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Application manualPROFINET master/slave

Trace back information:Workspace RW 5-15-01 version a4Checked in 2013-04-03Skribenta version 4.0.006

Application manualPROFINET master/slave

RobotWare 5.15

Document ID: 3HAC031975-001Revision: J

© Copyright 2008-2013 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.

© Copyright 2008-2013 ABB. All rights reserved.ABB AB

Robotics ProductsSE-721 68 Västerås

Sweden

Table of contents7Manual overview ...............................................................................................................................

10Product documentation, M2004 .......................................................................................................12Safety ................................................................................................................................................

131 Introduction to PROFINET131.1 PROFINET, general ...........................................................................................141.2 PROFINET, IRC5 ...............................................................................................171.3 Definition of I/O units .........................................................................................

192 Hardware description192.1 PROFINET master/slave, DSQC 678 .....................................................................222.2 LAN connection ................................................................................................232.3 Connections, general .........................................................................................242.4 PROFINET-IO Routing .......................................................................................

273 PROFINET Master/Slave configuration273.1 Introduction ......................................................................................................273.1.1 Software overview ...................................................................................283.2 Configuration overview .......................................................................................283.2.1 PROFINET master ...................................................................................293.2.2 IRC5 internal PROFINET slave ..................................................................313.2.3 Step 7 Configuration files ..........................................................................323.2.4 Upgrade or downgrade firmware using Step7 ...............................................383.2.5 Automatic firmware upgrade .....................................................................393.3 Workflows ........................................................................................................393.3.1 Configuring PROFINET master ..................................................................403.3.2 Configuring IRC5 internal PROFINET slave ..................................................413.3.3 Configuring PROFINET-IO Routing .............................................................433.4 Examples ........................................................................................................433.4.1 Overview ...............................................................................................443.4.2 Configuring digital I/O, example .................................................................543.4.3 Configuring IRC5 internal PROFINET slave, example .....................................603.4.4 Configuring PROFINET-IO Routing, example ................................................

654 System parameters654.1 Introduction ......................................................................................................664.2 Type Bus .........................................................................................................664.2.1 Path to Bus Configuration File ...................................................................674.2.2 Automatic Firmware Upgrade ....................................................................684.2.3 Connector ID ..........................................................................................694.3 Unit ................................................................................................................694.3.1 PROFINET Address .................................................................................704.4 Unit Type .........................................................................................................704.4.1 Input Size ..............................................................................................724.4.2 Output Size ............................................................................................

755 Trouble shooting755.1 Scenarios ........................................................................................................

81Index

3HAC031975-001 Revision: J 5© Copyright 2008-2013 ABB. All rights reserved.

Table of contents

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Manual overviewAbout this manual

This manual describes the PROFINET IO Master/Slave option and containsinstructions how to configure the PROFINET Master/Slave in an IRC5 system.

UsageThis manual should be used during installation and configuration of the PROFINETfieldbus.

Who should read this manual?This manual is intended for:

• Personnel that are responsible for installations and configurations of fieldbushardware/software.

• Personnel that make the configurations of the I/O system.• System integrators.

PrerequisitesThe reader should have the required knowledge of

• the PROFINET system• I/O system configuration• IRC5 Controller• Robot Studio

References

Document IDReference

3HAC17076-1Technical reference manual - System parameters

3HAC021313-001Product manual - IRC5

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC032104-001Operating manual - RobotStudio

Other references

DescriptionReference

The PROFINET fieldbus standard is describedin the international standards.

International standard IEC 61158 Type 3 In-ternational standard IEC 61784

Installation Guideline for PROFINET (Version2.00, September 1998)

PROFINET Cabling and InterconnectionTechnology

Release 12/2006 C79000-G8976-C156-08Commissioning PC Stations - Manual andQuick Start

Manual from SiemensET200S Distributed I/O System

The web site of PROFINET Internationalwww.profinet.com

Manual from SiemensOperating instructions CP1616

Continues on next page3HAC031975-001 Revision: J 7


Manual overview

Revisions

DescriptionRevision

First edition. RobotWare 5.11-

Released with RobotWare 5.12.APROFINET version changed to 2.2. Updated examples of PROFINETMaster/Slave configuration.

Added two new scenarios in the Trouble Shooting chapter.BInformation about the PROFINET Version V2.2 is added in the Specifica-tion Overview section.Added a NOTE in the Prerequisites section about the Robotware versionand firmware version in the Hardware Description chapter.

Updated the section Specification overview, Slave on page 16.CAdded the RobotWare version compatability information in the NOTE thatis available in the section Prerequisites on page 19.Added information about Step 7 configuration files in the Configurationsubsection in the section PROFINET master on page 28.Updated the Input and output size subsection in the section IRC5 internalPROFINET slave on page 29.Updated theCommunication status subsection in the sectionConfiguringIRC5 internal PROFINET slave on page 40.Added the new Type Bus system parameters Path to Bus ConfigurationFile on page 66 and Automatic Firmware Upgrade on page 67.Updated the Addition information section for the Type Unit Type systemparameters Input Size on page 70 and Output Size on page 72.Added the new sections Step 7 Configuration files on page 31 and Auto-matic firmware upgrade on page 38in the PROFINET Master/Slave Con-figuration chapter.

Added the new section Upgrade or downgrade firmware using Step7 onpage 32.

D

Updated for the RW 5.14 release.EThe section Configuration program on page 15 is updated.Updated the Number of I/O signals entry in the table in the section Spe-cification overview, Slave on page 16.Information about the location of the GSDML files in the RobotWare DVD,PC, and IRC5 Controller is added in the following section:

• GSDML files on page 28The following sections are updated for the change to increase the numberof I/O signals on I/O units:

• Specification overview, Slave on page 16• IRC5 internal PROFINET slave on page 29• Input Size on page 70• Output Size on page 72

Updated for the RW 5.14.02 release.• Added the new system parameter Connector ID.• Updated the Description and Usage sections for the system para-

meter PROFINET Address.• In the Trouble Shooting chapter, answer for the Scenario How do

I upgrade/downgrade the firmware on DSQC 678? is updated.

F

The section GSDML files on page 28 is updated for the RW 5.14.03 re-lease.

G

Continues on next page8 3HAC031975-001 Revision: J


Manual overview

Continued

DescriptionRevision

Updated for the RW 5.15 release.• Updated the section Introduction section in the chapter System

parameters on page 65.• Firmware versions usage made consistent through-out the manual.• Updated the firmware versions details for all the releases starting

from 5.11 till 5.14 in Upgrade or downgrade firmware using Step7on page 32.

• Added the steps to verify that the bus is not running before startingthe upgrade or downgrade procedure in Upgrade or downgradefirmware using Step7 on page 32.

H

Updated for the RW 5.15.01 release.• Updated the Overview and firmware file table in Upgrade or

downgrade firmware using Step7 on page 32.• Updated the section How to reset a DSQC 678 (CP1616) on

page 75.

J


Manual overview

Continued

Product documentation, M2004Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listingis based on the type of information in the documents, regardless of whether theproducts are standard or optional.All documents listed can be ordered from ABB on a DVD. The documents listedare valid for M2004 manipulator systems.

Product manualsManipulators, controllers, DressPack/SpotPack, and most other hardware will bedelivered with a Product manual that generally contains:

• Safety information.• Installation and commissioning (descriptions of mechanical installation or

electrical connections).• Maintenance (descriptions of all required preventive maintenance procedures

including intervals and expected life time of parts).• Repair (descriptions of all recommended repair procedures including spare

parts).• Calibration.• Decommissioning.• Reference information (safety standards, unit conversions, screw joints, lists

of tools ).• Spare parts list with exploded views (or references to separate spare parts

lists).• Circuit diagrams (or references to circuit diagrams).

Technical reference manualsThe technical reference manuals describe reference information for roboticsproducts.

• Technical reference manual - Lubrication in gearboxes: Description of typesand volumes of lubrication for the manipulator gearboxes.

• Technical reference manual - RAPID overview: An overview of the RAPIDprogramming language.

• Technical referencemanual - RAPID Instructions, Functions and Data types:Description and syntax for all RAPID instructions, functions, and data types.

• Technical reference manual - RAPID kernel: A formal description of theRAPID programming language.

• Technical reference manual - System parameters: Description of systemparameters and configuration workflows.

Application manualsSpecific applications (for example software or hardware options) are described inApplication manuals. An application manual can describe one or severalapplications.



Product documentation, M2004

An application manual generally contains information about:• The purpose of the application (what it does and when it is useful).• What is included (for example cables, I/O boards, RAPID instructions, system

parameters, DVD with PC software).• How to install included or required hardware.• How to use the application.• Examples of how to use the application.

Operating manualsThe operating manuals describe hands-on handling of the products. The manualsare aimed at those having first-hand operational contact with the product, that isproduction cell operators, programmers, and trouble shooters.The group of manuals includes (among others):

• Operating manual - Emergency safety information• Operating manual - General safety information• Operating manual - Getting started, IRC5 and RobotStudio• Operating manual - Introduction to RAPID• Operating manual - IRC5 with FlexPendant• Operating manual - RobotStudio• Operatingmanual - Trouble shooting IRC5, for the controller and manipulator.


Product documentation, M2004

Continued

SafetySafety of personnel

When working inside the robot controller it is necessary to be aware ofvoltage-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 powerfrom 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 doingmechanical and electrical installation work.

Safety regulationsBefore beginning mechanical and/or electrical installations, ensure you are familiarwith the safety regulations described in Product manual - IRC5.

12 3HAC031975-001 Revision: J© Copyright 2008-2013 ABB. All rights reserved.

Safety

1 Introduction to PROFINET1.1 PROFINET, general

What is PROFINET?PROFINET is an open standard for Industrial Ethernet. PROFINET satisfiesrequirements for automation technology. PROFINET solutions can be implementedfor factory and process automation, for safety applications, and for the entire rangeof drive technology right up to clock-synchronized motion control.

PROFINET standardizationThe use of open standards, simple operation, and the integration of existing systemsegments have driven the definition of PROFINET from the beginning. PROFINETis standardized in IEC 61158 and IEC 61784. The continual further developmentof PROFINET offers users a long term perspective for the implementation of theirautomation tasks.

PROFINET versionsPROFINET has a modular design and different PROFINET versions are allcombinations of modular elements from the groups transmission technology,communication protocol, and application profiles.Here are some examples of PROFINET versions:

• PROFINET-IO - Distributed I/O (Remote I/O). Here, the familiar I/O view ofPROFIBUS is retained, in which the user data from the field devices areperiodically transmitted into the process model of the control system.

• PROFINET-CBA - Based on the object-oriented modelling of technologicalmodules. Based on the object model, machines and installations arestructured in PROFINET in the form of technological modules.

• PROFIsafe - Defines how safety-oriented devices (emergency shutoffswitches, light grids, overfill protection systems, etc.) can communicatesafety control information over a network securely enough that they can beused in safety-oriented automation tasks up to EN954's KAT4, AK6, or SIL3(Safety Integrity Level).

• PROFIdrive - The PROFIdrive profile covers application scenarios from simplefrequency converters to highly dynamic servo drivers.

• PROFIenergy - A profile of the PROFINET communications protocol thatallows the power consumption of automation equipment in manufacturing(such as robot assembly cells, laser cutters and sub-systems such as paintlines) to be managed over a PROFINET network. It offers an open andstandardized means of controlling energy usage during planned andunplanned breaks in production.


1 Introduction to PROFINET1.1 PROFINET, general

1.2 PROFINET, IRC5

Hardware overviewThe hardware of the PROFINET fieldbus consists of a master/slave board, DSQC678, and distributed I/O units.

DSQC 678The DSQC 678 is connected to the PCI bus of the IRC5 robot controller. The I/Ounits are attached to the fieldbus network. The slave part of the master/slave unitis normally controlled by an external master on the same physical PROFINETnetwork. The DSQC 678 can act as a master and a slave simultaneously.The DSQC 678 has a built-in switch with four ports. The built-in switch can bepowered by external power supply. This allows the switch to be used even if theIRC5 controller is powered down, see Operating instructions CP1616 for details.

I/O unitsThe I/O units can have digital and/or analog signals. They are all controlled via themaster part of the DSQC 678.

Main computerThe DSQC 678 requires the main computer DSQC 639.

Note

If the IRC5 controller is powered down, the DSQC 678 built-in switch will notwork without external power supply.

PROFINET version compatibilityDSQC 678 supports the PROFINET version PROFINET-IO (seePROFINET versionson page 13).



1 Introduction to PROFINET1.2 PROFINET, IRC5

PROFINET networkThe following illustration is an example of a PROFINET network.

xx0800000131

Line PLC, PROFINET-masterA

IRC5 controllerB

I/O unitC

DSQC 678D

Ethernet switchE

Configuration programAn external PROFINET configuration tool such as Step 7 or NCM PC from Siemens,together with RobotStudio is needed for the configuration of DSQC 678. The NCMPC program can be downloaded from the Siemens hompage for free. The externalPROFINET configuration tool should be used according to the manual for theprogram.




Continued

Specification overview, Master

SpecificationItem

6GK1 161-6AA00GSDML ID

Maximum 30 I/O unitsNumber of I/O units connected to master

Maximum 8192 I/O signalsNumber of I/O signals

Specification overview, Slave

SpecificationItem

6GK1 161-6AA00GSDML ID

V2.2 or V 2.4 MigrationPROFINET Version

Slot 1-4: Digital input or output modules of variable sizeSlot configuration

SupportedPROFINET-IO Routing

Maximum 1024 digital inNumber of I/O signalsMaximum 1024 digital out

Expressions

SpecificationExpressions

Siemens CP1616 PCI-cardDSQC 678

PROFINET controllerMaster

PROFINET deviceSlave, I/O unit

Siemens Step7, V5.4, Service pack 5 and aboveExternal PROFINET configuration tool



Continued

1.3 Definition of I/O units

GeneralIt is possible to connect any type of PROFINET-IO compliant I/O unit on thePROFINET master bus. All I/O units should comply with the PROFINET standardand be conformance tested by PROFINET international. I/O units may be mountedinside the controller. There are no PROFINET compliant I/O units installed in astandard version controller.

Further informationThe table gives references to additional information:

SeeInformation

Technical reference manual - System para-meters.

Allowed configurations of I/O units and howto setup the configurations.


1 Introduction to PROFINET1.3 Definition of I/O units

2 Hardware description2.1 PROFINET master/slave, DSQC 678

DescriptionThe DSQC 678 is a PCI card mounted in the computer module. The card has bothmaster and slave functionality. The master functionality is used to communicatewith I/O units and the slave functionality is used to communicate with the IRC5controller from a master, e.g PLC.

PrerequisitesRobotWare 5.11 or later version and the PROFINET IO Master/Slave option arerequired to run the PROFINET master/slave board.

Note

Robotware 5.11 is compatible only with DSQC 678 firmware version 2.1.Robotware 5.12 is compatible only with DSQC 678 firmware version 2.2.RobotWare 5.13 is compatible with DSQC 678 firmware version 2.2 or 2.4.

Installation of DSQC 678For installation instructions for PROFINET, see the PROFINET specification, IEC61158 Type 3. See also the Commissioning PC Stations - Manual and Quick Start,chapter 6 from SIEMENS. For hardware installation refer to Product manual -IRC5,section Replacement of PCI cards in the computer unit slots.

xx0700000432

Possible slot for DSQC 678A,B,C, and D




IllustrationThe following figure shows the DSQC 678 PCI card.

xx0800000132

LED, SF (collective error), redA

LED, BF (bus error), redB

External power connectionsC

Link LED, greenD

Activity LED, yellowE

Port 1-4, RJ-45 connectorsF




Continued

Technical data

RemarksStateMeaningLED

Communications connection established.OffBus error (BF)B (red)

Link status error occurred.On

I/O device cannot be addressed or duplicateIP address on the network.

Flashingslowly

No error occurred or loading is in progress.OffCollective error(SF)

A (red)

Diagnostic information is available.On

Flash test for visual identifying of boards.Flashingslowly.

Bus error (BF)Collective error(SF)

A and B

Exception error occurred.Flashingquickly

Send and Receive.OnActivity LEDE (yellow)

Connection exists.OnLink LEDD (green)

Article number and firmware version

DescriptionFirmware versionArticle number

PROFINET master/slave, DSQC 6782.1.43HAC030327-001

PROFINET master/slave, DSQC 6782.2.13HAC033556-001

Connections, RJ-45 connectorsThe DSQC 678 board has four standard Ethernet RJ-45 connectors. Each connectoris a port to a built in switch on the DSQC 678 board.

Cables and connectorsCables used to connect the PROFINET network must comply with Cat 5 balancedLAN requirements or better according to ISO/IEC 11801. For details see PROFINETCabling and Interconnection Technology available from www.profinet.com.



Continued

2.2 LAN connection

Ethernet cable between DSQC 678 and LAN portDSQC 678 is connected with an ethernet cable to the LAN port of the maincomputer. The other three ethernet ports on DSQC 678 can be used for networkconnections such as factory LAN and PROFINET fieldbus.

xx0900000141

PROFINET in combination with option 707-1Option 707-1 offers an ethernet port on the connection plate of the controllercabinet. A cable normally connects this ethernet port on the connection plate withthe LAN port on the main computer.If both option 707-1 and 888-1 (PROFINET) are used, the ethernet cable from theconnection plate is instead connected to a port on DSQC 678.

xx0900000145

Main computerA

LAN portB

DSQC 678 (option 888-1)C

Connection plateD

Ethernet connection on connection plate (option 707-1)E


2 Hardware description2.2 LAN connection

2.3 Connections, general

GeneralAll I/O units are connected to Industrial Ethernet switches in a tree structure. SomeI/O units have built-in ehernet switches allowing I/O units to be connected in acascade structure.

xx0800000133

SwitchA

I/O unitB


2 Hardware description2.3 Connections, general

2.4 PROFINET-IO Routing

GeneralThe DSQC 678 has a built in functionality called PROFINET-IO Routing. Thisfunctionality makes it possible for a PLC that is connected to the internal slave ofthe DSQC 678 to read and write I/O signals on I/O units that operates as slavesunder the DSQC 678 master.

Note

In the IRC5 I/O configuration it is possible to configure digital output signals onsignal bits controlled by the PLC. These output signals will not affect the digitaloutputs on the I/O unit, but can still be used to monitor the actual value of thedigital outputs on that I/O unit. It is recommended to name these kind of outputsignals to reflect the fact that they are controlled by the PLC, or configure aproper access level on the signals to prevent the RAPID program to write tothese kind of signals. For more information see Technical referencemanual - System parameters.



2 Hardware description2.4 PROFINET-IO Routing

ExampleThe figure below shows a setup where the IRC5 Controller is connected to a PLCas a slave and an I/O unit as a master.

xx0800000137

PLCA

DSQC 678B

IRC5 controllerC

I/O unitsD

With the PROFINET-IO Routing functionality it is possible to configure:• Some of the I/O signals on the I/O unit to be controlled by the IRC5 controller

and some by the PLC.• Some I/O signals to be read both by the PLC and the IRC5 controller.


2 Hardware description2.4 PROFINET-IO Routing

Continued

3 PROFINET Master/Slave configuration3.1 Introduction

3.1.1 Software overview

Controller softwareThe IRC5 controller must be installed with software that supports the PROFINETIO Master/Slave option (that is, RobotWare 5.11 or later).

Note

The PROFINET IO Master/Slave option must be installed on the IRC5 controller.

PC softwareThe PROFINET communication is configured manually using RobotStudio orFlexPendant. For more information on:

• RobotStudio, refer to Operating manual - RobotStudio• FlexPendant, refer to Operating manual - IRC5 with FlexPendant

An external PROFINET configuration tool, such as Step7 or NCM PC from Siemens,is needed to configure the DSQC 678. The NCM PC program can be downloadedfrom the Siemens hompage for free. Refer to the respective manual for the externalPROFINET configuration tools.


3 PROFINET Master/Slave configuration3.1.1 Software overview

3.2 Configuration overview

3.2.1 PROFINET master

ConfigurationTo configure the PROFINET network in the IRC5 controller, a configuration fileneeds to be downloaded to DSQC 678 using an external PROFINET configurationtool.It is also possible to create a configuration file (an .XDB file) in Step 7, that holdsall the configuration data. This file can be downloaded directly to DSQC 678 fromthe IRC5 controller at the system startup. For more information see, Step 7Configuration files on page 31.The maximum number of I/O units that can be defined in an IRC5 controller withPROFINET IO Master/Slave option is described in the section PROFINET, IRC5on page 14.The following are counted I/O units:

• All PROFINET I/O units connected to the IRC5 PROFINET master.• The IRC5 internal PROFINET slave.• Simulated I/O units and other I/O units connected to other IRC5 fieldbuses.

Predefined BusWhen the system is installed with the PROFINET IO Master/Slave option, apredefined Bus Profinet1 is created.

Predefined Unit TypeWhen the system is installed with the PROFINET IO Master/Slave option, apredefined Unit Type PN_GENERIC is created. This I/O Unit Type is used for allI/O units except the IRC5 internal PROFINET slave.

GSDML filesIn order to configure a PROFINET network with an external PROFINET configurationtool, GSDML files need to be imported into the tool. These files contains vitalinformation about the PROFINET I/O units and they shall be supplied by thevendor/manufacturer of the specific PROFINET module.The GSDML file, GSDML-Vz.z-Siemens-CP16xx-YYYYMMDD.xml (for exampleGSDML-V2.2-Siemens-CP16xx-20100709.xml), for PROFINET master is availablein the RobotWare DVD, PC, or IRC5 controller at the following locations:

• On the RobotWare DVD: <DVD-drive>:\utility\fieldbus\PROFINET\GSDML\• On the PC where the RobotWare is installed: ...\ABBIndustrialIT\

RoboticsIT\Mediapool\<RobotWare_xx.xx.xxxx>\utility\service\GSDML\• On the IRC5 Controller:

\hd0a\<RobotWare_xx.xx.xxxx>\utility\service\GSDML\


3 PROFINET Master/Slave configuration3.2.1 PROFINET master

3.2.2 IRC5 internal PROFINET slave

ConfigurationThe DSQC 678 unit has an internal slave with maximum 1024 digital input signalsand 1024 digital output signals. This can, for example, be used:

• To connect the IRC5 controller to a PLC.• To connect the IRC5 controller to another IRC5 controller which acts as a

master.

Predefined Unit TypeWhen the system is installed with the PROFINET IO Master/Slave option, apredefined Unit Type PN_INTERNAL_SLAVE is available. This Unit Type is usedto define the internal slave in the IRC5 controller, which will enable a PLC to connectto the IRC5 controller. There can only be one I/O unit with this Unit Type definedin the IRC5 controller.

GSDML filesThe GSDML file for DSQC 678 (alias CP1616), that is included in the Step 7 softwarepackage, is needed to operate the DSQC 678 PCI board.

Input and output sizeThe Unit Type PN_INTERNAL_SLAVE has two Unit Type parameters, Input Sizeand Output Size. Input Size is used to configure the input size of the IRC5 internalPROFINET slave and Output Size configures the output size. A connecting PLCneeds to have a slot configuration created in the external PROFINET configurationtool that matches the configuration of the IRC5 internal PROFINET slave.The available module sizes of DSQC 678 are dependent on the firmware versionof DSQC 678.If firmware V2.2.X.X is used the supported module sizes are: 4 byte, 16 byte, 20byte, and 64 byte.If firmware V2.4.X.X is used the supported module sizes are: 4 byte, 8 byte, 16byte, 20 byte, 32 byte, 64 byte, and 128 byte.The IRC5 internal PROFINET slave uses a maximum of 2 input and 2 output slotsto configure the input and output size of the IRC5 internal PROFINET slave.Input Size and Output Size can be set to the values 4, 8, 16, 20, 32, 64, and 128(other values will be rounded up to one of these values).If firmware V2.2.X.X is used, the value 8 results in two slots with 4 bytes each. Thevalue 32 will result in two slots with 16 bytes each. Other values will result in oneslot with 4, 16, 20, or 64 bytes.If firmware V2.4.X.X is used, all values results in one slot with 4, 8,16, 20, 32, 64,or 128 bytes.

Note

The Input Size sets the size on digital outputs and Output size sets the size ondigital inputs, seen from the PLC’s point of view.



3 PROFINET Master/Slave configuration3.2.2 IRC5 internal PROFINET slave

The following table shows a few examples of how the Input Size and Output SizeUnit Type parameters can be used to create different slot configurations of aconnecting PLC when firmware V2.2.X.X is used:

Step 7 ConfigurationOutput SizeInput Size

Slot 1: DI 4 bytes4 bytes4 bytesSlot 2: DO 4 bytes

Slot 1: DI 4 bytes8 bytes4 bytesSlot 2: DI 4 bytesSlot 3: DO 4 bytes


Slot 1: DI 20 bytes20 bytes1 byteSlot 2: DO 4 bytes


Slot 1: DI 64 bytes64 bytes32 bytesSlot 2: DO 16 bytesSlot 3: DO 16 bytes

Slot 1: DI 16 bytes32 bytes32 bytesSlot 2: DI 16 bytesSlot 3: DO 16 bytesSlot 4: DO 16 bytes


If firmware V2.4.X.X is used the above table will differ in the following cases:

Step 7 ConfigurationOutput SizeInput Size


Slot 1: DI 64 bytes64 bytes32 bytesSlot 2: DO 32bytes



If a configuration mismatch between the connecting PLC and the IRC5 internalPROFINET slave occurs, the event message 71437 is generated. This eventmessage informs the user of the present slot configuration of the IRC5 internalPROFINET slave.

Note

The System Info menu in FlexPendant or RobotStudio can be used to view thecurrent slot configuration of the IRC5 internal PROFINET slave. On theFlexPendant, the System Info path is: "System Info/Hardwaredevices/Controller/Computer system/PCI bus/Profinet board".


3 PROFINET Master/Slave configuration3.2.2 IRC5 internal PROFINET slave

Continued

3.2.3 Step 7 Configuration files

ConfigurationThere are two ways to download the Step 7 configuration to DSQC 678. The mostcommon way is to download the configuration directly from within Step 7 to DSQC678. An alternate way is to create an .xdb configuration file in Step 7 and place thisfile in the HOME directory of the IRC5 controller.By specifying the configuration file name using the bus type parameter Path toBus Configuration File (see Path to Bus Configuration File on page 66), the IRC5controller will open and read the file at startup and send the configuration to theDSQC 678 board. This means that the current configuration in DSQC 678 is replacedby the one specified in the configuration file.

Configuration File TypeThe configuration file of type .xdb is created by default every time a Step 7 projectis compiled. The .xdb file is placed in the current project folder under the directoryXDBs. By default, this file is named as pcst_1.xdb.It is recommended to place the configuration file in the HOME directory of thecurrent system. If the configuration file is placed in the HOME directory it is onlynecessary to specify the name of the file in the Path to Bus Configuration Fileparameter and not the complete file path. All files in the HOME directory are includedin a backup of the system.

en0900001024


3 PROFINET Master/Slave configuration3.2.3 Step 7 Configuration files

3.2.4 Upgrade or downgrade firmware using Step7

OverviewYou can upgrade or downgrade firmware versions using the Firmware Loaderprogram which is included in the Step7 package. RobotWare 5.13 supports firmwareupgrade of the DSQC 678 board from within RobotWare itself (but no support fordowngrade).The firmware files (for example DSQC678_2425.fwl), for the DSQC 678 board isavailable in the PC or IRC5 controller at the following locations:

• On the PC where the RobotWare is installed:...\ABBIndustrialIT\RoboticsIT\Mediapool\<RobotWare_xx.xx.xxxx>\firmware\

• On the IRC5 Controller: \hd0a\<RobotWare_xx.xx.xxxx>\firmware\

Compatability limitations of RobotWare versions and firmware versionsDifferent releases of RobotWare are compatible only with specific firmware versionsin the DSQC 678 board, as shown in the following table. Therefore, an upgrade ordowngrade of RobotWare requires a change of firmware in the board.

Firmware fileFirmware versionRobotWare version

DSQC678_2425.fwl includedin RW

2.4.XX or 2.2.1.24RW 5.14.03


2.4.XX or 2.2.1.24RW 5.14.02


2.4.XX or 2.2.1.24RW 5.14.01


2.4.XX or 2.2.1.24RW 5.14

DSQC678_242.fwl included inRW

2.4.XX or 2.2.1.24RW 5.13.04


2.4.XX or 2.2.1.24RW 5.13.03


2.4.XX or 2.2.1.24RW 5.13.02


2.4.XX or 2.2.1.24RW 5.13.01


2.4.XX or 2.2.1.24RW 5.13

fw16xx-2.2.1.24.1.fwl*2.2.1.24RW 5.12

vxworks.fwl *2.1.4.0RW 5.11

Note

The system generates error messages if firmware 2.2.1.24 is used with RW5.11.*Firmware file delivered by Siemens.



3 PROFINET Master/Slave configuration3.2.4 Upgrade or downgrade firmware using Step7

Checking the firmware versionYou can check the version number of the firmware loaded in the DSQC 678 boardin one of the following ways.

• Using FlexPendant: Select ABB -> System Info -> Hardware devices ->Controller -> Computer system -> PCI bus -> Profinet board.

• Using RobotStudio: Right click on the controller in the Online view and selectProperties ->Device Browser ->Devices ->Hardware devices ->Controller-> Computer system -> PCI bus -> Profinet board.

Note

The PROFINET bus must be available in the I/O configuration to display thefirmware information.

Upgrading or downgrading firmware using step7Perform the steps 1 – 4 to verify that the bus is not running before starting theupgrade or downgrade procedure.

1 Open the hardware configuration window of a project and set the project“Online” with the menu View, Online.




Continued

2 Right click Station and choose Open Object.

3 Right click CP1616 and choose Operating Mode.

If the Current Operating Mode displays RUN, click STOP button to stop thebus.

4 Click Close.




Continued

Perform the steps 5 - 14 to upgrade or downgrade firmware version.5 Open SIMATIC Manager (Step7) and checkOptions -> Set PG/PC Interface.

Note

The TCP/IP address should be the IP address of your network card.

6 Go to PLC -> Edit Ethernet Node.The Edit Ethernet Node dialog box appears.

7 Click Browse, select the appropriate DSQC 678 (CP1616) board, and clickOK.

en1000000521

Note

To identify the DSQC 678 board click the Flash button. The LED of theselected board start flashing until you press Stop button.




Continued

8 Click the Reset button in the Reset to factory settings section.

en1000000522

Note

Before downloading the firmware, reset the board to factory settings usingsteps 1 to 4. If a reset is not carried out before performing an upgrade ordowngrade of the firmware, the DSQC 678 board might end up in an errorstate which cannot be recovered.

9 ClickBrowse, select the appropriate DSQC 678 board, and clickOK. It mighttake some time for the board to appear in the list after the reset.

10 Type the desired IP address and Subnet mask and click Assign IPConfiguration.

11 Close SIMATIC Manager and open SIMATIC NET Firmware - Loader.




Continued

12 Click Browse, select the firmware according to the RobotWare version, andclick Next.

en1000000523

13 Select IP protocol, type the IP address that was set from SIMATIC Manager,and click Next.

14 Follow PG/PC Interface instructions and load the firmware.



Continued

3.2.5 Automatic firmware upgrade

OverviewIt is possible to upgrade the firmware directly from within the IRC5 controller, if thecurrent version of RobotWare is compatible with more than one firmware versionsof DSQC 678.

ConfigurationThe bus type parameter Automatic Firmware Upgrade on page 67 activates theupgrade function. After activation, the IRC5 controller upgrades the firmware duringthe next system startup.

Note

On some systems the automatic firmware upgrade can take several minutes tocomplete. Since this is performed at system startup, it might appear as if theIRC5 controller has stopped responding.

Firmware versionThe firmware version is important in the Step 7 projects. A PLC configured tocommunicate with a V2.2.X.X firmware might not accept that the communicationpartner suddenly appears as a V2.4 device.To view the current firmware version available for upgrade in the current RobotWarerelease, refer to‘System Info/Hardware devices/Controller/Computer system/PCIbus/Profinet board’ on the FlexPendant.

Note

The current configuration data in DSQC 678 is not destroyed when performinga firmware upgrade operation. If the current configuration is not compatible withthe new firmware, DSQC 678 might perform illegal address operations againstthe IRC5 controller. This might cause a system failure. It is thereforerecommended to clear the DSQC 678 configuration data before upgrading thefirmware.


3 PROFINET Master/Slave configuration3.2.5 Automatic firmware upgrade

3.3 Workflows

3.3.1 Configuring PROFINET master

DescriptionThe PROFINET master configuration is set according to the I/O units and I/O signalsdefinitions.

Configuration

NoteAction

See Operating manu-al - RobotStudio.

Create a new system using RobotStudio. Make sure thePROFINET IO Master/Slave option is installed.

1

Download the system to the IRC5 controller and restart.2

Described in sectionConfiguring digital I/O,example on page 44.

Use the external PROFINET configuration tool to create aproject that contains the configuration of the PROFINETnetwork. If the I/O units are not available in the configurationtool, import the GSDML files.

Note

This step is always unique depending on the type of I/O unitto configure.

3

Download the configuration to the DSQC 678.4

Restart the IRC5 controller to start up with the new system.5

Configure the I/O units connected to the Profinet1 bus usingRobotStudio or FlexPendant.

6

See Technical referencemanual - System para-meters.

Configure the I/O signals.7

Restart the IRC5 controller.8


3 PROFINET Master/Slave configuration3.3.1 Configuring PROFINET master

3.3.2 Configuring IRC5 internal PROFINET slave

DescriptionWhen the IRC5 controller is connected, for example, to an external PLC, the IRC5controller acts as an ordinary slave unit on the PROFINET network. The PLCconnects to the IRC5 internal PROFINET slave to exchange data.

Configuration

NoteAction

Described in section ConfiguringIRC5 internal PROFINET slave,example on page 54.

Use the external PROFINET configuration tool tocreate a project for the master, for example a PLC,that contains the configuration of the PROFINETnetwork.

1


In the tool, configure the master to connect to theDSQC 678 internal slave that represents the IRC5controller.

2

See Configuring IRC5 internalPROFINET slave, example onpage 54 and Operating manu-al - RobotStudio.

Configure the IRC5 internal PROFINET slave unitin the IRC5 controller using RobotStudio or Flex-Pendant.

3

See Technical reference manu-al - System parameters.

Configure the I/O signals.4

SeeOperatingmanual - IRC5 withFlexPendant.



Download the configuration in the externalPROFINET configuration tool to the master.

6

Communication statusTo control the communication status between the master (for example a PLC) andthe IRC5 internal PROFINET slave, the following scheme is used:

1 Configure the master to set a signal during the startup or within the controllerloop.

2 Configure the internal PROFINET slave to attach the signal to a RAPID trapfunction in the robot controller. The signal then functions as a communicationsupervision signal.

If the communication between the master and the internal PROFINET slave isinterrupted, all the inputs of the internal slave will go to the fail safe state (that is,input value will be zero). This means that the user defined communicationsupervision signal will also have the value zero.


3 PROFINET Master/Slave configuration3.3.2 Configuring IRC5 internal PROFINET slave

3.3.3 Configuring PROFINET-IO Routing

GeneralThe PROFINET-IO Routing functionality is configured entirely using an externalPROFINET configuration tool. It is important to remember that the PROFINET-IORouting functionality also connects different projects in the configuration tools witheach other. A configuration change in one of the projects might also change theconfiguration in the connected project. In order to execute changes regardingPROFINET-IO Routing, all affected projects must be downloaded to respectivehardware, even if a change in configuration only was made in one of the connectedprojects.

PrerequisitesThe PROFINET master and the PROFINET internal slave has to be configured,see section Configuring PROFINET master on page 39, and section ConfiguringIRC5 internal PROFINET slave on page 40.

Master configurationUse this procedure to configure the master.

Action

Configure the master functionality as described in Configuring PROFINET master onpage 39.

1

Use an external PROFINET configuration tool to create a project and add a SimaticPC station with a CP1616 device and a network with the devices that shall be slavesto the IRC5 controller.

2

Configure the IRC5 controller I/O system and define the slave devices as I/O units.3

Configure the IRC5 controller I/O system and define the I/O signals that shall be ac-cessible from the IRC5 controller.

4

Slave configurationUse this procedure to configure the slave.

Action

Configure the IRC5 internal PROFINET slave functionality as described inConfiguringIRC5 internal PROFINET slave on page 40

1

Add a PLC station to the project created in Configuring PROFINET master on page39step 1 using an external PROFINET configuration tool.

2

Add a Simatic PC Station as a slave to the PLC, make sure the name and IP addressis the same as in the master configuration.

3

Configure the IRC5 controller I/O system and define a unit of type PN_INTERN-AL_SLAVE to activate the IRC5 internal PROFINET slave functionality.

4



3 PROFINET Master/Slave configuration3.3.3 Configuring PROFINET-IO Routing

PROFINET-IO Routing configurationConfigure PROFINET-IO Routing in the external PROFINET configuration tool.

Action

In the PLC configuration select the CP1616 device and add transfer modules to slot3 and above, as described inConfiguring PROFINET-IO Routing, example on page60.

1

Note

In the IRC5 I/O configuration it is still possible to configure digital output signalson signal bits controlled by the PLC. These output signals will not affect thedigital outputs on the I/O unit, but can still be used to monitor the actual valueof the digital outputs on that I/O unit. It is recommended to name these kind ofoutput signals to reflect the fact that they are controlled by the PLC, or configurea proper access level on the signals to prevent RAPID programs to write to thesekind of signals. For more information, see Technical reference manual - Systemparameters.


3 PROFINET Master/Slave configuration3.3.3 Configuring PROFINET-IO Routing

Continued

3.4 Examples

3.4.1 Overview

About the examplesAll the examples in this section are based on the Robotware 5.11 or 5.12 systemswith DSQC 678 firmware version V2.1.4.0 or V2.2.1.24. If you are using Robotware5.12 or above, you need to use the corresponding DSQC 678 (alias CP1616) moduletype that corresponds to the current firmware version of your DSQC 678 board.Robotware 5.12 uses CP1616 V2.2 module type. Robotware 5.13 or above usesCP1616 V2.2 or V2.4 module type.


3 PROFINET Master/Slave configuration3.4.1 Overview

3.4.2 Configuring digital I/O, example

DescriptionThis is an example of how to configure an I/O unit with four input signals and fouroutput signals.The I/O unit used in this example is an ET200S I/O unit with five submodulesattached to it:

• One power module.• Two modules with two DO in each module.• Two modules with two DI in each module.

The network is configured using Siemens Step7.

PROFINET configuration setupUse this procedure to set the configuration in Siemens Step7.

Action

Create a new empty project.1

On the Insert menu, point to Station, and then click SIMATIC PC Station.2

In SIMATIC Manager, expand the project tree and select the created station. Right-click the station and select Open Object to open the HW Config window.

xx0800000138

3

Expand the SIMATIC PC Station on the right-hand side catalog tree. Expand furtherin the tree, find SIMATIC PC Station\CP Industrial Ethernet\CP 1616\V2.2.

4

Double-click or drag the V2.2 device from the catalog tree to slot 1 of the PC rack.5



3 PROFINET Master/Slave configuration3.4.2 Configuring digital I/O, example

Action

Enter the IP address used for the DSQC 678, and then clickNew to create a PROFINETnetwork.

xx0800000139

6

ClickOK on the Industrial Ethernet dialog andOK in theProperties-Ethernet interfacePN-IO dialog.

xx0800000140

7




Continued

Action

Double-click the X1 slot in PC rack to open the PN-IO dialog.

xx0800000141

8

Enter Robot1 in the Device Name text box and click OK.

xx0800000142

9




Continued

Action

Expand the catalog tree view and locate the correct ET200S device,10PROFINET IO\I/O\ET 200S\IMI151-3 PN ST V6.0.

xx0800000143

Drag the device from the catalog and drop it on the Ethernet PROFINET-IO-System.11

Continue expanding the catalog tree to locate the modules that are connected in thehardware device.

xx0800000144

12

For each module double-click or drag it to the appropriate slots of the ET200S device.

Note

Make sure the catalog number matches the catalog number printed on the hardware.

13




Continued

Action

If the feature prioritized startup is desired for the ET200S, double-click on slot X1 andselect Prioritized startup. This will shorten the time it takes for the device to start dataexchange with the controller after losing and regaining power or after disconnectionand reconnection on the bus.

en0900000001

14

Note

Prioritized startup is available with PROFINET IO board firmware version 2.2.1.24 orlater.

On the File menu, click Save and compile.

xx0800000145

15

Make sure that you have an ethernet connection between the PC and the DSQC 678.16




Continued

Action

On the PLC menu, click Download and then click OK.

xx0800000146

17

Click View to search the network for the DSQC 678.

xx0800000147

18




Continued

Action

Select the appropriate DSQC 678 card and click OK.

xx0800000148

19

Click OK to stop the card. This finishes the setup in the Siemens tool.20Continue with configuring the IRC5 controller I/O system.

xx0800000149




Continued

IRC5 controller I/O configuration setupUse this procedure to setup the configuration in the IRC5 controller, usingRobotStudio.

Action

Start RobotStudio and connect to the IRC5 controller. Request write access.1

Click Configuration Editor and select I/O.2

In the type list, click Unit and then right-click in the workspace and select Add Unit.3

Enter the parameter values for the unit and click OK.• Name.• Type of Unit should be PN_GENERIC.• Profinet Address should be 1, same as the device number in the Step7 project.

xx0800000152

4

xx0800000155

Note

Device number 1 in the Siemens project.

In the type list, click Signal and then right-click in the workspace and selectAdd Signal.5




Continued

Action

Enter the parameter values for the signal and click OK.• Name• Type of signal• Assign to unit• Unit mapping

xx0800000156

6

The lower panel in Step7 can be a guide when specifying the parameterUnit Mapping.Select the device in the project and use the lower panel. See settings explanation inSignal mapping example on page 53.

xx0800000158


After the restart, start RobotStudio and make sure the configured I/O signals are ac-cessible.

8




Continued

Signal mapping example

xx0800000158

The panel shows that the signals are mapped to:

Unit mapping in IRC5 con-troller

Module mapping in Step7Module typeSlot

Out 0,1Out 0.0..0.12DO2

Out 8,9Out 1.0..1.12DO3

In 0,1In 0.0..0.12DI4

In 8,9In 1.0..1.12DI5

The I/O signals in the IRC5 controller should be mapped as:

Unit mappingAssigned to UnitType of signalName

0IM151Digital InputDI1




0IM151Digital OutputDO1




This example shows that even if a 2 bit module type is used, every slot occupiesatleast 1 byte. If an 8 bit module type is used, all signal bits (unit map 0-7) wouldhave valid data.



Continued

3.4.3 Configuring IRC5 internal PROFINET slave, example

DescriptionThis is a configuration example for an IRC5 internal PROFINET slave with 64 byteinput and 64 byte output size. The example also shows how to configure a PLCthat connects against the IRC5 internal PROFINET slave.This example comes from the Step7 project in section Configuring digital I/O,example on page 44

Configuring IRC5 internal PROFINET slaveUse this procedure to configure the configuring IRC5 internal PROFINET slaveusing Siemens Step 7.

Action

Start Simatic Manager and open the project containing the Simatic PC Station thatrepresents the IRC5 controller with DSQC 678.

1

This project was created in section Configuring digital I/O, example on page 44

Expand the project tree and select the Simatic PC station that represents the IRC5controller with the DSQC 678. Right-click the station and select Open Object to openthe HW Config window.

2

Double-click slot 1 in the PC Station rack to open the object properties and then selectthe PROFINET tab.

3

Make sure the Enable IO device mode is selected, if not select Enable IO devicemode and download the updated configuration to the DSQC 678.Click OK.

xx0800000159



3 PROFINET Master/Slave configuration3.4.3 Configuring IRC5 internal PROFINET slave, example

Action

Click OK and add a PLC station to the project.

Note

If using the PROFINET-IO Routing functionality, make sure that the PLC station andthe Simatic PC station are located in the same project.

4

Open the HW Config window for the PLC hardware configuration.

xx0800000160

5

Make sure the PROFINET network connected to the PLC is the same as the networkconnected to the Simatic PC station representing the IRC5 controller with DSQC 678.

6

Expand PROFINET IO\I/O\SIMATIC PC-CP\CP1616\6GK1 161-6AA00 (Migration) inthe catalog view to the right, to find the V2.2 device.

7




Continued

Action

Drag the V2.2 device to the PROFINET network workspace.

xx0800000161

8

Double-click the added CP1616 icon.

xx0800000162

9




Continued

Action

Make sure the device name is the same as the name selected for slot X1 in the config-uration of the Simatic PC Station configuration and that Assign IP address via IOcontroller is cleared.

10

Click OK.

xx0800000163

Note

Before clearing theAssign IP address via IO controller box, make sure the IP addressis set to the IP address of the CP1616 card in the Simatic PC Station configuration.

Click OK in the Properties-CP-1616 dialog and then click Yes to confirm the warning

xx0800000164

11




Continued

Action

Make sure the CP1616 icon is selected, expand the catalog view further to find theinput modules, PROFINET IO\I/O\SIMATIC PC-CP\CD1616\6GK1 161-6AA00 (Migra-tion)\ V2.2\DI. Double-click the 64 bytes module to insert it into slot 1 of the CP1616card.

12

Expand the output modules in the catalog tree and double-click or drag the 64 bytesmodule to slot 2 of the CP1616 card.

xx0800000165

13

On the Station menu, click Save and Compile.14

Make sure that you have an Ethernet connection between the PC and the PLC.15

On the PLC menu, click Download.16

IRC5 controller I/O configuration setupUse this procedure to configure the slave in the IRC5 controller, using Robot Studio.

Action

Start RobotStudio and connect to the IRC5 controller. Request write access.1

Click Configuration Editor and select I/O.2

In the type list, click Unit and then right-click in the workspace and select Add Unit.3




Continued

Action

Enter the parameter values for the unit and click OK.• Name.• Type of Unit should be PN_INTERNAL_SLAVE.• Connected to Bus should be Profinet1.• Profinet Address must be 0. (Not needed in Robotware 5.12 or above).

xx0800000166

4




Continued

3.4.4 Configuring PROFINET-IO Routing, example

DescriptionThis is an example of how to configure the DSQC 678, PROFINET-IO Routingfunctionality.

Note

This example requires both configurations described in example Configuringdigital I/O, example on page44, and Configuring IRC5 internal PROFINET slave,example on page 54.

PROFINET configuration setupUse this procedure to setup the configuration in Step7 (Siemens PROFINETconfiguration tool).

Action

Use Siemens Simatic Manager and open the PLC configuration made in examplePROFINET configuration setup on page 44.

1

Select the CP1616 icon representing the IRC5 internal PROFINET slave.2

In SIMATIC Manager, expand the catalog tree to the right of the window. Right-clickthe window and find PROFINET IO\I/O\SIMATIC PC-CP\CP1616\6GK1 161-6AA00(Migration)\V2.2\Transfer Module.

3

Drag one DI 1 byte transfer module to slot 3 of the CP1616 device.4

Drag one DO 1 byte transfer module to slot 4 of the CP1616 device.

xx0800000167

5



3 PROFINET Master/Slave configuration3.4.4 Configuring PROFINET-IO Routing, example

Action

Double-click DI 1 byte transfer module in slot 3 to open the Properties dialog.

xx0800000168

6

In the column Device name click the first cell named Empty to open a list of devicesthat are controlled by the PROFINET master in the IRC5 controller.

7

Click to select the IM151 device.8

Click the Module (slot) cell with white background to open a list of available slotmodules. This will show a list of all slot modules that the PLC can read.

9

Then select the input module in slot 4.




Continued

Action

Click the next cell labeled Empty and select the IM151 module, then select the outputmodule in slot 2. As seen in this example, it is possible to also choose to read outputs.This is generally not needed by the PLC, but shown here to illustrate that it's possible.

10

With this configuration, the PLC can read the input signals 0 and 1, and read back theoutput signals 0 and 1.

xx0800000170

Click OK to close the Properties dialog.11

Double-click the DO 1 byte transfer module in slot 4 of the CP1616device.12




Continued

Action

Configure the transfer module so that the PLC will be able to control the output signals0 and 1 of the output module in slot 3 of the IM151 device.

xx0800000171

13

Click OK to close the Properties dialog.14

On the Station menu, click Save and compile.15

Open the SIMATIC PC Station configuration.16

On the Station menu, click Save and compile.17

Download the PLC configuration to the PLC.18

Download the Simatic PC Station configuration to the DSQC 678.19

Note

In the IRC5 I/O configuration it is still possible to configure digital output signalson signal bits controlled by the PLC. These output signals will not affect thedigital outputs on the I/O unit, but can still be used to monitor the actual valueof the digital outputs on that I/O unit. It is recommended to name these kind ofoutput signals to reflect the fact that they are controlled by the PLC, or configurea proper access level on the signals to prevent RAPID programs to write to thesekind of signals. For more information, see Technical reference manual - Systemparameters.



Continued

4 System parameters4.1 Introduction

About the system parametersThere are both PROFINET specific parameters and more general parameters. Thischapter describes all PROFINET specific system parameters. The parameters aredivided into the type they belong to. For information about other parameters, seeTechnical reference manual - System parameters.

PROFINET system parameters

BusThese parameters belong to the type Bus in the topic I/O.

For more information, see ...Parameter

Technical reference manual - System parametersName

Technical reference manual - System parametersType of Bus

Connector ID on page 68Connector ID

Technical reference manual - System parametersLabel of Fieldbus Connect-or

Technical reference manual - System parametersUnit Recovery Time

Path to Bus Configuration File on page 66Path to Bus ConfigurationFile

Automatic Firmware Upgrade on page 67Automatic Firmware Up-grade

Unit TypeThese parameters belong to the type Unit Type in the topic I/O.

For more information, see ...Parameter

Technical reference manual - System parametersName

Technical reference manual - System parametersType of Bus

Technical reference manual - System parametersVendor Name

Technical reference manual - System parametersProduct Name

Technical reference manual - System parametersInternal Slave

Input Size on page 70Input Size

Output Size on page 72Output Size


4 System parameters4.1 Introduction

4.2 Type Bus

4.2.1 Path to Bus Configuration File

ParentPath to Bus Configuration File belongs to the type Bus, in the topic I/O.

Cfg nameCfgPath

DescriptionPath to Bus Configuration File specifies the path to a Step 7 configuration file oftype .XDB that is located on the IRC5 system.

UsageThe Path to Bus Configuration File system parameter is used to download a Step7 configuration to DSQC 678 without using Step 7. If the configuration file is placedin the HOME directory of the system, it will also be included in backups. For moreinformation see, Step 7 Configuration files on page 31.

PrerequisitesPROFINET IO Master/Slave option must be installed.

Default valueThe default value is an empty string.

Allowed valuesA-Z, a-z, _, .


4 System parameters4.2.1 Path to Bus Configuration File

4.2.2 Automatic Firmware Upgrade

ParentAutomatic Firmware Upgrade belongs to the type Bus, in the topic I/O.

Cfg namePN_AutoFirmwareUpgrade

DescriptionAutomatic Firmware Upgrade activates the firmware upgrade function of DSQC678.

UsageTheAutomatic Firmware Upgrade parameter specifies if the system should performa firmware upgrade of DSQC 678 to the firmware version specified in the ‘SystemInfo/Hardware devices/Controller/Computer system/PCI bus/Profinet board’ menu.For more information, see Automatic firmware upgrade on page 38.


LimitationsNot possible to upgrade to firmware version other than that included in RobotWare.

Default valueDeactivated.

Allowed valuesActivated or Deactivated.


4 System parameters4.2.2 Automatic Firmware Upgrade

4.2.3 Connector ID

ParentConnector ID belongs to the type Bus, in the topic I/O.

Cfg nameConnectorID

DescriptionThe parameter Connector ID specifies the hardware interface (connection port)that the PROFINET IO Master/Slave option shall use.

UsageTheConnector ID parameter is used to select one of the available connection portsto use.


Default valueFirst Board

Allowed valuesFirst Board


4 System parameters4.2.3 Connector ID

4.3 Unit

4.3.1 PROFINET Address

Cfg namePN_Address

DescriptionThe parameter PROFINET Address corresponds to the device number in theexternal PROFINET configuration tool.

UsagePROFINET Address specifies the address that the I/O unit uses on the network.


Default valuesThe default value is 0.

Allowed valuesAn integer value between 0 and 65535.The value must be zero (0) when configuring the internal slave.


4 System parameters4.3.1 PROFINET Address

4.4 Unit Type

4.4.1 Input Size

ParentInput Size belongs to the type Unit Type, in the topic I/O.

Cfg namePN_InputSize

DescriptionInput Size is used to configure the input slot configuration of the IRC5 internalPROFINET slave.Input Size sets the size of the digital inputs for PN_INTERNAL_SLAVE.


LimitationsInput Size is only available for the unit type PN_INTERNAL_SLAVE.

Allowed valuesAllowed values are the integers 0-128.The default value is 64.

Additional informationThe values other than 4, 8, 16, 20, 32, 64, and 128 results in digital input sizerounded up to the closest of these values.If DSQC 678 firmware version 2.2 is used:The Input Size set to 8 results in two slots with 4 bytes each. The Input Size set to32 results in two slots with 16 bytes each. For other values there will be one slotwith 4, 16, 20, or 64 bytes.

Slot sizeInput Size

4 bytes1-4

2 slots with 4 bytes each5-8

16 bytes9-16

20 bytes17-20


64 bytes33-64

If DSQC 678 firmware version 2.4 is used:

Slot sizeInput Size

4 bytes1-4

8 bytes5-8



4 System parameters4.4.1 Input Size

Slot sizeInput Size

16 bytes9-16

20 bytes17-20

32 bytes21-32

64 bytes33-64

128 bytes65-128


4 System parameters4.4.1 Input Size

Continued

4.4.2 Output Size

ParentOutput Size belongs to the type Unit Type, in the topic I/O.

Cfg namePN_OutputSize

DescriptionOutput Size is used to configure the output slot configuration of the IRC5 internalPROFINET slave.Output Size sets the size of the digital outputs for PN_INTERNAL_SLAVE.


LimitationsOutput Size is only available for the unit type PN_INTERNAL_SLAVE.

Allowed valuesAllowed values are the integers 0-128.The default value is 64.

Additional informationAny other values than 4, 8, 16, 20, 32, 64, and 128 results in digital output sizerounded up to the closest of these values.If DSQC 678 firmware version 2.2 is used:The Output Size set to 8 results in two slots with 4 bytes each. The Output Sizeset to 32 results in two slots with 16 bytes each. For other values there will be oneslot with 4, 16, 20, or 64 bytes.

Slot sizeOutput Size

4 bytes1-4


16 bytes9-16

20 bytes17-20


64 bytes33-64

If DSQC 678 firmware version 2.4 is used:


4 bytes1-4

8 bytes5-8

16 bytes9-16



4 System parameters4.4.2 Output Size


20 bytes17-20

32 bytes21-32

64 bytes33-64

128 bytes65-128


4 System parameters4.4.2 Output Size

Continued

5 Trouble shooting5.1 Scenarios

How to reset a DSQC 678 (CP1616)If the DSQC 678 doesn’t accept changed device name or IP address parametervia Step7 in the PLC – Edit Ethernet Node window, follow these steps to reset orset the values:

1 On the ABB menu, tap X-Start to restart the controller.This is to ensure that the controller will not attempt to connect to the DSQC678 for any reasons.

2 Unplug all the cables from the DSQC 678’s internal switch.This is to prevent communication to any connected device, if a project isloaded in the board and running.

3 Connect the programming unit (PC with Step7) via a cable directly to any ofthe DSQC 678’s internal ports.

4 Start the Simatic Manager at the programming unit.5 From the PLC menu select the Edit Ethernet Node entry.




6 Click Browse in the Ethernet node field.

en1200001205

7 Select DSQC 678 (CP1616) device and click OK.




Continued

To ensure if the selected device is the correct DSQC 678 device, click Flash.The selected device will then flash periodical with its LED’s.

en1200001206

8 Now try to change the device name and/or IP address. ClickAssign to confirmfor each of the two settings.




Continued

Alternatively, the DSQC 678 can be reset to its factory settings using theReset button in the Reset to factory settings field.

en1200001207

9 When all the settings have been successfully done, Click Close.10 Restart the controller using the power switch.

The controller will start without a system. Select the system you wish to useand warm restart the controller using the Flex Pendant.

11 Finally reconnect all the cables and unplug the programming pc if it is notneeded anymore.

How can I download configuration to DSQC 678 using Step 7See the preceding scenario, How to reset a DSQC 678 (CP1616) on page 75.




Continued

The Ethernet switch on the DSQC 678 can be operated using an external power supply unit. Why isit not working?

The DSQC 678 board must first be initialized by the PROFINET IO Master/Slaveoption software driver before the Ethernet switch can be used. When this is done,the external power supply unit can be connected to the DSQC 678 board.

In Step 7 the DSQC 678 board can be "Reset to factory settings". After that the IRC5 controller cannotdetect that the PCI-board is inserted.

When this command is issued from Step 7, the DSQC 678 board will performadditional operations next time it reboots. This will increase the startup time of theboard so much that the IRC5 controller will fail to detect it. The solution is to restartthe IRC5 controller again.

My digital group/analogue signal seem to be data inconsistent.With the DSQC 678 board data consistency is only guaranteed on a submodulebasis.For example, an I/O unit with the following configuration:

8 bits (1 byte)Slot 1

8 bits (1 byte)Slot 2

will not have data consistency on a 16 bit digital I/O group signal in the IRC5controller that stretches over both slot 1 and 2.

PROFINET-IO Routing is not workingMake sure that the Enable PROFINET IO device operation check box is selectedin the configuration that is downloaded to the DSQC 678 used as an IRC5 internalPROFINET slave. See Configuring IRC5 internal PROFINET slave on page 54.

How do I upgrade/downgrade the firmware on DSQC 678?For information about upgrading/downgrading the firmware on DSQC 678, referthe sectionsUpgrade or downgrade firmware using Step7 on page32 andAutomaticfirmware upgrade on page 38.

What should I do when the communication between my PLC and the DSQC 678 Slave is slow?When configuring the communication against the DSQC 678 in your PLC project,ensure that the I/O Cycle parameter of the DSQC 678 is set correctly. In someversions of Step 7, by default, this parameter is set to 128 ms. Set this parameterto automatic or fixed update time with a more useful value.



Continued

IndexAautomatic firmware upgrade, 38

Bbus error, 21

Ccollective error, 21Connector ID, 68controller software, 27

DDSQC 639, 14DSQC 678, 14, 22, 50

installation, 19PROFINET-IO routing, 24

Eethernet

RJ-45 connector, 21external PROFINET configuration tool, 15, 27, 42

Ffail safe state, 40

GGSDML file, 29GSDML ID, 16

II/O units, 14, 17

configuration, 44ET200S, 44, 47

industrial ethernet, 13, 23, 45internal PROFINET slave, 29, 40, 54

configuration, 40

LLED

activity LED, 20bus error, 21collective error, 21link LED, 20

Mmodule mapping, 53

Pprioritized startup, 48PROFINET, 13

cables, 21

configuration, 44configuration tool, 16, 27, 42hardware, 14master, 28, 39, 41network, 15, 21option 701-1, 22option 888-1, 22predefined I/O bus, 28predefined I/O unit type, 28–29slave, 29, 40–41, 54standardization, 13versions, 13

PROFINET-IO routing, 16, 24–25, 41configuration, 42, 60trouble shooting, 79

PROFINET master, 16, 28configuration, 39, 41

PROFINET network, 15, 45PROFINET slave, 16

configuration, 41PROFINET versions, 13

compatibility, 14PROFIdrive, 13PROFIenergy, 13PROFINET-CBA, 13PROFINET-IO, 13–14PROFIsafe, 13

RRJ-45 connector, 20–21

Ssafety, 12signal mapping, 53Step 7, 15, 27, 44

module mapping, 53Step 7 configuration file, 31system parameters, 65

Input Size, 29, 70Output Size, 29, 72Profinet Address, 51, 69

Ttopic I/O type

Bus, 65Unit, 69Unit Type, 65

trouble shooting, 75

Uunit mapping, 53


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VÄSTERÅS, SwedenTelephone +46 (0) 21 344 400

ABB AS, RoboticsDiscrete Automation and MotionBox 265N-4349 BRYNE, NorwayTelephone: +47 51489000

ABB Engineering (Shanghai) Ltd.5 Lane 369, ChuangYe RoadKangQiao Town, PuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

ABB Inc.Discrete Automation and MotionRobotics1250 Brown RoadAuburn Hills, MI 48326USATelephone: +1 248 391 9000

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