ABB 1KHL178025R0002 REV.Z

1. Product Overview

The ABB 1KHL178025R0002 is a COM02 communication module, a core communication component belonging to the ABB AC 500 PLC series. Serving as an extended communication interface for AC 500 CPUs (including PM572 and PM583 models), this module is mainly applied to connect distributed I/O boxes, Modbus instruments and HMI devices. It is perfectly suitable for production line and pump station control systems featured with long wiring distances and scattered control points.

2. Technical Parameters

Parameter Item	Specification
Order Number	1KHL178025R0002
Module Type	COM02 Communication Module
Product Series	ABB AC 500 PLC
Communication Interface	1-channel RS-232 + 1-channel RS-485 (independent channels)
Supported Protocols	Modbus RTU/ASCII (Master/Slave), CS31 (Slave Mode), Custom ASCII Protocol
Baud Rate	Adjustable
Operating Temperature	0°C to +55°C
Ingress Protection Rating	IP20
Dimensions	160mm × 100mm
Weight	0.68kg
Power Consumption	5W to 10W
Certifications	CE, UL, cUL

3. Product Features

• Dual Independent Communication Interfaces: Equipped with separate RS-232 and RS-485 channels, enabling simultaneous connection of different types of industrial devices to meet diverse communication demands.
• Multi-protocol Compatibility: Supports mainstream industrial communication protocols including Modbus RTU/ASCII and CS31, as well as custom ASCII protocols, delivering strong environmental adaptability and flexible application scenarios.
• Remote Configuration & Debugging: Communication libraries can be configured via Automation Builder software, supporting remote debugging functions and seamless access to SCADA systems for efficient system operation and maintenance.
• Intuitive Status Indication: Built-in LED indicators including RUN (Operation), COM (Communication) and ERR (Error) allow real-time equipment status monitoring and rapid on-site fault diagnosis.
• High Industrial Reliability: Designed for 24/7 continuous industrial operation, featuring a wide operating temperature range and high Mean Time Between Failures (MTBF) to ensure stable long-term operation.
• Low Power Consumption: Rated power consumption of 5W to 10W, which is energy-saving and highly suitable for embedded industrial application scenarios.

4. Structure and Composition

4.1 Physical Structure

• Installed on the I/O slots of the AC 500 main rack
• Powered by the CPU backplane bus
• Supports plug-and-play installation for convenient assembly and disassembly

4.2 Hardware Components

• RS-232 communication port
• RS-485 communication port
• LED status indication circuit
• Communication protocol processing chip
• Isolation protection circuit

4.3 Matching System Components

This module is commonly used in combination with the following ABB supporting modules to form a complete control system:

• CPM01 (1KHL160038R0002) – Processing Unit
• CPU01/CPU02 – Central Processing Unit
• BIO01 – Digital Input/Output Module

5. Application Fields

Application Field	Specific Applications
Industrial Automation	Large-scale production lines, automatic assembly lines, robot controllers
Power System	Substation automation, feeder protection, transformer monitoring, bus management
Process Control	Power plant control, industrial process monitoring, data acquisition systems
Building Automation	Pump station control systems, HVAC system monitoring
SCADA Integration	Access to SCADA systems as a Modbus slave station, edge computing platform connection

5.1 Typical Combined Application Scenarios

• Robot controllers (such as IRC5 and S4C+ series)
• Remote Terminal Units (RTU)
• Distributed I/O system expansion

6. Installation and Maintenance

6.1 Pre-installation Preparation

• Confirm the compatibility between the module firmware version and the host CPU
• Prepare an anti-static working environment to avoid static damage to electronic components
• Inspect the backplane slot integrity and verify stable power supply voltage

6.2 Physical Installation

• Insert the module into the reserved I/O slot of the AC 500 main rack
• Ensure firm and tight insertion to prevent poor contact caused by loose installation
• Adopt shielded cables for wiring to reduce electromagnetic interference and ensure stable communication

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