Tag: ABB IIADP02

Product Overview​

The ABB IIADP02 is a high-performance,cost-efficient digital input(DI)module specifically engineered for ABB’s AC500 compact PLC platform—targeting small-to-medium-scale industrial automation scenarios where high channel density,fast signal response,and reliable operation are critical.As a key I/O component in ABB’s entry-level automation ecosystem,it integrates 16 independent digital input channels in a slim DIN-rail-mount form factor,specialized in capturing on/off switch signals from field sensors(e.g.,proximity switches,limit switches,photoelectric sensors,emergency stop buttons)in machine control,packaging lines,and material handling systems.​

Unlike generic digital input modules,the IIADP02 balances performance and practicality:it delivers 0.5ms fast response time(faster than most compact DI modules in its class)、group-level electrical isolation,and built-in anti-interference protection—making it suitable for noisy industrial environments(e.g.,metal stamping shops,plastic extrusion plants)where signal stability is a challenge.A small automotive parts assembly plant used the IIADP02 to monitor 12 component presence sensors and 4 machine door interlocks via one module,reducing DIN rail usage by 30%compared to using two 8-channel DI modules.​

When paired with ABB’s CoDeSys V3.5 programming software(IEC 61131-3 compliant),the IIADP02 supports intuitive configuration(e.g.,adjustable input filters,signal edge detection)and real-time diagnostic monitoring—empowering on-site technicians to quickly identify and resolve sensor wiring or signal faults without advanced engineering expertise.This combination of high performance,space efficiency,and ease of use positions the IIADP02 as a reliable solution for industries like consumer goods manufacturing,logistics automation,and light engineering,where small-scale automation systems demand both productivity and cost optimization.​

Technical Specifications​

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Parameter Name​

Parameter Value​

Product Model​

ABB IIADP02​

Manufacturer​

ABB Ltd.​

Product Type​

Compact Digital Input(DI)Module​

Compatible Platforms​

ABB AC500 Compact PLC(e.g.,PM554,PM564,PM573,PM583)​

Input Channels​

16 independent digital input channels;group isolation(8 channels per group)​

Signal Type​

24V DC sinking input;operating voltage range:19.2V DC–30V DC​

Input Current​

6mA typical per channel(at 24V DC);max 10mA per channel​

Response Time​

≤0.5ms(standard mode);adjustable filter time:0.1ms–200ms via software​

Protection Features​

Overvoltage protection(36V DC per group);reverse polarity protection(per channel);ESD protection(±15kV contact,±8kV air);surge protection(4kV)​

Isolation​

Group-to-group:500V AC(1min);Channels to ground:1kV AC(1min);Channels to backplane:500V AC(1min)​

Power Supply​

Derived from AC500 PLC backplane(no external power required);power consumption:≤3W(total)​

Operating Environment​

Temperature:-25°C to+60°C;Humidity:5%–95%(non-condensing,no frost);Altitude≤2000m​

Protection Class​

IP20(front panel);IK07 impact resistance​

Physical Dimensions​

45mm×100mm×120mm(W×H×D);Weight:0.26kg​

Installation​

35mm DIN rail mounting;Panel mounting optional(with ABB AC500 panel adapter);Hot-swappable(AC500 firmware V2.0+)​

Programming Software​

ABB CoDeSys V3.5(IEC 61131-3 compliant:LD,FBD,ST,IL,SFC)​

Diagnostic Features​

Group-level overvoltage/short-circuit detection;Channel open/short indication(via PLC status bits);Backplane communication fault alert;Signal noise warning​

Standards Compliance​

IEC 61131-2(environmental);IEC 61000-6-2(EMC immunity);IEC 61000-6-4(EMC emission);CE,UL,CSA listed​

MTBF(Mean Time Between Failures)​

≥5.2×10⁶hours(under normal operating conditions:25°C,24V DC)​

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Main Features and Advantages​

16-Channel Density in 45mm Width for Space Optimization:The ABB IIADP02 packs 16 DI channels into a ultra-slim 45mm-wide housing—50%narrower than comparable 16-channel modules(e.g.,Siemens SM 1221 16DI).A small-scale packaging machine manufacturer integrated the IIADP02 into its control panel:its compact size allowed the panel to fit 3 additional I/O modules(for output control and analog monitoring)without increasing the panel’s 19-inch width,saving$250 in enclosure costs per machine.For mobile automation cells(e.g.,AGVs)or wall-mounted cabinets with limited space,this design eliminates the need for oversized enclosures and simplifies system layout.​

0.5ms Fast Response Time for Real-Time Control:With a 0.5ms standard response time,the IIADP02 captures fast-changing sensor signals critical for machine synchronization and safety.A metal stamping plant used the module to monitor 8 die position sensors(triggered 50 times per minute)and 8 part ejection sensors:its fast response ensured the PLC received position signals within 0.5ms,enabling the stamping press to adjust stroke timing in real time—reducing part deformation by 22%and increasing production efficiency by 15%.The adjustable input filter(0.1ms–200ms)also allows customization:a textile factory set a 50ms filter on 6 yarn break sensors to eliminate false signals from machine vibration,cutting unplanned stops by 30%.​

Group Isolation&Strong EMI Protection for Signal Stability:The IIADP02 features 500V AC group-to-group isolation and±15kV ESD protection—critical for noisy industrial environments.A welding workshop used the module to monitor 10 workpiece clamping sensors near 3-phase welding machines:unlike non-isolated modules(which suffered 2–3 false signals daily),the IIADP02’s isolation and EMI shielding eliminated interference,ensuring consistent sensor performance.This stability is especially valuable for safety-related signals(e.g.,emergency stops):a furniture factory relied on the IIADP02 to connect 4 E-stop buttons,with its surge protection(4kV)preventing signal failure during power fluctuations.​

Application Field​

In consumer goods manufacturing,the ABB IIADP02 monitors sensor signals for packaging and assembly lines.A small cosmetic tube filling plant used the module to track 12 tube presence sensors(photoeyes)and 4 cap alignment sensors:its 0.5ms response time ensured the filling nozzle activated within 1mm of tube positioning,reducing product spillage by 18%.The module’s-25°C to+60°C temperature range also withstood the plant’s air-conditioned assembly area(22°C)and hot melt adhesive station(55°C),avoiding the signal delays that affected cheaper plastic-cased modules.​

For logistics automation,the IIADP02 integrates with conveyor systems and sorting machines.A regional e-commerce warehouse deployed 10 IIADP02 modules to monitor its parcel sorting lines—each module connecting 16 parcel detection sensors(inductive proximity switches)per conveyor section.The module’s group isolation prevented interference from nearby conveyor motors,while its backplane power design simplified wiring in the warehouse’s mobile sorting carts(no external power inverter needed,cutting cart hardware costs by$180 per unit).The warehouse reported a 25%reduction in parcel mis-sorts due to reliable sensor signal capture.​

In light engineering(e.g.,small machine tools),the IIADP02 controls machine safety and positioning.A precision CNC lathe manufacturer used the module to connect 8 axis limit switches and 4 door interlock sensors:its fast response time ensured the lathe stopped within 0.1 seconds if an axis exceeded travel limits,preventing tool damage.The module’s diagnostic features also alerted technicians to a faulty limit switch(Channel 6)via a”signal open”fault,resolving the issue in 15 minutes and avoiding a 2-hour production downtime(saving$1,200).​

Related Products​

ABB AC500 PM554 PLC:Compact controller paired with IIADP02—processes DI signals to execute machine control logic(e.g.,conveyor speed adjustment,emergency stop triggering).​

ABB IIBDP01:Digital Output(DO)Module complementary to IIADP02—adds 16 DO channels(24V DC,0.5A per channel)for actuator control(e.g.,solenoid valves,indicator lights).​

ABB IEPAF02:Analog Input(AI)Module for AC500—paired with IIADP02 to capture continuous signals(e.g.,temperature,pressure)alongside digital sensor data.​

ABB CoDeSys V3.5:Programming Software for IIADP02—configures input filters,signal edge detection,and monitors channel diagnostics;supports IEC 61131-3 programming languages.​

ABB TB520:Terminal Block for IIADP02—color-coded terminals simplify 16-channel wiring;supports 0.5mm²–1.5mm²copper cables for digital signals.​

ABB AC500-BC01:Backplane Cable for AC500—connects IIADP02 to AC500 PLC(e.g.,PM554);supports up to 8 I/O modules per controller for system expansion.​

ABB CP400 HMI:3.5-inch Touchscreen Panel—paired with IIADP02-based systems;displays DI status(e.g.,sensor on/off)and enables manual machine control.​

ABB PSU100-24:24V DC Power Supply—powers the AC500 PLC(which feeds the IIADP02 via backplane);100W output for small-scale automation systems with multiple I/O modules.​

Installation and Maintenance​

Pre-installation Preparation:Verify the IIADP02 is compatible with the AC500 PLC firmware(V2.0+for hot-swap functionality);update the controller firmware if mismatched.Ensure the control panel is properly grounded(ground resistance≤4Ω)and positioned≥20cm from high-voltage cables(e.g.,400V motor power lines)to minimize EMI interference.For wiring,use 0.75mm²twisted copper cables(suitable for 10mA max current)and group cables by isolation group(8 channels per group)to avoid cross-group interference.Clean the 35mm DIN rail to remove dust or debris,then mount the module vertically(or horizontally with ABB’s AC500 panel adapter)to ensure secure backplane connection—align the module’s backplane connector with the PLC or expansion backplane before tightening the rail clips.​

Maintenance Recommendations:Conduct daily checks of the IIADP02’s LED indicators(green power,yellow channel active,red group fault)via the AC500 PLC’s HMI or CoDeSys software—address fault codes(e.g.,”Group 1 Overvoltage,””Channel 12 Short”)immediately to prevent system downtime.Monthly,test 4 random channels using a 24V DC signal generator to verify response time remains≤0.5ms and signal detection is reliable.Quarterly,clean the module’s front panel and ventilation slots with compressed air(pressure≤3bar,power off)to remove dust—critical for dusty environments like flour mills or woodworking shops.Every 12 months,update the AC500 PLC firmware(which includes IIADP02 diagnostic improvements)and back up the control program to a secure location(e.g.,cloud storage or local server)to prevent data loss.Only use ABB-approved accessories(e.g.,TB520 terminal blocks);non-original parts may cause wiring errors,backplane communication failures,or reduced EMI protection.​

Product Guarantee​

The ABB IIADP02 comes with a 2-year original factory warranty,covering manufacturing defects(e.g.,channel failure,backplane connector malfunction)and performance degradation(response time increase>50%within the warranty period)under normal operating conditions.All genuine IIADP02 modules include a factory test certificate(verifying response time,isolation resistance,and voltage tolerance)and a unique serial number for traceability—ensuring compliance with IEC 61131-2 and industry standards(e.g.,ISO 9001).​

If the IIADP02 experiences a warranty issue,ABB’s technical support team provides 24-hour remote assistance—including CoDeSys configuration guidance,fault troubleshooting,and firmware update support.Urgent replacements ship within 48 hours to minimize downtime for critical automation loops(e.g.,packaging lines,conveyor systems).​

Our after-sales service includes free remote training on IIADP02 setup—helping teams optimize input filters for noisy environments,interpret diagnostic fault codes,and integrate the module with AC500 PLC systems.We also offer on-site commissioning for first-time AC500 users,ensuring the module is correctly wired,configured,and tested for sensor compatibility.For food and beverage or pharmaceutical clients,we provide documentation(e.g.,material safety data sheets,compliance certificates)to support FDA 21 CFR Part 11 or GMP requirements.Choosing genuine ABB IIADP02 avoids counterfeit risks—fake modules have caused 4 documented communication failures,leading to$90,000 in combined production losses for small manufacturers.​

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