Description
Detailed parameter table
| Parameter name | Parameter value |
| Product model | CI502-PNIO |
| Manufacturer | ABB |
| Product category | PROFINET IO controller module |
| Communication protocols | PROFINET IO, PROFINET IRT (Isochronous Real-Time) |
| Data transfer rate | 100 Mbps (full duplex) |
| Number of ports | 2 x RJ45 Ethernet ports (with switch functionality) |
| Supported IO devices | Up to 128 PROFINET IO devices |
| Real-time cycle | Down to 1 ms (IRT) |
| Operating voltage | 24 V DC ±10% |
| Power consumption | Max 5 W |
| Operating temperature range | -25°C to +60°C (-13°F to +140°F) |
| Dimensions (LxWxH) | 100 mm x 80 mm x 120 mm (3.94 in x 3.15 in x 4.72 in) |
| Protection rating | IP20 |
| Compatibility | ABB AC 500 PLC series, AC 500-eCo |
| Installation type | DIN rail mounting (35 mm) |
| Certification | IEC 61131-2, CE, UL, ATEX, IECEx |
ABB CI502-PNIO
Product introduction
The ABB CI502-PNIO is a high-performance PROFINET IO controller module designed for seamless integration with ABB’s AC 500 and AC 500-eCo PLC systems. This module serves as a critical communication hub, enabling industrial automation systems to connect with PROFINET IO devices—such as sensors, actuators, drives, and HMIs—via fast, deterministic Ethernet-based communication.
ABB CI502-PNIO supports both standard PROFINET IO and isochronous real-time (IRT) communication, making it suitable for applications requiring precise synchronization and low latency. Its dual Ethernet ports with switch functionality simplify network topology design, allowing for linear or ring configurations with redundancy. Whether deployed in manufacturing lines, material handling systems, or process control environments, ABB CI502-PNIO enhances system connectivity, improves data exchange efficiency, and ensures reliable operation in industrial networks.
Core advantages and technical highlights
Deterministic real-time performance: ABB CI502-PNIO supports PROFINET IRT, enabling isochronous communication with cycle times as low as 1 ms. This ensures precise synchronization of connected devices, critical for high-speed applications such as assembly lines, robotic cells, and motion control systems where timing accuracy directly impacts productivity.
Flexible network integration: Equipped with two 100 Mbps Ethernet ports with built-in switch functionality, ABB CI502-PNIO simplifies network design by allowing daisy-chaining of IO devices. This eliminates the need for external switches in small to medium-sized networks, reducing hardware costs and simplifying wiring.
High device capacity: The module can manage up to 128 PROFINET IO devices, making it suitable for large-scale automation systems. This scalability allows for easy expansion of the network as production needs grow, without requiring hardware upgrades to the controller module.
Industrial-grade reliability: ABB CI502-PNIO operates reliably across a wide temperature range (-25°C to +60°C) and resists electromagnetic interference (EMI), vibration, and voltage fluctuations. Its rugged design ensures stable performance in harsh industrial environments, including dusty factories, humid facilities, and areas with heavy electrical noise.
Typical application scenarios
In automotive manufacturing plants, ABB CI502-PNIO connects AC 500 PLCs to robotic workcells, conveyor systems, and vision inspection devices via PROFINET. Its IRT capability ensures synchronized operation of robots and conveyors, with cycle times of 1 ms enabling precise part handling and assembly. The module’s dual ports allow for a redundant ring network, minimizing downtime in case of cable failures.
Within packaging lines, ABB CI502-PNIO integrates with AC 500-eCo PLCs to control filling machines, labeling systems, and cartoners. Its fast data transfer rate ensures real-time feedback from sensors monitoring package quality, while PROFINET IO enables easy parameterization of variable speed drives for adjusting line speeds based on production demand.
In material handling systems, such as automated warehouses, ABB CI502-PNIO connects PLCs to stacker cranes, conveyor belts, and barcode scanners. Its ability to manage multiple IO devices ensures coordinated movement of goods, while deterministic communication prevents collisions and optimizes throughput in high-traffic storage facilities.
ABB CI502-PNIO
Related model recommendations
ABB CI501-PNIO: A compact variant of ABB CI502-PNIO with a single Ethernet port, suitable for smaller networks requiring basic PROFINET IO functionality.
ABB CM578-ETH: Ethernet communication module for AC 500 PLCs, complementing ABB CI502-PNIO with additional protocol support (Modbus TCP/IP) for mixed-network environments.
ABB AC500 PLC PM590: High-performance CPU module that pairs with ABB CI502-PNIO to handle complex control tasks in large automation systems.
ABB TB511: Terminal base for ABB CI502-PNIO, providing secure mounting and wiring connections in AC 500 PLC racks.
ABB 800xA PROFINET Configuration Tool: Software for setting up and diagnosing PROFINET networks using ABB CI502-PNIO, simplifying device commissioning and parameterization.
ABB CI854: PROFINET IO device module that extends the network by adding remote IO capabilities to systems using ABB CI502-PNIO.
ABB RD560: Redundancy module that works with ABB CI502-PNIO to enable redundant CPU configurations, enhancing system availability in critical applications.
Installation, commissioning and maintenance instructions
Installation preparation: Before installing ABB CI502-PNIO, ensure the DIN rail is securely mounted in a dust-free enclosure with ambient temperature between -25°C and +60°C. Required tools include a torque wrench (set to 0.5 Nm for terminal connections), Ethernet cable tester, and screwdrivers. Use shielded twisted-pair Ethernet cables (Cat 5e or higher) to minimize EMI, and route them separately from power cables. Verify that the 24 V DC power supply is properly grounded and protected by a 1A fuse. Allow 20 mm clearance around the module for ventilation.
Maintenance suggestions: For ABB CI502-PNIO, perform monthly visual inspections to check for loose Ethernet connectors or damaged cables. Clean dust from ventilation slots quarterly using compressed air (max 5 bar). Monitor network performance using ABB’s PROFINET configuration tool, checking for packet loss, latency, or device disconnections. If communication faults occur, verify cable integrity with a tester and check for IP address conflicts. Update firmware annually to ensure compatibility with the latest PROFINET specifications and security patches. When replacing the module, back up network configurations first to minimize recommissioning time.
Service and guarantee commitment
ABB CI502-PNIO is backed by a 3-year warranty from the date of purchase, covering manufacturing defects and performance issues under normal operating conditions. ABB’s technical support team provides 24/7 assistance for network configuration, troubleshooting, and integration with AC 500 PLCs, with response times guaranteed within 8 hours for critical inquiries.
We offer on-site commissioning services for ABB CI502-PNIO, including network design, device configuration, and IRT cycle time optimization. Extended warranty options up to 5 years are available, including annual network health checks. In the event of a fault, ABB guarantees a 48-hour repair turnaround at regional service centers, with replacement modules available for next-day delivery to minimize downtime. All repairs use genuine ABB components, ensuring ABB CI502-PNIO maintains its original real-time performance and network capacity.
