INSTALLATION AND CONFIGURATION MANUAL

Getting started
AC500 V3 products
Table of contents

—
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

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 Getting started with AC500 V3 products
Introduction > Installing Automation Builder

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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

Fig. 1: Safety
instructions

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

Preconditions 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.

Installation 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.

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Getting started with AC500 V3 products
Engineering software Automation Builder > Licensing procedure

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- Fieldbus sup- Engineering
ming port productivity
tools
Basic Free license x -- --
Standard 30-day free trial, x x --
then purchase
required
Premium 30-day free trial, x x x
then purchase
required

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

Activate a Automation Builder software must be installed successfully.

license

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 Getting started with AC500 V3 products
Engineering software Automation Builder > Licensing procedure

PC is connected to the internet.

1. Start Automation Builder.
ð A 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”.

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Getting started with AC500 V3 products
Engineering software Automation Builder > Licensing procedure

6. Enable the single PC license and select “Next”.

7. Enable online activation and select “Next”.

ð License activation procedure starts. A successfully ended licensing procedure ends
with a success message.

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 Getting started with AC500 V3 products
Engineering software Automation Builder > Set-up communication parameters in windows

8. Select “OK” to end the wizard.

ð Automation 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.

Change the IP
address
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.

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Getting started with AC500 V3 products
Engineering software Automation Builder > Set-up communication parameters in windows

4. Double-click Internet Protocol Version 4 (TCP/IPv4).

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 Getting started with AC500 V3 products
Hardware AC500 V3 > Configuration for example projects

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 Second project
Ä Chapter 1.4 Ä Chapter 1.5
“Example project for “Example project for
central I/O expan- remote I/O expan-
sion” on page 12 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 x x
input/output (I/O)
module
TU516-H terminal unit for I/O x x
module
CM579-PNIO PROFINET communi- -- x
cation module

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Getting started with AC500 V3 products
Hardware AC500 V3 > Configuration for example projects

Product name Type First project Second project

Ä Chapter 1.4 Ä Chapter 1.5
“Example project for “Example project for
central I/O expan- remote I/O expan-
sion” on page 12 sion with
PROFINET”
on page 56
CI502-PNIO PROFINET communi- -- x
cation interface
module
TU508-ETH terminal unit for com- -- x
munication interface
module
TA524 blind cap for terminal x x
base

Electrical con-
nection

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:

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 Getting started with AC500 V3 products
Hardware AC500 V3 > System assembly, construction and connection

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.

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Example project for central I/O expansion > Create, set-up and save your AC500 V3 project

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”.

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Example project for central I/O expansion > Create, set-up and save your AC500 V3 project

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.

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Example project for central I/O expansion > Create, set-up and save your AC500 V3 project

10. Select “Add PLC” to add the CPU to your application.

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 Getting started with AC500 V3 products
Example project for central I/O expansion > Create, set-up and save your AC500 V3 project

1.4.2.2 Configure your CPU

1. Double-click “PLC_AC500_V3”.
ð A 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.

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Example project for central I/O expansion > Create, set-up and save your AC500 V3 project

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.

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Example project for central I/O expansion > Configure the I/O module

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.

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Example project for central I/O expansion > Configure the I/O module

1.4.3.1 Add an I/O bus module

1. Right-click “IO_Bus” in the device tree.

2. Select “Add object”.

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Example project for central I/O expansion > Configure the I/O module

3. Select “S500 I/O modules”.

4. Select “DA501” module.
5. Select “Add object” to add the module to the I/O bus.

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Example project for central I/O expansion > Configure the I/O module

1.4.3.2 DA501 variable mapping

1. Double-click “DA501” in the device tree.

ð A tab opens in the editor view.
2. Select “DA501 I/O Mapping”
ð Here, 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

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Example project for central I/O expansion > Programming and compiling

1.4.3.2.2 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

1.4.4 Programming and compiling

1.4.4.1 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.

In the device tree, you see the objects “Task configuration” and “Task”. Both created automati-
cally with the project.
For this project you will use only one cycling task.

Double-click “Task” in the device tree.

ð A tab opens in the editor view.
For this project you will use only one cyclic task. Keep the default settings for the task.

Priority This is how the CPU prioritizes the task, when more than one task is defined. Priority
0...15 = realtime tasks, priority 16 = non-realtime task.
Type In the CPU you can run tasks dependent on the demands of the process
Interval For cyclic tasks you can set the cyclical execution time. It is usually set in millisec-
onds with IEC time syntax
Watchdog To keep track of the time it takes to complete the task
Calls You can call in one or more program POUs in one single task

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Example project for central I/O expansion > Programming and compiling

1.4.4.2 Main program PLC_PRG

In the default task configuration, there is one call of a POU (program organization unit) i.e.
"PLC_PRG".
In your project the "PLC_PRG" will become a main program containing calls to other programs
(POUs) which you will create one by one.

The PLC_PRG POU has been defined by default in ST (structured text) editor. Keep this setting
because of good visibility of the instructions at a glance and good handling for troubleshooting.
To optimize the project readability, you will work with the previously created folder "10 POUs"
and add the created subroutines (POUs) to this folder. The subroutines will be created in FBD
(function block diagram) editor.

1.4.4.3 Boolean logic "NOT"

1.4.4.3.1 Application example "driller"
Recognizing of a driller by a photo sensor. "TRUE" input signal from sensor indicates that a
driller is broken. If driller has been found correct, then start drilling.

Table 3: Required behavior

Signal from photo sensor Required signal of motor ON
FALSE TRUE
TRUE FALSE

Table 4: Hardware set-up

Element HW channel Symbol Description
Switch I1 DA501 DI8 xDI_08_DA501_I1 Photo sensor
LED output DC16 DA501 DC16 xStartDrilling1 Motor on

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Example project for central I/O expansion > Programming and compiling

1.4.4.3.2 Implementation
Create a new program POU in the project

1. Right-click “10 POUs”.

2. Select “Add object”.
3. Select “POU”.
4. Select “Add object”.

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Example project for central I/O expansion > Programming and compiling

5. Enter “_01_Assignment_NOT”.
6. Select “Program”.
7. Select “Function Block Diagram (FBD)”.
8. Select “Add”.
ð POU has been added.

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 Getting started with AC500 V3 products
Example project for central I/O expansion > Programming and compiling

Assign the hardware DI signals to local variables

1. Double-click POU“_01_Assignement_NOT” in the device tree.

2. Select “Assignment” from the ToolBox.

3. Drag and drop “Assignment” into the "Start here" field in network “1”.

4. Select “???” on the left side of the assignment, then select “...”.
5. Open the “Io Config_Globals_Mapping” mapping list and select “xDI_08_DA501_I1”.
6. Select “OK” to add this variable to the left side of the assignment connector.

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Getting started with AC500 V3 products
Example project for central I/O expansion > Programming and compiling

7. Select “???” on the right side of the assignment connector and mark the "???".
8. Create a new local variable by typing in "xDrillerBroken1" which will replace the "???".
9. Press [Enter].
ð “Auto Declare” opens.
You see the written variable name and the data type BOOL. The scope is "VAR". It
means it is a local variable within this POU.
10. Select “OK” to accept the entries.

11. Drag and drop “Network” from the ToolBox to the down-arrow of network 1.
ð You added a network “2” below network 1.

Add assignments and a Boolean NOT to the DO signals

1. Add an assingment from the ToolBox.
2. Type in or copy & paste "xDrillerBroken1" to the left side of the instruction line.
3. Select “???” on the right side of the instruction line, then select “...”.
ð “Input Assistant” opens.

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 Getting started with AC500 V3 products
Example project for central I/O expansion > Programming and compiling

4. In the “IoConfig_Globals_ Mapping” variable list, select “xStartDrilling1”.

5. Select “OK” to close the dialog.

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Getting started with AC500 V3 products
Example project for central I/O expansion > Programming and compiling

6. Right-click the center of assignment pin.

7. Select “Negation” to add a negation to the assignment.

Call the POU in the PLC_PRG

1. Double-click “PLC_PRG”.
2. Select the first line in "PLC_PRG" and press [F2].
ð “Input Assistant” opens.

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Example project for central I/O expansion > Programming and compiling

3. Select “Module Calls”.

4. Open “Application”.
5. Open “10 POUs” and select “_01_Assignment_NOT”.
6. Select “OK” to close the dialog.

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Getting started with AC500 V3 products
Example project for central I/O expansion > Set-up the communication gateway

1.4.4.3.3 Compile the project

Before logging-in to the CPU, you need to compile the complete code without any errors.

Select menu “Build è Generate code”.

ð The result of the compiling is shown in the “Messages” field at the bottom of the
screen.

If you skip the compiling and select “Login”, the Automation Builder will automatically trigger
compiling in advance to logging-in.

1.4.4.3.4 Save the project

Select menu “File è Save Project”.

Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].

1.4.5 Set-up the communication gateway

IP is configured properly Ä Chapter 1.2.3 “Set-up communication parameters in windows”
on page 7.

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 Getting started with AC500 V3 products
Example project for central I/O expansion > Set-up the communication gateway

CPU and PC are connected with an Ethernet cable.

1. In the Automation Builder device tree right-click “PLC_AC500_V3”.

2. Select “Communication Settings”.

3. Keep the default value in the IP address of the CPU or type in the current IP address, if
differs.

The standard (default) IP address of the port ETH1 is: 192.168.0.10

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Example project for central I/O expansion > Set-up the communication gateway

4. Select “OK” to implement the IP address.

Network scan If you need to scan the network for the CPU or if you have multiple CPUs on the same network.
1. Right-click “PLC_AC500_V3” in the device tree.
2. Select “Communication Settings”.

3. Select “...”.
ð “Pick IP Address for "PLC_AC500_V3"” opens.

The automatic scan runs.

The results will appear in this field.
4. Select the CPU in the field and select “OK” to implement the needed communications
gateway.

Check commu- If you need to check the communications settings or if you want to see more information about
nication set- the current selected CPU.
tings

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 Getting started with AC500 V3 products
Example project for central I/O expansion > AC500 V3 firmware installation and update

1. Double-click “PLC_AC500_V3” in the device tree.

2. Select “Communication Settings”.
ð The selected IP address is shown.
3. If the IP address is not visible, enter the IP address manually.
4. To test the connection and/or to see the CPU information press [Enter] or click on the
black dot next to the PLC picture.

1.4.6 AC500 V3 firmware installation and update

The PLC firmware can be updated via Automation Builder.

This is also necessary for commissioning V3 CPUs.

A very new CPU has no pre-installed firmware. To guarantee the authenticity of delivered
AC500 firmware, V3 CPUs are delivered with a boot loader only. You need to download a valid
firmware to the CPU. After download, the functionality of the CPU is given.
An Automation Builder project with an AC500 V3 CPU is open.
CPU is in "stop" mode or shows uPdAtE (update) on the display.
After update the CPU shows either donE or StoP on the display

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Getting started with AC500 V3 products
Example project for central I/O expansion > AC500 V3 firmware installation and update

For new modules: IP address is set. (The default IP address is 192.168.0.10)

1. Double-click CPU “PLC_AC500_V3”.
2. Select “Version information”.

3. Select “Update Firmware”.

ð While the update process is running, the RUN and ERR LEDs are toggling, i.e., they
are flashing alternating.
4. Wait for the PLC to finish the update.
A completed update is indicated by a message on the display. Either donE, or StoP.

NOTICE!
Do not disconnect the power supply during the update process! The PLC
could be damaged.

ð StoP indicates a restart has been performed by the CPU. When donE is displayed
sometimes it is necessary to re-boot the CPU manually, e.g., by powering-off. Manual
re-boot might be, e.g., for some older CPU versions or if downgrading to an older firm-
ware version according to application settings.

The CPU display shows "stop" after re-boot. The update process is finished.

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 Getting started with AC500 V3 products
Example project for central I/O expansion > Log-in to CPU and download the program

5. If necessary, refresh the version information by switching to another tab and back.
ð Successful firmware update:

Behavior of
LEDs during
firmware update

LED LED flashes Status

RUN and ERR Toggling Update pending
RUN Flashing slow Done successful
ERR Flashing slow Done failed

1.4.7 Log-in to CPU and download the program

Logging-in to the CPU will load the project into the AC500 V3 CPU. The first log-in will also load
the hardware set-up.

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Example project for central I/O expansion > Test the program

1. In the Automation Builder menu select “Online è Login [PLC_AC500_V3]”.

ð A pop-up will appear.
2. Select “Yes” to download the application to the AC500V3 CPU.

ð PLC is in "stop" mode.

3. Start the PLC Ä Chapter 1.4.8.1 “Start the program execution” on page 36.

Generally, if the CPU is in "run" mode, i.e. in program execution mode, a down-
load will always cause the mode change to "stop". In stop mode the CPU is not
controlling the system!
Always, after selecting the "Login" command, read carefully the dialog box text
to ensure that you are aware of the CPU’s behavior after the command confir-
mation.

By default, a download generates following actions in the CPU:

● The project is stored in the RAM memory.
● The project is stored in the flash EEPROM, if boot application was created.

1.4.8 Test the program

1.4.8.1 Start the program execution
You are logged in the CPU.
An executable project is loaded to the CPU.

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The CPU is in "stop" mode.

Select menu “Debug è Start [PLC_AC500_V3]”.

Alternatively, select the "start" icon in the tool bar.
Alternatively, press [F5].

1.4.8.2 Test the function

Operate the switch I1 and observe:
● The LEDs of the relevant DA501 inputs and outputs.
● The online status of inputs and outputs within the POU.

1.4.8.3 Stop the program execution

You are logged in the CPU.
An executable project is loaded to the CPU.

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Example project for central I/O expansion > Set-up visualization

The CPU is in "run" mode.

Select menu “Debug è Stop [PLC_AC500_V3]”

Alternatively, select the "stop” icon in the tool bar.
Alternatively, press [Shift] + [F8].

1.4.9 Set-up visualization

1.4.9.1 Add the VisualizationManager

1. Right-click “Application” in the device tree.

2. Select “Add object”.
3. Select “VisualizationManager”.
4. Select “Add object” to add the VisualizationManager to the project.
ð Dialog “Add Visualization Manager” opens.

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5. Select “Add”.

ð You added the objects “VisualizationManager” and “VISU-TASK” to the device tree.

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Example project for central I/O expansion > Set-up visualization

1.4.9.2 Set-up the VisualizationManager

1. Double-click VisualizationManager in the device tree.

ð A tab opens in the editor view.

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Example project for central I/O expansion > Set-up visualization

2. Select “Settings”.
3. Open the drop-down menu “Selected style”.
4. Select “Default, x.x.x” (exemplary).
5. Open the drop-down menu “Selected language”.
6. Select “en” for English language in the visualization.
7. Enable “Visible” for advanced settings.
8. Keep the file transfer to enable the visualization on the PLC (mandatory for web server
function Ä Chapter 1.4.11 “Enable web visualization” on page 50).

1.4.9.3 Save the project

Select menu “File è Save Project”.

Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].

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Getting started with AC500 V3 products
Example project for central I/O expansion > Create visualization

1.4.10 Create visualization

1.4.10.1 Add a folder for visualization screens

1. Right-click “Application” in the device tree.

2. Select “Add Folder”.

3. Type in "02 VISUs".

4. Select “OK” to add the folder.

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1.4.10.2 Add a screen for "_01_Assignment_NOT" POU

1. Right-click “02 VISUs”.

2. Select “Add object”.
3. Select object “Visualization”.
4. Select [OK].

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Getting started with AC500 V3 products
Example project for central I/O expansion > Create visualization

5. Type in "PLC_VISU".
6. Select “Add”.
ð A tab opens in the editor view.

Fig. 4: PLC_VISU_tab

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 Getting started with AC500 V3 products
Example project for central I/O expansion > Create visualization

The name "PLC_VISU" has been chosen, because it is the default name for a
home screen in a web visualization.
If you have more than one visualization object in your project, it will be useful to
choose another name, e.g. "_01_Assignment_NOT_v". And to choose
"PLC_VISU" as a home screen to access all available visualization screens.
The name of a visualization object can be modified afterwards.

1.4.10.3 Creating and configuring of visualization

1.4.10.3.1 Change background color
1. Double-click “PLC_VISU” in the device tree.
ð A tab opens in the editor view.

2. Right-click anywhere on the "PLC_VISU" editor page.

3. Select “Background”.

4. Enable the check box “Use Color”.

ð This enables the drop-down menu.
5. Select a color, e.g., “Lightgray”.
6. Select [OK] to add the color to "PLC_VISU".

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Getting started with AC500 V3 products
Example project for central I/O expansion > Create visualization

1.4.10.3.2 Add a screen title

1. Double-click on “PLC_VISU” in the device tree.

2. Select “ToolBox”.

3. Select “Common controls”.

4. Drag and drop “Label” to the page.

5. Type in "Start drilling condition".

1.4.10.3.3 Further lines and labels

1. Double-click on “PLC_VISU” in the device tree.

2. Select “ToolBox”.
3. Select “Basic”.
4. Drag and drop the line. Then drag the line to the needed length.

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Example project for central I/O expansion > Create visualization

5. Follow the same procedure to create the other shapes and labels.

1.4.10.3.4 Lamp element for signal indication

1. Double-click on “PLC_VISU” in the device tree.

2. Select “ToolBox”.
3. Select “Lamps/Switches/Bitmaps”.
4. Drag and drop “Lamp” to the screen.
5. Adapt the size, if required.

6. Under “Image”, select “Gray”.

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7. Double-click on “Variable” and select “...” to select a variable from the list.

8. Under “IoConfig_Globals_Mapping”, select “xStartDrilling1”.

9. Select [OK].

1.4.10.3.5 Compile the project

Before logging-in to the CPU, you need to compile the complete code without any errors.

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Select menu “Build è Generate code”.

ð The result of the compiling is shown in the “Messages” field at the bottom of the
screen.

If you skip the compiling and select “Login”, the Automation Builder will automatically trigger
compiling in advance to logging-in.

1.4.10.3.6 Save the project

Select menu “File è Save Project”.

Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].

1.4.10.4 Loading the project to the CPU

1. Download the project to the CPU Ä as described in Chapter 1.4.7 , on page 35.
2. Check the notification window at the end of the download. In case of message "Boot
parameters were changed. These changes will be applied after reboot", a reboot of the
CPU is required after creation of the boot project.

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Getting started with AC500 V3 products
Example project for central I/O expansion > Enable web visualization

1.4.10.5 Test the program

Operate the switches and observe the visualization screen.

1.4.11 Enable web visualization

1.4.11.1 Add a web server object to the device tree
Ethernet ports can be configured for web server protocol. This description deals with ETH1 con-
figuration for the webserver

1. Right-click “ETH1” in the device tree.

2. Select “Add object”.
3. Select “Web Server”.

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4. Select “Add object”.

ð You added and activated a web server on Ethernet port 1 on the AC500 V3 CPU.

1.4.11.2 Set-up the web server

1. Double-click “WebVisu” in the device tree.

2. Under “Start Visualization”, select “...”.

ð A list opens.
3. Select the “PLC_VISU” screen from the list.
4. Keep all further settings with default values.

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Example project for central I/O expansion > Enable web visualization

5. Select the link “Show used visualizations”.

ð The VisualizationManager editor and there the tab “Visualizations” opens. All screens
and dialog elements created in the project are visible.
Here, you can select which screens are enabled or disabled for web visualization.

If you want to select another screen as a start visualization, you must modify the adequate
parameter in the webvisu.htm file: <param name="STARTVISU" value="PLC_VISU">

1.4.11.3 Compile the project

Before logging-in to the CPU, you need to compile the complete code without any errors.

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Example project for central I/O expansion > Enable web visualization

Select menu “Build è Generate code”.

ð The result of the compiling is shown in the “Messages” field at the bottom of the
screen.

If you skip the compiling and select “Login”, the Automation Builder will automatically trigger
compiling in advance to logging-in.

1.4.11.4 Save the project

Select menu “File è Save Project”.

Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].

1.4.11.5 Loading the project to the CPU

1. Download the project to the CPU Ä as described in Chapter 1.4.7 , on page 35.
2. Check the notification window at the end of the download. In case of message "Boot
parameters were changed. These changes will be applied after reboot", a reboot of the
CPU is required after creation of the boot project.

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Example project for central I/O expansion > Reset the CPU

1.4.11.6 Create a boot project

By default, after project download, the boot project is created automatically.

1.4.11.7 Rebooting the CPU

Reboot the CPU by switching OFF and ON the power supply. (The parameter for web-
server activation is a boot pamater which is loaded during boot of the CPU)

1.4.11.8 Test the web visualization

You have downloaded the project and created the boot project.
The CPU has been rebooted.
You are logged in.
CPU is in "stop" mode.
1. Start the project execution, e.g., from the tool bar.
2. Launch an internet browser.
3. Type in the URL field: http://192.168.0.10/webvisu.htm.
192.168.0.10 is the IP address of CPU’s ETH1 port.
/webvisu.htm is the default htm file.
ð Web visualization will be loaded.
The start screen “PLC_VISU” is displayed in a responsive view.

4. Test the function by operating switch I1.

5. Test the results for responsive view by changing the web browser window size.

1.4.12 Reset the CPU

Reset values In some cases, it could be required to do a CPU reset, e.g., for resetting of counter values,
and parameters parameters etc.

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Fig. 5: Reset commands in “Online” menu

Reset All variables are reset, except RETAIN PERSISTENT variables.
warm
Reset cold Causes initialization of all variables, except PERSISTENT variables. By recom-
mended creation of remanent variables always with both properties: PERSISI-
TENT and RETAIN, this command resets all variables, except PERSISTENT
RETAIN variables.
Reset All variables and the application project are reset.
origin

Table 5: Behavior of variables of type VAR (local or global) and variables of type PERSISTENT
RETAIN
VAR VAR PERSISTENT RETAIN
After online command “Online change” no change no change
After online command “Download” initialization no change
After online command “Reset warm” initialization no change
After online command “Reset cold” initialization no change
After online command “Reset origin” initialization initialization
After power supply off initialization no change

Complete reset To do a complete reset of the CPU thereby erasing the application from the RAM and flash
of the CPU EEPROM do the following.

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Example project for remote I/O expansion with PROFINET > Set-up PROFINET controller

1. Right-click the station object “PLC_AC500_V3” in the device tree.

2. Select “Reset origin device [station name]”.
ð The application is completely erased from the CPU (complete project from all memory
areas).

1.5 Example project for remote I/O expansion with PROFINET

This example introduces the configuration of the PLC with remote I/O. The use of I/O channels
in a program and commissioning of the configuration is shown.

1.5.1 Preconditions
● Automation Builder is installed and licensed as, at least, standard edition Ä Chapter 1.2
“Engineering software Automation Builder” on page 3.
● AC500 V3 CPU is assembled and connected to the PC.
● Configuration and programming of this example project will be made in the existing example
project for central I/O expansion Ä Chapter 1.4 “Example project for central I/O expansion”
on page 12.
● CM579-PNIO communication module is inserted in terminal base and connected to the
PLC.
● CI502-PNIO communication interface module is inserted in terminal unit and connected to
the PLC.

1.5.2 Set-up PROFINET controller

1.5.2.1 Add the CM579-PNIO to the device tree
1. In the Automation Builder device tree under “Extension_Bus”, right-click “Slot_1”.
2. Select “Add object”.
3. Select “CM579-PNIO”.

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4. Select “Replace object” to add the CM579-PNIO.

1.5.2.2 Set-up the general behavior

1. Under “Extension_Bus”, double-click “CM579_PNIO” in the device tree.

ð A tab opens in the editor view.
2. Select “CM579-PNIO Parameters”.

Run on configuration This parameter will prohibit the PLC from running if the CM579-PNIO
fault has a configuration error/fault.
Bus behavior This parameter sets how the data from the bus flows in/out of the
CM579-PNIO.

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Example project for remote I/O expansion with PROFINET > Set-up PROFINET controller

3. Select “Status”.
ð This opens the bus controller status and gives a basic status overview.
4. Select “Information”.
ð This page contains general information about the CM579-PNIO.
5. For the example project, you can keep the default settings.

1.5.2.3 Set-up the PROFINET IO controller

To edit settings for the controller, you must not be logged-in to the PLC.

1. Under “CM579_PNIO”, double-click “PNIO_Controller” in the device tree.

ð A tab opens in the editor view.
2. Select “PROFINET IO CONTROLLER”

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Example project for remote I/O expansion with PROFINET > Set-up PROFINET device

3. Select “General”.
4. Here, you can set-up the way, IP addresses are distributed out to the industrial bus net-
work. You can even set, what IP-address and DNS name (station name) the PROFINET
controller has.
For the example project, keep the default settings.

1.5.3 Set-up PROFINET device

1.5.3.1 Hardware preparation
1. Switch off the power supply of your PLC.
2. Use a screw driver to set the CI502 module address to "02" by positioning of the upper
rotary switch to "0" and lower switch to "2". Note, that the numbers have hexadecimal
format.
3. Switch on the power supply.

1.5.3.2 Add the CI502-PNIO to the device tree

1. Right-click “PNIO_Controller” in the device tree.
2. Select “Add object”.
3. Select “CI502-PNIO-Device”.

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4. Select “Add object” to add the device.

1.5.3.3 Configure the CI502-PNIO device

1.5.3.3.1 Configure the CI502-PNIO PROFINET IO device

1. Double-click “CI502_PNIO_Device”.
ð A tab opens in the editor view.

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2. Select “General”.

Station name Default station name

IP Parameter IP-addressing parameters of the node. If modifications are required for “IP
Parameter”, they must be done also for CM579-PNIO and all other devices in
this PROFINET line.
Communication Communication time set-up
VLAN Virtual local area network ID
RT Class PROFINET IO RT (real time) type settings
3. Set station name to "ci502-pn-02" according to hardware settings.
For numbers greater than 09 always make sure, that the last two decimal digits of the
node’s “Station Name” in Automation Builder correspond to the position of module’s rotary
switches (hexadecimal values): e.g., "ci502-pn-10" <-> "0A" or "ci502-pn-16" <-> "10".
4. Leave the default settings for “IP Parameter”.
5. Adjust the communication time settings to get a Watchdog (ms) 24:
● “Send clock (ms)”: 4
● “Reduction ratio”: 2
● “Phase”: 1
6. Leave the default settings for “VLAN ID”.
7. Leave the default settings for “RT Class”.

If the node has the same device address (the last two digits of the device name)
as set by means of the rotary switches on the module, all the node parameters
will be loaded automatically upon initialization scan of the CI50x module. This
allows, e.g., the module exchange without an engineering tool.

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Example project for remote I/O expansion with PROFINET > Set-up PROFINET device

1.5.3.3.2 Create CI502-PNIO I/O mapping to symbols

1. Double-click “CI502_IO”.

2. Select “PNIO Module I/O Mapping”.

3. Fill in the variable names:

Element Hardware channel Symbol

Switch I5 CI502 DI8 xDI_08_CI502_I5
LED output DO8 CI502 DO 8 xDO_08_CI502

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1.5.4 Add remote I/O expansion to project

1.5.4.1 Add a program POU to the project

1. Right-click “01 - POUs” in the device tree.

2. Select “Add object”.
3. Select “POU”.
4. Select “Add object”.

5. Fill in "_30_PNIO_test".
6. Select “Program”.
7. Select “Function Block Diagram”.

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8. Select [Add] to add the POU.

1.5.4.2 Create a POU logic

1. Double-click “30_PNIO_test” in the device tree.

2. In the ToolBox, select “Assignment”.

3. Drag and drop “Assignment” into the "Start here" field in network "1".

4. Select “???” on the left side of the assignment, then select “...”.
5. In “IoConfig_Globals_Mapping” list, select “xDI_08_CI502_I5”.
6. Select [OK] to add this variable to the left side of the assignment connector.

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7. Select “???” on the right side of the assignment, then select “...”.
8. In “IoConfig_Globals_Mapping” list, select “xDO_08_CI502”.
9. Select [OK].

1.5.4.3 Call the POU in PLC_PRG

1. Double-click “PLC_PRG”.
2. Select the next free line in “PLC_PRG” and press [F2].
ð “Input Assistent” opens.
3. Select “Module Calls”.
4. Open “Application”.
5. Open “10 POUs” and select “_30_PNIO test”.
6. Select [OK] to close the dialog.

1.5.4.4 Compile the project

Before logging-in to the CPU, you need to compile the complete code without any errors.

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Example project for remote I/O expansion with PROFINET > Add remote I/O expansion to project

Select menu “Build è Generate code”.

ð The result of the compiling is shown in the “Messages” field at the bottom of the
screen.

If you skip the compiling and select “Login”, the Automation Builder will automatically trigger
compiling in advance to logging-in.

1.5.4.5 Save the project

Select menu “File è Save Project”.

Alternatively, select the save icon in the tool bar.
Alternatively, press [Ctrl] + [S].

1.5.4.6 Loading the project to the CPU

1. Download the project to the CPU Ä as described in Chapter 1.4.7 , on page 35.
2. Check the notification window at the end of the download. In case of message "Boot
parameters were changed. These changes will be applied after reboot", a reboot of the
CPU is required after creation of the boot project.

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Example project for remote I/O expansion with PROFINET > Test the program

1.5.5 Test the program

1.5.5.1 Start the program execution
You are logged in the CPU.
An executable project is loaded to the CPU.
The CPU is in "stop" mode.

Select menu “Debug è Start [PLC_AC500_V3]”.

Alternatively, select the "start" icon in the tool bar.
Alternatively, press [F5].

1.5.5.2 Test the function

Operate the switch I5 and observe:
● The LEDs of the relevant CI502 inputs and outputs.
● The online status of inputs and outputs within the POU.

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Example project for remote I/O expansion with PROFINET > Reset the CPU

1.5.6 Reset the CPU

Reset values In some cases, it could be required to do a CPU reset, e.g., for resetting of counter values,
and parameters parameters etc.

Fig. 6: Reset commands in “Online” menu

Reset All variables are reset, except RETAIN PERSISTENT variables.
warm
Reset cold Causes initialization of all variables, except PERSISTENT variables. By recom-
mended creation of remanent variables always with both properties: PERSISI-
TENT and RETAIN, this command resets all variables, except PERSISTENT
RETAIN variables.
Reset All variables and the application project are reset.
origin

Table 6: Behavior of variables of type VAR (local or global) and variables of type PERSISTENT
RETAIN
VAR VAR PERSISTENT RETAIN
After online command “Online change” no change no change
After online command “Download” initialization no change
After online command “Reset warm” initialization no change
After online command “Reset cold” initialization no change
After online command “Reset origin” initialization initialization
After power supply off initialization no change

Complete reset To do a complete reset of the CPU thereby erasing the application from the RAM and flash
of the CPU EEPROM do the following.

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1. Right-click the station object “PLC_AC500_V3” in the device tree.

2. Select “Reset origin device [station name]”.
ð The application is completely erased from the CPU (complete project from all memory
areas).

1.6 Further information on our AC500 portfolio

● PLC homepage: abb.com/plc
● PLC catalog as PDF: to.abb/SZTxDTqG, and also as flipbook
● The manual for Automation Builder and all AC500 products is available via Automation
Builder. Go to menu “Help è Contents”, the manual will open.

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Index

—
2 Index
A
Automation Builder
getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
licensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

C
communication parameters
in Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compiling a project . . . . . . . . . . . . . . . . 30, 48, 52, 65

E
example project with Automation Builder and
AC500 AC500 V3 products . . . . . . . . . . . . . . . 12, 56

I
IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

L
log-in to a CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

P
PLC_PRG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

T
testing a program . . . . . . . . . . . . . . . . . . . . . . . 36, 67

V
visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
VisualizationManager . . . . . . . . . . . . . . . . . . . . . . . 38

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—
ABB Automation Products GmbH
Eppelheimer Str. 82
69123 Heidelberg, Germany
Telephone: +49 (0)6221 701 1444
3ADR010584, 2, en_US

Fax: +49 (0)6221 701 1382

E-mail: [email protected]
abb.com/plc

—
© Copyright 2020 ABB.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden.