AC500 CONVERTING AN AC500 V2 PROJECT TO AN AC500 V3 … · AC500 CONVERTING AN AC500 V2 PROJECT TO...

— APPLICATION NOTE

AC500 CONVERTING AN AC500 V2

PROJECT TO AN AC500 V3 PROJECT HINTS AND TIPS

2 3ADR010397, 1, en_US

Contents

1 Introduction ...................................................................................................................................... 3 1.1 Scope of the document .............................................................................................................. 3 1.2 Compatibility ................................................................................................................................ 3

2 General Differences ......................................................................................................................... 4 2.1 Hardware, OS ................................................................................................................................ 4 2.2 Source Download/Upload ......................................................................................................... 6 2.3 Task Priorities ............................................................................................................................... 6 2.4 PLC Configuration ....................................................................................................................... 6 2.5 Interfaces and Slots .................................................................................................................... 7 2.6 SD Card........................................................................................................................................... 7 2.7 Update Rate of Communication Modules .............................................................................. 8 2.8 Ethernet Protocols ...................................................................................................................... 9 2.9 Protocol Features ....................................................................................................................... 10 2.10 CAN Protocols ............................................................................................................................. 10 2.11 Symbol File Configuration ....................................................................................................... 10 2.12 Memory Allocation/Byte Order .............................................................................................. 11 2.13 Libraries ....................................................................................................................................... 12 2.14 Library Manager ......................................................................................................................... 14 2.15 Licenses ....................................................................................................................................... 15 2.16 PLC Load / CPU Load ................................................................................................................ 16 2.17 Diagnosis ..................................................................................................................................... 18 2.18 Input- / Output Addresses ...................................................................................................... 19 2.19 Addressable Variables .............................................................................................................. 20 2.20 Vizualization ................................................................................................................................ 21

3 Analyze Application ....................................................................................................................... 24

4 Convert Application ....................................................................................................................... 25 4.1 Update Project or new Project ................................................................................................ 25 4.2 Convert Project with Automation Builder ............................................................................ 25 4.3 Adapt AC500 Libraries ............................................................................................................. 27 4.4 Error Handling Customer Specific Libraries ........................................................................ 27 4.5 Adapt %M Addresses ................................................................................................................ 28 4.6 Adapt %R Addresses ................................................................................................................. 28

AC500 CONVERTING AN AC500 V2 PROJECT TO AN AC500 V3 PROJECT

3ADR010397, 1, en_US 3

1 Introduction

1.1 Scope of the document

Support Users to convert a project made for AC500 V2 to project for AC500 V3. Conversion is

partly supported by Automation Builder, but in most cases some manual conversion steps

have to be done.

The document describes the general differences between the AC500 V2 and AC500 V3 and

gives some hints to execute all necessary steps for conversion.

1.2 Compatibility

The application example explained in this document have been used with the below

engineering system versions. They should also work with other versions, nevertheless some

small adaptations may be necessary, for future versions.

• AC500 V2/V3 PLC

• Automation Builder 2.1.0 or newer

4 3ADR010397, 1, en_US

2 General Differences

2.1 Hardware, OS

PM5xx PM56xx

Power PC TI ARM

Processor Speed Up to 400 MHz Up to 600 MHz

Memory Up to

• 4MB Code

• 4MB Data

• 32k %I

• 32k %Q

• 2MB Config

Up to 160 MB

(Code + Data + %I + %Q +

Config + IEC Driver)

M(odbus) Memory Up to 8 Segments with 64k each 128kB

Persistent Memory Up to 8 Segments %R with 64k

each

128kB

VAR GLOBAL PERSISENT

RETAIN

Operating System SMX Linux

IO Bus Up to 10 S500 Devices Up to 10 S500 Devices

Ethernet 1 or 2 Onboard Ethernet Ports 2 Onboard Ethernet Ports


3ADR010397, 1, en_US 5

Memory Sizes

eCo-E PM556 PM573 PM583 PM585 PM590 PM592 PM595 PM5630 PM5650 PM5670/5

User Prog.

Memory 128kB 512kB 512kB 1 MB 1 MB 2 MB 4 MB 16 MB

8 MB 80 MB 160 MB

User Data 10kB 64kB 224kB 736kB 1536kB 1536kB 4096kB 16 MB

%M 2kB 64kB 128kB 128kB 512B 512kB 512kB 1024kB 128 kB 128 kB 512 kB

VAR-Retain 1kB 1kB 32kB 32kB 512B 512kB 512kB 1024kB 128 kB 128 kB 1024 kB

%R 1kB 1kB 128kB 128kB 512B 512kB 512kB 1024kB n/a n/a n/a

Total

Variables 14kB 130kB 512kB 1024kB 3072kB 3072kB 5632kB 19456kB

SRAM Disk - - 32 kB 64 kB 256 kB 256 kB 256 kB 960 kB Part of

Flash

Part of

Flash

Part of

Flash

Flash

without File

System

1024kB 1512kB 3072kB 4096kB 12288kB 12288kB 16384kB 40960kB

Flash with

File System 40 MB 381 MB 858 MB

User RAM

Disk 912kB 1424kB 1424kB 4096kB 4096kB 8 MB 8 MB 32 MB

Part of

Flash

Part of

Flash

Part of

Flash

Flash Disk 4 GB 4 GB 8 GB

Flash in AC500 V3

Partitioning of Flash and Firmware files of PM56xx-2ETH (≥V3.1.0)

6 3ADR010397, 1, en_US

2.2 Source Download/Upload

PM5xx PM56xx

Only possible together with

inserted SD Card

Possible direct to and from PLC

Separate Note:

AC500 V3 Source Code -

Download and Upload with

AC500 V3.pdf

2.3 Task Priorities

PM5xx PM56xx

Task Prio’s 0..31 0..16

Application Tasks 10..31 0..16

Realtime Tasks 0..15

Non Realtime Task 16

2.4 PLC Configuration

PM5xx PM56xx

CPU Parameter for Configuration

of the System Behavior

PLC Settings for Configuration of

System behavior

IO-Bus and CS31-Bus will be

directly configured in Config Tree

IO-Bus will be directly configured

in Config Tree

AC500 CONVERTING AN AC500 V2 PROJEC T TO AN AC500 V3 PROJECT

3ADR010397, 1, en_US 7

2.5 Interfaces and Slots

PM5xx PM56xx

1 (2) Onboard Ethernet 2 Onboard Ethernet

2 COM Ports (incl. CS31-Bus Master at

COM1)

1 COM Port

1 CAN Onboard Port

1 FBP Port

SD Card Slot SD Card Slot

Battery Slot Battery Slot

Up to 4 external CM Modules Up to 6 external CM Modules

Slot Number automatically configured

with plugging CM Module in AB

Slot Number for CM will be handled

by AB during Build of Application

2.6 SD Card

PM5xx PM56xx

Size Max. 2 GB (ABB tested Cards) Max. 2GB from ABB

Format Standard SDHC supported (Delivery from

ABB in preparation)

File System DOS 8.3 – Filesystem (Short

Names)

FAT 32, Long Names

Card Function Function Description of Card in

Init File

SDCARD.INI

Function Description of Card in

Init File

SDCARD.INI

Functionality One Card for

• FW Update (CPU, CM

Module, Display)

• Application Prog.

• CM Module Conf.

• User Data

• Project Source Code

• Retain-/Persitent- Data

One Card for

• FW Update (System,

Boot, Update, Display)

• User Data

• Retain-/Persitent- Data

8 3ADR010397, 1, en_US

2.7 Update Rate of Communication Modules

PM5xx

PM56xx

PLC Settings

Create Task

Choose Task

No Program Call


3ADR010397, 1, en_US 9

2.8 Ethernet Protocols

PM5xx PM56xx

Modbus TCP, Client + Server Modbus TCP, Client + Server

TCP/IP Sockets TCP/IP Sockets (CAA)

UDP (Standard UDP + ABB UDP) TCP/UDP

Online Access (3S and ABB Diver) 3S Online Access

IEC60870-5-104 (Control - +

Substation)

IEC60870-5-104 (Control - + Substation)

IEC61850 (MMS Server, Goose, Edition 1)

SNTP (Client + Server) SNTP (Client + Server)

SMTP

FTP Server (Client as Lib) FTP Server (connected to both Interfaces)

WEBserver 3S WEB Visu

CODESYS Network Variables

OPC DA (Server installed at PC) OPC DA (Server installed at PC)

OPC UA Server

MQTT MQTT

HTTP HTTP + HTTPS

Client Protocols added to Protocols

Server Protocols added below dedicated

Ethernet Port

10 3ADR010397, 1, en_US

2.9 Protocol Features

PM5xx PM56xx

IEC60870-5-104 Substation

can be deactivated by

Application

IEC60870-5-104 Substation can be

deactivated by Application

Modbus TCP Server can be

deactivated by Application

2.10 CAN Protocols

PM5xx PM56xx

CM598 CANOpen Master

CAN2A/2B

in preparation

CM588 CANOpen Slave in preparation

Onboard CAN CANOpen Manager (Master)

CAN2A/2B

J1939

2.11 Symbol File Configuration

PM5xx PM56xx

Configuration in CODESYS

Project -> Options -> Symbol File

Configuration in Project Tree in AB

• Application

• Right Mouse Click -> Add

Object

• Symbol Configuration

Different Symbol Sets possible (for

different user’s)


3ADR010397, 1, en_US 11

2.12 Memory Allocation/Byte Order

PM5xx PM56xx

Big Endian (Motorola byte order) Little Endian (Intel byte order)

PM5xx

ADR adr adr+1 adr+2 adr+3

BOOL %IX0.x %IX1.x %IX2.x %IX3.x

BYTE %IB0 %IB1 %IB2 %IB3

WORD %IW0 %IW1

DWORD %ID0

%IX0.0 :=TRUE

%IB0 :=16#01 :=1

%IW0 :=16#0100 :=256 (Bit 8)

%ID0 :=16#01000000 :=16777216

%IX3.0 :=TRUE

%IB3 :=16#01 :=1

%IW1 :=16#0001 :=1 (Bit 0)

%ID0 :=16#00000001 :=1

PM56xx


BOOL %IX3.x %IX2.x %IX1.x %IX0.x

BYTE %IB3 %IB2 %IB1 %IB0

WORD %IW1 %IW0

DWORD %ID0

%IX0.0 :=TRUE

%IB0 :=16#01 :=1

%IW0 :=16#0100 :=1 (Bit 0)

%ID0 :=16#00000001 :=1 (Bit 0)

%IX3.0 :=TRUE

%IB3 :=16#01 :=1

%IW1 :=16#0001 :=1 (Bit 8)

%ID0 :=16#01000000 := 16777216

12 3ADR010397, 1, en_US

2.13 Libraries

PM5xx PM56xx

3S Standard Libs V2.3 3S Standard Libs V3

3S V2.3 Compatible Libs for V3

3S System Libs (SysLibxx.lib) 3S System Libs (SysLibxx_V3.lib)

ABB Libs for CM Modules and

Diagnosis

Basic set of ABB Libs (V2.3 and

PLCopen Style)

Common Naming for FB’s, Inputs,

Outputs, Edge trigger sending)

PLCopen compatible Lib Style

C/C++ Interface C Code Interface (3S) scheduled

for 2019

V2 Libraries V3 Libraries (compatible)

Standard Standard

Standard64

Util Util

SysLibCallback SysCallback23

SysLibCom SysCom23

SysLibEvent SysEvent23

SysLibFile SysFile23

SysLibIECTasks SysIecTasks23

SysLibMem SysMem23

SysLibPlcCtrl SysPlcCtrl23

SysLibProjectInfo SysProjectInfo23

SysLibRtc SysRtc23

SysLibSem SysSem23

SysLibSockets SysSocket23

SysLibStr SysStr23

SysLibTaskls SysTask23

SysLibtime SysTime23

SysTaskInfo SysTaskInfo23

CAA_File CAA File


3ADR010397, 1, en_US 13

V2.3 Libraries V3.1 Libraries

SysInt_AC500_V10 AC500_IO

SysInt_AC500_V10

SysExt_AC500_V10

AC500_Pm

Ethernet_AC500_V10 AC500_Ethernet

Ethernet_AC500_V10 AC500_ModbusTCP

Modbus_AC500_V10 AC500_ModbusRtu

Modbus_Ext_AC500_V20 Not yet available

PROFINET_AC500_V13 AC500_Pnio

PROFINET_Ext_AC500_V20 Not yet available

ETHERCAT_AC500_V10 AC500_EtherCAT

CANopen_AC500_V25 CANbusDevice

CANopen_CME_AC500_V25 CANopenStack

CANopen_CMN_AC500_V25

CMN_AC500_V24

IoDrvJ1939

ASCII_AC500_V10 SerialCom

RTC_AC500_V20 SysTimeRTC

IEC60870_AC500_V20 AC500_Iec60870_5_104

Counter_AC500_V20 Partly in AC500_Io

Diag_AC500_V20

PROFIBUS_AC500 Not yet available

CD522_AC500_V13 Not yet available

DC541_AC500_V11 Not yet available

CS31_AC500_V20 Coming with CM574-RS

Arcnet_AC500 Won’t be supported

FBP Won’t be supported

RCOM_AC500_V13 Won’t be supported

14 3ADR010397, 1, en_US

2.14 Library Manager

PM5xx PM56xx

Part of CODESYS 2.3 Project

Menu View/Library Manager

Optional two Library manager

• Below Application in Device

Tree, one Manager for each PLC

• Optional in POU View in

Automation Builder, if more than

one PLC is in the Project. POU’s

can be used for all PLC’s

In general, it is a big difference in Library Handling between AC500 V2 and AC500 V3:

1. In Automation Builder a Library Repository is there for all Libraries needed for AC500 V3

projects. Library Manager(s) in projects are based on Library Repository. By Creating a

new project Automation Builder moves all necessary (based on Project tree) Libraries to

the Library Manager. Additional Libraries (e.g. Modbus TCP) can be add from Repository.


3ADR010397, 1, en_US 15

2. All Libraries are versioned. In Library Repository can be different versions from a Library.

With Placeholder Dialog and Double Click to Library (Library Column) you are able to

choose the version of the Library within your project.

3. In AC500 V3 (CODESYS V3) Library names have a dedicated Name Space. That mean all

ABB Libraries for AC500 start with “AC500_”.

4. Own Libraries can be created as

a. Implementation Library (*. Library) where the code is transparent

b. Compiled Library (*.compiled-library), Code of POU’s is not visible in the Project

5. Installation of an additional Library must be done via the Library Repository, which is the

Repository for your installation on PC. Library Manager of the Project access then at first

the Repository.

Missing Libraries from 3S can be directly installed from Internet via a Button in

Library Manager.

2.15 Licenses

PM5xx PM56xx

AB 1.x

• AB License

• 3S License (Libraries)

X

X

AB 2.x

• AB License

• Libraries (AB)

• Runtime Licenses

X

X

X

X

X

16 3ADR010397, 1, en_US

2.16 PLC Load / CPU Load

PM5xx PM56xx

PLC Browser plcload

cpuload

PLC Shell plcload

cpuload

PM56xx

Show Load in a Trace

Mouse to PLC Name

Right Mouse Click

Add Object

cpuload plcload

Linux

Nonrealt ime load

Linux

Realt ime loadCODESYS (Prio 0-15)

Realt ime loadCODESYS (Prio 16)

Nonrealt ime load

Sometimes Linux Real Time Load will be

calculated also in the PLCLoad. This

happens if Linux Real Time Task interrupts

a CODESYS Real Time Task depending on a

higher Priority


3ADR010397, 1, en_US 17

Fill in “CPU Load” in Object Name

Double Click to “CPU Load”

Right Mouse Click in View

Choose Upload Trace

Push Upload

18 3ADR010397, 1, en_US

If Trace is not running

• Right Mouse Click in View

• Start Trace

Do the same for PLC Load

2.17 Diagnosis

PM5xx PM56xx

Diagnosis System for 100 Indications

(ring buffer) for CPU, IO-Bus, CS31-Bus

Standard 3S Diagnosis

32 Bit-Value (class, component, device,

module, channel, error)

AC500 V3 Diagnosis System available

from AB 2.2.0 (initial scope: CPU, IO-

Bus)

Visu via State Flag in AB device tree


3ADR010397, 1, en_US 19

FB’s for Access of Field Bus Diag Field Busses provide detailed

Diagnosis in dedicated Filed Bus

Diagnosis View

Online Number for Text Output in CODESYS

State Line, AB Device Tree and Visualization

(e.g. for Access via WebServer)

Logging Entries

2.18 Input- / Output Addresses

PM5xx

AC500.hll AC500 Alignment

IEC-Variable *) Belegung

%IB0 - %IB999 I/O-Bus

%IB1000 - %IB1999 COM1 (CS31-Bus)

%IB2000 - %IB2999 COM2

%IB3000 - %IB3999 FBP-Interface

%IB4000 - %IB4095 Onboard-I/O (AC500-eCo)

%IB0.0 - %IB0.4095 Slot 0 (Interner CM module)

%IB1.0 - %IB1.4095 Slot 1 (Externer CM module1)


%IB3.0 - %IB3.4095 Slot 3 (Externer CM module 3)


All Inputs and Outputs are flat and Byte oriented

CM Modules: Inputs and Outputs with Slot Offset as Prefix

PM56xx

One flat Address Range for

• IO-Bus

• Onboard CAN

• COM1

• CM Module

Will be filled without Gaps

20 3ADR010397, 1, en_US

2.19 Addressable Variables

PM5xx

• %M- and %R- Area (each max. 512k)

• Max 8 Segments with 64kB

Linie IEC - Variable

0 %MB0.0 .. %MB0.65535 %RB0.0 .. %RB0.65535

1 %MB1.0 .. %MB1.65535 %RB0.0 .. %RB0.65535

.. .. ..

6 %MB6.0 .. %MB6.65535 %RB0.0 .. %RB0.65535

7 %MB7.0 .. %MB7.65535 %RB0.0 .. %RB0.65535

• Bits are Byte oriented


BOOL %MX0.0.

0 .. 7

%MX0.1.

0 .. 7

%MX0.2.

0 .. 7

%MX0.3.

0 .. 7

BYTE %MB0.0 %MB0.1 %MB0.2 %MB0.3

WORD %MW0.0 %MW0.1

DWORD %MD0.0

PM56xx

• %M, one common Area (128kB)

o %MB0…%MB131071

• Bits are Byte oriented

• Persistent Option: %M without init (pragma: no init)?

• No %R Area, only VAR GLOBAL PERSISTENT RETAIN

• All have to be declared in one Global Variable List


3ADR010397, 1, en_US 21

2.20 Vizualization

Master Layout

• Master layout function is not available in PM56xx Visualization.

• Master layout function in PM5xx Visualization is converted into “Frame” widget in

PM56xx Visualization.

Date and Time Display

• In PM5xx Visualization, date and time display with the syntax below.

%t%a %b %d.%m.%y %H:%M:%S

> Display in online mode: Wed Aug 28.08.02 16:32:45

• In PM56xx Visualization, date and time display with the syntax below.

%t[dddd yyyy-MM-dd HH:mm:ss]

> Display in online mode: Wednesday 2002.08.28 16:32:45

Bitmap Widget

• Bitmap widget in PM5xx Visualization is converted into “Image” widget in PM56xx,

but without the image.

• User need to create the “Image Pool” object and add the image to it. After that, user

need to add the link to the image widget.

Alarm Table Widget

• The alarm widget “Show statusline” in PM5xx Visualization is not available in the in

PM56xx. User need to create the relevant widget and link them to the Alarm widget

“Control variables”.

22 3ADR010397, 1, en_US

Histogram Widget

• After convert the Histogram widget from PM5xx Visualization to PM56xx

Visualization, user required to adjust the widget properties in-order to display

widget properly.

Trend Widget

• Trend Widget in PM5xx Visualization are not converted into PM56xx Visualization.

• User need to add the Trend widget manually in the PM56xx Visualization. After that,

the “TrendRecordingTask” and “Trend Recording Manager” will be created

automatically.

Placeholder

• Any string enclosed in two dollar signs ($) is a valid placeholder (e.g. $variable1$,

variable$x$) in PM5xx Visualization.


3ADR010397, 1, en_US 23

• In PM56xx Visualization, the placeholder variables are created in the “Interface Editor”

as variables.

• When insert the frame, the placeholder is configured in the “References”.

24 3ADR010397, 1, en_US

3 Analyze Application Action Can be

used

without

change

Conversion

with AB

Conversion

manually

Symbolic programming for IO

variables

X

Standard ST code without

calling FB’s

X

V2 specific Library Look for a V3

Lib

Check/Change

call of FB’s

X

Customer specific Library Check Code

Check/Change

call of FB’s

X

Variables with %M Addresses Change

Addresses

X

Variables with %R Addresses Move to VAR

GLOBAL

PERSISTENT

RETAIN

X

IO’s to Modbus Move to new

Address Range

X

Replace/Remove Hardware

which is not supported from

actual V3 Platform

• CM592/CM582

• CM598/CM588

• CS31

• CD522

• DC541

• CM574

• etc.

Remove

hardware from

Tree

Check if HW

from V3 can be

used, e.g.

Replace

PROFIBUS by

PROFINET

X


3ADR010397, 1, en_US 25

4 Convert Application

4.1 Update Project or new Project

Update Project can be done by “Change PM” (see chapter 4.2)

• Target PLC will be Changed

• Standard IEC Code will be transferred

• Depending on the Project, a lot of Error messages could appear

o V2.3 Libraries (Compatible Libraries will be automatically replaced)

o Call of FB’s which are no more available

o Wrong Variables at Inputs of FB’s

o Wrong %M Addresses

o Declared Variables wit %R Addresses

• It could come to some 100 Errors

Alternatively, it could be easier to create a new V3 project and take over Standard ST Code

with Copy and Paste

4.2 Convert Project with Automation Builder

• Open Automation Builder with V2 Project

• Double Click to PLC Name

• Choose PM5xx-ETH Hardware

• Select Checkbox “Change to AC500 V3 PLC“

• Push Button right to PM5xx Type

• Choose the V3 PLC e.g. PM5650

26 3ADR010397, 1, en_US

• Push Create V3 PLC

• Push Yes

• New PLC will be created, the old V2 PLC still remain.

• First steps to do

o Delete AlarmConfiguration and AlarmManager Task

o Delete Recipe Manager

o Delete CODESYS V2 Libries

o Delete “Task”, new Task remain

o Delete Global Variables

o Remaining errors could have the following reasons


3ADR010397, 1, en_US 27

▪ Customer specific Libs

▪ Call of Wrong FB’s

▪ Wrong %M Address

▪ Use of %R Addresses

▪ etc.

4.3 Adapt AC500 Libraries

Look for FB’s in Program Code from old Libraries (Standard Libraries)

• Check if new similar FB’s are available

• Replace FB

• Adapt FB call

• Delete old (V2) Libraries

4.4 Error Handling Customer Specific Libraries

Check if Code can be used in V3 Environment

Check if FB’s from other Libraries are called

• Check if new similar FB’s are available

• Replace FB

• Adapt FB call

• Create new Customer specific Library

• Delete old Libraries

28 3ADR010397, 1, en_US

4.5 Adapt %M Addresses

Check for addressed Variables in Global Variable Lists and in POU’s.

• Change Addresses

o %MW0.100 -> MW100

o %MW1.0 -> MW32768

4.6 Adapt %R Addresses

Check for addressed Variables in Global Variable Lists and in POU’s.

In AC500 V3 add Persistent Variables below Application


3ADR010397, 1, en_US 29

Add Variable’s to List

__

__

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69123 Heidelberg, Germany

Phone: +49 62 21 701 1444

Fax: +49 62 21 701 1382

E-Mail: [email protected]

www.abb.com/plc

We reserve the right to make technical

changes or modify the contents of this

document without prior notice. With

regard to purchase orders, the agreed

particulars shall prevail. ABB AG does not

accept any responsibility whatsoever for

potential errors or possible lack of

information in this document.

We reserve all rights in this document and

in the subject matter and illustrations

contained therein. Any reproduction,

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AC500 CONVERTING AN AC500 V2 PROJECT TO AN AC500 V3 … · AC500 CONVERTING AN AC500 V2 PROJECT TO...

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