ABB AC500-eCo Starter-Kit User manual

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Getting Started with AC500-eCo Starter-Kit - 1 -
Getting Started
with
AC500-eCo
Starter-Kit

About this heft:
This is an introduction to descript how to use the AC500-eCo Starter-Kit. For further
information about the AC500-eCo please refers to the system date of the AC500.
Chapter 1 Starter-Kit Descriptions: describes the contents of the AC500-eCo Starter-Kit, a
short information of the hardware and how to mounting the Starter-Kit.
After that, when you want directly program, you can start with the chapter 3.
Chapter 2 AC500 Software Description: gives general information about the PS501 Control
Builder.
Chapter 3 Programming Example: gives 2 little examples to describe how to create a
program with the AC500-eCo Starter-Kit.
The Appendix (Chapter 4) gives the further information of the AC500-eCo Hardware and the
Software. It contains also another example.

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Getting Started with AC500-eCo Starter-Kit - 3 -
Table of Contents
About this heft: ...............................................................................................................- 2 -
1. AC500-eCo Starter-Kit Description ...........................................................................- 4 -
1.1 General Information about the AC500-eCo Starter-Kit...............................................- 4 -
1.2 Mounting of the AC500-eCo Starter-Kit .....................................................................- 5 -
1.3 Installation the PS501 Control Builder ........................................................................- 7 -
2. Short Description PS501 Control Builder.................................................................- 8 -
2.1 Features of the PS501 Control Builder ........................................................................- 8 -
2.2 PS501 Control Builder Overview ..............................................................................- 10 -
3. Programming Example.............................................................................................- 11 -
3.1 Example for electric Motor Initiation Control and Rotation......................................- 11 -
3.2 Simple Example for Getting started ...........................................................................- 18 -
3.2.1 Creating a new Project ........................................................................................- 18 -
3.2.2 Saving the Project to the PC................................................................................- 19 -
3.2.3 Specifying the Hardware Configuration .............................................................- 20 -
3.2.4 Opening the function Block Diagram Editor and Program.................................- 21 -
3.2.5 Compiling the Project..........................................................................................- 22 -
3.2.6 Setting the Communication Parameters ..............................................................- 23 -
3.2.7 Testing the Program without PLC Hardware connected.....................................- 24 -
3.2.8 Downloading the Program to the PLC ................................................................- 24 -
3.2.9 Program Visualization.........................................................................................- 25 -
3.2.10 Change the Inputs Status with the Simulator ....................................................- 28 -
3.2.11 Exit the Software...............................................................................................- 29 -
4. Appendix ...................................................................................................................- 30 -
4.1 PS501 Control Builder Operators Overview..............................................................- 30 -
4.2 Order Number ............................................................................................................- 33 -
4.3 Detail Faulty Code .....................................................................................................- 34 -
4.4 Bus System Overview ................................................................................................- 35 -
4.5 Example for a Hot Water Tank ..................................................................................- 37 -

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Getting Started with AC500-eCo Starter-Kit - 4 -
1. AC500-eCo Starter-Kit Description
1.1 General Information about the AC500-eCo Starter-Kit
The AC500-eCo Starter-Kit contents following elements:
1. AC500 CPU PM554-R with AC power supply;
2. RS485-USB Programming cable;
3. A simulator;
4. A 5 poles terminal block for the power supply;
5. Software installs CD with the technical information AC500 in PDF and the getting started
program examples;
6. Getting Started heft for AC500-eCo Starter-Kit (this heft);
7. AC500 brochure
8. Screw driver
Short introduction about the CPU PM554-R:
Power Supply: 100-240V AC;
Onboard I/O: 8 digital inputs, 6 digital relay outputs;
Interrupt inputs: 4 configurable (I0…I3);
Fast counter: I0 as a configurable fast counter input;
Output Voltage: 24V DC;
PWM: 2 configurable PWM outputs;
LED: displayed for the signal status
Elements of the PM554-R:
1. LED PWR is green = CPU power on
2. LED RUN is green = CPU in run mode
3. LED ERR is red = Error indicated
4. Allocation of signal name (with 6 and 7
correspondences)
5. yellow LEDs to display the inputs and the
output (8 IN and 6 OUT)
6. Allocation of terminal number
7. Allocation of signal name
8. AC Power Supply terminal block
9+10. 9 and 11 poles I/O terminal block( fixed
screw-type terminals)
11. RUN/STOP switch (only be used with
screw driver)
12. COM1 RS485

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Getting Started with AC500-eCo Starter-Kit - 5 -
1.2 Mounting of the AC500-eCo Starter-Kit
1. Wiring of the CPU Power Supply
CAUTION Failure to heed precaution can result in injury to people or product to property.
Be sure that the CPU is in STOP mode.
100-240V AC
The supply voltage 100~240V AC is connected to
a 5-pole removable terminal block. At first, you
must insert the 5 pole terminal block to the CPU.
The 5 poles from left to right are L, N, FE, L+ and
M. FE is for functional earth. L and N are
connected to AC power supply source. L+ and M
are for the voltage outputs 24V DC and 0V.
After wiring, you will see the LED PWR turn to
green that means Power ON like follow:
2. Wiring the onboard I/Os of the CPU
The following figure shows the electrical connection of the PM554 onboard digital inputs:
Figure 1 Wiring of the PM554 onboard digital inputs (sink or source)
L N FE L+ M
100-240V 0V FE 24V 0V

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Getting Started with AC500-eCo Starter-Kit - 6 -
The following figure shows the electrical connection of the onboard digital relay outputs.
Figure 2 Wiring of the PM554-R onboard digital outputs (source)
3. Connect the PLC with your PC
Figure 3 PLC connect the PC with programming cable
4. Install the drive of the USB cable
TK503 Programming cable

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Getting Started with AC500-eCo Starter-Kit - 7 -
1.3 Installation the PS501 Control Builder
If "Auto run" is set for the CD-ROM drive on your PC, the CD-ROM menu is opened
automatically.
Otherwise, you can start it by executing the file "CD_Menu_V5x.exe" which is located in the
root directory of the CD-ROM. For instance, select "Start" -> "Run" and then enter
"[X]:\CD_Menu_V5x.exe" (Where [x:] is the CD-ROM drive) to execute this file.
You can switch the user interface language by selecting the desired language from the
"Please select language" list box.
The installation menu of PS501 is opened by clicking the button "Installation PS501".
Figure 4 Installation Menu
Clicking on "Read me for installation" to display the read me file containing additional
information regarding the installation of the software.
Sequence of the installation
The following installation menus are available:
1. Step 1: Installation of the Control Builder software
2. Step 2: Installation the GSD and EDS files
3. Opt. 1: Installation of the documentation
If you require all components, carry out the installation following the order given above
(steps 1-3).
If only the programming software is required, you just have to install the Control Builder (step
1). During the installation of the programming software, the communication drivers and the
OPC server are installed as well.
The following system requirements must be fulfilled:
- Windows 2000 or Windows XP
- Internet Explorer 4.01 ("Version 4.72.2106.7" or higher)
Registry: HKEY_LOCAL_MACHINE\Software\Microsoft\Internet Explorer\Version

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2. Short Description PS501 Control Builder
2.1 Features of the PS501 Control Builder
As one member of Automation Alliance, the PS501 Control Builder is the engineering tool for
all CPU performance classes of the AC500, designed for standardized IEC61131-3
programming in six different languages. Use of the editor and debugging functions is based
upon the proven development program environments of advanced programming languages.
Figure 5 Features of PS501
This software has following features:
 Programming in conformity with IEC 61131-3
• Five standardized programming languages: Function Block Diagram (FBD),
Instruction List (IL), Ladder Diagram (LD), Structured Text (ST) and Sequential
Function Chart (SFC)
• free graphical function chart (CFC)
Debugging functions for the program test: Single step, Single cycle, Breakpoint
Offline simulation
IEC 61131-3 commands can be simulated without a PLC being connected, including the
relevant malfunctions. After the program test, the application can be downloaded to the
control system.
Sampling trace
Timing diagrams for process variables and storage of data in a ring buffer with event
trigger.

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Recipe management and watch lists
Values of selected variables are displayed. Pre-defined values can be assigned to
variables which can then be downloaded to the control system all at once (“Write recipe”).
Ongoing values from the control system can also be pre-assigned for reading into the
Watch and Recipe Manager, and stored in memory there (“Read recipe). These functions
are also helpful, for example, for setting and entering control parameters.
Visualization
Includes color change, moving elements, bitmaps, text display, allows input of set point
values and display of process variables read from the PLC, dynamic bar diagrams, alarm
and event management, function keys and ActiveX elements.
Configurators of the communication interfaces
Integrated configurator for Ethernet, Modbus and CS31.
Open interfaces
DDE and OPC.
Programming
Serial or via Ethernet networks.
Engineering interface
Provides access from the programming system to an external project database in which
the program source code of one or several automation projects is managed. Optionally, a
version control system, such as Visual Source Safe, can be used in order to ensure data
consistency of the program code for several different users and projects.
• Comprehensive libraries.
• Windows 32-bit standard.
• Operating systems Windows 2000 and XP.

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2.2 PS501 Control Builder Overview
Figure 6 PS501 Overview
A project is put into a file named after the project. The first POU (Program Organization Unit)
created in a new project will automatically be named PLC_PRG. The process begins here and
other POUs can be accessed from the same point (programs, function blocks and functions).
PS501 Control Builder provides extensive online help. Use the Help button of the menu bar or
press F1 to obtain the information.

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3. Programming Example
This chapter will show you how to use the Starter-Kit with 2 different examples. You will find
another example with PM554 and expansion S500-eCo module in the appendix.
3.1 Example for electric Motor Initiation Control and Rotation
We take the widespread use's three-phase mouse cage type asynchronous motor as the
examples.
Introduced that the electric motor starts (network 1) after 15 seconds later, it’s carries on the
star – triangle (Y-∆) voltage dropping transformation (network 2). And only after the initiation
(network 3) can this motor to the forward (network 4) or reversing (network 5) rotation control.
This program used LD (Ladder Diagram) as program language.
Following symbol table we use for all onboard I/Os configuration.
Symbol name Comment in PLC configuration Meaning
ObDI00 Motor START with SB1 Switch SB1 to start the Motor
ObDI01 Triangle initialization START
with SB2
Switch SB2 to start the Y->Δinitialization
ObDI02 Transistor ON with KH1 Transistor KH1 must always ON
ObDO00 Motor ON KM1 Motor is on
ObDO01 Triangle KM2 Motor is on with triangle type
ObDO02 Star KM3 Motor is on with star type
ObDI03 Transistor ON with KH2 Transistor KH2 must always ON
ObDI04 Motor forward rotation with SB3 Switch SB3 to start the motor forward
rotation
ObDI05 Motor reversing with SB4 Switch SB3 to start the motor reversing
rotation
ObDO03 Motor forward KM4 Motor is forward
ObDO04 Motor reversing KM5 Motor is reversing
Need circuit diagram

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1. Open a new project:
2. Open the program “Motor” from the CD
Click on the open folder button: in the Tool bar or click “file/open” and select the
program “Motor.pro”. After that the program has been downloaded into your PC.
1. Open the PS501 Control
Builder software:
Start
Program
3S Software
CoDeSys V2.3
CoDeSys V2.3

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3. How to understand the program
4. Setting the communication Parameters
In order to send the program out of
the PC we have to define the PC
interface settings. Select the menu
item "Online/Communication
Parameters".
Network
Contact negated Contact
Series contact
Comment
Coil
Parallel contact
Function Block TIMER
PT is the turn on delay time, in this example is 15
second. After that enter the Output。T36.Q
means the output value of the TON36.

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In the "Communication Parameters" dialog window, click on the "Gateway" button and then
following the steps below:
Confirm your settings with "OK".
5. Compiling the project.
In order to build the project, select the menu item “Project/Build”.
If no errors were detected, the message “0 errors, 0 warnings” is displayed in the message
box.
6. Downloading the program to the PLC
Now we can download the program to the PLC. Change the RUN/STOP switch to the RUN
mode.
First we have to load the program to the controller. To do this, select the menu item
“Online/Login”.

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When no more Errors and Warning message appear, select the menu item “Online/RUN”.
.
7. Error Code
When the CPU connects with the PC, it can detect carious errors according to the error
classes. Error class E1 to E4 can be showed by applying the commands “diagshow all” in
PLC browser in Resources.
You can also find all commands of the PLC browser by click the button on the right
side.
More detailed Error code information please check Appendix 4.3
8．
．．
．Check the program with the PLC
In PLC Configuration windows you can change the digital input status to check your program.
First you change the onboard digital inputs (ObDI00, ObDI01 and ObDI02) status from 0 to 1,
in order to do this, double click on the quarter before the input name or you can open the first
three switch of the simulator. After the program run, the status of the onboard digital outputs
will be changed.

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After 15 seconds start the triangle initialization.

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After that the motor can forward rotation.
Or reversing.

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3.2 Simple Example for Getting started
Now we will learn how to program with the PS501 Control Builder.
In this example, we use the programming language FBD.
3.2.1 Creating a new Project
1. Open the Software
2. Create the new project
1.Open the PS501 Control
Builder software:
Start
Program
3S Software
CoDeSys V2.3
CoDeSys V2.3

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The “New POU” window shows which is used to define the type of the POU.
In this example, only “PLC_PRG” is used, we do not need to add more POUs, moreover, the
FBD is used for programming in this POU. Finally, click the “OK” button. The PLC_PRG is the
main program.
Note: All necessary libraries are loaded automatically.
You have finish to open a new project.
3.2.2 Saving the Project to the PC
Before designing, we should save the project, click the shortcut “Save” on the top of the
window, or go to menu: “File/Save”.

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3.2.3 Specifying the Hardware Configuration
In order to specifying the hardware configuration, you must configuring the I/O parameters
and define the symbolic names for I/Os.
Use the same procedure like above for the rest necessary inputs and outputs. Choose the
I05 for Input5, O00 and O01 for Output0 and Output1.
Now you finish the AC500 basic set-up.