This ABB PLC lab manual teaches AC500-eco programming with Automation Builder in four modules: setup and communication (Labs 1–4), I/O mapping and program transfer (Labs 5–10), ladder programming for real machines (Labs 11–18) and PLC-to-ACS580 Modbus RTU control (Labs 19–20). Every lab uses the same trainer kit and tag names, so each one builds on the last.
- 20 labs in 4 modules, in the order a real project is built
- Same hardware, IP plan and tag names in every lab
- Interactive ladder simulators and calculators on the page
- Each lab ends with a checklist you can use as a test sheet
Start with the ABB AC500 PLC Selection Guide if you are still choosing hardware. Otherwise begin at Lab 1 and follow the modules in order.
The Lab Kit Used in Every Lab
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 |
Module 1: Setup and Communication (Labs 1–4)
ABB Automation Builder Installation and AC500-eco PM564-ETH Setup
Install ABB Automation Builder, understand the AC500-eco PM564-ETH lab kit, wire 24 VDC power and check the CPU LEDs before your first PLC project.
Open lab 1 →How to Connect ABB AC500-eco PLC to Automation Builder via Ethernet
Set the PC IP, find and change the AC500-eco IP address, set the gateway in Automation Builder and log in to the PLC over Ethernet, step by step.
Open lab 2 →How to Create a New Project in ABB Automation Builder
Create an AC500-eco PM564-ETH project in Automation Builder: pick the CPU, read the device tree, name the application and save a clean project structure.
Open lab 3 →ABB AC500-eco IO Configuration: Onboard and Expansion Modules
Configure AC500-eco onboard I/O and S500-eco expansion modules like DX561 in Automation Builder: slot order, channel settings, addresses and checks.
Open lab 4 →Module 2: I/O Mapping and Program Transfer (Labs 5–10)
ABB AC500-eco Digital Input Mapping for Push Buttons and Sensors
Map AC500-eco digital inputs in Automation Builder: NO/NC wiring, PNP sensors, DI_ tag naming, I/O Mapping variables and a live input test on the kit.
Open lab 5 →ABB AC500-eco Digital Output Mapping for Motors, Valves and Lamps
Map AC500-eco transistor outputs to contactors, valves and lamps in Automation Builder, separate command bits from physical outputs and test safely.
Open lab 6 →Your First ABB Ladder Program: Motor Start/Stop Logic
Write your first ABB Automation Builder ladder program: motor start/stop with seal-in, NC stop button, E-stop and MPCB interlocks, plus a live simulator.
Open lab 7 →How to Download a Program to ABB AC500-eco PLC (Compile, Login, Run)
Download a program to an ABB AC500-eco PLC: build, login, full download vs online change, RUN, and create a boot project so it survives power off.
Open lab 8 →How to Upload a Program from ABB AC500-eco PLC to Automation Builder
Upload a program from an ABB AC500-eco PLC: what can be read back, storing source in the CPU, opening the project from the PLC and backup best practice.
Open lab 9 →ABB Automation Builder Online Monitoring, Force and Write Values
Monitor an AC500-eco program live in Automation Builder, use watch lists, and safely write and force values for testing, with a clear force vs write guide.
Open lab 10 →Module 3: Ladder Programming for Machines (Labs 11–18)
ABB PLC Timers and Counters in Ladder Logic (TON, TOF, CTU)
Use TON, TOF, TP and CTU in ABB Automation Builder ladder logic: a pre-start warning horn, run-on timer and batch counter, with a live simulator.
Open lab 11 →ABB PLC Tag Mapping and Ladder Program Structure (%MW, HMI)
Organise ABB AC500 ladder logic into mapped POUs and networks, apply a tag naming standard, and map status, command and alarm words for HMI and Modbus.
Open lab 12 →ABB PLC Alarm Logic: Fault Latching, Reset and HMI Alarm Word
Build alarm mapping in ABB Automation Builder ladder: alarm list, SET/RESET latching, delayed feedback faults, reset logic, first-out and an HMI alarm word.
Open lab 13 →Tower Lamp Logic in ABB PLC: Red, Amber, Green and Buzzer Control
Program a stack light in ABB Automation Builder: machine state to red, amber and green lamps, flashing for new faults, buzzer silence and lamp test.
Open lab 14 →ABB PLC Emergency Stop and Safety Interlock Logic in Ladder
Combine a hardwired safety relay with ABB PLC ladder logic: E-stop monitoring, guard interlock, restart prevention, permissives and reset sequence.
Open lab 15 →Manual Mode Logic in ABB PLC Ladder: Jog and Individual Control
Program manual mode in ABB Automation Builder ladder: mode selection with selector fault check, hold-to-run jog forward and reverse, interlocks and lamps.
Open lab 16 →Auto Mode Sequence Logic in ABB PLC Ladder Programming
Write an auto mode step sequence for an ABB AC500 conveyor: step table, transitions, jam watchdog timer, part counting and stop/fault handling in ladder.
Open lab 17 →ABB AC500 Structured Text (ST) Programming for Beginners
Learn Structured Text on ABB AC500-eco in Automation Builder: syntax, IF and CASE, timers in ST, ladder vs ST, and calling an ST function block from ladder.
Open lab 18 →Module 4: PLC to VFD Communication (Labs 19–20)
ABB AC500-eco to ACS580 Modbus RTU: Wiring and Parameter Setup
Connect an ABB AC500-eco PLC to an ACS580 drive on Modbus RTU: RS-485 wiring, termination, ACS580 group 58 parameters, COM1 setup and a frame builder.
Open lab 19 →How to Control ABB ACS580 via Modbus RTU from an AC500-eco PLC
Start, stop and set ACS580 speed from an AC500-eco PLC over Modbus RTU: ABB Drives control word, reference scaling, status word, fault reset and watchdog.
Open lab 20 →Suggested Study Plan
| Day | Labs | Outcome |
|---|---|---|
| 1 | Selection guide, Labs 1–4 | Kit powered, PC connected, project with I/O configured |
| 2 | Labs 5–10 | Mapped I/O, first ladder program downloaded, monitoring and forcing |
| 3 | Labs 11–15 | Timers, structure, alarms, tower lamp, safe stop logic |
| 4 | Labs 16–18 | Manual and auto modes, ST and function blocks |
| 5 | Labs 19–20 | ACS580 on Modbus RTU under PLC control, full conveyor test |
Frequently asked questions
Is this ABB PLC lab manual free?
Yes. All 20 labs, simulators and checklists are free to read online. Softwell also runs hands-on ABB PLC training with real AC500 and ACS580 kits in Pune, online and in-plant.
Which ABB PLC is used in the labs?
An AC500-eco PM564-T-ETH CPU with a DX561 module, an ACS580 drive and an optional CP604 HMI. Notes in each lab cover V3 CPUs too.
Do I need real hardware to follow the labs?
No for understanding: every logic lab has an on-page simulator. Yes for Labs 2, 8 and 19–20 if you want to practise communication with a real CPU and drive.
What software do I need?
ABB Automation Builder. The free Basic edition supports AC500-eco programming used in this series.
In what order should I do the labs?
In number order. Each lab uses the project, tags and logic from the labs before it.