ABB AC500 V2 User manual

INSTALLATION AND CONFIGURATION MANUAL
Getting started
AC500 V2 products

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Table of contents
1 Getting started with example projects.......................................................................................................... 3
1.1 Introduction................................................................................................................................................ 3
1.2 Safety instructions..................................................................................................................................... 3
1.3 Engineering software Automation Builder................................................................................................. 6
1.3.1 Installing Automation Builder...................................................................................................... 6
1.3.2 Licensing procedure................................................................................................................... 7
1.3.3 Set-up communication parameters in Windows......................................................................... 9
1.4 Hardware AC500 V2............................................................................................................................... 10
1.4.1 Configuration for example projects.......................................................................................... 10
1.4.2 System assembly, construction and connection...................................................................... 12
1.5 Example project for central I/O expansion.............................................................................................. 13
1.5.1 Preconditions........................................................................................................................... 13
1.5.2 Create, set-up and save your AC500 V2 project..................................................................... 13
1.5.3 Configure the I/O module......................................................................................................... 17
1.5.4 Programming and compiling.................................................................................................... 19
1.5.5 Setting up the communication gateway................................................................................... 30
1.5.6 Log-in to CPU and download the program............................................................................... 35
1.5.7 Test the program...................................................................................................................... 37
1.5.8 Set-up visualization.................................................................................................................. 39
1.5.9 Reset the CPU......................................................................................................................... 51
1.6 Example project for remote I/O expansion with PROFINET................................................................... 52
1.6.1 Preconditions........................................................................................................................... 52
1.6.2 Set-up PROFINET controller.................................................................................................... 52
1.6.3 Set-up PROFINET device........................................................................................................ 55
1.6.4 Add remote I/O expansion to project........................................................................................ 59
1.6.5 Test the program...................................................................................................................... 62
1.6.6 Reset the CPU......................................................................................................................... 63
1.7 Further information on our AC500 portfolio............................................................................................. 64
2 Index............................................................................................................................................................... 65
Table of contents
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1 Getting started with example projects
1.1 Introduction
This document gives an overview of the steps for the first use of a PLC with AC500 V2
processor module and describes:
● installation of the engineering software Ä Chapter 1.3 “Engineering software Automation
Builder” on page 6
● hardware needed for example projects
Ä Chapter 1.4 “Hardware AC500 V2” on page 10
● setting up a first, simple project for a stand-alone CPU with central I/O expansion, including
visualization and web visualization Ä Chapter 1.5 “Example project for central I/O expan-
sion” on page 13
● commissioning a project for remote I/O expansion with PROFINET
Ä Chapter 1.6 “Example
project for remote I/O expansion with PROFINET” on page 52
1.2 Safety instructions
Relevant standards and regulations, accident prevention regulations and regulations on spe-
cial environmental conditions must be observed (e.g., hazardous areas due to explosive sub-
stances, heavy soiling or corrosive influences).
The devices must be handled and operated within the specified technical data and system data.
The devices contain no serviceable parts and must not be opened.
Removable covers must be closed during operation unless otherwise specified.
Any liability for the consequences of incorrect use or unauthorized repairs is rejected.
Both the AC500 control system and other components in the vicinity are operated with dan-
gerous touch voltages. Touching live components can lead to serious health implications or
even death.
To avoid such risks and the occurrence of property damage, persons involved in the installation,
commissioning and maintenance must have relevant knowledge about:
● Automation technology
● Handling of hazardous voltages
● Application of relevant standards and regulations, accident prevention regulations and reg-
ulations on special environmental conditions (e.g., hazardous areas due to explosive sub-
stances, heavy soiling or corrosive influences).
The AC500-S safety user manual must be read and understood before using the safety configu-
ration and programming tools of Automation Builder/PS501 Control Builder Plus. Only qualified
personnel are permitted to work with AC500-S safety PLCs.
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.
The PLC was developed according to the relevant standards. Any module-specific measures
are described in the individual descriptions of the modules.
Qualified per-
sonnel
Functional
safety
General infor-
mation
Getting started with example projects
Safety instructions
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The product family AC500 control system is designed according to the EN
61131-2 and IEC 61131-2 standards. Any data that differs from IEC 61131-2,
is due to 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 are 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!
Use of suitable enclosure
The devices must be mounted in a control cabinet that ensures compliance with
the specified environmental conditions.
Cleaning instructions
Do not use cleaning agent for cleaning the device.
Use a damp cloth instead.
Connection plans and a user program must be created so that no dangerous situations can
occur during normal operation or failure.
The application must be tested to ensure that no dangerous situations can occur during opera-
tion.
Do not operate devices outside of the specified, technical data!
Trouble-free functioning cannot be ensured outside of the specified data.
NOTICE!
PLC damage due to missing grounding
– Make sure to ground the devices.
– The grounding (switch cabinet grounding) is supplied both by the mains
connection (or 24 V supply voltage) and via the DIN rail. The DIN rail
must be connected to ground before power is supplied to the device. The
grounding may be removed only if it is certain that no more power is being
supplied to the control system.
– In case of screw mounting, grounding must be ensured by the screws.
PLC-specific
safety notices
Getting started with example projects
Safety instructions
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CAUTION!
Do not obstruct the ventilation for cooling!
The ventilation slots on the upper and lower sides 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!
Warning sign on the module!
This indicates that dangerous voltages may be present or that surfaces may
have dangerous temperatures.
WARNING!
Splaying of strands can cause hazards!
Avoid splayed strands when wiring terminals with stranded conductors.
– Ferrules can be used to prevent splaying.
WARNING!
Removal/Insertion under power
Removal or insertion under power is permissible only if all conditions for hot
swapping are fullfilled.
The devices are not designed for removal or insertion under power when the
conditions for hot swap do not apply. Because of unforeseeable consequences,
it is not allowed to plug in 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 they are energized in a hazardous
location could result in an electric arc, which could create an ignition source
resulting in fire or explosion.
Prior to proceeding, make sure that power is been disconnected and that the
area has been thoroughly checked to ensure that flammable materials are not
present.
The devices must not be opened when in operation. The same applies to the
network interfaces.
Getting started with example projects
Safety instructions
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CAUTION!
Use only ABB approved lithium battery modules!
At the end of the battery’s lifetime, always replace it only with a genuine battery
module.
CAUTION!
Risk of explosion!
Do not open, re-charge or disassemble lithium batteries. Attempting to charge
lithium batteries will lead to overheating and can cause explosions.
Protect them from heat and fire and store them in a dry place.
Never short-circuit or operate lithium batteries with the polarities reversed. The
batteries are likely to overheat and explode. Avoid unintentional short circuiting
do not store batteries in metal containers and do not place them on metallic
surfaces. Escaping lithium is a health hazard.
Environment considerations
Recycle exhausted batteries. Dispose of batteries in an environmentally con-
scious manner in accordance with regulations issued by the local authorities.
1.3 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 6.
1.3.1 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 upgrading 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.
5. Keep the default type of installation to “Premium Edition” if available.
6. Select software packages to be installed:
Enable the check box “PLC - AC500 V2” to activate installation of all options for AC500
V2.
7. Click “Download and install” and follow the instructions of the setup.
Information on
batteries
Preconditions
Installation
Getting started with example projects
Engineering software Automation Builder > Installing Automation Builder
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1.3.2 Licensing procedure
When you start Automation Builder software for the first time, you will be asked to choose a
license option.
See also:
●Details about the license model, the features of the editions and the latest license
information
●Detailed description of the installation and the licensing possibilities of Automation Builder
Automation Builder software must be installed successfully.
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”.
Activate a trial
license
Getting started with example projects
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 with example projects
Engineering software Automation Builder > Licensing procedure
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8. Select “OK” to end the wizard.
ðAutomation Builder license is activated and starts.
1.3.3 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
conflict 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”.
ð
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].
4. Double-click “Internet Protocol Version 4 (TCP/IPv4)”.
Setting up com-
munication
parameters
Change the IP
address
Getting started with example projects
Engineering software Automation Builder > Set-up communication parameters in Windows
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5. Enter your desired IP address and subnet mask.
1.4 Hardware AC500 V2
1.4.1 Configuration for example projects
The example projects require a small PLC configuration with I/O devices, e.g., as available in
the training case TA515-CASE.
Table 1: Modules for example projects to get started with AC500 V2 PLC
Product name Type First project
Ä Chapter 1.5
“Example project for
central I/O expan-
sion” on page 13
Second project
Ä Chapter 1.6
“Example project
for remote
I/O expansion
with PROFINET”
on page 52
PM585-ETH AC500 V2 CPU x x
TB521-ETH 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
Getting started with example projects
Hardware AC500 V2 > Configuration for example projects
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Product name Type First project
Ä Chapter 1.5
“Example project for
central I/O expan-
sion” on page 13
Second project
Ä Chapter 1.6
“Example project
for remote
I/O expansion
with PROFINET”
on page 52
CM579-PNIO PROFINET communi-
cation module
-- x
CI502-PNIO PROFINET commu-
nication interface
module
-- x
TU508-ETH terminal unit for com-
munication interface
module
-- x
TA524 blind cap for terminal
base
x x
Fig. 1: Training case TA515
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:
Connections
Getting started with example projects
Hardware AC500 V2 > Configuration for example projects
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Fig. 2: 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.
1.4.2 System assembly, construction and connection
NOTICE!
Avoidance of electrostatic charging
PLC devices and equipment are 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 example projects
Hardware AC500 V2 > System assembly, construction and connection
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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).
1.5 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 web server
for visualization.
1.5.1 Preconditions
● Automation Builder is installed and licensed as, at least, basic edition.
● AC500 V2 CPU is assembled and connected to the PC Ä Chapter 1.4 “Hardware AC500
V2” on page 10.
1.5.2 Create, set-up and save your AC500 V2 project
1.5.2.1 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 example projects
Example project for central I/O expansion > Create, set-up and save your AC500 V2 project
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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 V2”.
9. Select the CPU according to your hardware set-up.
Getting started with example projects
Example project for central I/O expansion > Create, set-up and save your AC500 V2 project
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10. Select [Add PLC] to add the CPU to your application.
Getting started with example projects
Example project for central I/O expansion > Create, set-up and save your AC500 V2 project
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1.5.2.2 Configure your CPU
1. Double-click “PLC_AC500_V2”.
ðA tab opens in the editor view.
2. Select “CPU 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.
Getting started with example projects
Example project for central I/O expansion > Create, set-up and save your AC500 V2 project
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1.5.2.3 Save the project
Select menu “File è Save Project”.
Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].
1.5.3 Configure the I/O module
● The types and order of modules in the Automation Builder project must match the real
hardware configuration.
● The position of the modules in the device tree can be changed by drag and drop.
1.5.3.1 Add an I/O bus module
1. Right-click “IO_Bus” in the device tree.
2. Select “Add object”.
Getting started with example projects
Example project for central I/O expansion > Configure the I/O module
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3. Select “S500 I/O modules”.
4. Select “DA501” module.
5. Select [Add object] to add the module to the I/O bus.
1.5.3.2 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
program.
Getting started with example projects
Example project for central I/O expansion > Configure the I/O module
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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.
1.5.3.2.1 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
1.5.3.2.2 Handle the digital output variables
1. Open the list of the digital outputs.
2. Fill in the variable names:
Channel Type Variable
Digital output DC16 BOOL xStartDrilling1
1.5.4 Programming and compiling
You write the program code in a separate IEC 61131-3 editor (CODESYS). You can open
CODESYS out of Automation Builder.
Supported programming languages:
● ST (Structured Text)
● IL (Instruction List)
● FBD (Function Block Diagram)
● LD (Ladder Diagram)
● SFC (Sequential Function Chart)
● CFC (Continuous Function Chart)
Getting started with example projects
Example project for central I/O expansion > Programming and compiling
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1.5.4.1 Starting the IEC 61131 programm editor CODESYS
To start the IEC 61131 programm editor CODESYS:
Open an AC500 V2 project in Automation Builder
In the Automation Builder device tree double-click “Application”
ðThis will start the IEC 61131 programm editor CODESYS
1.5.4.2 Task configuration
A task is a time unit in the processing of a user program (IEC application), which defines by
parameters the way and the speed the CPU is executing the user program.
For this project you will use only one cycling task.
Open CODESYS editor Ä Chapter 1.5.4.1 “Starting the IEC 61131 programm editor
CODESYS” on page 20
1. In the CODESYS editor menu select the “Resources” tab.
2. Double click “Task configuration”.
ðThe Task configuration window opens.
Getting started with example projects
Example project for central I/O expansion > Programming and compiling
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