ABB DC522 1SAP440600R0001
ABB DC522 1SAP440600R0001
ABB DC522 1SAP440600R0001
ABB DC522 1SAP440600R0001
ABB DC522 1SAP440600R0001

ABB DC522 1SAP440600R0001 | Industrial PLC Remote I/O Coupler for AC500 Systems

  • Brand: ABB
  • Model: DC522
  • Product Code: 1SAP440600R0001
  • Product Type: Digital Communication Coupler Module
  • Series: AC500 Series (ABB Advant Controller 500 I/O Family)
  • Core Function: Connects remote I/O stations to AC500 PLC CPUs, manages fieldbus communication (DeviceNet/Profibus DP), and transmits digital signals between controllers and distributed field devices.
  • Key Specs: Supports DeviceNet (up to 500 kbps) and Profibus DP (up to 12 Mbps), 24V DC power input, -25°C to +60°C operating temperature, hot-swappable design, 2W power consumption.
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Description

DC522 1SAP440600R0001: Product Overview
The ABB DC522 (1SAP440600R0001) is a digital communication coupler module within ABB’s AC500 series of I/O systems, designed to bridge AC500 PLC CPUs with remote I/O stations in distributed control architectures. Its primary role is to act as a fieldbus gateway, managing communication between the central controller and geographically dispersed I/O modules (e.g., digital/analog input/output units) via DeviceNet or Profibus DP protocols. This module is critical for reducing wiring complexity in large-scale industrial facilities, where running individual cables from field devices to a central rack is impractical.
Functionally, the DC522 processes cyclic data (real-time I/O updates) and acyclic messages (diagnostic/config commands) from remote stations, converting them into a format compatible with AC500 CPUs. It supports both DeviceNet (for CIP-based networks) and Profibus DP (for Siemens/ABB I/O integration), enabling flexibility in mixed-vendor environments. As part of the AC500 family, the module leverages the platform’s modular scalability, compatibility with CODESYS V3 programming, and seamless integration with ABB 800xA DCS. Benefits include simplified system expansion, reduced installation labor, and unified configuration via ABB’s Automation Builder software.

ABB DC522 1SAP440600R0001

ABB DC522 1SAP440600R0001

DC522 1SAP440600R0001: Technical Specifications
  • Model Number: DC522
  • Product Code: 1SAP440600R0001
  • Manufacturer: ABB
  • Product Type: Digital Communication Coupler Module
  • Communication Protocols: DeviceNet (up to 500 kbps), Profibus DP (up to 12 Mbps)
  • I/O Station Capacity: Up to 8 remote I/O stations per coupler
  • Input Voltage: 24V DC (nominal, 18-32V DC range)
  • Power Consumption: 2W (typical)
  • Operating Temperature: -25°C to +60°C
  • Humidity Range: 5% to 95% non-condensing
  • Dimensions: 25mm x 128mm x 115mm (width x height x depth, fits AC500 I/O rack)
  • Weight: 0.19kg
  • Isolation: 1500VAC (channel-to-bus)
  • Hot Swap Support: Yes (plug-and-play replacement without system shutdown)
  • Certifications: CE, UL, cULus, RoHS
Core Features & Customer Value​
The DC522 1SAP440600R0001 addresses key challenges in distributed I/O integration. Its support for dual protocols (DeviceNet/Profibus DP) eliminates the need for protocol converters, allowing engineers to integrate ABB S800 I/O and third-party devices (e.g., Siemens ET 200) into a single AC500 system. This reduces component count and upfront integration costs.
The module’s ability to connect up to 8 remote I/O stations per coupler minimizes the number of couplers needed in large facilities. For a water treatment plant with 50 distributed sensors, this means fewer couplers to mount and wire, streamlining installation. Remote I/O placement also reduces cable lengths, lowering material costs and susceptibility to electromagnetic interference (EMI).
Hot-swap capability is critical for minimizing downtime. During maintenance, technicians can replace a faulty coupler without de-energizing the AC500 rack, as the CPU automatically reallocates communication tasks. Built-in diagnostics (LED indicators for power, communication status, and faults) accelerate troubleshooting; for example, a broken DeviceNet cable can be identified via error codes without tracing field wiring.
Integration with Automation Builder software enables engineers to configure remote I/O stations, map signals, and monitor communication health from a single interface. This reuse of configuration templates across projects cuts commissioning time by 15-20%, particularly in multi-site rollouts like municipal water systems.

ABB DC522 1SAP440600R0001

ABB DC522 1SAP440600R0001

Typical Applications​
The ABB DC522 1SAP440600R0001 is deployed in AC500 PLC systems requiring distributed I/O. In a petroleum refinery’s crude oil storage area, it connects 6 remote I/O stations (each with 16 digital inputs) monitoring tank level switches and valve positions via Profibus DP. This eliminates 500+ feet of individual sensor cabling to the central control room.
At a chemical plant’s batch reactor complex, the module interfaces 4 DeviceNet-linked I/O stations with agitator motor starters and temperature switch inputs. Its -25°C cold-start capability supports winter startups, and hot-swap functionality allows maintenance during planned turnarounds without halting reactions.
In a municipal wastewater treatment facility, the DC522 links 8 remote pump station I/O racks (monitoring pump status, flow meters) to the central AC500 PLC via DeviceNet. Data is transmitted for remote adjustment of chemical dosing, with the module’s compact size (25x128x115mm) fitting into space-constrained control panels.

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