There are many manufacturers of Programmable Logic Controllers
that are used in the Automation industry.
One of the leading PLC manufacturers in the world is ABB.
In the previous video,
I introduced you to the various PLC models that make up the AC500 product line,
the wide range of I/O cards, interfaces, and modules available,
and the powerful “Automation Builder” software.
I will now configure a small ABB AC500 PLC system
to demonstrate how the components I introduced in the introductory video are connected.
I will define a small system that will include a CPU
and interfaces for Profibus DP and Ethernet.
The CPU will be located in a cabinet in the main automation equipment room.
will require 24 volt DC I/O with one Digital Input card,
one Digital Output card, and one Analog Input card
located remotely from the CPU in an I/O panel located in the process area.
Additionally, I will include one CP600 operator control panel
that will also be mounted in the process area.
This HMI will provide the operator access to the process
through a touchscreen interface.
I consult the latest ABB PLC Automation catalog
to learn more about the hardware offered in the AC500 product line
and the specifications for each device.
First, I select a CPU that will be able to handle the communication interfaces
and the small number of I/O points in my system.
I choose the “PM583 ETH” CPU,
which comes with one megabyte of memory,
one Ethernet port, and two serial ports.
I choose a “TB 511” terminal base to support the CPU’s Ethernet port
and to provide one additional communication card slot
for a Profibus DP communication card.
I select a CM592-DP Profibus DP Master communication card
to fit next to the CPU in the terminal base.
This Profibus interface has a standard 9 pin Profibus connector
and supports baud rates from a 9.6 Kilo Bits per second
to a 12 Mega Bits per second communication rate.
To support the three I/O cards in a remote configuration,
I first need a Profibus interface card in the I/O panel
to communicate with the “CM592 DP” card on the CPU terminal base.
I select a “CI541 DP” Profibus card
and a “TU509” terminal unit base.
I will need three TU518 I/O bases,
one for a single DI524 32 point 24 volt DC Digital Input card,
one for a DO526 8 point 24 volt DC Digital Output card,
and one for an AI523 16 point Analog Input card.
To finish the hardware setup,
I will select a CP6615 operator control panel with an Ethernet port.
This panel has a 15 inch touch screen and high definition resolution.
I will connect this HMI to the Ethernet port on the PM583 PLC.
I open the “Automation Builder” software to add the CPU to a new project,
which I name “SmallSystem”.
I double click on the AC500 template icon.
When the new project window appears,
I select “PM583 ETH” from the selection list
and then I press “Add PLC”.
I right click on the PLC and select “Edit Object”.
I then select the “PM583 ETH Hardware” tab in the configuration window,
and I select the “TB 511” terminal base from the drop-down list.
I select “Change PM/TB Type” and acknowledge the warning message.
I now create the Profibus segment by right clicking on “Slot 1”
under “Extension Bus” and select “Add object”.
When the “Replace Object” window opens,
I select the “CM592 DP Profibus Master” card
and then I select “Replace object”.
The Profibus card now appears in the device tree.
I right click on “Profibus Master” and select “Add Object”.
In the “Add Object” window,
I select the “CI541 DP” card, and then I select “Add object”.
The device tree updates and shows the “CI541” module.
I right click on the “CI541 DP” device and select “Add object”.
I select “AI523”, the analog input card from the device list,
and select “Add object”.
I repeat this process to add the “DI524” digital input card
and the “DO526” digital output card.
I now see all of the hardware components listed in the device tree.
Now I need to add the HMI panel to the hardware configuration.
I right click on the project name, “SmallSystem”, and select “Add object”.
In the “Add Object” window,
I select “Panel CP600” in the left pane to filter the device list
and then select “CP600 Control Panel” from the list.
I double click on “Panel CP600” in the device tree
and when the information window appears,
I see the connection from the CP600 to the CPU is selected by default.
The hardware is now ready
and the PLC and Operator Panel can be programmed
to meet the requirements of my project.
The PLC is programmed with the “Automation Builder” software,
and the Control Panel is programmed with a software application called
“Panel Builder 600”.
This video has provided a basic understanding of the features
and capabilities of the ABB AC500 family of PLCs and hardware.
Once you understand the requirements for your process,
choosing the right AC500 PLC,
communication interfaces, and I/O modules should be no problem.
Want to learn PLC programming
in an easy to understand format
and take your career to the next level?
Head on over to realpars.com