Profinet Master - Slave 3HAC031975 001 - Rev - en PDF

Application manual
PROFINET master/slave
Controller software IRC5

RobotWare 5.0
Application manual
PROFINET master/slave
RobotWare 5.0
Document ID: 3HAC031975-001

Revision: -
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Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Introduction to PROFINET 11
1.1 PROFINET, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 PROFINET, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Definition of I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Hardware description 17
2.1 PROFINET master/slave, DSQC 678 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Connections, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 PROFINET-IO Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 PROFINET Master/Slave configuration 25

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.1 Software overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Configuration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 PROFINET master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 IRC5 internal PROFINET slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Workflows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Configuring PROFINET master. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Configuring IRC5 internal PROFINET slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 Configuring PROFINET-IO Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.1 Configuring digital I/O, example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.2 Configuring IRC5 internal PROFINET slave, example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.3 Configuring PROFINET-IO Routing, example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4 System parameters 53
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2.1 Profinet Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3 Unit Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.1 Input Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.2 Output Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 Trouble shooting 57
5.1 Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Index 59
3HAC031975-001 Revision: - 3
Table of Contents
4 3HAC031975-001 Revision: -
Overview
Overview
About this manual

This manual describes the PROFINET master/slave option and contains instructions how to
configure the PROFINET master/slave in an IRC5 system.
Usage
This manual should be used during installation and configuration of the PROFINET fieldbus.
Who should read this manual?

This manual is intended for:
• Personnel that are responsible for installations and configurations of fieldbus
hardware/software.
• Personnel that make the configurations of the I/O system.
• System integrators.
Prerequisites
The reader should have the required knowledge of
• the PROFINET system
• I/O system configuration
• IRC5 Controller
• Robot Studio
References
Reference Document Id
Technical reference manual - System parameters 3HAC17076-1
Product manual - IRC5 3HAC021313-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - RobotStudio 3HAC032104-001
Other references
Reference Description
International standard IEC 61158 Type 3 The PROFINET fieldbus standard is
International standard IEC 61784 described in the international standards.
PROFINET Cabling and Interconnection Installation Guideline for PROFINET (Version
Technology 2.00, September 1998)
Commissioning PC Stations - Manual and Release 12/2006 C79000-G8976-C156-08
Quick Start
ET200S Distributed I/O System Manual from Siemens
www.profinet.com The web site of PROFINET International
Operating instructions CP1616 Manual from Siemens
Continues on next page

3HAC031975-001 Revision: - 5
Overview
Continued
Revisions
Revision Description
- First edition. RobotWare 5.11
6 3HAC031975-001 Revision: -
Product documentation, M2004
General
The robot documentation is divided into a number of categories. This listing is based on the
type of information contained within the documents, regardless of whether the products are
standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals
All hardware, robots and controllers, will be delivered with a Product manual that contains:
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Technical reference manuals

The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
• System parameters: Description of system parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software)
• How to use the application
• Examples of how to use the application

3HAC031975-001 Revision: - 7
Continued
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
• Emergency safety information
• General safety information
• Getting started, IRC5
• IRC5 with FlexPendant
• RobotStudio
• Introduction to RAPID
• Trouble shooting, for the controller and robot
8 3HAC031975-001 Revision: -
Safety
Safety
Safety of personnel
When working inside the robot controller it is necessary to be aware of voltage-related risks.
A danger of high voltage is associated with the following parts:
• Units inside the controller, for example I/O units can be supplied with power from an
external source.
• The mains supply/mains switch.
• The power unit.
• The power supply unit for the computer system (230 VAC).
• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!
• The drive unit (700 VDC).
• The service outlets (115/230 VAC).
• The power supply unit for tools, or special power supply units for the machining
process.
• The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
• Additional connections.
Therefore, it is important that all safety regulations are followed when doing mechanical and
electrical installation work.
Safety regulations
Before beginning mechanical and/or electrical installations, make sure you are familiar with
the safety regulations described in Product manual - IRC5.
3HAC031975-001 Revision: - 9
10
Safety
3HAC031975-001 Revision: -
1 Introduction to PROFINET
1.1. PROFINET, general
1.1. PROFINET, general
What is PROFINET?
PROFINET is an open standard for Industrial Ethernet. PROFINET satisfies requirements for
automation technology. PROFINET solutions can be implemented for factory and process
automation, for safety applications, and for the entire range of drive technology right up to
clock-synchronized motion control.
PROFINET standardization
The use of open standards, simple operation, and the integration of existing system segments
have driven the definition of PROFINET from the beginning. PROFINET is standardized in
IEC 61158 and IEC 61784. The continual further development of PROFINET offers users a
long-term perspective for the implementation of their automation tasks.
PROFINET versions
PROFINET has a modular design and different PROFINET versions are all combinations 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 of
PROFIBUS is retained, in which the user data from the field devices are periodically
transmitted into the process model of the control system.
• PROFINET-CBA - Based on the object-oriented modelling of technological modules.
Based on the object model, machines and installations are structured in PROFINET in
the form of technological modules.
• PROFIsafe - Defines how safety-oriented devices (emergency shutoff switches, light
grids, overfill protection systems, etc.) can communicate safety control information
over a network securely enough that they can be used in safety-oriented automation
tasks up to EN954's KAT4, AK6, or SIL3 (Safety Integrity Level).
• PROFIdrive - The PROFIdrive profile covers application scenarios from simple

frequency converters to highly dynamic servo drivers.
3HAC031975-001 Revision: - 11
1.2. PROFINET, IRC5
1.2. PROFINET, IRC5
Hardware overview
The hardware of the PROFINET fieldbus consists of a master/slave board, DSQC 678, and
distributed I/O units.
DSQC 678
The DSQC 678 is connected to the PCI bus of the IRC5 robot controller. The I/O units are
attached to the fieldbus network. The DSQC 678 supports PROFINET Version 2.0. The slave
part of the master/slave unit is normally controlled by an external master on the same physical
PROFINET network. 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 be powered by
external power supply. This allows the switch to be used even if the IRC5 controller is
powered down, see Operating instructions CP1616 for details.
I/O units
The I/O units can have digital and/or analog signals. They are all controlled via the master
part of the DSQC 678.
Main computer
The DSQC 678 requires main computer DSQC 639.
NOTE!
If the IRC5 controller is powered down, the switch will not work without external power
supply.
PROFINET version compatibility

DSQC 678 supports the PROFINET version PROFINET-IO (see PROFINET versions on
page 11).

12 3HAC031975-001 Revision: -
1.2. PROFINET, IRC5
Continued
PROFINET network
The illustration below is an example of a PROFINET network.
xx0800000131
A Line PLC, PROFINET-master

B IRC5 controller
C I/O unit
D DSQC 678
E Ethernet switch
Configuration program
An external PROFINET configuration tool such as Step7 or NMPC from Siemens, together
with RobotStudio is needed for configuration of the DSQC 678. The external PROFINET
configuration tool should be used according to the manual for the program.
Specification overview, Master

Item Specification
GSDML ID 6GK1 161-6AA00
PROFINET Version V2.1(PROFINET specification 2.0)

3HAC031975-001 Revision: - 13
1.2. PROFINET, IRC5
Continued
Item Specification
Number of I/O units connected to master Maximum 30 I/O units
Number of I/O signals Maximum 8192 I/O signals
Specification overview, Slave

Item Specification
GSDML ID 6GK1 161-6AA00
PROFINET Version V2.1 Migration.
Slot configuration (default) Slot 1: 64 bytes digital input module
Slot 2: 64 bytes digital output module
PROFINET-IO Routing Supported
Number of I/O signals 512 digital in
512 digital out
Expressions
Expressions Specification
DSQC 678 Siemens CP1616 PCI-card
master PROFINET controller
slave, I/O unit PROFINET device
external PROFINET configuration tool Siemens Step7
14 3HAC031975-001 Revision: -
1.3. Definition of I/O units
General
It is possible to connect any type of PROFINET-IO compliant I/O unit on the PROFINET
master bus. All I/O units should comply with the PROFINET standard and be conformance
tested by PROFINET international. I/O units may be mounted inside the controller. There are
no PROFINET compliant I/O units installed in a standard version controller.
Further information
The table gives references to additional information:
Information See
Allowed configurations of I/O units and how Technical reference manual - System
to setup the configurations. parameters.
3HAC031975-001 Revision: - 15
16 3HAC031975-001 Revision: -
2 Hardware description
2.1. PROFINET master/slave, DSQC 678
Description
The DSQC 678 is a circuit board mounted in the computer module. The PROFINET board
has both master and slave functionality. The master functionality is used to communicate with
I/O units and the slave functionality is used to communicate with the IRC5 controller from a
master, e.g PLC.
Prerequisites
RobotWare 5.11 or later version, and the PROFINET option are required to run the
PROFINET master/slave board.

3HAC031975-001 Revision: - 17
Continued
Installation of DSQC 678

For installation instructions for PROFINET, see the PROFINET specification, IEC 61158
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.
xx0800000208
A-D Possible slot for DSQC 678

18 3HAC031975-001 Revision: -
Continued
Illustration
The figure below shows the DSQC 678 board.
xx0800000132
A LED, SF (collective error), red

B LED, BF (bus error), red
C External power connections

D Link LED, green
E Activity LED, yellow
F Port 1-4, RJ-45 connectors
Technical data
LED Meaning State Remarks

B (red) Bus error (BF) Off Communications connection established.
On Link status error occurred.
Flashing I/O Device cannot be addressed or duplicate
slowly IP address on the network.
A (red) Collective error Off No error occurred or loading is in progress.
(SF) On Diagnostic information is available.

3HAC031975-001 Revision: - 19
Continued
LED Meaning State Remarks

A and B Bus error (BF) Flashing Flash test for visual identifying of boards.
Collective error slowly.
(SF) Flashing Exception error occurred.
quickly
E (yellow) Activity LED On Send and Receive.
D (green) Link LED On Connection exists.
Description article number
Description Article number

PROFINET master/slave, DSQC 678 3HAC030327-001
Connections, RJ-45 connectors

The DSQC 678 board has four standard Ethernet RJ-45 connectors. Each connector is a port
to a built in switch on the DSQC 678 board.
Cables and connectors

Cables used to connect the PROFINET network must comply with Cat 5 balanced LAN
requirements or better according to ISO/IEC 11801. For details see PROFINET Cabling and
Interconnection Technology available from www.profinet.com.
20 3HAC031975-001 Revision: -
2.2. Connections, general
2.2. Connections, general
General
All I/O units are connected to Industrial Ethernet switches in a tree structure. Some I/O units
have built-in Ethernet switches allowing I/O units to be connected in a cascade structure.
xx0800000133
A Switch
B I/O unit
3HAC031975-001 Revision: - 21
2.3. PROFINET-IO Routing
General
The DSQC 678 has a built in functionality called PROFINET-IO Routing. This functionality
makes it possible for a PLC that is connected to the internal slave of the DSQC 678 to read
and write I/O signals on I/O units that operates as slaves under the DSQC 678 master.
NOTE!
In the IRC5 I/O configuration it is still possible to configure digital output signals on signal
bits controlled by the PLC. These output signals will not affect the digital outputs on the I/O
unit, but can still be used to monitor the actual value of the digital outputs on that I/O unit. It
is recommended to name these kind of output signals to reflect the fact that they are controlled
by the PLC, or configure a proper access level on the signals to prevent the RAPID program
to write to these kind of signals. For more information see Technical reference manual -
System parameters.
Example
The figure below shows a setup where the IRC5 Controller is connected to a PLC as a slave
and an I/O unit as a master.
xx0800000137
A PLC
B DSQC 678
22 3HAC031975-001 Revision: -
Continued
C IRC5 controller
D I/O units
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.
3HAC031975-001 Revision: - 23
24 3HAC031975-001 Revision: -
3 PROFINET Master/Slave configuration
3.1.1. Software overview

3.1 Introduction
3.1.1. Software overview
Controller software
The IRC5 controller must be installed with software that supports the PROFINET master/
slave option (that is, RobotWare 5.11 or later).
NOTE!
The option for PROFINET must be installed on the IRC5 controller.
PC software
The PROFINET communication is configured manually using RobotStudio or FlexPendant.
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 NMPC from Siemens, is needed
to configure the DSQC 678. Refer to the respective manual for the external PROFINET
configuration tools.
3HAC031975-001 Revision: - 25
3.2.1. PROFINET master
3.2 Configuration overview
3.2.1. PROFINET master
Configuration
To correctly configure the PROFINET network in the IRC5 controller, a configuration needs
to be downloaded to the DSQC 678 using an external PROFINET configuration tool.
The maximum number of I/O units that can be defined in an IRC5 controller with
PROFINET option is described in the section PROFINET, IRC5 on page 12.
Counted I/O units are:
• 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 I/O bus

When the system is installed with the PROFINET option, a predefined I/O bus Profinet1 is
created.
Predefined I/O unit type

When the system is installed with the PROFINET option, a predefined unit type
PN_GENERIC is created. This I/O unit type is used for all I/O units except the IRC5 internal
PROFINET slave.
GSDML files
In order to configure a PROFINET network with an external PROFINET configuration tool,
GSDML files need to be imported into the tool. These files contains vital information about
the PROFINET I/O units and they shall be supplied by the vendor/manufacturer of the
specific PROFINET module.
26 3HAC031975-001 Revision: -
3.2.2. IRC5 internal PROFINET slave
Configuration
The DSQC 678 unit has an internal slave with 512 digital input signals and 512 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 act as a master.
Predefined I/O unit type

When the system is installed with the PROFINET option, a predefined unit type
PN_INTERNAL_SLAVE is available. This unit type is used to define the internal slave in the
IRC5 controller, which will enable a PLC to connect to the IRC5 controller. There can only
be one I/O unit with this unit type defined in the IRC5 controller.
GSDML-files
A GSDML-file for DSQC 678 is located on the RobotWare release DVD:
• Utility\Fieldbus\Profinet\GSDML\GSDML-V2.0-Siemens-CP16xx-2007\0524.xml
Input and output size

The unit type PN_INTERNAL_SLAVE has two unit type parameters, Input Size and Output
Size. Input Size is used to configure the input size of the IRC5 internal PROFINET slave and
Output Size configures the output size. A connecting PLC needs to have a slot configuration
created in the external PROFINET configuration tool that matches the configuration of the
IRC5 internal PROFINET slave.
The available module sizes of the DSQC 678 are 1 byte (not used), 4 byte, 16 byte, 20 byte
and 64 byte. The IRC5 internal PROFINET slave uses max 2 input and 2 output slots to
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 and 64 (other values will
be rounded up to one of these values). The value 8 will result in two slots with 4 bytes each.
The value 32 will result in two slots with 16 bytes each. Other values will result in one slot
with 4, 16, 20 or 64 bytes.
Note that Input Size sets size of digital outputs and Output size sets the size on digital inputs,
seen from the PLC’s point of view.

The following table shows a few examples of how the Input Size and Output Size unit type
parameters can be used to create different slot configurations of a connecting PLC.
Input Size Output Size Step 7 Configuration

4 bytes 4 bytes Slot 1: DI 4 bytes
Slot 2: DO 4 bytes
Slot 2: DI 4 bytes
Slot 3: DO 4 bytes
Slot 2: DO 16 bytes
1 byte 20 bytes Slot 1: DI 20 bytes
Slot 2: DO 4 bytes

3HAC031975-001 Revision: - 27
Continued
Input Size Output Size Step 7 Configuration

Slot 2: DO 16 bytes
Slot 2: DO 16 bytes
Slot 3: DO 16 bytes
Slot 2: DI 16 bytes
Slot 3: DO 16 bytes
Slot 4: DO 16 bytes
Slot 2: DO 64 bytes
If a configuration mismatch between the connecting PLC and the IRC5 internal PROFINET
slave occurs, the event message 71437 is generated on the Flex Pendant. This event message
informs the user of the present slot configuration of the IRC5 internal PROFINET slave.
28 3HAC031975-001 Revision: -
3.3.1. Configuring PROFINET master
3.3 Workflows
3.3.1. Configuring PROFINET master
Description
The PROFINET master configuration is set according to the I/O units and I/O signals
definitions.
Configuration
Action Note
1. Create a new system using RobotStudio. Make sure the See Operating manual -
PROFINET option is installed. RobotStudio.
2. Download the system to the IRC5 controller and restart.
3. Use the external PROFINET configuration tool to create a Described in section
project that contains the configuration of the PROFINET Configuring digital I/O,
network. If the I/O units are not available in the configuration example on page 33.
tool, import the GSDML files.
NOTE!
This step is always unique depending on the type of I/O unit
to configure.
4. Download the configuration to the DSQC 678.
5. Restart the IRC5 controller to start up with the new system.
6. Configure the I/O units connected to the Profinet1 bus using
RobotStudio or FlexPendant.
7. Configure the I/O signals. See Technical reference
manual - System
parameters.
8. Restart the IRC5 controller.
3HAC031975-001 Revision: - 29
3.3.2. Configuring IRC5 internal PROFINET slave
3.3.2. Configuring IRC5 internal PROFINET slave
Description
When the IRC5 controller is connected, for example, to an external PLC, the IRC5 controller
acts as an ordinary slave unit on the PROFINET network. The PLC connects to the IRC5
internal PROFINET slave to exchange data.
Configuration
Action Note
1. Use the external PROFINET configuration tool to create a Described in section
project for the master, for example a PLC, that contains Configuring IRC5 internal
the configuration of the PROFINET network. PROFINET slave, example
on page 43.
2. In the tool, configure the master to connect to the DSQC Described in section
678 internal slave that represents the IRC5 controller. Configuring IRC5 internal
PROFINET slave, example
on page 43.
3. Configure the IRC5 internal PROFINET slave unit in the See Configuring IRC5
IRC5 controller using RobotStudio or FlexPendant. internal PROFINET slave,
example on page 43 and
Operating manual - Robot-
Studio.
4. Configure the I/O signals. See Technical reference
manual - System
parameters.
5. Restart the IRC5 controller. See Operating manual -
IRC5 with FlexPendant.
6. Download the configuration in the external PROFINET Described in section
configuration tool to the master. Configuring IRC5 internal
PROFINET slave, example
on page 43.
Communication status
To have control of the communication status, that is, to know if the master (for example a © Copyright 2008 ABB. All rights reserved.
PLC) to slave communication is working or not, the following scheme could be used.
The master can set one signal during start-up or within the controller loop, this signal (on the
internal slave) could then be attached to a system input in the robot controller as a
communication supervision signal. If the communication between the master and the slave is
interrupted, all the inputs of the internal slave will go to fail safe state (that is, be set to zero
only) .This means that the user defined communication supervision signal will also go to zero.
NOTE!
If the IRC5 internal PROFINET slave loses connection with the master, the configured input
signals are cleared (reset to zero).
30 3HAC031975-001 Revision: -
3.3.3. Configuring PROFINET-IO Routing
General
The PROFINET-IO Routing functionality is configured entirely using an external
PROFINET configuration tool. It is important to remember that the PROFINET-IO Routing
functionality also connects different projects in the configuration tools with each other. A
configuration change in one of the projects might also change the configuration in the
connected project. In order to execute changes regarding PROFINET-IO Routing, all affected
projects must be downloaded to respective hardware, even if a change in configuration only
was made in one of the connected projects.
Prerequisites
The PROFINET master and the PROFINET internal slave has to be configured, see section
Configuring PROFINET master on page 29, and section Configuring IRC5 internal
PROFINET slave on page 30.
Master configuration
Use this procedure to configure the master.
Action
1. Configure the master functionality as described in Configuring PROFINET master on
page 29.
2. Use an external PROFINET configuration tool to create a project and add a Simatic PC
station with a CP1616 device and a network with the devices that shall be slaves to the
IRC5 controller.
3. Configure the IRC5 controller I/O system and define the slave devices as I/O units.
4. Configure the IRC5 controller I/O system and define the I/O signals that shall be
accessible from the IRC5 controller.
Slave configuration
Use this procedure to configure the slave.
Action
1. Configure the IRC5 internal PROFINET slave functionality as described in Configuring
IRC5 internal PROFINET slave on page 30
2. Add a PLC station to the project created in Configuring PROFINET master on page 29
step 1 using an external PROFINET configuration tool.
3. Add a Simatic PC Station as a slave to the PLC, make sure the name and IP address is
the same as in the master configuration.
4. Configure the IRC5 controller I/O system and define a unit of type
DN_INTERNAL_SLAVE to activate the IRC5 internal PROFINET slave functionality.
PROFINET-IO Routing configuration

Configure PROFINET-IO Routing in the external PROFINET configuration tool
Action
1. In the PLC configuration select the CP1616 device and add transfer modules to slot 3
and above, as described in Configuring PROFINET-IO Routing, example on page 49.
3HAC031975-001 Revision: - 31
Continued
NOTE!
System parameters.
32 3HAC031975-001 Revision: -
3.4.1. Configuring digital I/O, example
3.4 Examples
Description
This is an example of how to configure an I/O unit with four input signals and four output
signals.
The I/O unit used in this example is an ET200S I/O unit with five submodules attached 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 set-up

Use this procedure to set the configuration in Siemens Step7.
Action
1. Create a new empty project.
2. On the Insert menu, point to Station, and then click SIMATIC PC Station.
3. 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
4. Expand the SIMATIC PC Station on the right-hand side catalog tree. Expand further in
the tree, find SIMATIC PC Station\CP Industrial Ethernet\CP 1616\V2.1(PN V2.0).
5. Double-click or drag the V2.1(PN V2.0) device from the catalog tree to slot 1 of the PC
rack.

3HAC031975-001 Revision: - 33
Continued
Action
6. Enter the IP address used for the DSQC 678, and then click New to create a PROFINET
network.
xx0800000139
7. Click OK on the Industrial Ethernet dialog and OK in the Properties-Ethernet

interface PN-IO dialog.
xx0800000140

34 3HAC031975-001 Revision: -
Continued
Action
8. Double-click the X1 slot in PC rack to open the PN-IO dialog.
xx0800000141
9. Enter Robot1 in the Device Name text box and click OK.
xx0800000142

3HAC031975-001 Revision: - 35
Continued
Action
10. Expand the catalog tree view and locate the correct ET200S device,
PROFINET IO\I/O\ET 200S\IMI151-3 PN ST V5.0.
xx0800000143
11. Drag the device from the catalog and drop it on the Ethernet PROFINET-IO-System.
12. Continue expanding the catalog tree to locate the modules that are connected in the
hardware device.
xx0800000144

36 3HAC031975-001 Revision: -
Continued
Action
13. 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.
14. 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. On the PLC menu, click Download and then click OK.
xx0800000146

3HAC031975-001 Revision: - 37
Continued
Action
17. Click View to search the network for the DSQC 678.
xx0800000147

38 3HAC031975-001 Revision: -
Continued
Action
18. Select the appropriate DSQC 678 card and click OK.
xx0800000148
19. Click OK to stop the card. This finishes the set-up in the Siemens tool.
Continue with configuring the IRC5 controller I/O system.
xx0800000149

3HAC031975-001 Revision: - 39
Continued
IRC5 controller I/O configuration set-up

Use this procedure to set up the configuration in the IRC5 controller, using RobotStudio.
Action
1. Start RobotStudio and connect to the IRC5 controller. Request write access.
2. Click Configuration Editor and select I/O.
3. In the type list, click Unit and then right-click in the workspace and select Add Unit.
4. 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
xx0800000155
NOTE!
Device number 1 in the Siemens project.
5. In the type list, click Signal and then right-click in the workspace and select Add Signal.

40 3HAC031975-001 Revision: -
Continued
Action
6. Enter the parameter values for the signal and click OK.
• Name
• Type of signal
• Assign to unit
• Unit mapping
xx0800000156
The lower panel in Step7 can be a guide when specifying the parameter Unit Mapping.
Select the device in the project and use the lower panel. See settings explanation in
Signal mapping example on page 42.
xx0800000158

8. After the restart, start RobotStudio and make sure the configured I/O signals are
accessible.

3HAC031975-001 Revision: - 41
Continued
Signal mapping example
xx0800000158
The panel shows that the signals are mapped to:

Unit mapping in IRC5
Slot Module type Module mapping in Step7
controller
2 2DO Out 0.0..0.1 Out 0,1
3 2DO Out 1.0..1.1 Out 8,9
4 2DI In 0.0..0.1 In 0,1
5 2DI In 1.0..1.1 In 8,9
The I/O signals in the IRC5 controller should be mapped as:

Name Type of signal Assigned to Unit Unit mapping
DI1 Digital Input IM151 0
DO1 Digital Output IM151 0
DO2 Digital Output IM151 1 © Copyright 2008 ABB. All rights reserved.
42 3HAC031975-001 Revision: -
3.4.2. Configuring IRC5 internal PROFINET slave, example
Description
This is a configuration example for an IRC5 internal PROFINET slave with 64 byte input and
64 byte output size. The example also shows how to configure a PLC that connects against
the IRC5 internal PROFINET slave.
This example comes from the Step7 project in section Configuring digital I/O, example on
page 33
Configuring IRC5 internal PROFINET slave

Use this procedure to configure the configuring IRC5 internal PROFINET slave using
Siemens Step 7.
Action
1. Start Simatic Manager and open the project containing the Simatic PC Station that
represents the IRC5 controller with DSQC 678.
This project was created in section Configuring digital I/O, example on page 33
2. Expand the project tree and select the Simatic PC station that represents the IRC5
controller with the DSQC 678. Right-click the station and select Open Object to open
the HW Config window.
3. Double-click slot 1 in the PC Station rack to open the object properties and then select
the PROFINET tab.
Make sure the Enable PROFINET IO device operation is selected, if not select Enable
PROFINET IO device operation and download the updated configuration to the DSQC
678.
Click OK.
xx0800000159

3HAC031975-001 Revision: - 43
Continued
Action
4. Click OK and add a PLC station to the project.
NOTE!
If using the PROFINET-IO Routing functionality, make sure that the PLC station and the
Simatic PC station are located in the same project.
5. Open the HW Config window for the PLC hardware configuration.
xx0800000160
6. Make sure the PROFINET network connected to the PLC is the same as the network
connected to the Simatic PC station representing the IRC5 controller with DSQC 678.
7. Expand PROFINET IO\I/O\SIMATIC PC-CP\CP1616\Migration in the catalog view to
the right, to find the V2.1 device. © Copyright 2008 ABB. All rights reserved.

44 3HAC031975-001 Revision: -
Continued
Action
8. Drag the V2.1 device to the PROFINET network workspace.
xx0800000161
9. Double-click the added CP1616 icon.

xx0800000162

3HAC031975-001 Revision: - 45
Continued
Action
10. 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 IO
controller is cleared.
Click OK.
xx0800000163
NOTE!
Before clearing the Assign IP address via IO controller box, make sure the IP address
is set to the IP address of the CP1616 card in the Simatic PC Station configuration.
11. Click OK in the Properties-CP-1616 dialog and then click Yes to confirm the warning
xx0800000164

46 3HAC031975-001 Revision: -
Continued
Action
12. Make sure the CP1616 icon is selected, expand the catalog view further to find the input
modules, PROFINET IO\I/O\SIMATIC PC-CP\CD1616\Migration\V2.1\DI. Double-click
the 64 bytes module to insert it into slot 1 of the CP1616 card.
13. Expand the output modules in the catalog tree and double-click or drag the 64 bytes
module to slot 2 of the CP1616 card.
xx0800000165
14. On the Station menu, click Save and Compile.

15. Make sure that you have an Ethernet connection between the PC and the PLC.
16. On the PLC menu, click Download.
IRC5 controller I/O configuration set-up

Use this procedure to configure the slave in the IRC5 controller, using Robot Studio.
Action
1. Start RobotStudio and connect to the IRC5 controller. Request write access.
2. Click Configuration Editor and select I/O.
3. In the type list, click Unit and then right-click in the workspace and select Add Unit.

3HAC031975-001 Revision: - 47
Continued
Action
4. Enter the parameter values for the unit and click OK.
• Name.
• Type of Unit should be PN_INTERNAL_SLAVE.
• Connected to Bus should be PROFINET 1.
• PROFINET Address must be 0.
xx0800000166
48 3HAC031975-001 Revision: -
3.4.3. Configuring PROFINET-IO Routing, example
Description
This is an example of how to configure the DSQC 678, PROFINET-IO Routing functionality.
NOTE!
This example requires both configurations described in example Configuring digital I/O,
example on page 33, and Configuring IRC5 internal PROFINET slave, example on page 43.
PROFINET configuration set-up

Use this procedure to set up the configuration in Step7 (Siemens PROFINET configuration
tool).
Action
1. Use Siemens Simatic Manager and open the PLC configuration made in example
PROFINET configuration set-up on page 33.
2. Select the CP1616 icon representing the IRC5 internal PROFINET slave.
3. In SIMATIC Manager, expand the catalog tree to the right of the window. Right-click the
window and find PROFINET IO\I/O\SIMATIC PC-CP\CP1616\Migration\V2.1\Transfer
Module.
4. Drag one DI 1 byte transfer module to slot 3 of the CP1616 device.
5. Drag one DO 1 byte transfer module to slot 4 of the CP1616 device.
xx0800000167

3HAC031975-001 Revision: - 49
Continued
Action
6. Double-click DI 1 byte transfer module in slot 3 to open the Properties dialog.
xx0800000168
7. In the column Device name click the first cell named Empty to open a list of devices
that are controlled by the PROFINET master in the IRC5 controller.
8. Click to select the IM151 device.
xx0800000169
9. Click the Module (slot) cell with white background to open a list of available slot
modules. This will show a list of all slot modules that the PLC can read.
Then select the input module in slot 4.

50 3HAC031975-001 Revision: -
Continued
Action
10. Click the next cell labeled Empty and select the IM151 module, then select the output
module in slot 2.
With this configuration, it is possible to read the input signals 0 and 1, and read back the
output signals 0 and 1.
xx0800000170
11. Click OK to close the Properties dialog.

12. Double-click the DO 1 byte transfer module in slot 4 of the CP1616 device.

3HAC031975-001 Revision: - 51
Continued
Action
13. Configure the transfer module so that the PLC will be able to control the output signals
0 and 1 of the output module in slot 3 of the IM151 device.
xx0800000171
14. Click OK to close the Properties dialog.

15. On the Station menu, click Save and compile.
16. Open the SIMATIC PC Station configuration.
17. On the Station menu, click Save and compile.
18. Download the PLC configuration to the PLC.
19. Download the Simatic PC Station configuration to the DSQC 678.
NOTE!
System parameters.
52 3HAC031975-001 Revision: -
4 System parameters
4.1. Introduction
4 System parameters
4.1. Introduction
PROFINET specific system parameters

There are both PROFINET specific parameters and more general parameters. This chapter
describes all PROFINET specific system parameters. The parameters are divided into the
type they belong to. For information about other parameters refer to Technical reference
manual - System parameters.
3HAC031975-001 Revision: - 53
4 System parameters
4.2.1. Profinet Address
4.2 Unit
4.2.1. Profinet Address
Cfg name
PN_Address
Description
The parameter Profinet Address corresponds to the device number in the external PROFINET
configuration tool.
Usage
Profinet Address specifies the address that the I/O unit uses on the network.
Prerequisites
PROFINET option must be installed.
Default values
The default value is 0.
Allowed values
An integer value between 0 and 65535.
The value must be zero (0) when configuring the internal slave.
54 3HAC031975-001 Revision: -
4 System parameters
4.3.1. Input Size
4.3 Unit Type
4.3.1. Input Size
Parent
Input Size belongs to the type Unit Type, in the topic I/O.
Cfg name
PN_InputSize
Description
Input Size is used to configure the input slot configuration of the IRC5 internal PROFINET
slave.
Input Size sets the size of the digital inputs for PN_INTERNAL_SLAVE.
Prerequisites
Profinet Master/Slave option must be installed.
Limitations
Input Size is only available for the unit type PN_INTERNAL_SLAVE.
Allowed values
Allowed values are the integers 0-64.
Additional information
Any other values than 4, 8, 16, 20, 32 and 64 will result in digital input size rounded up to the
closest of these values.
If Input Size is set to 8, there will be two slots with 4 bytes each. If Input Size is set to 32, there
will be two slots with 16 bytes each. For other values there will be one slot with 4, 16, 20 or
64 bytes.
Input Size Slot size

1-4 4 bytes
5-8 2 slots with 4 bytes each
9-16 16 bytes
17-20 20 bytes
33-64 64 bytes
3HAC031975-001 Revision: - 55
4 System parameters
4.3.2. Output Size
4.3.2. Output Size
Parent
Output Size belongs to the type Unit Type, in the topic I/O.
Cfg name
PN_OutputSize
Description
Output Size is used to configure the output slot configuration of the IRC5 internal PROFINET
slave.
Output Size sets the size of the digital outputs for PN_INTERNAL_SLAVE.
Prerequisites
Profinet Master/Slave option must be installed.
Limitations
Output Size is only available for the unit type PN_INTERNAL_SLAVE.
Allowed values
Allowed values are the integers 0-64.
Additional information
Any other values than 4, 8, 16, 20, 32 and 64 will result in digital output size rounded up to
the closest of these values.
If Output Size is set to 8, there will be two slots with 4 bytes each. If Output Size is set to 32,
there will be two slots with 16 bytes each. For other values there will be one slot with 4, 16,
20 or 64 bytes.
Output Size Slot size © Copyright 2008 ABB. All rights reserved.
1-4 4 bytes
9-16 16 bytes
17-20 20 bytes
33-64 64 bytes
56 3HAC031975-001 Revision: -
5 Trouble shooting
5.1. Scenarios
5 Trouble shooting
5.1. Scenarios
Cannot assign the DSQC 678 a device name or IP address using Step 7
Sometimes the DSQC 678 hardware will not accept configuration changes when the
PROFINET option software driver is running. If this situation occurs, an X-start of the IRC5
controller is needed. The IRC5 controller will then restart in a mode where the PROFINET
option software driver is not running.
Action
1. Perform an X-start of the IRC5 controller.
2. Download the configuration changes using Step 7.
3. When the configuration changes are downloaded, tap the Select System button on the
FlexPendant.
4. Select the system that was used before the X-start.
5. Restart the IRC5 controller with the selected system by tapping the Restart Controller
button on the FlexPendant.
Cannot download configuration to the DSQC 678 using Step 7

See the preceding scenario, Cannot assign the DSQC 678 a device name or IP address using
Step 7 on page 57.
The Ethernet switch on the DSQC 678 can be operated using an external power supply unit. Why is
it not working?
The DSQC 678 board must first be initialized by the PROFINET software option 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
cannot detect that the PCI-board is inserted.
When this command is issued from Step 7, the DSQC 678 board will perform additional
operations next time it reboots. This will increase the startup time of the board so much that
the IRC5 controller will fail to detect it. The solution is to restart the 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 submodule basis.
For example, an I/O unit with the following configuration:
Slot 1 8 bits (1 byte)

Slot 2 8 bits (1 byte)
will not have data consistency on a 16 bit digital I/O group signal in the IRC5 controller that
stretches over both slot 1 and 2.

3HAC031975-001 Revision: - 57
5 Trouble shooting
5.1. Scenarios
Continued
PROFINET-IO Routing is not working

Make sure that the Enable PROFINET IO device operation check box is selected in the
configuration that is downloaded to the DSQC 678 used as an IRC5 internal PROFINET
slave. See Configuring IRC5 internal PROFINET slave on page 43.
58 3HAC031975-001 Revision: -
Index
C
computer module 17
I
Industrial Ethernet 21
Input Size 55
O
Output Size 56
P
PLC configuration 49
PN_Address 54
PN_InputSize 55
PN_OutputSize 56
PROFIdrive 11
Profinet Address 54
PROFINET CP1616 17
PROFINET network 12
PROFINET-CBA 11
PROFINET-IO 11
PROFIsafe 11
R
Routing 49
3HAC031975-001 Revision: - 59
60
Index
3HAC031975-001 Revision: -
3HAC-031975-001, Revision -, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

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© Copyright 2006 ABB. All rights reserved.

Copyright 2008 ABB All rights reserved.

3 PROFINET Master/Slave configuration 25

4.3.2 Output Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

© Copyright 2008 ABB. All rights reserved.

About this manual

Who should read this manual?

Continues on next page

© Copyright 2008 ABB. All rights reserved.

Product documentation, M2004

Technical reference manuals

Continues on next page

© Copyright 2008 ABB. All rights reserved.

• PROFIdrive - The PROFIdrive profile covers application scenarios from simple

1.2. PROFINET, IRC5

PROFINET version compatibility

© Copyright 2008 ABB. All rights reserved.

Continues on next page

A Line PLC, PROFINET-master

Specification overview, Master

Continues on next page

Specification overview, Slave

© Copyright 2008 ABB. All rights reserved.

1.3. Definition of I/O units

© Copyright 2008 ABB. All rights reserved.

Continues on next page

Installation of DSQC 678

© Copyright 2008 ABB. All rights reserved.

A-D Possible slot for DSQC 678

Continues on next page

A LED, SF (collective error), red

C External power connections

LED Meaning State Remarks

Continues on next page

LED Meaning State Remarks

Description article number

Description Article number

Connections, RJ-45 connectors

Cables and connectors

© Copyright 2008 ABB. All rights reserved.

2.2. Connections, general

2.3. PROFINET-IO Routing

© Copyright 2008 ABB. All rights reserved.

With the PROFINET-IO Routing functionality it is possible to configure:

© Copyright 2008 ABB. All rights reserved.

3 PROFINET Master/Slave configuration

3.1.1. Software overview

3.2 Configuration overview

3.2.1. PROFINET master

Predefined I/O bus

Predefined I/O unit type

© Copyright 2008 ABB. All rights reserved.

3.2.2. IRC5 internal PROFINET slave

Predefined I/O unit type

Input and output size

seen from the PLC’s point of view.

Input Size Output Size Step 7 Configuration

Continues on next page

Input Size Output Size Step 7 Configuration

© Copyright 2008 ABB. All rights reserved.