Automation Builder is ABB's single engineering tool for AC500 and AC500-eco PLCs, drives and HMIs. Download it from ABB, install it as administrator with the AC500 V2 package (for PM5xx eco CPUs such as PM564-ETH) and the V3 package (for PM50xx CPUs), then power the CPU from a 24 VDC supply and check the status LEDs. The Basic edition is free and is enough for every lab in this series.
- Install Automation Builder as administrator and include the AC500 V2 and V3 device packages
- PM564-ETH is an AC500-eco V2 CPU; PM50xx-ETH CPUs are V3. The programming screens differ, the workflow does not
- Use a separate 24 VDC feed for the CPU and the I/O process supply, and check polarity before switching on
- Record the PC, PLC and HMI IP plan now: you will use it in every lab
This series uses one trainer kit and one conveyor example from Lab 1 to Lab 20. Every tag name, IP address and wiring point you meet here appears again in later labs, so it pays to set things up carefully now.
Step 1: Understand the AC500-eco Lab Kit Architecture
Before installing anything, look at what you will be programming. The drawing below is the full lab kit. Orange lines are Ethernet, the yellow dotted line is the I/O bus between the CPU and the expansion module, and the blue dashed line is the RS-485 link to the drive.
Click or tab to a device to see its role in the lab kit.
| Device | Location | Address | Role |
|---|---|---|---|
| AC500-eco CPU PM564-T-ETH | Control panel | 192.168.0.10 (Ethernet), COM1 RS-485 | Runs the program; onboard DI/DO/AI/AO |
| DX561 digital I/O module | I/O bus, slot 1 | n/a | 8 DI + 8 DO (24 VDC) for extra field signals |
| 24 VDC power supply | Control panel | n/a | CPU supply plus process supply for inputs and outputs |
| CP604 HMI (optional) | Panel door | 192.168.0.20 | Operator screens, alarms (Labs 12–13) |
| ACS580 VFD | Drive panel | Modbus RTU node 1 on COM1 | Conveyor motor speed control (Labs 19–20) |
| Engineering PC | Portable | 192.168.0.100 | Automation Builder, download, monitoring |
| Unmanaged Ethernet switch | Control panel | n/a | Connects PC, PLC and HMI |
Step 2: Check PC Requirements and Download Automation Builder
Automation Builder comes in editions. The Basic edition is free and covers configuring and programming AC500-eco CPUs, which is all this series needs. Paid editions add features such as simulation and advanced diagnostics.
| Item | Recommendation | Why it matters |
|---|---|---|
| Operating system | Windows 10 or 11, 64-bit | Older Windows versions are not supported by current releases |
| User rights | Local administrator for installation | The installer adds drivers and the communication gateway |
| Disk space | Allow at least 20 GB free | Device packages and libraries are large |
| Edition | Automation Builder Basic | Free; supports AC500-eco programming |
| Download | ABB website: Automation Builder product page | Always use the latest version that supports your CPU firmware |
| Antivirus | Allow the gateway service through the firewall | Blocked gateway = no online connection in Lab 2 |
Note the CPU firmware version printed on the label or shown later in the online diagnostics. Projects should be built with an Automation Builder version that supports that firmware.
Step 3: Install Automation Builder with the AC500 Device Packages
- Right-click the installer and choose Run as administrator.
- Accept the licence and pick the Basic edition (or the edition your licence covers).
- In the feature selection, tick AC500 V2 (needed for PM554/PM556/PM564/PM566-ETH eco CPUs) and AC500 V3 (for PM50xx eco and PM56xx CPUs). Drive and panel packages are optional.
- Let the installer add the communication gateway and USB/serial drivers when asked.
- Restart the PC, start Automation Builder and open Help > About to confirm the version and installed packages.
Step 4: Wire 24 VDC Power to the CPU and I/O
The AC500-eco CPU needs a 24 VDC supply for its electronics, and the digital inputs and transistor outputs need a 24 VDC process supply. On the trainer they come from the same power supply through separate MCBs, so an output short circuit cannot take the CPU down.
| Circuit | Feeds | Protection | Check before power on |
|---|---|---|---|
| CPU supply | CPU 24 VDC terminals (L+ / M) | MCB / fuse 2 A | Polarity: + to L+, 0 V to M |
| Input supply | Push buttons, selectors, sensors | MCB 2 A | Common of the input group to the correct rail (sink/source wiring) |
| Output process supply | Transistor outputs (UP / ZP) | MCB 4 A | Outputs will not switch without this supply |
| Shield / earth | Panel earth bar | n/a | Cable shields and FE terminal bonded |
Step 5: Power Up and Run the Lab 1 Checklist
Switch on the CPU supply first, then the I/O supplies. A new CPU with no program normally comes up in STOP with the power LED on and no error. Use the checklist to record the result; it updates the progress bar as you go.
| ID | Check | How to check | Pass criterion | Result |
|---|---|---|---|---|
| Software | ||||
| S-01 | Automation Builder starts | Open it from the Start menu | No licence or package errors | |
| S-02 | AC500-eco CPUs in catalogue | Add device dialog, search PM564 | PM564-T-ETH listed | |
| Hardware | ||||
| H-01 | CPU power LED | Switch on CPU supply | Power LED steady | |
| H-02 | No CPU error | Look at the error LED | Error LED off (or explained by missing program) | |
| H-03 | Input LEDs follow buttons | Press Start, turn selector | Matching input LED lights | |
| H-04 | DX561 recognised | Module status LED | No module error indication | |
| H-05 | IP plan recorded | Write PC/PLC/HMI IPs on the kit sheet | Matches the table in Step 1 | |
Practice Exercise
Draw the lab kit architecture from memory on paper, label every device with its IP or bus position, then compare with Fig. 1. Next, find the firmware version on your CPU label and check that your installed Automation Builder version supports it.
Troubleshooting
| Symptom | Likely cause | Fix |
|---|---|---|
| Installer stops with access denied | Not run as administrator | Right-click the installer and run as administrator |
| PM564 not found in the device catalogue | AC500 V2 package not installed | Run the installer again and add the AC500 V2 feature |
| CPU power LED off | Wrong polarity or tripped MCB | Check L+/M polarity and the MCB, measure 24 VDC at the terminals |
| Input LED does not light | Input common not wired to the right rail | Check sink/source wiring of the input group common |
| Error LED on at first power up | No program or a configuration mismatch | Normal on a blank CPU; it clears after the first download in Lab 8 |
Frequently asked questions
Is ABB Automation Builder free?
Yes. Automation Builder Basic is free of charge and supports configuring and programming AC500-eco PLCs. Paid Standard and Premium editions add features such as simulation and extended diagnostics.
Which Automation Builder package do I need for PM564-ETH?
PM564-ETH is an AC500-eco V2 CPU, so install the AC500 V2 package. If you also use newer PM50xx eco CPUs, add the AC500 V3 package.
What is the difference between AC500-eco V2 and V3 CPUs?
V2 eco CPUs (PM554, PM556, PM564, PM566) are programmed with the CoDeSys 2.3-based editor inside Automation Builder. V3 eco CPUs (PM50xx) use the CODESYS V3-based editor, offer more memory and newer features. The lab workflow is the same.
Can I wire the CPU and the outputs from one 24 V supply?
Yes, but feed them through separate MCBs or fuses so a short on an output circuit cannot switch off the CPU.
What should a new AC500-eco CPU show at first power up?
The power LED on and the CPU in STOP. An error indication on a blank CPU usually just means there is no valid program yet.