/O
  • Primary Use: Connecting AC500 PLC CPUs to DeviceNet-enabled sensors, actuators, and remote I/O stations
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Part number: ABB 1SAP220700R0001 CI502
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Description

Key Technical Specifications​
  • Model Number: 1SAP220700R0001 CI502
  • Manufacturer: ABB
  • Protocol Support: DeviceNet (CIP, V1-compliant, up to 500 kbps)
  • Number of I/O Channels: 16 (8 inputs, 8 outputs, individually configurable)
  • Input Type: 24V DC, sinking/sourcing (per channel)
  • Output Type: 24V DC, sourcing (0.5A max per channel)
  • Isolation Voltage: 500V AC (channel-to-bus, channel-to-channel)
  • Operating Temperature: 0°C to +55°C
  • Humidity Range: 5% to 95% non-condensing
  • Power Supply: 24V DC (from AC500 rack backplane, 20.4-28.8V DC range)
  • Power Consumption: 2.0W (typical, all channels active)
  • Dimensions: 160mm x 30mm x 100mm (width x height x depth)
  • Weight: 0.25kg
  • Certifications: CE, UL, cULus, RoHS

    3BHB030310R0001 GVC736CE101

    3BHB030310R0001 GVC736CE101

Field Application & Problem Solved​
In the field, the biggest headache with AC500 PLCs is integrating DeviceNet devices—proximity switches, pneumatic valves, or remote I/O stations—without cluttering the control panel with multiple adapters. Before this module, engineers often jury-rigged solutions with third-party gateways, leading to wiring nightmares and scan time overruns. The CI502 solves that by being a native AC500 I/O rack resident: plug it into a communication slot, and it becomes the PLC’s DeviceNet gateway.
You’ll find this module in automotive assembly lines (welding stations syncing robots with part sensors), electronics manufacturing (pick-and-place robots with vacuum sensors), and logistics warehouses (palletizers talking to conveyor I/O). Its core value is consolidation: 16 channels (8 in/8 out) replace multiple single-channel adapters, cutting wiring by 30-40%. More importantly, it offloads DeviceNet polling from the CPU—critical for high-speed applications where scan time matters. In a 24/7 plant, that means fewer missed part detections and less downtime chasing communication faults.
Installation & Maintenance Pitfalls (Expert Tips)​
Termination Resistors Are Non-Negotiable: A rookie mistake is skipping the 121-ohm termination resistors on the DeviceNet trunk line. Without them, signal reflection corrupts data—you’ll see intermittent “device not found” errors. Install one at each physical end of the network, period.
Verify Sink/Source Configuration: Each input channel can be sinking or sourcing, but leaving it default when connecting a sourcing sensor (or vice versa) causes a dead short. Check the field device’s datasheet beforewiring—match the CI502’s setting in ABB Automation Builder. I’ve seen entire production lines halt because someone assumed “auto” worked.
Grounding the Shield Correctly: The module has 500V isolation, but the DeviceNet cable shield must be grounded at one end only(usually the PLC rack). Double-grounding introduces ground loops, leading to noise-induced false triggers. Use a shielded twisted-pair cable with the drain wire connected to the rack’s ground bar.
Hot-Swap Only When Rack Has Redundant Power: The CI502 is hot-swappable, but if the AC500 rack’s power isn’t redundant, yanking it live can brown out the backplane. Always confirm redundant power status first—better to schedule a 5-minute stop than risk a full rack reset.
Use LEDs for Fast Diagnosis: The module has power (green), communication (yellow), and I/O status (red) LEDs. If a valve isn’t actuating, check the output LED first—if it’s off, the PLC isn’t sending the signal; if it’s on but the valve doesn’t move, the output channel or wiring is bad. Saves hours of digging through code.

3BHB030310R0001 GVC736CE101

3BHB030310R0001 GVC736CE101

Technical Deep Dive & Overview​
The CI502 is an intelligent communication coupler designed for ABB’s AC500 PLC ecosystem. It acts as a protocol translator: the AC500 CPU sends digital commands (e.g., “open valve”) via the rack backplane to the CI502, which converts them to DeviceNet CIP messages for field devices. Conversely, it reads DeviceNet inputs (e.g., “part present”) and maps them to AC500 I/O addresses.
Inside, it has a dedicated processor for DeviceNet message handling, isolating this task from the PLC’s main CPU—this prevents scan time spikes when polling multiple devices. The 16 channels share a single DeviceNet port, with each channel’s I/O state updated cyclically (every 10-20ms, depending on network load). Isolation (500V AC) protects the PLC from ground loops, a common issue in motor control centers where VFDs induce noise.
It’s not just a gateway; it’s a diagnostic tool. Built-in error logging captures faults like overcurrent (output channel short) or communication timeouts, viewable in Automation Builder. For field work, that means you can pull the module, swap it with a spare, and upload the logged faults to troubleshoot offline—no need to keep the machine running while you debug.

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