ABB AC500-eCo V3 User manual
MANUAL
AC500-eCo V3 products
Overview and getting started
—
Table of contents
1 About this document...................................................................................................................................... 4
2 Introduction to AC500-eCo V3....................................................................................................................... 5
3 Safety instructions........................................................................................................................................ 10
4 Cyber security............................................................................................................................................... 13
5 Getting Started.............................................................................................................................................. 14
5.1 Introduction.............................................................................................................................................. 14
5.2 Engineering software Automation Builder............................................................................................... 14
5.2.1 Installing Automation Builder.................................................................................................... 14
5.2.2 Licensing procedure................................................................................................................. 15
5.2.3 Set-up communication parameters in windows........................................................................ 18
5.3 Hardware AC500-eCo V3........................................................................................................................ 20
5.3.1 Configuration for example projects.......................................................................................... 20
5.3.2 System assembly, construction and connection...................................................................... 21
5.4 Example project....................................................................................................................................... 22
5.4.1 Preconditions........................................................................................................................... 22
5.4.2 Create, set-up and save your AC500 V3 project..................................................................... 22
5.4.3 Configure the onboard I/O channels........................................................................................ 27
5.4.4 Programming and compiling.................................................................................................... 29
5.4.5 Set-up the communication gateway......................................................................................... 39
5.4.6 AC500 V3 firmware installation and update............................................................................. 42
5.4.7 Log-in to CPU and download the program............................................................................... 44
5.4.8 Test the program...................................................................................................................... 45
5.4.9 Set-up visualization.................................................................................................................. 46
5.4.10 Create visualization................................................................................................................ 50
5.4.11 Enable web visualization........................................................................................................ 58
5.4.12 Reset the CPU....................................................................................................................... 62
5.5 Further information on our AC500 portfolio............................................................................................. 64
6 Device specifications.................................................................................................................................... 65
6.1 Processor modules.................................................................................................................................. 65
6.1.1 PM50xx.................................................................................................................................... 65
6.2 Option boards........................................................................................................................................ 103
6.2.1 TA5101-4DI - Digital input module option board.................................................................... 103
6.2.2 TA5105-4DOT - Digital output module option board.............................................................. 109
6.2.3 TA5110-2DI2DOT - Digital input/output module option board................................................ 117
6.2.4 TA5141-RS232I - RS-232 serial adapter isolated option board............................................. 125
6.2.5 TA5142-RS485I - RS-485 serial adapter isolated option board............................................. 128
6.2.6 TA5142-RS485 - RS-485 serial adapter non isolated option board....................................... 134
6.2.7 TA5131-RTC option board for real time clock........................................................................ 140
6.2.8 TA5130-KNXPB option board for KNX address switch.......................................................... 141
6.3 Accessories........................................................................................................................................... 142
6.3.1 MC5102 - micro memory card with micro memory card adapter........................................... 142
6.3.2 TA5300-CVR Option board cover for option slot.................................................................... 147
6.3.3 Pluggable connectors for screw and spring connection......................................................... 149
6.4 System data AC500-eCo V3................................................................................................................. 154
6.4.1 Environmental conditions....................................................................................................... 154
6.4.2 Creepage distances and clearances...................................................................................... 155
6.4.3 Insulation test voltages, routine test....................................................................................... 155
Table of contents
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6.4.4 Power supply units................................................................................................................. 155
6.4.5 Electromagnetic compatibility................................................................................................. 155
6.4.6 Mechanical data..................................................................................................................... 156
6.4.7 Approvals and certifications................................................................................................... 156
6.5 Installation............................................................................................................................................. 157
6.5.1 Mechanical dimensions.......................................................................................................... 157
6.5.2 Mounting and demounting..................................................................................................... 160
6.5.3 Connection and wiring............................................................................................................ 164
6.5.4 Handling of accessories......................................................................................................... 167
7 Software handling and programming........................................................................................................ 169
8 Simple motion.............................................................................................................................................. 170
8.1 Introduction............................................................................................................................................ 170
8.2 Hardware components for motion control............................................................................................. 171
8.2.1 Basic CPU – PM5012-R-ETH and PM5012-T-ETH............................................................... 171
8.2.2 Standard and Pro CPU - PM5032-x-ETH / PM5052-x-ETH / PM5072-T-2ETH..................... 172
8.3 System technology................................................................................................................................ 172
8.3.1 Use the onboard I/Os as encoder with A and B signals......................................................... 173
8.3.2 Use the onboard I/Os as forward counter.............................................................................. 177
8.3.3 Use the onboard I/Os as interrupt input with dedicated interrupt task................................... 178
8.3.4 Use the onboard I/Os as output limit switch........................................................................... 180
8.3.5 Use the onboard I/Os as PTO (pulse-train output) with 100 kHz frequency (max. 2 PTO
using PTO HW channels)....................................................................................................... 181
8.3.6 Use the onboard I/Os as PTO (pulse-train output) with 200 kHz frequency (max. 2 PTO
using PTO HW channels) and Simple Motion OBIOMotionPTO function block..................... 184
8.3.7 Use the onboard I/Os as PTO (pulse-train output) with 100 kHz frequency (Max. 4 PTO
using PWM HW channels) and Simple Motion OBIOMotionPWM function bloc................... 185
8.3.8 Use the onboard I/Os as output PWM (pulse-width modulation)........................................... 187
8.4 Function block description .................................................................................................................... 188
8.5 AC500-eCo V3 option board slots for processor modules PM50xx...................................................... 190
8.5.1 Option board for serial interface extension............................................................................ 191
8.5.2 Option board for digital I/O extension.................................................................................... 191
8.6 Option board for specific function.......................................................................................................... 192
9 Contact ABB................................................................................................................................................ 193
10 Index............................................................................................................................................................. 194
Table of contents
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2 Introduction to AC500-eCo V3
As part of ABB’s AC500 PLC platform, the AC500-eCo V3 product line enables cost-effective
automation of industrial applications in which small and flexible PLCs represent the ideal solu-
tion. The AC500 platform ranges from entry-level to high-end PLC solutions and includes the
easy-to-use Automation Builder engineering suite.
● Save money by starting small - the flexibility of the AC500 platform enables to scale up as
and when needs dictate.
● ABB’s AC500-eCo V3 has been designed to integrate seamlessly into the broader AC500
family, offering you the decisive benefit of having a fully scalable and modular system.
● The AC500-eCo V3 PLC range provides three performance/feature-set classes to answer
the specific needs of lot of applications
–Basic PLC - for basic and compact applications with few I/O channels
–Standard PLC – for modular and distributed applications
–Pro PLC – for logic, motion and IoT-ready demanding applications
● The AC500-eCo V3 offers individually customized solutions to be created by using S500
and S500-eCo I/O modules for small applications.
● The Automation Builder engineering suite available across the entire AC500 PLC range will
save you time with easy configuration, many libraries and function blocks for the most
diverse specific customer requirements.
Scalable
Introduction to AC500-eCo V3
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● Basic and compact application
● Few I/O channels
Basic
Introduction to AC500-eCo V3
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● For modular and distributed applicationsStandard
Introduction to AC500-eCo V3
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● For Logic, Motion and IoT-ready demanding applications
(1) Licensed
(2) In preparation
Pro
Introduction to AC500-eCo V3
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● The user program can be downloaded via a micro memory card without the need for pro-
gramming tools.
● CPUs with integrated I/Os for small applications available.
● Extension of I/O channels can be done using standard S500-eCo but also S500 I/O
modules.
● Pre-wiring is possible via the use of pluggable terminal blocks.
● The modules can be fitted to the DIN rail with easy-to-use snap-on mechanism.
● Insert option board for special features:
– Simple I/O extension for digital or analog channels
– Serial interface RS232/RS485
– KNX address switch
● The AC500-eCo V3 is approved for customer use by accredited certification organizations
around the world. This means the entire range can be deployed safely, reliably and globally.
Easy handling
Flexible
Introduction to AC500-eCo V3
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3 Safety instructions
The examples and diagrams in this manual are included solely for illustrative purposes.
Because of the many variants and requirements associated with any particular installation, ABB
cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by ABB with respect to use of information, circuits, equipment or
software described in this manual. No liability is assumed for the direct or indirect conse-
quences of the improper use, improper application or inadequate maintenance of these devices.
In no event will ABB be responsible or liable for indirect or consequential damages resulting
from the use or application of this equipment.
The product family AC500 control system is designed according to EN 61131-2
IEC 61131-2 standards. Data, different from IEC 61131, are caused by the
higher requirements of Maritime Services. Other differences are described in
the technical data description of the devices.
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.
NOTICE!
PLC damage due to operation conditions
Protect the devices from dampness, dirt and damage during transport, storage
and operation!
NOTICE!
PLC damage due to wrong enclosures
Due to their construction (degree of protection IP 20 according to EN 60529)
and their connection technology, the devices are suitable only for operation in
enclosed switchgear cabinets.
Cleaning instruction
Do not use cleaning agent for cleaning the device.
Use a damp cloth instead.
PLC specific
safety notices
Safety instructions
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Connection plans and user software must be created so that all technical safety aspects, legal
regulations and standards are observed. In practice, possible shortcircuits and breakages must
not be able to lead to dangerous situations. The extent of resulting errors must be kept to a min-
imum.
Do not operate devices outside of the specified, technical data!
Trouble-free functioning cannot be guaranteed outside of the specified data.
NOTICE!
PLC damage due to missing earthing
– Ensure to earth the devices.
– The earthing (switch cabinet earthing, PE) is supplied both by the mains
connection (or 24 V supply voltage) and via DIN rail. The DIN rail must be
connected to the earth before the device is subjected to any power. The
earthing may be removed only if it is certain that no more power is being
supplied to the control system.
In the description for the devices (operating manual or AC500 system description), reference is
made at several points to earthing, electrical isolation and EMC measures. One of the EMC
measures consists of discharging interference voltages into the earthing via Y-type capacitors.
Capacitor discharge currents must basically be able to flow off to the earthing (in this respect,
see also VBG 4 and the relevant VDE regulations).
CAUTION!
Do not obstruct the ventilation for cooling!
The ventilation slots on the upper and lower side of the devices must not be
covered.
CAUTION!
Run signal and power wiring separately!
Signal and supply lines (power cables) must be laid out so that no malfunctions
due to capacitive and inductive interference can occur (EMC).
WARNING!
Labels on or inside the device alert people that dangerous voltage may be
present or that surfaces may have dangerous temperatures.
WARNING!
Splaying of strands can cause hazards!
During wiring of terminals with stranded conductors, splaying of strands shall be
avoided.
– Ferrules can be used to prevent splaying.
Safety instructions
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WARNING!
Removal/Insertion under power
The devices are not designed for removal or insertion under power. Because of
unforeseeable consequences, it is not allowed to plug or unplug devices with
the power being ON.
Make sure that all voltage sources (supply and process voltage) are switched
off before you
– connect or disconnect any signal or terminal block
– remove, mount or replace a module.
Disconnecting any powered devices while energized in a hazardous location
could result in an electric arc, which could create a flammable ignition resulting
in fire or explosion.
Make sure that power is removed and that the area has been thoroughly
checked to ensure that flammable materials are not present prior to proceeding.
The devices must not be opened when in operation. The same applies to the
network interfaces.
This equipment is intended for use in a Pollution Degree 2 industrial environ-
ment, in overvoltage Category II applications (as defined in IEC publication
60664-1), at altitudes up to 2.000 meters without derating.
This equipment is considered Group 1, Class A industrial equipment according
to IEC/CISPR Publication 11. Without appropriate precautions, there may be
potential difficulties ensuring electromagnetic compatibility in other environ-
ments due to conducted as well as radiated disturbance.
This equipment is supplied as "open type" equipment. It must be mounted
within an enclosure that is suitably designed for those specific environmental
conditions that will be present and appropriately designed to prevent personal
injury resulting from accessibility to live parts. The interior of the enclosure must
be accessible only by the use of a tool. Subsequent sections of this publication
may contain additional information regarding specific enclosure type ratings that
are required to comply with certain product safety certifications.
Refer to NEMA Standards publication 250 and IEC publication 60529, as appli-
cable, for explanations of the degrees of protection provided by different types
of enclosure. Also see the appropriate sections in this manual.
NOTICE!
Read safety technical instructions first
Read the safety technical instructions before first use of the products.
https://to.abb/eER6E15m
Environment
and enclosure
information
Fig. 1: Safety
instructions
Safety instructions
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4 Cyber security
This product is designed to be connected to a network interface and to transfer information and
data. ABB assists you to provide secure connections. Information about cyber security is pro-
vided in a whitepaper and in the complete documentation for AC500-eCo V3.
Cyber security
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5 Getting Started
5.1 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
● hardware needed for example projects
● setting up a first, simple project for a stand-alone CPU, including visualization and web visu-
alization
5.2 Engineering software Automation Builder
For configuring and programming of any AC500-eCo V3 CPU you need the engineering soft-
ware suite Automation Builder. Automation Builder is available for download
Ä
Further informa-
tion on page 14.
5.2.1 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.
Preconditions
Installation
Getting Started
Introduction > Installing Automation Builder
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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.
5.2.2 Licensing procedure
When you start Automation Builder software for the first time, you will be asked to choose a
license option.
A basic license is enough for AC500-eCo V3.
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
Engineering software Automation Builder > Licensing procedure
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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 basic license.
5. Select [Next].
Getting Started
Engineering software Automation Builder > Licensing procedure
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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
Engineering software Automation Builder > Licensing procedure
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8. Select [OK] to end the wizard.
ðAutomation Builder license is activated and starts.
5.2.3 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
Engineering software Automation Builder > Set-up communication parameters in windows
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4. Double-click Internet Protocol Version 4 (TCP/IPv4).
Getting Started
Engineering software Automation Builder > Set-up communication parameters in windows
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5. Enter your desired IP address and subnet mask.
5.3 Hardware AC500-eCo V3
5.3.1 Configuration for example projects
The example projects require a AC500-eCo V3 CPU. The onboard I/O channels are used.
The visualization example is running on CPUs as of PM5032-T-ETH.
Table 2: Modules for example projects to get started with AC500 V3 PLC
Product name Type First project
PM5032-T-ETH CPU x
Getting Started
Hardware AC500-eCo V3 > Configuration for example projects
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