3HAC023008-001 Reva en

Application manual
PROFIBUS-DP
Robot Controller RobotWare 5.0
Application manual PROFIBUS-DP

RobotWare 5.0 Document ID: 3HAC023008-001 Revision: A
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2004 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
Table of Contents
Overview ..........................................................................................................................................5 Product documentation, M2004 .......................................................................................................7 Safety................................................................................................................................................9 1 Reference information, PROFIBUS 11
1.1 Introduction .............................................................................................................................11 1.2 References ................................................................................................................................12 2 Overview 13
2.1 PROFIBUS, general .................................................................................................................13 2.2 PROFIBUS, IRC5 ....................................................................................................................14 2.3 Definition of I/O units ..............................................................................................................17 3 PROFIBUS-DP Master/Slave hardware 19
3.1 Hardware description .............................................................................................................19
3.1.1 DSQC 637 PROFIBUS-DP master/slave.......................................................................19 3.1.2 Definition of communication units, IRC5 .....................................................................23
3.2 Connections ............................................................................................................................25
3.2.1 Connections, general ......................................................................................................25 3.2.2 Selecting cables ..............................................................................................................26 4 PROFIBUS-DP Master/Slave configuration 27
4.1 Introduction .............................................................................................................................27
4.1.1 Software overview..........................................................................................................27 4.1.2 Software, how to start.....................................................................................................29 4.1.3 PROFIBUS-DP configuration software .........................................................................30
4.2 Workflows, PROFIBUS-DP master bus................................................................................31
4.2.1 Introduction ....................................................................................................................31 4.2.2 Configuration overview .................................................................................................32 4.2.3 Bus configuration ...........................................................................................................35 4.2.4 Download PROFIBUS configuration file to the controller............................................37
4.3 Workflows, PROFIBUS-DP internal slave ............................................................................38
4.3.1 Introduction ....................................................................................................................38 4.3.2 Internal slave configurations ..........................................................................................39

4.4 Parameters ..............................................................................................................................41
4.4.1 System parameters..........................................................................................................41

4.5 Examples .................................................................................................................................43
4.5.1 Digital I/O configuration example (non modular station)..............................................43 4.5.2 Modular station configuration example .........................................................................47
Table of Contents
4.5.3 Internal slave configuration example ............................................................................ 53 4.5.4 IRC5 master/slave configuration example .................................................................... 54 Index 59
Overview
Overview
About this manual This manual is primarily a description of the PROFIBUS-DP fieldbus data communication between the IRC5 system and its distributed I/O units. It also describes the PROFIBUS Master/Slave configuration. This manual does not include a description of how to install and operate a PROFIBUS system in general. Usage This manual should be used during installation and configuration of the PROFIBUS, as well as during upgrading of the PROFIBUS option. For mechanical installation descriptions, refer to the Product manual, IRC5. Who should read this manual? This manual is intended for Prerequisites The reader should have the required knowledge of the PROFIBUS system I/O system configuration personnel that are responsible for installations and configurations of fieldbus hardware/software personnel that configure the I/O system system integrators.
Continues on next page

3HAC023008-001 Revision: A 5
Overview Continued
Organization of chapters The manual is organized in the following chapters: Chapter

1 2
Contents
This chapter gives reference information, both to external documentation and other ABB manuals. This chapter gives an overview of the PROFIBUS fieldbus and includes following: a general description of PROFIBUS and the communication protocol description of how the PROFIBUS master/slave unit and I/O units are connected in a robot system definition of I/O units in the control cabinet and the configuration of the control cabinet This chapter describes the PROFIBUS Master/Slave board. The chapter also describes communication units in the IRC5 controller. This chapter gives an overview of the controller and configuration software and includes following: Bus configuration Workflows Examples
3 4
Revisions Revision Description

A First edition, released with IRC5 RW 5.05. Second edition, released with IRC5 RW 5.07. Section GSD-file importation is added in chapter 4.2.2 Configuration overview. Chapter 4.2.4 Download PROFIBUS configuration file to the controller is added.
3HAC023008-001 Revision: A
Product documentation, M2004
Product documentation, M2004

General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning)
Product manual, reference information Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams

Product documentation, M2004 Continued
RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: RAPID Overview: An overview of the RAPID programming language. RAPID reference manual part 1: Description of all RAPID instructions. RAPID reference manual part 2: Description of all RAPID functions and data types. Technical reference manual - System parameters: Description of system parameters and configuration workflows.
Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: The purpose of the application (what it does and when it is useful) What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) How to use the application Examples of how to use the application
Operators manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals includes: Getting started - IRC5 and RobotStudio Online Operators manual - IRC5 with FlexPendant Operators manual - RobotStudio Online Trouble shooting manual for the controller and robot
Safety
Safety
Safety of personnel When working inside the controller it is necessary to be aware of voltage related risks. A danger of high voltage is associated with the following parts: Units inside the controller, for example I/O units can be supplied with power from an external source. The mains supply/mains switch. The power unit. The power supply unit for the computer system (230 VAC). The rectifier unit (400-480 VAC and 700 VDC). Capacitors! The drive unit (700 VDC). The service outlets (115/230 VAC). The power supply unit for tools, or special power supply units for the machining process. The external voltage connected to the controller remains live even when the robot is disconnected from the mains. Additional connections.
Therefore, it is important that all safety regulations are followed when doing mechanical and electrical installation work. Safety regulations Before beginning mechanical and/or electrical installations, make sure you are familiar with the safety regulations described in Product manual IRC5, M2004.
Safety
10
1 Reference information, PROFIBUS

1.1. Introduction

1.1. Introduction
General This chapter includes general information, complementing the more specific information in the following chapters.
11

1.2. References
1.2. References
Document references References
Application manual - Robot communication and I/O control Operators manual - IRC5 with FlexPendant Operators manual - RobotStudio Product manual IRC5, M2004 Technical reference manual - System parameters
Online
Document ID
3HAC 020435-001 3HAC 16590-1 3HAC 18236-1 3HAC 021313-001 3HAC 17076-1
Other references References

International standard IEC 61158 Type 3 International standard IEC 61784 PROFIBUS Technical Guideline User Manual DP Configurator ET200S Distributed I/O System Manual www.profibus.com
Description
The PROFIBUS fieldbus standard is described in the international standards. Installation Guideline for PROFIBUS-DP/FMS (Version 1.0, September 1998) Manual for the PROFIBUS configuration tool (PC software) Manual from Siemens The web site of PROFIBUS International
12
2 Overview
2.1. PROFIBUS, general
2 Overview
2.1. PROFIBUS, general
What is PROFIBUS? PROFIBUS is a vendor independent open fiel bus standard for a wide range of applications, particulary in the fields of factory and process automation. PROFIBUS is suitable for high-speed time critical applications as well as for complex communication tasks. PROFIBUS specification The PROFIBUS communication is specified in the international standard IEC 61158 Type 3, which includes the entire range of PROFIBUS versions. PROFIBUS versions PROFIBUS has a modular design and different PROFIBUS versions are all combinations of modular elements from the groups transmission technology, communication protocol and application profiles. Here are some examples of PROFIBUS versions: PROFIBUS-DP - optimized for factory automation PROFIBUS PA - optimized for process automation PROFIsafe - PROFIBUS for safety-related systems PROFIdrive - PROFIBUS for motion control
Communication protocols DP (Decentralized Periphery) is the simple, fast, cyclic and deterministic communication protocol between a bus master and the assigned slaves. The forerunner of DP was FMS (Fieldbus Message Specification), which is obsolete today. The original version of DP called DP-V0 has been expanded to DP-V1, and it provides acyclic data exchange between master and slave. A further version DP-V2 offers direct slaveto-slave data exchange with an isochronous bus cycle.
13
2 Overview
2.2. PROFIBUS, IRC5
2.2. PROFIBUS, IRC5

Hardware overview The hardware of the PROFIBUS-DP fieldbus consists of a master/slave unit, DSQC 637, and distributed I/O units (called slave units). DSQC 637 unit The DSQC 637 unit is connected to the PCI bus of the IRC5 robot controller. The slave units are attached to the fieldbus network. The DSQC 637 unit supports PROFIBUS-DP with DPV0, which means that DP-V1 and DP-V2 are not supported. The slave part of the DSQC 637 unit is normally controlled by an external master on a separate PROFIBUS-DP network. This network is a different one than the network holding the slave units for the master part of the board. Slave units The slave units can be I/O units with digital and/or analog signals. They are all controlled via the master part of the DSQC 637 unit.

14 3HAC023008-001 Revision: A
2 Overview
2.2. PROFIBUS, IRC5 Continued
The PROFIBUS-DP network The illustration below is an overview of the hardware, and shows the PROFIBUS network.
xx0400000851
A B C D E F
Line PLC, DP-Master IRC5 controller Robot I/O unit, DP-Slave DP-Slave (IRC5 - DSQC 637) DP-Master (IRC5 - DSQC 637)

2 Overview
2.2. PROFIBUS, IRC5 Continued
Configuration program The configuration program PROFIBUS DP Configurator (from Softing), together with the RobotStudioOnline , is used to configure the bus correctly. The configuration program must be executed on a PC according to the manual for the program. Specification overview, Master Item
Fieldbus type Addressing Number of units connected to master Number of signals Baudrate PROFIBUS product ID
Specification
PROFIBUS-DP master with DP-V0 1-125 The number is defined by the limitations of the general I/O systems, see Technical reference manual - System parameters. The number is defined by the limitations of the general I/O systems, see Technical reference manual - System parameters. The PROFIBUS-DP master is configurable for all baudrates up to 12 Mbit/s. 0xB203
Specification overview, Slave Item

Fieldbus type Addressing Number of units connected to slave Number of signals Baudrate PROFIBUS product ID
Specification
PROFIBUS-DP slave with DP-V0 1-125 The number is defined by the limitations of the general I/O systems, see Technical reference manual - System parameters. Max 512 digital in Max 512 digital out The PROFIBUS-DP slave autobauds for all baudrates up to 12 Mbit/s. 0xB205
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2 Overview
2.3. Definition of I/O units
2.3. Definition of I/O units

General The controller may be mounted with I/O units inside the controller. Standard configuration In the standard form, no fieldbus is mounted to the controller. It is possible to connect any type of PROFIBUS compliant I/O unit on the DSQC 637 master bus. All I/O units should comply with the PROFIBUS standard and be conformance tested by PNO/PI (PROFIBUS Ntzer Organisation/PROFIBUS International). Configuration of the controller
xx0500002046
A B C
Control module of the dual cabinet Drive module of the dual cabinet Single cabinet

2 Overview
2.3. Definition of I/O units Continued
Further information The table gives references to additional information:
Information:
Allowed configurations of I/O units and how to setup the configurations: How to install the software of the I/O units related in a new system:
Found in:
Technical reference manual - System parameters Product manual IRC5, M2004
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3 PROFIBUS-DP Master/Slave hardware

3.1.1. DSQC 637 PROFIBUS-DP master/slave

3.1 Hardware description 3.1.1. DSQC 637 PROFIBUS-DP master/slave
Description The DSQC 637 is a circuit board normally mounted in the controller. The PROFIBUS-DP M/S unit has both a master and a slave channel on the same unit. The master channel is used to communicate with I/O units within the robot cell and the slave channel is used to communicate with the robot controller from a master PLC. The master channel and the slave channel are physically separated. Installation and configuration For installation instructions for PROFIBUS, see the PROFIBUS specification, IEC 61158 Type 3. See also the Installation Guideline for PROFIBUS-DP/FMS published by the user organization of PROFIBUS (PNO). Instructions on how to configure the PROFIBUS network for the master and the slave channel are found in the chapterPROFIBUS-DP Master/Slave configuration on page 27. Typical applications An example of how the DSQC 637 may be connected is illustrated in section The PROFIBUS-DP network on page 15.


3.1.1. DSQC 637 PROFIBUS-DP master/slave Continued
Illustration The figure below shows the DSQC 637 board. The upper connector is the slave connector and the lower connector is the master connector.
xx0400001188
S M
Indicates the status of the Slave channel. Lit when the slave is in data exchange mode. Indicates the status of the Master channel. Lit when the master has the PROFIBUS token.
For connection table, see section Connections, Master and Slave connector on page 21.


Technical data Description

PROFIBUS DP master/slave, DSQC 637
Art. number
3HAC023047-001
Connections, Master and Slave connector
xx0100000220
The table below shows the connections to the master connector and the slave connector, which are two physically separated connectors on the DSQC 637 board. Signal name
Shield NC RxD/TxD-P Control-P GND +5 VDC NC RxD/TxD-N NC
Master/Slave channel pin

1 2 3 4 5 6 7 8 9
Function
Cable screen Not connected Receive/Transmit data P Repeat control signal (direction control) Ground connection Supply voltage Not connected Receive/Transmit data N Not connected


Termination To reduce the reflections on the data lines it is very important that both ends of the PROFIBUS network are terminated according to PROFIBUS-DP specification, IEC 61158 Type 3. The termination used by PROFIBUS is an active termination as showed in the figure below:
en0400001144
After connecting the PROFIBUS network always check that the termination is in place on both ends of the network and that there are no other terminations on the network. If a termination is missing or an extra termination is added somewhere in the PROFIBUS network the communication will probably fail. Cables and connectors Cables used to connect the PROFIBUS network must be according to PROFIBUS-DP specification, IEC 61158 Type 3. Drop cables are not allowed for PROFIBUS, so special D-subs must be used when the PROFIBUS-DP unit is not the last in line. The connector must have the possibility to insert two PROFIBUS cables in the same D-sub. It is also important that the cables are mounted from the top of the connector, otherwise it will not fit into the limited space around the PROFIBUS-DP unit (DSQC 637).
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3.1.2. Definition of communication units, IRC5
3.1.2. Definition of communication units, IRC5

General The IRC5 computer unit may include a number of communication functions. Any allowed combination of these is specified below. Board definition The figure and table below specify which combinations are allowed:
xx0400000847
Description
Robot Com. Card
Art. no.
3HAC 12816-1
Note
DSQC 602 Always mounted in slot 1 as shown in the figure above! DSQC 612 Only used in MultiMove control applications. DSQC 603
Pos.
1
Ethernet card
3HAC 15639-1
2, 3, 4 or 5 2, 3, 4 or 5 2, 3, 4 or 5
DeviceNet master/slave PROFIBUS DP master/ slave INTERBUS master/ slave, copper interface
3HAC 12817-1
3HAC 023047-001 DSQC 637 3HAC 11819-1
DSQC 529 2, 3, 4 or 5 Two physical boards, i.e. the master board and the slave board are placed in two separate slots.


3.1.2. Definition of communication units, IRC5 Continued
Description
INTERBUS master/ slave, fiber optical interface -
Art. no.
3HAC 5579-1
Note
Pos.
DSQC 512 2, 3, 4 or 5 Two physical boards, i.e. the master board and the slave board are placed in two separate slots. Not used 6
Installation of communication units For installation descriptions refer to Product manual IRC5, section Replacement of PCI cards in the Computer unit slots, IRC5.
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3.2.1. Connections, general
3.2 Connections 3.2.1. Connections, general

General All devices are connected in a bus structure. Each bus segment can have a maximum of 32 active devices. In order to be able to connect a larger number of stations (masters and slaves), the bus must be segmented. The segments are then interconnected with repeaters that amplify and refresh the data signals. Each repeater allows the PROFIBUS system to be extended by an additonal bus segment. The beginning and end of each segment is fitted with an active bus terminator, see illustration in section Termination on page 22.
25

3.2.2. Selecting cables
3.2.2. Selecting cables

Cable parameters, PROFIBUS-DP Electrical cables are used for data transfer. For specification of the different electrical data cables refer to PROFIBUS Technical Guideline, see References on page 12. The cable parameters for the standard bus cables result in the maximum length of each bus segment for the respective data transfer rate, se table:
Data rate in kbit/s

9.6 19.2 45.45 93.75 187.5 500 1500 3000 6000 12 000
Max. segment length in m

1200 1200 1200 1200 1000 400 200 100 100 100
Cable type A The values in the table refer to cable type A with the following properties:
Parameter
Impedance Capacity Loop resistance Wire diameter Core cross-section
Value
135 to 165 : d 30 pF/m d 110 :/km > 0.64 mm > 0.34 mm
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4 PROFIBUS-DP Master/Slave configuration

4.1.1. Software overview

4.1 Introduction 4.1.1. Software overview
Controller software The IRC5 controller must be installed with a software that supports the use of the PROFIBUS-DP network, i.e. the option for PROFIBUS-DP must be installed. Predefined master bus and I/O unit types When the IRC5 system is booted with the PROFIBUS option the system is started up with a predefined master bus, Profibus1 of type PBUS. The IRC5 controller software also contains a number of predefined I/O unit types for PROFIBUS-DP. The I/O unit types are described in the configuration files located in the PROFIBUS option directory, in the RobotWare release media directory. If another I/O unit type is required, it has to be created by the user. PC software RobotStudioOnline is a PC software that is used for setting up connections to robots and to work with robots. The configuration for the PROFIBUS-DP communication is done either manually by RobotStudioOnline/FlexPendant , or by loading a configuration file from RobotStudioOnline. For information on how to work with RobotStudioOnline and FlexPendant refer to, respectively, Operators manual - RobotStudioOnline and Operators manual - IRC5 with FlexPendant, see References on page 12 .


4.1.1. Software overview Continued
Configuration software To correctly configure the PROFIBUS-DP option a binary configuration file must be created using Softing PROFIBUS DP Configurator (or PROFI-KON-DP), which is an external PROFIBUS configuration PC tool. For more information about the configuration software, see section PROFIBUS-DP configuration software on page 30. GSD-files In order to configure the DSQC 637 with the PROFIBUS DP Configurator, GSD-files have to be imported into PROFI-KON-DP. These files contain vital information about the PROFIBUS units and they shall be supplied by the vendor/manufacturer of the specific PROFIBUS module. The GSD-files for the DSQC 637 master/slave are supplied on the RobotWare CD-ROM and can be found in following directory: <CD-ROM unit>:\Utility\fieldbus\PROFIBUS\gsd\ The directory contains following files:
GSD-file
softb203.gsd softb205.gsd abb_0600.gsd
Description
Softing DP-Master PROFIboard Softing DP-Slave PROFIboard DSQC 352, DeviceNet to PROFIBUS DP gateway
Updating DSQC 637 firmware The firmware that is executing on the DSQC 637 board is included in the RobotWare software package. The board is automatically updated to the actual firmware that is included in a specific release of RobotWare, i.e. there is no need for any manual procedure to update the firmware. During an automatic firmware upgrade of the board, lock-files are created on the flash disk. The lock-files have names of the format /hd0a/firmwareXY.lock, where X and Y are figures in the range 0-9. Note! File names of the specified format above are to be considered as reserved names that must not be used by the user.
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4.1.2. Software, how to start
4.1.2. Software, how to start

Step-by-step The following procedure gives an overview of how the different software is used together. For more detailed description, refer to section I/O configuration on page 32. Step Action
1. Create a new system using RobotStudioOnline. Make sure the PROFIBUS-DP option is installed. 2. Import the GSD-files to Softing PROFIBUS DP Configurator and create the binary configuration file, which contains the configuration of the PROFIBUS network. 3. Download the binary configuration file and the created system to the IRC5 controller using RobotStudioOnline.
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4.1.3. PROFIBUS-DP configuration software
4.1.3. PROFIBUS-DP configuration software

Description Softing PROFIBUS DP configurator is an external PROFIBUS configuration PC tool. The usage of the tool is described below. Installing PROFIBUS-DP configurator For installation instructions refer to chapter 2 Installation in User Manual DP Configurator. Bus parameter set - changing parameters All the parameters that are defined in the "PROFIBUS Bus parameter set" are possible to modify by using the Softing PROFIBUS DP Configurator. These parameters and default values for them (depending on the baudrate) are defined in the PROFIBUS specification. The default values are encouraged to be used and it is rarely necessary to modify these parameters. By selecting the desired baudrate the Softing PROFIBUS DP Configurator will automatically select the default "PROFIBUS Bus parameter set" for this baudrate. Note! The PROFIBUS user is strongly recommended not to change any of these parameters without having a really good knowledge of PROFIBUS and how the changes affect the communication. Slave parameter set - changing parameters By using the Softing PROFIBUS DP Configurator it is possible to change the parameters that are defined in the "Slave parameter set" according to the PROFIBUS specification. It is usually not necessary to modify the parameters in the "Slave parameter set", but in some cases it can be interesting to change parameters (like the Watchdog Time and the UserPrm Data). Description of how the parameters in the "Slave parameter sets" are modified is found in the manual for the Softing PROFIBUS DP Configurator. Note! The PROFIBUS user is strongly recommended not to change any of these parameters without having a really good knowledge of PROFIBUS and how the changes affect the communication.
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4.2.1. Introduction
4.2 Workflows, PROFIBUS-DP master bus 4.2.1. Introduction

Configuration set-up To set-up a PROFIBUS-DP communication, follow the workflows described in this section. Power-up When all configuration definitions are set, a new startup is required. The robot controller will automatically start the communication with the DP-slaves, and the controller will report any errors that may occur.
31

4.2.2. Configuration overview
4.2.2. Configuration overview

Description The PROFIBUS-DP master configuration is set according to the contents of the I/O signal and Unit definitions. I/O configuration To perform a proper I/O configuration follow the steps in this procedure: Step Action
1. Create a new system using RobotStudioOnline. Make sure to install the PROFIBUS-DP option . 2. Import the GSD-files, see GSD-file importation on page 33 for details. 3. Run Softing PROFIBUS DP Configurator to create the binary configuration file that contains the configuration of the PROFIBUS network. Note! This step is always unique depending on the type of I/O unit to configure. 4. Download the system to the IRC5 controller. 5. Reboot the controller to start up with the new system. 6. Add the binary configuration file to the HOME directory and configure the bus. See section Bus configuration on page 35. 7. Configure the units connected to the bus using RobotStudioOnline or FlexPendant. See Unit configuration on page 33. 8. Configure the signals, see Technical reference manual - System parameters . 9. Reboot the controller.


4.2.2. Configuration overview Continued
Unit configuration The following procedure details how to configure the units connected to the bus. Step Action
1. Add a new unit to the system parameters, see Technical reference manual System parameters. 2. Enter the unit name. 3. Select the Profibus1 bus, to which the unit is connected. 4. Select the actual unit type. If the unit type is not predefined, it must be added. 5. Enter the Profibus Address.
GSD-file importation The following procedure details how to import a GSD-file to the Softing PROFIBUS DP Configurator. Note! Import the GSD-file before you create a new project or open an existing project. Otherwise you may not find the DDB menu, which disappears when projects are open. When all projects are closed, the DDB menu will be available again. Step Action
1. Start Softing PROFIBUS DP Configurator. 2. Click the DDB menu. 3. In the DDB (DeviceDataBase) dialog, click Add.


4.2.2. Configuration overview Continued
Step Action
4. An Open dialog appears. Select the GSD-file and click OK.
en0500002355
5. Now the imported GSD-file appears in the Imported DDB list.
34

4.2.3. Bus configuration
4.2.3. Bus configuration

Description The configuration of the bus consists of specifying the configuration path to the PROFIBUS configuration file, which is created using the tool Softing PROFIBUS DP Configurator. Bus parameter The bus parameter set is defined in the PROFIBUS standard and contains parameters that influences the behaviour of the bus. The only way to modify the bus parameters, i.e. master address and baudrate, is to use the Softing PROFIBUS DP Configurator and generate a new binary configuration file. Note! The bus parameters should only be changed by a person that is familiar with the PROFIBUS-DP specification. Predefined bus If the system is installed with the PROFIBUS option, a predefined bus PROFIBUS1 is created. The default configuration path is: HOME/pbus_cfg.bin HOME specifies the current system directory, for example "MySystem/Home". It is possible to configure this path to any place on the IRC5 controller by first using the path /hd0a, which corresponds to the system flash drive. The equivalent to HOME/pbus_cfg.bin in this example would be /hd0a/MySystem/Home/pbus_cfg.bin. Binary configuration file The first step in the configuration of the bus is to create a binary configuration file using the Softing PROFIBUS DP Configurator tool on an off-line PC. This file needs to be supplied to the system to give a description of how the actual PROFIBUS network is physically configured. The binary configuration file contains all the parameters needed to get a PROFIBUS network up and running at the lowest level, i.e. what the DSQC 637 board needs to start the data exchange on the network.


4.2.3. Bus configuration Continued
Where to find descriptions of PROFIBUS DP configurator How the Softing PROFIBUS DP Configurator works is described in the manual that is delivered together with the actual configurator software package.
36

4.2.4. Download PROFIBUS configuration file to the controller
4.2.4. Download PROFIBUS configuration file to the controller

How to download the file There are the following different ways to transfer the file: Use...
the system builder in RobotStudioOnline
To...
perform the file transfer at the same time as the rest of a newly created system is transferred from the RobotStudioOnline PC to the controller. While creating the system, put the binary configuration file in the home directory of the created robot system by using the Add Files to Home Directory in the system builder of RobotStudioOnline. For instructions, refer to the Operators manual - RobotStudio Online. download the configuration file directly to the controller. For instructions, refer to the Operators manual - RobotStudio Online. download the configuration file directly to the controller.
the file manager in RobotStudioOnline a third party FTP client
37

4.3.1. Introduction
4.3 Workflows, PROFIBUS-DP internal slave 4.3.1. Introduction

Configuration set-up This section describes the workflows for the necessary configurations to set-up a PROFIBUS-DP internal slave communication. Built-in digital slave module The DSQC 637 unit has a built-in digital slave module with up to 512 digital inputs and 512 digital outputs. This can be used to connect the IRC5 controller to a PLC. for connection of the slave channel of several robots to the master channel of one controlling robot.
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4.3.2. Internal slave configurations
4.3.2. Internal slave configurations

Unit type configuration The unit type definition for the IRC5 PROFIBUS-DP slave is called DP_SLAVE and is predefined during system start-up. The default sizes of input and output areas for DP_SLAVE are 16 bytes in and 16 bytes out. EXT_DP_SLAVE is another predefined unit type, and this shall only be used for configuring the master channel of an IRC5 controller that is connected to the slave channel of another IRC5 controller. I/O unit configuration The following steps describe how to configure the system parameters for the IRC5 PROFIBUS-DP slave: Step Action Description
Note! The internal slave is special in its behaviour since outputs from the master/PLC will become inputs to the controller and vice versa.
1. Create a new unit of type DP_SLAVE. 2. If the default input size or output size for DP_SLAVE is not suited, edit the Internal Slave Output Size and/or Internal Slave Input Size for the unit type DP_SLAVE.
PLC configuration To configure the PROFIBUS master that will control the internal slave, use the GSD file supplied on the RobotWare CD-ROM, in the directory: <CD-ROM unit>:\Utility\fieldbus\PROFIBUS\gsd\softb205.gsd The modules to be chosen depend on the current I/O definition (input/output sizes as defined for the Unit type).


4.3.2. Internal slave configurations Continued
Communication status To have control of the communication status, i.e. to know if the PLC to slave communication is in DATA_EXCHANGE mode or not, the PROFIBUS watchdog timer should be used. The master/PLC can set one signal during startup or within the controller loop, this signal (on the internal slave) could then be attached to a system input in the robot controller as a communication supervision signal. If the communication between the master/PLC and the slave will be interrupted (i.e. the slave leaves the DATA_EXCHANGE mode), all the inputs of the internal slave will go to fail safe state (i.e. be set to zeros only) after the specified watchdog time. This means that the user defined communication supervision signal will also go to zero.
40

4.4.1. System parameters
4.4 Parameters 4.4.1. System parameters

Introduction There are both PROFIBUS specific parameters and more general parameters. This chapter gives brief descriptions of all system parameters that are necessary for the correct installation and configuration of PROFIBUS. The parameters are divided into the type they belong to. The PROFIBUS specific parameters are described here, for information about other parameters refer to Technical reference manual - System parameters. Type name Unit These parameters belong to the topic I/O and the type Unit. For more information, see the respective parameter in Technical reference manual - System parameters. Parameter
Profibus Address
Description
This parameter is used to specify the address that the I/O unit uses on the network, and to which the master should try to setup a connection. Allowed values: 0-125


4.4.1. System parameters Continued
Type name Unit Type These parameters belong to the topic I/O and the type Unit Type. For more information, see the respective parameter in Technical reference manual - System parameters. Parameter
Product ID
Description
This parameter is used as an identification of the I/O unit and is only available for PROFIBUS unit types. If the parameter is assigned the value 0 (zero), the robot controller ignores what product ID the connected unit has. The value of the parameter can be found in the Electronic Data Sheet (GSD) for the unit (called Ident_number in GSD file). Note that Ident_number is often expressed as a hexadecimal number in the GSD file. Allowed values are integers 0-65535. This parameter specifies the type of the slave device. A slave device is either internal or external. The DSQC 637 unit has a built-in slave module and it is defined as internal slave. All other slave devices are defined as external slaves. Allowed values: Yes or No This parameter defines the data size transmitted by the unit and is only available for internal slave unit types. Allowed values: A value between 0-64, specifying the data size in bytes. This parameter defines the data size received by the unit and is only available for internal slave unit types. Allowed values: A value between 0-64, specifying the data size in bytes.
Internal Slave
Internal Slave Output Size
Internal Slave Input Size
42

4.5.1. Digital I/O configuration example (non modular station)
4.5 Examples 4.5.1. Digital I/O configuration example (non modular station)
Description This is an example of how to configure an ET200B 16 DI/16 DO unit to the master. The bus is configured using the Softing PROFIBUS DP Configurator, with the master at address 2 and the slave unit at address 10. The baudrate is 12 Mbit/s and the slave watchdog time is set to 100 ms. The whole procedure for this example is described in section I/O configuration on page 32. This example is a detailed description of step 2 in the I/O configuration section and contains information that is unique to this example. PROFIBUS DP configurator setup The following procedure is a step-by-step description of how to set the configuration in the Softing PROFIBUS DP Configurator. Step Action
1. Start Softing PROFIBUS DP Configurator and import GSD-files for the Profiboard from the RobotWare CD (i.e. if the files have not been imported before). For details, see the Softing PROFIBUS DP Configurator manual. 2. Import GSD-files for the unit that shall be used, see GSD-file importation on page 33 for details. (GSD-file is provided by the manufacturer of the unit.) 3. On the Options menu, click Advanced Mode. (Basic mode does not allow the user to change the watchdog time.) 4. On the Project menu, click New Project.


4.5.1. Digital I/O configuration example (non modular station) Continued
Step
Action
5. In the Master Selection List, double-click on the PROFIboard.
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6. In the DP-Master-Configuration window, set Station Address to 2 and Baudrate to 12 MBaud. Click OK.
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Step
Action
7. In the Slave Selection List, double-click on the B-16DI/16DO.
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8. In the DP Slave Configuration window, click the Basic tab and set Station Address to 10.
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Step
Action
9. In the DP Slave Configuration window, click the Settings tab and set Watchdog Time to 100 ms. Click OK.
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10. On the Download menu, choose Binary File. Name the binary file pbus_cfg.bin (this is the default file name used by the predefined bus, Profibus1), and download it to the IRC5 controller using either RobotStudioOnline or a third-party FTP client. For description of how to download the file, see Operators manual - RobotStudioOnline . 11. Reboot the controller.
46

4.5.2. Modular station configuration example
4.5.2. Modular station configuration example

Description The ET200S is a modular unit. You can choose which type of modules to use and in which order to connect them. This is an example of how to configure an ET200S unit to the master. The bus is configured using the Softing PROFIBUS DP Configurator, with the master at address 1 and the slave unit at address 10. The baudrate is 12 Mbit/s. In this example the ET200S has physically 7 modules, and these are connected in following order: One Power module Two modules with 2 DO in each module Two modules with 2 DI in each module One module with 2 AO One module with 2 AI
The whole procedure for this example is described in section I/O configuration on page 32. This example contains a detailed description of step 2 in the I/O configuration section and the information is unique to this example, see PROFIBUS DP configurator setup on page 47. This example also contains a detailed description of step 7 in the I/O configuration section and it is described in section Physical signal configuration on page 49. PROFIBUS DP configurator setup The following procedure is a step-by-step description of how to set the configuration in Softing PROFIBUS DP Configurator. Step Action
1. Start Softing PROFIBUS DP Configurator and import GSD-files for the Profiboard from the RobotWare CD (i.e. if the files have not been imported before). For details, see the Softing PROFIBUS DP Configurator. 2. Import GSD-files for the unit that shall be used, see GSD-file importation on page 33 for details. (GSD-file is provided by the manufacturer of the unit.)


4.5.2. Modular station configuration example Continued
Step
Action
3. On the Options menu, click Advanced Mode. (Basic mode does not allow the user to change the watchdog time.) 4. On the Project menu, click New Project. 5. In the Master Selection List, double-click on the Profiboard. See figure in step 5, in section PROFIBUS DP configurator setup on page 43 (Digital I/O configuration example). 6. In the DP-Master-Configuration window, set Station Address to 1 and Baudrate to 12. 7. In the Slave Selection List, double-click the ET200S.
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8. In the DP Slave Configuration window, click the Basic tab and set Station Address to 10. See figure in step 8, in section PROFIBUS DP configurator setup on page 43 (Digital I/O configuration example). 9. In the DP Slave Configuration window, click the Modules tab. For module selection, follow the steps in Module selection on page 51 .


Step
Action
10. On the Download menu, choose Binary File. Name the binary file pbus_cfg.bin (this is the default file name used by the predefined bus, Profibus1), and download it to the IRC5 controller using either RobotStudioOnline or a third-party FTP client. For description of how to download the file, see Operators manual - RobotStudioOnline. 11. Reboot the controller.
Physical signal configuration According to the ET200S Distributed I/O System Manual (chapter 13.1.1, Analog value representation for measuring ranges with S7) from Siemens: The analog values are represented in complements of two. The values are represented with 16 bits. Physical max. value: 10 V is represented by the value 27648. Physical min. value: -10 V is represented by the value -27648. The high byte is sent first, byte swap is needed.
For the configuration procedure, refer to Technical reference manual - System parameters. Unit mapping Unit mapping is necessary when specifying which bit(s) in the I/O memory map of the assigned unit the signal is mapped to. All physical signals (i.e. signals connected to a physical unit) must be mapped. The table shows an example of unit mapping: Signal
DO_1 DO_2 DO_3 DO_4 DI_1 DI_2 DI_3
Unit map
0 1 8 9 0 1 8
Description
Digital output signal Digital output signal Digital output signal Digital output signal Digital input signal Digital input signal Digital input signal


Signal
DI_4 AO_1 AO_2 AI_1 AI_2
Unit map
9 24-31, 16-23 40-47, 32-39 24-31, 16-23 40-47, 32-39
Description
Digital input signal Analog output signal Byte swap is needed Analog output signal Byte swap is needed Analog input signal Byte swap is needed Analog input signal Byte swap is needed


Module selection When configuring the modules, make sure the different modules are added in correct order. I.e. the slot numbers depend on the physical order of the modules. See the User Manual DP Configurator for further details. The following procedure is a detailed description of how to make the module selection. Step Action
1. In the Available modules list, select the appropriate power supply module (6ES7 138-xxxxx-xxxx) and click Add.
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2. In the Available modules list, select the appropriate module with 2 DO (6ES7 132xxxxx-xxxx) and click Add.
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3. Repeat step 2 to select the other module with 2 DO.


Step
Action
4. In the Available modules list, select the appropriate module with 2 DI (6ES7 131xxxxx-xxxx) and click Add. 5. Repeat step 4 to select the other module with 2 DI. 6. In the Available modules list, select the appropriate module with 2 AO (6ES7 134xxxxx-xxxx) and click Add. 7. In the Available modules list, select the appropriate module with 2 AI (6ES7 134xxxxx-xxxx) and click Add.
52

4.5.3. Internal slave configuration example
4.5.3. Internal slave configuration example

Description This is an example of how to configure the IRC5 Profibus-DP slave to address 12. The slave unit has 128 digital inputs (16 bytes) and 128 digital outputs (16 bytes). NOTE! The unit type DP_SLAVE is a predefined unit type, i.e. the user does not need to make any Unit Type definition for this slave. The default values for DP_SLAVE are 16 bytes inputs and 16 bytes outputs. The default sizes can be changed either by editing the unit type DP_SLAVE or by creating a new unit type. Internal slave configuration procedure The following procedure is a step-by-step description of how to make the system parameter configuration of the internal slave. Step Action
1. Add a new unit to the system parameters. 2. Enter the unit name. 3. Select the Profibus1 bus, to which the unit is connected. 4. Select the DP_SLAVE unit type. 5. Enter the Profibus Address.
53

4.5.4. IRC5 master/slave configuration example
4.5.4. IRC5 master/slave configuration example

Description This example demonstrates how two IRC5 systems can be configured to communicate with each other, one as the master and one as a slave. The bus is configured using the Softing PROFIBUS DP Configurator, with the master at address 2 and with baudrate 12 Mbit/s. The whole procedure for this example is described in section I/O configuration on page 32. This example is a detailed description of step 2 in the I/O configuration section and contains information that is unique to this example. Overview - how to start Step Action Info
The slave system will be set up as an ordinary PROFIBUS-DP slave unit with 128 DI and 128 DO. The address is 12.
1. Start by configuring the slave system according to section Internal slave configuration example on page 53. 2. Configure the master system with one unit at address 12 of type EXT_DP_SLAVE.
NOTE! The unit type EXT_DP_SLAVE shall be used when configuring an IRC5 PROFIBUS master to communicate via a PROFIBUS connection to the slave channel of another IRC5 system. The unit type DP_SLAVE shall be used for configuring of the internal PROFIBUS slave, i.e. the definition of a DP_SLAVE unit type will determine what the internal slave will look like when seen from the PROFIBUS side. The unit types EXT_DP_SLAVE and DP_SLAVE are predefined unit types, i.e. the user does not need to make any Unit Type definition for these slaves.


4.5.4. IRC5 master/slave configuration example Continued
PROFIBUS DP configurator setup The following procedure is a step-by-step description of how to set the configuration in the Softing PROFIBUS DP Configurator. Step Action
1. Start Softing PROFIBUS DP Configurator and import GSD-files for the Profiboard from the RobotWare CD (i.e. if the files have not been imported before). For details, see the Softing PROFIBUS DP Configurator manual. 2. On the Project menu, click New Project. 3. In the Master Selection List, double-click on the Profiboard.
en0400000888


Step
Action
4. In the DP-Master-Configuration window, set Station Address to 2 and Baudrate to 12 MBaud. Click OK.
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5. In the Slave Selection List, double-click on the PROFIboard/PROFI104.
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Step
Action
6. In the DP Slave Configuration window, click the Basic tab and set Station Address to 12.
en0400000904
7. In the DP Slave Configuration window, click the Modules tab. In the Available Modules list, select 8 Word Out, 8 Word In and click Add.
en0400000905
8. On the Download menu, choose Binary File. Name the binary file pbus_cfg.bin (this is the default file name used by the predefined bus, Profibus1), and download it to the IRC5 controller using either RobotStudioOnline or a third-party FTP client. For description of how to download the file, see Operators manual - RobotStudioOnline. 9. Restart the controller.


58
Index
B
Bus termination 22
C
Cable parameters 26
D
DSQC 637 19 DSQC 637, Master and Slave connector 21
E
Example, ET200B unit 43 Example, ET200S unit 47
G
GSD-files 28 GSD-files, importing 33
I
I/O configuration 32 Internal Slave Input Size 42
S
Softing PROFIBUS DP Configurator 16, 28, 30 System parameters, Internal Slave 42 System parameters, Internal Slave Input Size 42 System parameters, Internal Slave Output Size 42 System parameters, Product ID 42 System parameters, Profibus Address 41 System parameters, Unit 41 System parameters, Unit Type 42
U
Unit configuration 33
59
Index
60
ABB Automation Technologies AB Robotics S-721 68 VSTERS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592
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Application manual

Application manual PROFIBUS-DP

3.1 Hardware description .............................................................................................................19

4.1 Introduction .............................................................................................................................27

4.3.1 Introduction ....................................................................................................................38 4.3.2 Internal slave configurations ..........................................................................................39

4.4.1 System parameters..........................................................................................................41

Continues on next page

Organization of chapters The manual is organized in the following chapters: Chapter

Revisions Revision Description

Product documentation, M2004

Product documentation, M2004

Continues on next page

Product documentation, M2004 Continued

1 Reference information, PROFIBUS

1 Reference information, PROFIBUS

1 Reference information, PROFIBUS

Other references References

2.2. PROFIBUS, IRC5

Continues on next page

Continues on next page

Specification overview, Slave Item

2.3. Definition of I/O units

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Further information The table gives references to additional information:

3 PROFIBUS-DP Master/Slave hardware

3 PROFIBUS-DP Master/Slave hardware

Continues on next page

3 PROFIBUS-DP Master/Slave hardware

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3 PROFIBUS-DP Master/Slave hardware

Technical data Description

Connections, Master and Slave connector

Master/Slave channel pin

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3 PROFIBUS-DP Master/Slave hardware

3 PROFIBUS-DP Master/Slave hardware

3.1.2. Definition of communication units, IRC5

3HAC 023047-001 DSQC 637 3HAC 11819-1

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3 PROFIBUS-DP Master/Slave hardware

3 PROFIBUS-DP Master/Slave hardware

3.2 Connections 3.2.1. Connections, general

3 PROFIBUS-DP Master/Slave hardware

3.2.2. Selecting cables

Data rate in kbit/s

Max. segment length in m

4 PROFIBUS-DP Master/Slave configuration

4 PROFIBUS-DP Master/Slave configuration

Continues on next page

4 PROFIBUS-DP Master/Slave configuration

4 PROFIBUS-DP Master/Slave configuration

4.1.2. Software, how to start

4 PROFIBUS-DP Master/Slave configuration

4.1.3. PROFIBUS-DP configuration software

4 PROFIBUS-DP Master/Slave configuration

4.2 Workflows, PROFIBUS-DP master bus 4.2.1. Introduction

4 PROFIBUS-DP Master/Slave configuration

4.2.2. Configuration overview

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