ABB 560CMD11 1KGT023400R0001 Replacement for AC500

Product Overview

ABB 560CMD11 1KGT023400R0001 Replacement for AC500: Smooth Transition & Legacy System Upgrade

The ABB 560CMD11 (1KGT023400R0001) is an Ethernet Communication Module engineered for the ABB AC500 PLC series — one of the most widely deployed programmable logic controller platforms in global industrial automation, process control, power distribution, and building management systems. As legacy AC500 installations age and original communication modules approach end-of-life or become increasingly difficult to source through standard distribution channels, plant engineers and procurement managers require a verified, drop-in replacement that preserves existing wiring infrastructure, maintains communication protocol compatibility, and minimises unplanned production downtime during the transition window.

This listing provides a tested replacement and upgrade solution for the 560CMD11 module, sourced from authorised supply channels and subjected to a structured pre-shipment inspection prior to dispatch. Whether you are executing a planned retrofit during a scheduled maintenance shutdown, responding to an emergency module failure on a live production line, or building a strategic spare-parts inventory for a critical facility, this unit is available from our Xiamen warehouse with a 12-month warranty and express international shipping.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful migration from an older AC500 serial or PROFIBUS communication architecture to the 560CMD11 Ethernet module rarely involves a single component swap in isolation. In practice, field engineers encounter a broader set of interdependencies spanning the control cabinet, the field device network, the software project, and the power distribution architecture. The following describes the typical upgrade pathway and the associated components that are commonly addressed within the same project scope.

When replacing a legacy CM572-DP PROFIBUS master module, the first engineering task is to audit the existing field device network. PROFIBUS DP slaves — including remote I/O stations, variable-frequency drives, and intelligent field instruments — must either be re-addressed with Ethernet-capable equivalents or bridged via a PROFIBUS-to-PROFINET coupler. In many brownfield installations, the AC500 PM583 or PM591 CPU module remains fully serviceable and does not require replacement; only the communication slot needs to be updated, which significantly reduces project cost and re-commissioning time. The PM595 CPU, ABB’s high-performance AC500 controller, is natively compatible with the 560CMD11 and supports simultaneous multi-protocol communication across multiple Ethernet ports.

The backplane itself — typically a TB5210 or TB5230 terminal base — is fully compatible with the 560CMD11 and requires no mechanical modification. This is a critical advantage for installations where the control cabinet has limited DIN-rail space or where existing cable management is tightly routed around the module positions. Engineers can slide the new module into the same slot, connect the RJ-45 Ethernet cable, and proceed directly to software configuration without any cabinet rework or additional mounting hardware.

On the software side, projects originally developed in CoDeSys 2.3 under Automation Builder 1.x require migration to Automation Builder 2.x to take full advantage of the 560CMD11’s Modbus TCP and PROFINET IO capabilities. ABB’s built-in migration wizard handles the bulk of the project conversion, though engineers should validate all function block libraries — particularly those referencing the CM577-ETH legacy Ethernet module or the CM574-RS serial communication module — and update the communication configuration objects accordingly. I/O mapping tables and variable declarations typically carry over without modification, minimising re-engineering effort.

For installations that include ABB ACS880 or ACS580 variable-speed drives previously connected via PROFIBUS DP or Modbus RTU serial links, the upgrade to Ethernet-based communication via the 560CMD11 opens the path to drive monitoring and parameter access over standard TCP/IP. This enables direct integration with SCADA systems and MES platforms without additional protocol converters or serial gateways. Similarly, ABB CP600 or CP620 HMI panels already equipped with Ethernet ports can be reconfigured to communicate directly with the AC500 CPU over the same network segment, eliminating the need for a dedicated HMI serial link and simplifying the overall network topology.

Power distribution within the cabinet should also be reviewed during the upgrade window. The AC500 PS501 or PS560 power supply modules provide the 24 V DC backplane rail that feeds the 560CMD11 and all other modules in the rack. If the existing PSU is approaching its rated service life or operating near its current capacity, co-replacement during the same maintenance window is strongly recommended to avoid a secondary failure shortly after commissioning the new communication module. This is a common oversight in retrofit projects that leads to avoidable repeat downtime.

For sites that require signal isolation between the PLC I/O and field instruments — particularly in environments with high electromagnetic interference, long cable runs, or mixed-voltage signal circuits — the addition of DIN-rail signal isolators or surge protection modules on the I/O terminal strips is a best practice that protects the new module investment and ensures measurement integrity over the long term. These components are typically installed on the same DIN rail as the AC500 rack and require no additional cabinet space beyond what is already allocated for terminal blocks.

Retrofit Guidance FAQ

Q: Can I install the 560CMD11 without replacing the CPU module?
A: Yes. The 560CMD11 occupies a dedicated communication slot on the AC500 backplane and operates independently of the CPU variant. PM573, PM583, PM591, and PM595 CPUs are all compatible, provided the firmware is updated to a version that supports the module’s communication stack. No CPU replacement is required in the majority of retrofit scenarios.

Q: Will my existing Ethernet wiring work with the 560CMD11?
A: The module uses a standard RJ-45 interface at 10/100 Mbps with auto-negotiation. Any Cat5e or Cat6 cabling already installed in the cabinet or routed to the network switch is fully compatible. No rewiring is required if the physical Ethernet infrastructure is already in place. For new installations, Cat6 is recommended for improved noise immunity in industrial environments.

Q: How do I migrate from PROFIBUS DP to PROFINET IO using this module?
A: The 560CMD11 supports PROFINET IO as both a controller and a device. Field devices that natively support PROFINET can be connected directly to the Ethernet network. For legacy PROFIBUS DP slaves that cannot be replaced, a PROFIBUS-to-PROFINET coupler allows the existing field network to remain intact while the PLC communicates over Ethernet. This hybrid approach is common in phased migration projects where full field device replacement is deferred to a later project phase.

Q: Is the physical installation space the same as the module I am replacing?
A: Yes. The 560CMD11 uses the standard AC500 single-slot form factor and mounts on the same TB5xx or TB6xx terminal base as earlier communication modules. No cabinet modifications, additional DIN-rail space, or new mounting hardware are required. The identical footprint is one of the primary reasons this module is preferred for brownfield retrofits where cabinet space is constrained.

Q: What programming software is required after replacement?
A: ABB Automation Builder 2.x or later, which includes the CoDeSys 3.5 runtime environment and the IEC 61131-3 compliant programming tools. Projects originally created in Automation Builder 1.x can be migrated using the built-in project conversion tool. Communication configuration objects for the 560CMD11 are available in the Automation Builder device library and do not require manual GSD or GSDML file import.

Q: How long does commissioning typically take after the module swap?
A: For a like-for-like replacement where the network topology and IP addressing remain unchanged, commissioning typically takes 1–4 hours including firmware verification, communication parameter upload, and functional testing. More complex migrations involving protocol changes from serial to Ethernet, or topology changes from point-to-point to switched Ethernet, may require 1–2 days of engineering time. TOPNLMS technical support is available to assist with configuration questions during the commissioning phase.

Q: What are the wiring differences between the legacy serial module and the 560CMD11?
A: Legacy serial and PROFIBUS modules use screw-terminal or Sub-D9 connectors for field wiring. The 560CMD11 uses a standard RJ-45 Ethernet connector. Existing serial field wiring does not connect directly to the 560CMD11; field devices must either be replaced with Ethernet-capable equivalents or connected via a protocol gateway. Cabinet-side wiring to the backplane terminal base remains unchanged.

Warranty Assurance

Every ABB 560CMD11 (1KGT023400R0001) unit dispatched from TOPNLMS undergoes a structured pre-shipment inspection that includes visual examination for physical damage, connector integrity verification, label and marking confirmation, and functional power-on testing. Units that do not pass all inspection criteria are quarantined and never dispatched to customers.

All units are covered by a 12-month warranty from the date of dispatch. In the event of a confirmed module defect within the warranty period, TOPNLMS will arrange priority replacement dispatch or issue a full refund at the buyer’s discretion. Warranty claims are acknowledged within 1 business day and processed within 3 business days of receiving the returned unit and a completed fault report. No restocking fees apply to warranty returns.

Stock is maintained in our Xiamen warehouse and is available for same-day or next-business-day dispatch for orders confirmed before 15:00 CST. International shipments are routed via DHL Express, FedEx International Priority, or equivalent express carriers, with typical transit times of 3–7 business days to most destinations. Export documentation — including commercial invoice, packing list, and certificate of origin — is prepared as standard for all international orders at no additional charge.

For urgent plant-down situations or time-critical procurement requirements, please contact our technical sales team directly to confirm real-time stock availability and arrange priority dispatch. We maintain buffer stock of high-demand AC500 communication modules specifically to support emergency replacement scenarios.