ABB AC500 Series Manual

INSTALLATION AND CONFIGURATION MANUAL
Getting started
AC500 V3 products

—
Table of contents
1 Getting started with AC500 V3 products....................................................................................................... 3
1.1 Introduction................................................................................................................................................ 3
1.2 Engineering software Automation Builder................................................................................................. 3
1.2.1 Installing Automation Builder...................................................................................................... 3
1.2.2 Licensing procedure................................................................................................................... 4
1.2.3 Set-up communication parameters in windows.......................................................................... 7
1.3 Hardware AC500 V3................................................................................................................................. 9
1.3.1 Configuration for example projects............................................................................................ 9
1.3.2 System assembly, construction and connection....................................................................... 11
1.4 Example project for central I/O expansion.............................................................................................. 12
1.4.1 Preconditions........................................................................................................................... 12
1.4.2 Create, set-up and save your AC500 V3 project..................................................................... 12
1.4.3 Configure the I/O module......................................................................................................... 17
1.4.4 Programming and compiling.................................................................................................... 21
1.4.5 Set-up the communication gateway......................................................................................... 30
1.4.6 AC500 V3 firmware installation and update............................................................................. 33
1.4.7 Log-in to CPU and download the program............................................................................... 35
1.4.8 Test the program...................................................................................................................... 36
1.4.9 Set-up visualization.................................................................................................................. 38
1.4.10 Create visualization................................................................................................................ 42
1.4.11 Enable web visualization........................................................................................................ 50
1.4.12 Reset the CPU....................................................................................................................... 54
1.5 Example project for remote I/O expansion with PROFINET................................................................... 56
1.5.1 Preconditions........................................................................................................................... 56
1.5.2 Set-up PROFINET controller.................................................................................................... 56
1.5.3 Set-up PROFINET device........................................................................................................ 59
1.5.4 Add remote I/O expansion to project........................................................................................ 63
1.5.5 Test the program...................................................................................................................... 67
1.5.6 Reset the CPU......................................................................................................................... 68
1.6 Further information on our AC500 portfolio............................................................................................. 69
2 Index............................................................................................................................................................... 70
Table of contents
2021/05/143ADR010584, 2, en_US2

—
1 Getting started with AC500 V3 products
1.1 Introduction
This document gives an overview of the steps for the first use of a PLC with AC500 V3 CPU
and describes:
● installation of the engineering software Ä Chapter 1.2 “Engineering software Automation
Builder” on page 3
● hardware needed for example projects
Ä Chapter 1.3 “Hardware AC500 V3” on page 9
● setting up a first, simple project for a stand-alone CPU with central I/O expansion, including
visualization and web visualization Ä Chapter 1.4 “Example project for central I/O expan-
sion” on page 12
● commissioning a project for remote I/O expansion with PROFINET
Ä Chapter 1.5 “Example
project for remote I/O expansion with PROFINET” on page 56
NOTICE!
Read safety instructions first
Read the safety instructions before first use of the products.
https://to.abb/eER6E15m
1.2 Engineering software Automation Builder
For configuring and programming of any AC500 CPU you need the engineering software suite
Automation Builder. Automation Builder is available for download Ä Further information
on page 3.
1.2.1 Installing Automation Builder
You must have admininstrator rights on your PC to install Automation Builder.
In case of an update installation:
Create a project archive before updating Automation Builder. Project archives
contain all project data, including data that is not stored with a *.project file, e.g.
device description files for third party devices.
1. Go to abb.com/automationbuilder to access the homepage of Automation Builder.
2. In the “Downloads” section, select “Download Automation Builder”.
3. In the “Latest Automation Builder” section, select “Automation Builder x.x. Download” (x.x
= latest version). This downloads the installer on your PC.
4. Open the downloaded installer and follow the instructions of the installation manager.
Fig. 1: Safety
instructions
Preconditions
Installation
Getting started with AC500 V3 products
Introduction > Installing Automation Builder
2021/05/14 3ADR010584, 2, en_US 3

5. Keep the default type of installation to “Premium Edition”.
6. Select software packages to be installed:
Enable the check box “PLC - AC500 V3” to activate installation of all options for AC500
V3.
7. Click “Download and install” and follow the instructions of the setup.
1.2.2 Licensing procedure
When you start Automation Builder software for the first time, you will be asked to choose a
license option.
However, a basic license is enough for the example project for central I/O expansion, we recom-
mend to activate a trial license which is required for the example project for remote I/O expan-
sion. This way, you do not have to change licenses when programming the second example
project.
Table 1: Available editions and licenses for Automation Builder
Edition License PLC program-
ming
Fieldbus sup-
port
Engineering
productivity
tools
Basic Free license x -- --
Standard 30-day free trial,
then purchase
required
x x --
Premium 30-day free trial,
then purchase
required
x x x
Refer to our website to get details about the license model, the features of the editions and the
latest license information. new.abb.com/plc/automationbuilder/platform/software
Automation Builder software must be installed successfully.
Activate a
license
Getting started with AC500 V3 products
Engineering software Automation Builder > Licensing procedure
2021/05/143ADR010584, 2, en_US4

PC is connected to the internet.
1. Start Automation Builder.
ðA licensing wizard starts and guides you through the licensing procedure.
2. Enter user information.
In case of future support requests, your registration details enable ABB support team to
handle your questions quickly.
3. Select “OK”.
4. Enable the trial license.
5. Select “Next”.
Getting started with AC500 V3 products
Engineering software Automation Builder > Licensing procedure
2021/05/14 3ADR010584, 2, en_US 5

6. Enable the single PC license and select “Next”.
7. Enable online activation and select “Next”.
ðLicense activation procedure starts. A successfully ended licensing procedure ends
with a success message.
Getting started with AC500 V3 products
Engineering software Automation Builder > Licensing procedure
2021/05/143ADR010584, 2, en_US6

8. Select “OK” to end the wizard.
ðAutomation Builder license is activated and starts.
1.2.3 Set-up communication parameters in windows
To set-up the communication between the PC and the PLC, e.g., for downloading the compiled
program, you have to set-up the communication parameters.
The IP address of your PC must be in the same class as the IP address of the CPU.
The factory setting of the IP address of the CPU is 192.168.0.10.
The IP address of your PC should be 192.168.0.X. Avoid X = 10 in order to prevent an IP con-
flict with the CPU.
Subnet mask should be 255.255.255.0.
1. Open Windows Control Panel. Click “Network and Internet
è Network and Sharing Center”.
2. Click Change adapter settings.
If using existing network with several devices, please pay attention on
given network rules or contact your system administrator.
3. Right-click Local Area Connection (Ethernet) and select Properties.
Change the IP
address
Getting started with AC500 V3 products
Engineering software Automation Builder > Set-up communication parameters in windows
2021/05/14 3ADR010584, 2, en_US 7

4. Double-click Internet Protocol Version 4 (TCP/IPv4).
Getting started with AC500 V3 products
Engineering software Automation Builder > Set-up communication parameters in windows
2021/05/143ADR010584, 2, en_US8

5. Enter your desired IP address and subnet mask.
1.3 Hardware AC500 V3
1.3.1 Configuration for example projects
The example projects require a small PLC configuration with I/O devices, e.g., as available in
the training case TA5450-CASE. https://to.abb/AfO9-ftT
Table 2: Modules for example projects to get started with AC500 V3 PLC
Product name Type First project
Ä Chapter 1.4
“Example project for
central I/O expan-
sion” on page 12
Second project
Ä Chapter 1.5
“Example project for
remote I/O expan-
sion with
PROFINET”
on page 56
PM5630- 2ETH AC500 V3 CPU x x
TB5620-2ETH terminal base for CPU x x
DA501 analog/digital mixed
input/output (I/O)
module
x x
TU516-H terminal unit for I/O
module
x x
CM579-PNIO PROFINET communi-
cation module
-- x
Getting started with AC500 V3 products
Hardware AC500 V3 > Configuration for example projects
2021/05/14 3ADR010584, 2, en_US 9

Product name Type First project
Ä Chapter 1.4
“Example project for
central I/O expan-
sion” on page 12
Second project
Ä Chapter 1.5
“Example project for
remote I/O expan-
sion with
PROFINET”
on page 56
CI502-PNIO PROFINET communi-
cation interface
module
-- x
TU508-ETH terminal unit for com-
munication interface
module
-- x
TA524 blind cap for terminal
base
x x
Fig. 2: Training case TA5450
In the training case, the control panel CP6607 is included. A control panel is not
needed for the example projects.
For testing the example project some inputs require to be connected as follows:
Electrical con-
nection
Getting started with AC500 V3 products
Hardware AC500 V3 > Configuration for example projects
2021/05/143ADR010584, 2, en_US10

Fig. 3: Wiring of training case
For the example projects, not all input switches and none of the potentiometers
included in training case are necessary.
You will need switch I1 for the example project for central I/O expansion.
You will need switch I5 for the example project for remote I/O expansion.
1.3.2 System assembly, construction and connection
NOTICE!
Avoidance of electrostatic charging
PLC devices and equipment is sensitive to electrostatic discharge, which can
cause internal damage and affect normal operation. Observe the following rules
when handling the system:
– Touch a grounded object to discharge potential static.
– Wear an approved grounding wrist strap.
– Do not touch connectors or pins on component boards.
– Do not touch circuit components inside the equipment.
– If available, use a static-safe workstation.
– When not in use, store the equipment in appropriate static-safe packaging.
You can mount AC500 PLC either to DIN rail or to a metal plate. Here, we recommend to mount
on DIN rail.
1. Snap the terminal base onto DIN rail.
2. Snap the additional terminal units for I/O modules onto DIN rail.
3. Make the sensor/actuator wire connections according to the dedicated electronic module
you want to use. Provide external process power supply as required.
4. If required, make the fieldbus connections according to the dedicated master communica-
tion module you want to use.
Getting started with AC500 V3 products
Hardware AC500 V3 > System assembly, construction and connection
2021/05/14 3ADR010584, 2, en_US 11

5. Plug the appropriate electronic and I/O modules in the correct locations (processor
module, communication modules on terminal base, and eventually also communication
interface modules and I/O modules onto dedicated terminal units).
6. Connect a programming cable (Ethernet cable between ETH port of CPU and PC with
engineering software).
1.4 Example project for central I/O expansion
The following steps show how to set-up an application project and configure the hardware. A
simple logic is used as example to introduce in programming and commissioning of the PLC.
The workflow for creation of a visualization is explained, as well as how to set-up a webserver
for visualization.
1.4.1 Preconditions
● Automation Builder is installed and licensed as, at least, basic edition Ä Chapter 1.2 “Engi-
neering software Automation Builder” on page 3.
● AC500 V3 CPU is assembled and connected to the PC.
1.4.2 Create, set-up and save your AC500 V3 project
1.4.2.1 Create a project
1. Launch Automation Builder either out of the desktop icon or out of the Windows menu.
2. Select “New Project” or go to menu “File è New Project”.
Getting started with AC500 V3 products
Example project for central I/O expansion > Create, set-up and save your AC500 V3 project
2021/05/143ADR010584, 2, en_US12

3. Select “Projects”.
4. Select “AC500 project”.
5. Fill in project name.
6. Choose a location to save the project to.
7. Select “OK”.
8. Select “PLC - AC500 V3”.
9. Select the CPU according to your hardware set-up.
Getting started with AC500 V3 products
Example project for central I/O expansion > Create, set-up and save your AC500 V3 project
2021/05/14 3ADR010584, 2, en_US 13

10. Select “Add PLC” to add the CPU to your application.
Getting started with AC500 V3 products
Example project for central I/O expansion > Create, set-up and save your AC500 V3 project
2021/05/143ADR010584, 2, en_US14

1.4.2.2 Configure your CPU
1. Double-click “PLC_AC500_V3”.
ðA tab opens in the editor view.
2. Select “CPU-Parameters Parameters”.
3. Under parameter “Check battery”, choose the value “Off” since there is no battery present
inside the CPU module.
4. Keep the default values for all other parameters.
1.4.2.3 Create folders in the device tree
To optimize the project readability, you will create different folders to group similar objects. The
folder names are exemplary. Because the device tree view follows an alphabetical order, we use
number prefixes to determine the order.
Getting started with AC500 V3 products
Example project for central I/O expansion > Create, set-up and save your AC500 V3 project
2021/05/14 3ADR010584, 2, en_US 15

1. Right-click “Application”.
2. Select “Add Folder”.
3. Type in "10 POUs". This is a name example. Here, the intention is to see this folder as a
last one.
The folder "10 POUs" is for program organization units (POU). POUs are objects of type
program, function or function block that are used to create a user program.
Getting started with AC500 V3 products
Example project for central I/O expansion > Create, set-up and save your AC500 V3 project
2021/05/143ADR010584, 2, en_US16

1.4.2.4 Save the project
Select menu “File è Save Project”.
Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].
1.4.3 Configure the I/O module
● The types and order of modules in the Automation Builder project must match the real hard-
ware configuration.
● The position of the modules in the device tree can be changed by drag and drop.
Getting started with AC500 V3 products
Example project for central I/O expansion > Configure the I/O module
2021/05/14 3ADR010584, 2, en_US 17

1.4.3.1 Add an I/O bus module
1. Right-click “IO_Bus” in the device tree.
2. Select “Add object”.
Getting started with AC500 V3 products
Example project for central I/O expansion > Configure the I/O module
2021/05/143ADR010584, 2, en_US18

3. Select “S500 I/O modules”.
4. Select “DA501” module.
5. Select “Add object” to add the module to the I/O bus.
Getting started with AC500 V3 products
Example project for central I/O expansion > Configure the I/O module
2021/05/14 3ADR010584, 2, en_US 19

1.4.3.2 DA501 variable mapping
1. Double-click “DA501” in the device tree.
ðA tab opens in the editor view.
2. Select “DA501 I/O Mapping”
ðHere, you will map variable names (symbols) for the channels you will need in the pro-
gram.
The suggested name convention is based on "Hungarian notation". A name prefix is describing
variable type: e.g., "x" = variable of type BOOL, "w" = WORD, "i" = INT (integer) etc. This
increases the code readability and is helpful for program analysis.
1.4.3.2.1 Handle the digital input variables
1. Open the list of the digital inputs.
2. Fill in the variable names:
Channel Type Variable
Digital input DI8 BOOL xDI_08_DA501_I1
Getting started with AC500 V3 products
Example project for central I/O expansion > Configure the I/O module
2021/05/143ADR010584, 2, en_US20