IRC5 + DeviceNet AC500 + FBP-DN as slave Application Example AC500 & IRC5 Fieldbus Connection IRC5 ...

abb

Application Example AC500 & IRC5

Fieldbus ConnectionIRC5 <-> AC500 PLC

IRC5 with DNLean as masterconnected to AC500-FBP-DNas DeviceNet slave

IRC5 +DeviceNet

<->AC500

+ FBP-DNas slave

abb ABB Automation Products GmbH 1 Application Example 23.06.2014

Contents

Contents ............................................................................................................................. 1

1 Disclaimer .................................................................................................................. 2

1.1 For customers domiciled outside Germany/Für Kunden mit Sitz außerhalb Deutschlands ........................................................................ 2

1.2 Nur für Kunden mit Sitz in Deutschland ........................................................................ 2

2 Overview of this manual ........................................................................................... 3

3 Workflow overview .................................................................................................... 4

4 Hardware setup ......................................................................................................... 5

4.1 IRC5 with DeviceNet coupler .......................................................................................... 5

4.2 AC500 PLC as DeviceNet slave with FBP-DN ................................................................ 5

4.2.1 Needed Products ....................................................................................................... 5

4.2.2 AC500 components documentation ........................................................................... 6

5 Configuration of AC500 with Automation Builder (Control Builder Plus) ............ 7

5.1 AC500 configuration ....................................................................................................... 7

5.1.1 Configuration of DeviceNet slave ............................................................................... 7

5.1.2 Download configuration and program into AC500 .................................................... 10

6 IRC5 IO configuration according the EDS file ....................................................... 11

6.1 Bus configuration .......................................................................................................... 11

6.2 EIO_UNIT_TYPE ............................................................................................................ 11

6.3 EIO_UNIT........................................................................................................................ 11

5.4 EIO_SIGNAL .................................................................................................................. 12

5.4.1 General calculation of IO mapping ........................................................................... 12

6.5 Warmstart of the IRC5 controller.................................................................................. 12

7 Compatibility Hints .................................................................................................. 13

8 Related documents ................................................................................................. 14


1 Disclaimer

1.1 For customers domiciled outside Germany/Für Kunden mit Sitz außerhalb Deutschlands

"Warranty, Liability:The user shall be solely responsible for the use of this application example described within this file.ABB shall be under no warranty whatsoever. ABB's liability in connection with this application example or thefiles included within this file, irrespective of the legal ground, shall be excluded. The exclusion of liability shallnot apply in the case of intention or gross negligence. The present declaration shall be governed by andconstrued in accordance with the laws of Switzerland under exclusion of its conflict of laws rules and of theVienna Convention on the International Sale of Goods (CISG).""Gewährleistung und Haftung:Der Nutzer ist allein für die Verwendung des in dieser Datei beschriebenen Anwendungsbeispielsverantwortlich.ABB unterliegt keiner Gewährleistung. Die Haftung von ABB im Zusammenhang mit diesemAnwendungsbeispiel oder den in dieser Datei enthaltenen Dateien - gleich aus welchem Rechtsgrund - istausgeschlossen. Dieser Ausschluß gilt nicht im Falle von Vorsatz oder grober Fahrlässigkeit. DieseErklärung unterliegt Schweizer Recht unter Ausschluß der Verweisungsnormen und des UN-Kaufrechts(CISG)."

1.2 Nur für Kunden mit Sitz in Deutschland"Gewährleistung und Haftung:Die in diesem Anwendungsbeispiel enthaltenen Dateien beschreiben eine mögliche Anwendung derSteuerung AC500 bzw. zeigen eine mögliche Einsatzart der Steuerung. Sie stellen nur Beispiele fürProgrammierungen dar, sind aber keine fertigen Lösungen. Eine Gewähr kann nicht übernommen werden.Der Nutzer ist für die ordnungsgemäße, insbesondere vollständige und fehlerfreie Programmierung derSteuerungen selbst verantwortlich. Im Falle der teilweisen oder ganzen Übernahme derProgrammierbeispiele können gegen ABB keine Ansprüche geltend gemacht werden.Die Haftung von ABB, gleich aus welchem Rechtsgrund, im Zusammenhang mit den Anwendungsbeispielenoder den in dieser Datei enthaltenen Dateien wird ausgeschlossen. Der Haftungsausschluß gilt jedoch nichtin Fällen des Vorsatzes, der groben Fahrlässigkeit, bei Ansprüchen nach dem Produkthaftungsgesetz, imFalle der Verletzung des Lebens, des Körpers oder der Gesundheit oder bei schuldhafter Verletzung einerwesentlichen Vertragspflicht. Im Falle der Verletzung einer wesentlichen Vertragspflicht ist die Haftungjedoch auf den vertragstypischen, vorhersehbaren Schaden begrenzt, soweit nicht zugleich ein anderer derin Satz 2 dieses Unterabsatzes erwähnten Fälle gegeben ist. Eine Änderung der Beweislast zum Nachteildes Nutzers ist hiermit nicht verbunden.Es gilt materielles deutsches Recht unter Ausschluß des UN-Kaufrechts."

Only for customers with seat in Germany"Warranties and Liability:

The files contained in this application sample are only describing a possible use of the AC 500 controlsystem showing a possible kind of operation of it. These are only examples of the programming features andin no way working solutions. No warranty can be accepted.Each user himself is exclusively responsible for the correct, i.e. complete and faultless programming of thecontrol system. In case of a partial or complete adoption of programming samples no resulting claims may beasserted against ABB.In connection with the application examples or the files contained therein any liability of ABB regardless ofthe legal cause shall be excluded. The exclusion of liability does not apply in the case of willful misconduct orgross negligence by ABB, claims under product liability law, in case of damage to life, body or health orbreach of an essential contractual obligation. In case of breach of an essential contractual obligation theliability will, however, be limited to compensation for the foreseeable damage, that is typical for this type ofcontract in as far as no other exceptions are listed under sentence 2 of this subparagraph is present at thesame time. An amendment of the burden of proof to the disadvantage of the user shall not be associatedwith this.German substantive law shall apply excluding the UN Convention on the International Sale of Goods."


2 Overview of this manual

About this manual

This application manual describes the preconditions, tools and configuration steps to connect anAC500 PLC to an IRC5 DeviceNet or DeviceNetLean master.

The AC500 PLC will be connected to the IRC5 via a DeviceNet FieldBusPlug (FBP) as slave.

Usage

This application manual should be used during design of an IRC5 system with attached AC500 PLC toDeviceNet / DeviceNetLean as well as during configuration and commissioning of the IRC5 EIOconfiguration.

This manual is should also be used for configuration of the AC500 PLC as DeviceNet slave.

The programming of the AC500 PLC is not described in this manual.

Who should read this manual?

This manual is intended for:

· Personnel that are responsible for installations and configurations of fieldbus hardware/softwareof IRC5 system

· Personnel that make the configurations of the IRC5 I/O system

· Personnel that make the configuration and programming of the AC500 systems

· System integrators

Prerequisites

The reader should have the required knowledge of:

· Mechanical installation work

· Electrical installation work

· System and fieldbus parameter configuration of IRC5 systems

· Fieldbus configuration of AC500 systems.


3 Workflow overview

The following chapter gives a short overview of the steps that have to be performed to setup andcommission the connection from IRC5 DeviceNet / DeviceNetLean master to an S500 IO cluster andwhere to find the detailed information in this manual.

1. Hardware configuration and installation:

- IRC5 with DeviceNet / DeviceNetLean master option (chap4.1, page 5)

- AC500 + FieldbusPlug DeviceNet (FBP-DN) (chap 4.2, page.5)

2. Configuration of AC500 as DeviceNet slave with Control Builder Plus

- Create new AC500 project (chap. 5.1, page 7)

- Add DeviceNet slave and IO signal mapping (chap 5.1.1, page 7)

- Download program and configuration to AC500 (chap 5.1.2, page 10)

3. Create IRC5 EIO_UNIT_TYPE for AC500 (chap. 6.2, page 11)

4. Create EIO_UNIT for AC500 (chap. 6.3, page 11)

5. Create IO Signal mapping (chap 6.4.1, page 12)

6. Warmstart the IRC5 controller (twice) (chap. 6.5, page 12)


4 Hardware setup

4.1 IRC5 with DeviceNet couplerThe DeviceNet coupler are part of the ordered IRC5 controller. See related documents.

4.2 AC500 PLC as DeviceNet slave with FBP-DN

4.2.1 Needed Products

Product Description Order code Version / Remark

PM5xx AC500 CPU(higher than PM56x)

e.g PM573-ETHe.g.

Firmware Ver. 3.xIndex on Lable: C0or higher

TB511,TB521,TB541

Terminal base for AC500-FBPwith 1, 2 or 4 slots for fieldbuscouplers

1SAP111100R02701SAP112100R02701SAP114100R0270

Choose neededterminal type

DNP21 FBP.025

DNP21 FBP.050

DNP21 FBP.100

DNP21-FBP.500

FBP to connect the DC505-FBP

DeviceNet-FBP cable 0,25 m




1SAJ230000R0003

1SAJ230000R0005

1SAJ230000R0010

1SAJ230000R0050

Choose needed cabellength

DNR11-FBP.120

Termination Resistor for last FBP

DNR11-FBP.120 1SAJ923007R0001

Needed if FBP is lastdevice on the bus.

DNF11-FBP.050

FBP-Cabel with one open end toconnect to a plug for the IRC5DeviceNet connector

1SAJ923002R0001 Connection from FBP toDeviceNet coupler(IRC5)

Optional:S500-IO moduls with Terminalunits that can be connected toAC500 IO-Bus directly

Please check S500product range


4.2.2 AC500 components documentationThe documentation of the AC500 PLC and S500 IO modules is part of the AC500 PLC documentation ofthe PS501 Automation Builder (Control Builder Plus)

It can be accessed via the “Help” menu button in CoDeSys or Control Builder Plus.

It also could be downloaded and installed separately as described here:

4.2.2.1 Download the PS501 Online HelpTry this Link or follow the next steps:

è Goto www.abb.com/PLC

è Select English as language and doubleclick onDownloads \ Programmable Logic Controllers PLCs

è Search for “Online Help”

è Select the AC500 control Builder Plus PS501 Documentation and download this3ADR025078M0203.ZIP file.

è Unzip the file to a local folder on your Windows PC

notice

è The AC500 Online Help can only be used on Windows PCs and must be storedto a local folder.

è Doubleclick the file CAA-Merger-2.chm. The Online Help Chapter for AC500 / S500 Hardware willopen.

è In the chapter Hardware AC500 the documentation of AC500 and IO-Moduls can be found.

4.2.2.2 Example description of CPUs PM57x, PM58x and PM59x


5 Configuration of AC500 with Automation Builder(Control Builder Plus)

5.1 AC500 configurationOpen Automation Builder / Control Builder Plus (CBP)

Create new AC500 project and select the appropriate CPU type, e.g. PM583-ETH

5.1.1 Configuration of DeviceNet slave

5.1.1.1 Add DeviceNet FBPRight click on Interfaces \ FBP_Online_Access node,select “Plug Device…” and choose “FBP-Slave (DeviceNet)”


5.1.1.2 Configure DeviceNet SlaveDouble click on the new node FBP_Slave_DNP21 and adapt the address if needed.

5.1.1.3 Add Data IO DevicesRight click on the changed node FBP_Slave_DNP21select “Add Device…” and choose the needed Devices according to the needed amount of data transfer.Several devices can be added.

5.1.1.4 Check configurationCheck the amount of possible and actual configured IOs under FBP_Slave_DNP21 in the „Checkconfiguration“ tab.


5.1.1.5 Mapping of variables

Double click on the data elementsGive variable symbolic names in the “Variable” column (space bar can be used to enter the fields)

Same procedure for the Output signals

TIP

Signals can be named for the whole byte as well as for single bits at the sametime.

In CoDeSys the variables can be found under Resources in the according global variable list.


5.1.2 Download configuration and program into AC500To download the configuration a normal program download to AC500 has to be made.

· Check IP-Address of AC500 with IP-Config Tool in Control Builder Plus

· Open CoDeSys 2.3 Program by double click on the AC500 symbol in Control Builder Plus.

· Create Communication parameters in CoDeSys via Online \ Communication parameters..

· Download Program

· Create Boot project

· Start Program


6 IRC5 IO configuration according the EDS file

6.1 Bus configurationThe needed bus definition (DeviceNet or DeviceNetLean) is supplied by the robot system within thebasic installation. It must be ordered as option with the robot.

6.2 EIO_UNIT_TYPEAs the AC500 PLC Slave does not need to be set up with EIO_COMMANDS it is not necessary todefine an own EIO_UNIT_TYPE.A predefinied EIO_UNIT_TYPE for AC500 FBP slaves is already definied as “AC500_PLC” and canbe used to create own EIO_UNIT_TYPES for AC500 PLCs by adding the found values from the busscan.

Example

#EIO_UNIT_TYPE:

-Name "AC500_PLC"-BusType "DNET"-VendorName "ABB" (text)-ProductName "AC500 PLC - FPB" (text)-DN_VendorId 760-DN_ProductCode 16002 (see scan)-DN_DeviceType 12 (see scan after second warmstart or AC500 config)-DN_ExplicitMsgEnabled-DN_C1Type "COS" (change of state - optional)-DN_C1OutputSize 48 (see scan or AC500 configuration)-DN_C1InputSize 48 (see scan or AC500 configuration)

The DN_C1OutputSize and DN_C1InputSize must be identical to the number of added Bytes in theControl Builder Plus configuration for the AC500 PLC.See chapter 5.1.1.4 Check configurationCheck configuration for actual length.

6.3 EIO_UNITDefine an EIO_UNIT of AC500_PLC EIO_UNIT_TYPE

#EIO_UNIT:

-Name "AC500"-UnitType " AC500_PLC "-Bus "DeviceNet1"-DN_Address 20

Alternatively a scan of the Devicenet bus can be performed. Therefore the parameter “Automaticconfiguration” of the DeviceNet1 bus must be set to any of the following options:

· Group and Bit Signals: defines group signals covering bytes and single bit signals· Group Signals: defines only group signals for the in- and output bytes.· Single Bit Signals: defines only single bit signals for all channels / bits· Without Signals: only messages showing the unit parameters will be generated.


6.4 EIO_SIGNALDefine Signals or groups according to the EIO_UNIT on the unit.Either by DeviceNet bus scan (see chapter 6.3 EIO_UNIT) or manually.

Example:#EIO_SIGNAL:

-Name "doIRBinHome" -SignalType "DO" -Unit " AC500"\-SignalLabel "Roboter in Grundstellung" -UnitMap "0" -Access "ReadOnly"

-Name "doMotorOn" -SignalType "DO" -Unit " AC500"\-SignalLabel "Roboter Motoren sind Ein" -UnitMap "1"

-Name "doPrgRunning" -SignalType "DO" -Unit " AC500"\-SignalLabel "Roboter Programm läuft" -UnitMap "2"

6.4.1 General calculation of IO mappingTo calculate the unit mapping of one signal in the IRC5 following rule has to be used:

Unit mapping = (Byte number – offset) x 8 + Bit number

The offset of the IO mapping can be seen in the Control Builder Plus in the column “Address” of theIO-Device and is given as the first address in PLC.

Example: IRB_PrgStartCmd in IRC5 has the following mapping:

In AC500 In IRC5

3000.5 (3000 – 3000) x 8 + 5 = 5

6.5 Warmstart of the IRC5 controllerTo activate the configured changes the IRC5 controller has to be restarted.

At least once after changing parameters manually.

Twice if automatic bus scan is used. Because the first restart will scan the bus. The second warmstart willactivate the found units.


7 Compatibility Hints

The functionality described in this application manual was originally tested with the following componentsand software versions:

Component Hardware Firmware Remark

IRC5 Controller RW 5.60.00

DeviceNet adapter RW5.60DSQC1006

3HAC043383-001 / 0

DN21-FBP Index D1

PM583-ETH Firmware V2.3.3


8 Related documents

Titel Doc ID Revision

Technical Reference manualSystem parameters IRC5

Document ID: 3HAC17076-1 Revision: R (RW 5.15)Revision: S (RW 5.60)

Application manualDeviceNet

Document ID: 3HAC020676-001 Revision: P (RW 5.15)

Application manualDeviceNet Lean

Document ID: 3HAC034095-001 Revision: F (RW 5.15)

Application manualDeviceNet

Document ID: 3HAC0047125-001 Revision: - (RW 5.60)

AC500 Online Help Online in Control Builder Plus /CoDeSys 2.3Document ID 3ADR025078M0203

V2.3.0,Issue Date 2013-04-30

abb

ABB Automation Products GmbHWallstadter Str. 59D-68526 LadenburgTel. : +49 62 21 / 701-1444Fax : +49 62 21 / 701-1382E-Mail : [email protected]

www.abb.com/plc

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Application Note / Manual 16

Title: Lang.:

IRC5 <-> AC500 PLC as DN slave English

Doc. No

3ADR025199M0201

HISTORYHistoryIndex

Page (P)Chapter (C)

Description DateDept./Initials

A First release May 2014DEAPR/ACM2

IRC5 + DeviceNet AC500 + FBP-DN as slave Application Example AC500 & IRC5 Fieldbus Connection IRC5 ...

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