Application Manual

Application manual
PROFIBUS-DP
Robot Controller
RobotWare 5.0
Application manual
PROFIBUS-DP
RobotWare 5.0
Document ID: 3HAC023008-001

Revision: A
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview ..........................................................................................................................................5
Product documentation, M2004 .......................................................................................................7
Safety................................................................................................................................................9
1 Reference information, PROFIBUS 11

1.1 Introduction .............................................................................................................................11
1.2 References ................................................................................................................................12
2 Overview 13
2.1 PROFIBUS, general .................................................................................................................13
2.2 PROFIBUS, IRC5 ....................................................................................................................14
2.3 Definition of I/O units ..............................................................................................................17
3 PROFIBUS-DP Master/Slave hardware 19

3.1 Hardware description .............................................................................................................19
3.1.1 DSQC 637 PROFIBUS-DP master/slave.......................................................................19
3.1.2 Definition of communication units, IRC5 .....................................................................23
3.2 Connections ............................................................................................................................25
3.2.1 Connections, general ......................................................................................................25
3.2.2 Selecting cables ..............................................................................................................26
4 PROFIBUS-DP Master/Slave configuration 27

4.1 Introduction .............................................................................................................................27
4.1.1 Software overview..........................................................................................................27
4.1.2 Software, how to start.....................................................................................................29
4.1.3 PROFIBUS-DP configuration software .........................................................................30
4.2 Workflows, PROFIBUS-DP master bus................................................................................31
4.2.1 Introduction ....................................................................................................................31
4.2.2 Configuration overview .................................................................................................32
4.2.3 Bus configuration ...........................................................................................................35
4.2.4 Download PROFIBUS configuration file to the controller............................................37
4.3 Workflows, PROFIBUS-DP internal slave ............................................................................38
4.3.1 Introduction ....................................................................................................................38
4.3.2 Internal slave configurations ..........................................................................................39
4.4 Parameters ..............................................................................................................................41
4.4.1 System parameters..........................................................................................................41
4.5 Examples .................................................................................................................................43
4.5.1 Digital I/O configuration example (non modular station)..............................................43
4.5.2 Modular station configuration example .........................................................................47
3
Table of Contents
4.5.3 Internal slave configuration example ............................................................................ 53

4.5.4 IRC5 master/slave configuration example .................................................................... 54
Index 59
4
Overview
Overview
About this manual

This manual is primarily a description of the PROFIBUS-DP fieldbus data communication
between the IRC5 system and its distributed I/O units. It also describes the PROFIBUS
Master/Slave configuration.
This manual does not include a description of how to install and operate a PROFIBUS system
in general.
Usage
This manual should be used during installation and configuration of the PROFIBUS, as well
as during upgrading of the PROFIBUS option.
For mechanical installation descriptions, refer to the Product manual, IRC5.
Who should read this manual?

This manual is intended for
• personnel that are responsible for installations and configurations of fieldbus
hardware/software
• personnel that configure the I/O system
• system integrators.
Prerequisites
The reader should have the required knowledge of
• the PROFIBUS system
• I/O system configuration
Continues on next page
3HAC023008-001 Revision: A 5
Overview
Continued
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
1 This chapter gives reference information, both to external documentation and
other ABB manuals.
2 This chapter gives an overview of the PROFIBUS fieldbus and includes
following:
• a general description of PROFIBUS and the communication protocol
• description of how the PROFIBUS master/slave unit and I/O units are
connected in a robot system
• definition of I/O units in the control cabinet and the configuration of the
control cabinet
3 This chapter describes the PROFIBUS Master/Slave board.
The chapter also describes communication units in the IRC5 controller.
4 This chapter gives an overview of the controller and configuration software and
includes following:
• Bus configuration
• Workflows
• Examples
Revisions
Revision Description
- First edition, released with IRC5 RW 5.05.
A Second edition, released with IRC5 RW 5.07.
Section GSD-file importation is added in chapter 4.2.2 Configuration overview.
Chapter 4.2.4 Download PROFIBUS configuration file to the controller is added.
6 3HAC023008-001 Revision: A
Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Continued
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
• How to use the application
• Examples of how to use the application
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
includes:
• Getting started - IRC5 and RobotStudio Online
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudio Online
• Trouble shooting manual for the controller and robot
Safety
Safety
Safety of personnel
When working inside the controller it is necessary to be aware of voltage related risks.
A danger of high voltage is associated with the following parts:
• Units inside the controller, for example I/O units can be supplied with power from an
external source.
• The mains supply/mains switch.
• The power unit.
• The power supply unit for the computer system (230 VAC).
• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!
• The drive unit (700 VDC).
• The service outlets (115/230 VAC).
• The power supply unit for tools, or special power supply units for the machining
process.
• The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
• Additional connections.
Therefore, it is important that all safety regulations are followed when doing mechanical and
electrical installation work.
Safety regulations
Before beginning mechanical and/or electrical installations, make sure you are familiar with
the safety regulations described in Product manual IRC5, M2004.
Safety
1 Reference information, PROFIBUS
1.1. Introduction

1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the following chapters.
1.2. References
1.2. References
Document references
References Document ID
Application manual - Robot communication and I/O control 3HAC 020435-001
Operator’s manual - IRC5 with FlexPendant 3HAC 16590-1
Online
Operator’s manual - RobotStudio 3HAC 18236-1
Product manual IRC5, M2004 3HAC 021313-001
Technical reference manual - System parameters 3HAC 17076-1
Other references
References Description
International standard IEC 61158 Type 3 The PROFIBUS fieldbus standard is
International standard IEC 61784 described in the international standards.
PROFIBUS Technical Guideline Installation Guideline for PROFIBUS-DP/FMS
(Version 1.0, September 1998)
User Manual DP Configurator Manual for the PROFIBUS configuration tool
(PC software)
ET200S Distributed I/O System Manual Manual from Siemens
www.profibus.com The web site of PROFIBUS International
2 Overview
2.1. PROFIBUS, general
2 Overview
2.1. PROFIBUS, general
What is PROFIBUS?
PROFIBUS is a vendor independent open fiel bus standard for a wide range of applications,
particulary in the fields of factory and process automation.
PROFIBUS is suitable for high-speed time critical applications as well as for complex
communication tasks.
PROFIBUS specification
The PROFIBUS communication is specified in the international standard IEC 61158 Type 3,
which includes the entire range of PROFIBUS versions.
PROFIBUS versions
PROFIBUS has a modular design and different PROFIBUS versions are all combinations of
modular elements from the groups transmission technology, communication protocol and
application profiles.
Here are some examples of PROFIBUS versions:
• PROFIBUS-DP - optimized for factory automation
• PROFIBUS PA - optimized for process automation
• PROFIsafe - PROFIBUS for safety-related systems
• PROFIdrive - PROFIBUS for motion control
Communication protocols
DP (Decentralized Periphery) is the simple, fast, cyclic and deterministic communication
protocol between a bus master and the assigned slaves. The forerunner of DP was FMS
(Fieldbus Message Specification), which is obsolete today.
The original version of DP called DP-V0 has been expanded to DP-V1, and it provides
acyclic data exchange between master and slave. A further version DP-V2 offers direct slave-
to-slave data exchange with an isochronous bus cycle.
2 Overview
2.2. PROFIBUS, IRC5
2.2. PROFIBUS, IRC5
Hardware overview
The hardware of the PROFIBUS-DP fieldbus consists of a master/slave unit, DSQC 637, and
distributed I/O units (called slave units).
DSQC 637 unit

The DSQC 637 unit is connected to the PCI bus of the IRC5 robot controller. The slave units
are attached to the fieldbus network. The DSQC 637 unit supports PROFIBUS-DP with DP-
V0, which means that DP-V1 and DP-V2 are not supported.
The slave part of the DSQC 637 unit is normally controlled by an external master on a
separate PROFIBUS-DP network. This network is a different one than the network holding
the slave units for the master part of the board.
Slave units
The slave units can be I/O units with digital and/or analog signals. They are all controlled via
the master part of the DSQC 637 unit.
2 Overview
2.2. PROFIBUS, IRC5
Continued
The PROFIBUS-DP network

The illustration below is an overview of the hardware, and shows the PROFIBUS network.
xx0400000851
A Line PLC, DP-Master

B IRC5 controller
C Robot
D I/O unit, DP-Slave
E DP-Slave (IRC5 - DSQC 637)
F DP-Master (IRC5 - DSQC 637)
2 Overview
2.2. PROFIBUS, IRC5
Continued
Configuration program
The configuration program PROFIBUS DP Configurator (from Softing), together with the
RobotStudioOnline , is used to configure the bus correctly.
The configuration program must be executed on a PC according to the manual for the
program.
Specification overview, Master
Item Specification
Fieldbus type PROFIBUS-DP master with DP-V0
Addressing 1-125
Number of units The number is defined by the limitations of the general I/O
connected to master systems, see Technical reference manual - System parameters.
Number of signals The number is defined by the limitations of the general I/O
systems, see Technical reference manual - System parameters.
Baudrate The PROFIBUS-DP master is configurable for all baudrates up to
12 Mbit/s.
PROFIBUS product ID 0xB203
Specification overview, Slave
Item Specification
Fieldbus type PROFIBUS-DP slave with DP-V0
Addressing 1-125
Number of units The number is defined by the limitations of the general I/O
connected to slave systems, see Technical reference manual - System parameters.
Number of signals Max 512 digital in
Max 512 digital out
Baudrate The PROFIBUS-DP slave autobauds for all baudrates up to 12
Mbit/s.
PROFIBUS product ID 0xB205
2 Overview
2.3. Definition of I/O units
General
The controller may be mounted with I/O units inside the controller.
Standard configuration
In the standard form, no fieldbus is mounted to the controller.
It is possible to connect any type of PROFIBUS compliant I/O unit on the DSQC 637 master
bus. All I/O units should comply with the PROFIBUS standard and be conformance tested by
PNO/PI (PROFIBUS Nützer Organisation/PROFIBUS International).
Configuration of the controller
xx0500002046
A Control module of the dual cabinet

B Drive module of the dual cabinet
C Single cabinet
2 Overview
Continued
Further information
The table gives references to additional information:
Information: Found in:

Allowed configurations of I/O units and how Technical reference manual - System
to setup the configurations: parameters
How to install the software of the I/O units Product manual IRC5, M2004
related in a new system:
3 PROFIBUS-DP Master/Slave hardware
3.1.1. DSQC 637 PROFIBUS-DP master/slave
3.1 Hardware description
Description
The DSQC 637 is a circuit board normally mounted in the controller.
The PROFIBUS-DP M/S unit has both a master and a slave channel on the same unit. The
master channel is used to communicate with I/O units within the robot cell and the slave
channel is used to communicate with the robot controller from a master PLC.
The master channel and the slave channel are physically separated.
Installation and configuration

For installation instructions for PROFIBUS, see the PROFIBUS specification, IEC 61158
Type 3. See also the Installation Guideline for PROFIBUS-DP/FMS published by the user
organization of PROFIBUS (PNO).
Instructions on how to configure the PROFIBUS network for the master and the slave
channel are found in the chapterPROFIBUS-DP Master/Slave configuration on page 27.
Typical applications
An example of how the DSQC 637 may be connected is illustrated in section The
PROFIBUS-DP network on page 15.
Continued
Illustration
The figure below shows the DSQC 637 board. The upper connector is the slave connector and
the lower connector is the master connector.
xx0400001188
S Indicates the status of the Slave channel. Lit when the slave is in data exchange
mode.
M Indicates the status of the Master channel. Lit when the master has the
PROFIBUS token.
For connection table, see section Connections, Master and Slave connector on page 21.
Continued
Technical data
Description Art. number

PROFIBUS DP master/slave, DSQC 637 3HAC023047-001
Connections, Master and Slave connector
xx0100000220
The table below shows the connections to the master connector and the slave connector,
which are two physically separated connectors on the DSQC 637 board.
Signal name Master/Slave channel pin Function

Shield 1 Cable screen
NC 2 Not connected
RxD/TxD-P 3 Receive/Transmit data P
Control-P 4 Repeat control signal (direction control)
GND 5 Ground connection
+5 VDC 6 Supply voltage
NC 7 Not connected
RxD/TxD-N 8 Receive/Transmit data N
NC 9 Not connected
Continued
Termination
To reduce the reflections on the data lines it is very important that both ends of the
PROFIBUS network are terminated according to PROFIBUS-DP specification, IEC 61158
Type 3.
The termination used by PROFIBUS is an active termination as showed in the figure below:
en0400001144
After connecting the PROFIBUS network always check that the termination is in place on
both ends of the network and that there are no other terminations on the network. If a
termination is missing or an extra termination is added somewhere in the PROFIBUS
network the communication will probably fail.
Cables and connectors

Cables used to connect the PROFIBUS network must be according to PROFIBUS-DP
specification, IEC 61158 Type 3.
Drop cables are not allowed for PROFIBUS, so special D-subs must be used when the
PROFIBUS-DP unit is not the last in line. The connector must have the possibility to insert
two PROFIBUS cables in the same D-sub. It is also important that the cables are mounted
from the top of the connector, otherwise it will not fit into the limited space around the
PROFIBUS-DP unit (DSQC 637).
3.1.2. Definition of communication units, IRC5
General
The IRC5 computer unit may include a number of communication functions. Any allowed
combination of these is specified below.
Board definition
The figure and table below specify which combinations are allowed:
xx0400000847
Description Art. no. Note Pos.

Robot Com. Card 3HAC 12816-1 DSQC 602 1
Always mounted in slot 1 as
shown in the figure above!
Ethernet card 3HAC 15639-1 DSQC 612 2, 3, 4 or
Only used in MultiMove control 5
applications.
DeviceNet master/slave 3HAC 12817-1 DSQC 603 2, 3, 4 or
5
PROFIBUS DP master/ 3HAC 023047-001 DSQC 637 2, 3, 4 or
slave 5
INTERBUS master/ 3HAC 11819-1 DSQC 529 2, 3, 4 or
slave, copper interface Two physical boards, i.e. the 5
master board and the slave board
are placed in two separate slots.
Continued
Description Art. no. Note Pos.

INTERBUS master/ 3HAC 5579-1 DSQC 512 2, 3, 4 or
slave, fiber optical Two physical boards, i.e. the 5
interface master board and the slave board
are placed in two separate slots.
- - Not used 6
Installation of communication units

For installation descriptions refer to Product manual IRC5, section Replacement of PCI cards
in the Computer unit slots, IRC5.
3.2.1. Connections, general
3.2 Connections
3.2.1. Connections, general
General
All devices are connected in a bus structure. Each bus segment can have a maximum of 32
active devices. In order to be able to connect a larger number of stations (masters and slaves),
the bus must be segmented. The segments are then interconnected with repeaters that amplify
and refresh the data signals. Each repeater allows the PROFIBUS system to be extended by
an additonal bus segment.
The beginning and end of each segment is fitted with an active bus terminator, see illustration
in section Termination on page 22.
3.2.2. Selecting cables
3.2.2. Selecting cables
Cable parameters, PROFIBUS-DP

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

9.6 1200
19.2 1200
45.45 1200
93.75 1200
187.5 1000
500 400
1500 200
3000 100
6000 100
12 000 100
Cable type A
The values in the table refer to cable type A with the following properties:
Parameter Value
Impedance 135 to 165 :
Capacity d 30 pF/m
Loop resistance d 110 :/km
Wire diameter > 0.64 mm
Core cross-section > 0.34 mm
4 PROFIBUS-DP Master/Slave configuration
4.1.1. Software overview
4.1 Introduction
Controller software
The IRC5 controller must be installed with a software that supports the use of the
PROFIBUS-DP network, i.e. the option for PROFIBUS-DP must be installed.
Predefined master bus and I/O unit types

When the IRC5 system is booted with the PROFIBUS option the system is started up with a
predefined master bus, Profibus1 of type PBUS.
The IRC5 controller software also contains a number of predefined I/O unit types for
PROFIBUS-DP. The I/O unit types are described in the configuration files located in the
PROFIBUS option directory, in the RobotWare release media directory.
If another I/O unit type is required, it has to be created by the user.
PC software
RobotStudioOnline is a PC software that is used for setting up connections to robots and to
work with robots.
The configuration for the PROFIBUS-DP communication is done either manually by
RobotStudioOnline/FlexPendant , or by loading a configuration file from RobotStudioOnline.
For information on how to work with RobotStudioOnline and FlexPendant refer to,
respectively, Operator’s manual - RobotStudioOnline and Operator’s manual - IRC5 with
FlexPendant, see References on page 12 .
Continued
Configuration software
To correctly configure the PROFIBUS-DP option a binary configuration file must be created
using Softing PROFIBUS DP Configurator (or PROFI-KON-DP), which is an external
PROFIBUS configuration PC tool. For more information about the configuration software,
see section PROFIBUS-DP configuration software on page 30.
GSD-files
In order to configure the DSQC 637 with the PROFIBUS DP Configurator, GSD-files have
to be imported into PROFI-KON-DP. These files contain vital information about the
PROFIBUS units and they shall be supplied by the vendor/manufacturer of the specific
PROFIBUS module. The GSD-files for the DSQC 637 master/slave are supplied on the
RobotWare CD-ROM and can be found in following directory:
<CD-ROM unit>:\Utility\fieldbus\PROFIBUS\gsd\
The directory contains following files:
GSD-file Description
softb203.gsd Softing DP-Master PROFIboard
softb205.gsd Softing DP-Slave PROFIboard
abb_0600.gsd DSQC 352, DeviceNet to PROFIBUS DP gateway
Updating DSQC 637 firmware

The firmware that is executing on the DSQC 637 board is included in the RobotWare software
package. The board is automatically updated to the actual firmware that is included in a
specific release of RobotWare, i.e. there is no need for any manual procedure to update the
firmware.
During an automatic firmware upgrade of the board, lock-files are created on the flash disk.
The lock-files have names of the format /hd0a/firmwareXY.lock, where X and Y are figures
in the range 0-9.
Note! File names of the specified format above are to be considered as reserved names that
must not be used by the user.
4.1.2. Software, how to start
4.1.2. Software, how to start
Step-by-step
The following procedure gives an overview of how the different software is used together.
For more detailed description, refer to section I/O configuration on page 32.
Step Action
1. Create a new system using RobotStudioOnline. Make sure the PROFIBUS-DP
option is installed.
2. Import the GSD-files to Softing PROFIBUS DP Configurator and create the binary
configuration file, which contains the configuration of the PROFIBUS network.
3. Download the binary configuration file and the created system to the IRC5
controller using RobotStudioOnline.
4.1.3. PROFIBUS-DP configuration software
4.1.3. PROFIBUS-DP configuration software
Description
Softing PROFIBUS DP configurator is an external PROFIBUS configuration PC tool. The
usage of the tool is described below.
Installing PROFIBUS-DP configurator

For installation instructions refer to chapter 2 Installation in User Manual DP Configurator.
Bus parameter set - changing parameters

All the parameters that are defined in the "PROFIBUS Bus parameter set" are possible to
modify by using the Softing PROFIBUS DP Configurator. These parameters and default
values for them (depending on the baudrate) are defined in the PROFIBUS specification. The
default values are encouraged to be used and it is rarely necessary to modify these parameters.
By selecting the desired baudrate the Softing PROFIBUS DP Configurator will automatically
select the default "PROFIBUS Bus parameter set" for this baudrate.
Note! The PROFIBUS user is strongly recommended not to change any of these parameters
without having a really good knowledge of PROFIBUS and how the changes affect the
communication.
Slave parameter set - changing parameters

By using the Softing PROFIBUS DP Configurator it is possible to change the parameters that
are defined in the "Slave parameter set" according to the PROFIBUS specification. It is
usually not necessary to modify the parameters in the "Slave parameter set", but in some cases
it can be interesting to change parameters (like the Watchdog Time and the UserPrm
Data).
Description of how the parameters in the "Slave parameter sets" are modified is found in the
manual for the Softing PROFIBUS DP Configurator.
Note! The PROFIBUS user is strongly recommended not to change any of these parameters
without having a really good knowledge of PROFIBUS and how the changes affect the
communication.
4.2.1. Introduction
4.2 Workflows, PROFIBUS-DP master bus
4.2.1. Introduction
Configuration set-up
To set-up a PROFIBUS-DP communication, follow the workflows described in this section.
Power-up
When all configuration definitions are set, a new startup is required. The robot controller will
automatically start the communication with the DP-slaves, and the controller will report any
errors that may occur.
4.2.2. Configuration overview
Description
The PROFIBUS-DP master configuration is set according to the contents of the I/O signal
and Unit definitions.
I/O configuration
To perform a proper I/O configuration follow the steps in this procedure:
Step Action
1. Create a new system using RobotStudioOnline. Make sure to install the
PROFIBUS-DP option .
2. Import the GSD-files, see GSD-file importation on page 33 for details.
3. Run Softing PROFIBUS DP Configurator to create the binary configuration file
that contains the configuration of the PROFIBUS network.
Note! This step is always unique depending on the type of I/O unit to configure.
4. Download the system to the IRC5 controller.
5. Reboot the controller to start up with the new system.
6. Add the binary configuration file to the HOME directory and configure the bus.
See section Bus configuration on page 35.
7. Configure the units connected to the bus using RobotStudioOnline or FlexPendant.
See Unit configuration on page 33.
8. Configure the signals, see Technical reference manual - System parameters .
9. Reboot the controller.
Continued
Unit configuration
The following procedure details how to configure the units connected to the bus.
Step Action
1. Add a new unit to the system parameters, see Technical reference manual -
System parameters.
2. Enter the unit name.
3. Select the Profibus1 bus, to which the unit is connected.
4. Select the actual unit type.
If the unit type is not predefined, it must be added.
5. Enter the Profibus Address.
GSD-file importation
The following procedure details how to import a GSD-file to the Softing PROFIBUS DP
Configurator.
Note! Import the GSD-file before you create a new project or open an existing project.
Otherwise you may not find the DDB menu, which disappears when projects are open. When
all projects are closed, the DDB menu will be available again.
Step Action
1. Start Softing PROFIBUS DP Configurator.
2. Click the DDB menu.
3. In the DDB (DeviceDataBase) dialog, click Add.
Continued
Step Action
4. An Open dialog appears. Select the GSD-file and click OK.
en0500002355
5. Now the imported GSD-file appears in the Imported DDB list.
4.2.3. Bus configuration
Description
The configuration of the bus consists of specifying the configuration path to the PROFIBUS
configuration file, which is created using the tool Softing PROFIBUS DP Configurator.
Bus parameter
The bus parameter set is defined in the PROFIBUS standard and contains parameters that
influences the behaviour of the bus. The only way to modify the bus parameters, i.e. master
address and baudrate, is to use the Softing PROFIBUS DP Configurator and generate a new
binary configuration file.
Note! The bus parameters should only be changed by a person that is familiar with the
PROFIBUS-DP specification.
Predefined bus
If the system is installed with the PROFIBUS option, a predefined bus PROFIBUS1 is
created. The default configuration path is:
HOME/pbus_cfg.bin
HOME specifies the current system directory, for example "MySystem/Home". It is possible
to configure this path to any place on the IRC5 controller by first using the path /hd0a, which
corresponds to the system flash drive. The equivalent to HOME/pbus_cfg.bin in this example
would be /hd0a/MySystem/Home/pbus_cfg.bin.
Binary configuration file

The first step in the configuration of the bus is to create a binary configuration file using the
Softing PROFIBUS DP Configurator tool on an off-line PC. This file needs to be supplied to
the system to give a description of how the actual PROFIBUS network is physically
configured.
The binary configuration file contains all the parameters needed to get a PROFIBUS network
up and running at the lowest level, i.e. what the DSQC 637 board needs to start the data
exchange on the network.
Continued
Where to find descriptions of PROFIBUS DP configurator

How the Softing PROFIBUS DP Configurator works is described in the manual that is
delivered together with the actual configurator software package.
4.2.4. Download PROFIBUS configuration file to the controller
4.2.4. Download PROFIBUS configuration file to the controller
How to download the file

There are the following different ways to transfer the file:
Use... To...
the system builder in perform the file transfer at the same time as the rest of a newly
RobotStudioOnline created system is transferred from the RobotStudioOnline PC to
the controller. While creating the system, put the binary config-
uration file in the home directory of the created robot system by
using the Add Files to Home Directory in the system builder of
RobotStudioOnline.
For instructions, refer to the Operator’s manual - RobotStudio
Online.
the file manager in Robot- download the configuration file directly to the controller.
StudioOnline For instructions, refer to the Operator’s manual - RobotStudio
Online.
a third party FTP client download the configuration file directly to the controller.
4.3.1. Introduction
4.3 Workflows, PROFIBUS-DP internal slave
4.3.1. Introduction
Configuration set-up
This section describes the workflows for the necessary configurations to set-up a
PROFIBUS-DP internal slave communication.
Built-in digital slave module

The DSQC 637 unit has a built-in digital slave module with up to 512 digital inputs and 512
digital outputs.
This can be used
• to connect the IRC5 controller to a PLC.
• for connection of the slave channel of several robots to the master channel of one
controlling robot.
4.3.2. Internal slave configurations
Unit type configuration

The unit type definition for the IRC5 PROFIBUS-DP slave is called DP_SLAVE and is
predefined during system start-up. The default sizes of input and output areas for DP_SLAVE
are 16 bytes in and 16 bytes out.
EXT_DP_SLAVE is another predefined unit type, and this shall only be used for configuring
the master channel of an IRC5 controller that is connected to the slave channel of another
IRC5 controller.
I/O unit configuration

The following steps describe how to configure the system parameters for the IRC5
PROFIBUS-DP slave:
Step Action Description

1. Create a new unit of type DP_SLAVE.
2. If the default input size or output size for Note! The internal slave is special in its
DP_SLAVE is not suited, edit the behaviour since outputs from the
Internal Slave Output Size and/or master/PLC will become inputs to the
Internal Slave Input Size for the controller and vice versa.
unit type DP_SLAVE.
PLC configuration
To configure the PROFIBUS master that will control the internal slave, use the GSD file
supplied on the RobotWare CD-ROM, in the directory:
<CD-ROM unit>:\Utility\fieldbus\PROFIBUS\gsd\softb205.gsd
The modules to be chosen depend on the current I/O definition (input/output sizes as defined
for the Unit type).
Continued
Communication status
To have control of the communication status, i.e. to know if the PLC to slave communication
is in DATA_EXCHANGE mode or not, the PROFIBUS watchdog timer should be used.
The master/PLC can set one signal during startup or within the controller loop, this signal (on
the internal slave) could then be attached to a system input in the robot controller as a
communication supervision signal. If the communication between the master/PLC and the
slave will be interrupted (i.e. the slave leaves the DATA_EXCHANGE mode), all the inputs
of the internal slave will go to fail safe state (i.e. be set to zeros only) after the specified
watchdog time. This means that the user defined communication supervision signal will also
go to zero.
4.4.1. System parameters
4.4 Parameters
Introduction
There are both PROFIBUS specific parameters and more general parameters. This chapter
gives brief descriptions of all system parameters that are necessary for the correct installation
and configuration of PROFIBUS. The parameters are divided into the type they belong to.
The PROFIBUS specific parameters are described here, for information about other
parameters refer to Technical reference manual - System parameters.
Type name Unit

These parameters belong to the topic I/O and the type Unit. For more information, see the
respective parameter in Technical reference manual - System parameters.
Parameter Description
Profibus Address This parameter is used to specify the address that the I/O unit
uses on the network, and to which the master should try to
setup a connection.
Allowed values: 0-125
Continued
Type name Unit Type

These parameters belong to the topic I/O and the type Unit Type. For more information, see
the respective parameter in Technical reference manual - System parameters.
Parameter Description
Product ID This parameter is used as an identification of the I/O unit and
is only available for PROFIBUS unit types.
If the parameter is assigned the value 0 (zero), the robot
controller ignores what product ID the connected unit has.
The value of the parameter can be found in the Electronic Data
Sheet (GSD) for the unit (called Ident_number in GSD file).
Note that Ident_number is often expressed as a hexadecimal
number in the GSD file.
Allowed values are integers 0-65535.
Internal Slave This parameter specifies the type of the slave device.
A slave device is either internal or external. The DSQC 637
unit has a built-in slave module and it is defined as internal
slave. All other slave devices are defined as external slaves.
Allowed values: Yes or No
Internal Slave Output Size This parameter defines the data size transmitted by the unit
and is only available for internal slave unit types.
Allowed values: A value between 0-64, specifying the data
size in bytes.
Internal Slave Input Size This parameter defines the data size received by the unit and
is only available for internal slave unit types.
Allowed values: A value between 0-64, specifying the data
size in bytes.
4.5.1. Digital I/O configuration example (non modular station)
4.5 Examples
Description
This is an example of how to configure an ET200B 16 DI/16 DO unit to the master. The bus
is configured using the Softing PROFIBUS DP Configurator, with the master at address 2 and
the slave unit at address 10. The baudrate is 12 Mbit/s and the slave watchdog time is set to
100 ms.
The whole procedure for this example is described in section I/O configuration on page 32.
This example is a detailed description of step 2 in the I/O configuration section and contains
information that is unique to this example.
PROFIBUS DP configurator setup

The following procedure is a step-by-step description of how to set the configuration in the
Softing PROFIBUS DP Configurator.
Step Action
1. Start Softing PROFIBUS DP Configurator and import GSD-files for the Profiboard
from the RobotWare CD (i.e. if the files have not been imported before).
For details, see the Softing PROFIBUS DP Configurator manual.
2. Import GSD-files for the unit that shall be used, see GSD-file importation on page 33
for details.
(GSD-file is provided by the manufacturer of the unit.)
3. On the Options menu, click Advanced Mode.
(Basic mode does not allow the user to change the watchdog time.)
4. On the Project menu, click New Project.
Continued
Step Action
5. In the Master Selection List, double-click on the PROFIboard.
en040000088
6. In the DP-Master-Configuration window, set Station Address to 2 and Baudrate to

12 MBaud. Click OK.
en0400000892
Continued
Step Action
7. In the Slave Selection List, double-click on the B-16DI/16DO.
en0400000889
8. In the DP Slave Configuration window, click the Basic tab and set Station Address
to 10.
en0400000890
Continued
Step Action
9. In the DP Slave Configuration window, click the Settings tab and set Watchdog
Time to 100 ms. Click OK.
en0400000891
10. On the Download menu, choose Binary File.

Name the binary file pbus_cfg.bin (this is the default file name used by the
predefined bus, Profibus1), and download it to the IRC5 controller using either
RobotStudioOnline or a third-party FTP client.
For description of how to download the file, see Operator’s manual - RobotStudioOn-
line
.
4.5.2. Modular station configuration example
Description
The ET200S is a modular unit. You can choose which type of modules to use and in which
order to connect them.
This is an example of how to configure an ET200S unit to the master. The bus is configured
using the Softing PROFIBUS DP Configurator, with the master at address 1 and the slave unit
at address 10. The baudrate is 12 Mbit/s.
In this example the ET200S has physically 7 modules, and these are connected in following
order:
• One Power module
• Two modules with 2 DO in each module
• Two modules with 2 DI in each module
• One module with 2 AO
• One module with 2 AI
This example contains a detailed description of step 2 in the I/O configuration section and the
information is unique to this example, see PROFIBUS DP configurator setup on page 47.
This example also contains a detailed description of step 7 in the I/O configuration section
and it is described in section Physical signal configuration on page 49.

The following procedure is a step-by-step description of how to set the configuration in
Step Action
For details, see the Softing PROFIBUS DP Configurator.
2. Import GSD-files for the unit that shall be used, see GSD-file importation on page 33
for details.
(GSD-file is provided by the manufacturer of the unit.)
Continued
Step Action
3. On the Options menu, click Advanced Mode.
(Basic mode does not allow the user to change the watchdog time.)
5. In the Master Selection List, double-click on the Profiboard.
See figure in step 5, in section PROFIBUS DP configurator setup on page 43 (Digital
I/O configuration example).
12.
7. In the Slave Selection List, double-click the ET200S.
en0400000896
to 10.
See figure in step 8, in section PROFIBUS DP configurator setup on page 43 (Digital
I/O configuration example).
9. In the DP Slave Configuration window, click the Modules tab.
For module selection, follow the steps in Module selection on page 51 .
Continued
Step Action
For description of how to download the file, see
Operator’s manual - RobotStudioOnline.
Physical signal configuration

According to the ET200S Distributed I/O System Manual (chapter 13.1.1, Analog value
representation for measuring ranges with S7) from Siemens:
• The analog values are represented in complements of two.
• The values are represented with 16 bits.
• Physical max. value: 10 V is represented by the value 27648.
• Physical min. value: -10 V is represented by the value -27648.
• The high byte is sent first, byte swap is needed.
For the configuration procedure, refer to Technical reference manual - System parameters.
Unit mapping
Unit mapping is necessary when specifying which bit(s) in the I/O memory map of the
assigned unit the signal is mapped to. All physical signals (i.e. signals connected to a physical
unit) must be mapped.
The table shows an example of unit mapping:
Signal Unit map Description

DO_1 0 Digital output signal
DI_1 0 Digital input signal
Continued
Signal Unit map Description

AO_1 24-31, 16-23 Analog output signal
Byte swap is needed
AO_2 40-47, 32-39 Analog output signal
Byte swap is needed
AI_1 24-31, 16-23 Analog input signal
Byte swap is needed
AI_2 40-47, 32-39 Analog input signal
Byte swap is needed
Continued
Module selection
When configuring the modules, make sure the different modules are added in correct order.
I.e. the slot numbers depend on the physical order of the modules. See the User Manual DP
Configurator for further details.
The following procedure is a detailed description of how to make the module selection.
Step Action
1. In the Available modules list, select the appropriate power supply module (6ES7
138-xxxxx-xxxx) and click Add.
en0400000898
2. In the Available modules list, select the appropriate module with 2 DO (6ES7 132-
xxxxx-xxxx) and click Add.
en0400000897
3. Repeat step 2 to select the other module with 2 DO.
Continued
Step Action
4. In the Available modules list, select the appropriate module with 2 DI (6ES7 131-
5. Repeat step 4 to select the other module with 2 DI.
6. In the Available modules list, select the appropriate module with 2 AO (6ES7 134-
7. In the Available modules list, select the appropriate module with 2 AI (6ES7 134-
4.5.3. Internal slave configuration example
4.5.3. Internal slave configuration example
Description
This is an example of how to configure the IRC5 Profibus-DP slave to address 12. The slave
unit has 128 digital inputs (16 bytes) and 128 digital outputs (16 bytes).
NOTE!
The unit type DP_SLAVE is a predefined unit type, i.e. the user does not need to make any
Unit Type definition for this slave. The default values for DP_SLAVE are 16 bytes inputs and
16 bytes outputs. The default sizes can be changed either by editing the unit type DP_SLAVE
or by creating a new unit type.
Internal slave configuration procedure

The following procedure is a step-by-step description of how to make the system parameter
configuration of the internal slave.
Step Action
1. Add a new unit to the system parameters.
2. Enter the unit name.
3. Select the Profibus1 bus, to which the unit is connected.
4. Select the DP_SLAVE unit type.
5. Enter the Profibus Address.
4.5.4. IRC5 master/slave configuration example
Description
This example demonstrates how two IRC5 systems can be configured to communicate with
each other, one as the master and one as a slave.
The bus is configured using the Softing PROFIBUS DP Configurator, with the master at
address 2 and with baudrate 12 Mbit/s.
This example is a detailed description of step 2 in the I/O configuration section and contains
information that is unique to this example.
Overview - how to start
Step Action Info

1. Start by configuring the slave system The slave system will be set up as an
according to section Internal slave con- ordinary PROFIBUS-DP slave unit with
figuration example on page 53. 128 DI and 128 DO. The address is 12.
2. Configure the master system with one
unit at address 12 of type
EXT_DP_SLAVE.
NOTE!
The unit type EXT_DP_SLAVE shall be used when configuring an IRC5 PROFIBUS master
to communicate via a PROFIBUS connection to the slave channel of another IRC5 system.
The unit type DP_SLAVE shall be used for configuring of the internal PROFIBUS slave, i.e.
the definition of a DP_SLAVE unit type will determine what the internal slave will look like
when seen from the PROFIBUS side.
The unit types EXT_DP_SLAVE and DP_SLAVE are predefined unit types, i.e. the user does
not need to make any Unit Type definition for these slaves.
Continued

The following procedure is a step-by-step description of how to set the configuration in the
Step Action
For details, see the Softing PROFIBUS DP Configurator manual.
3. In the Master Selection List, double-click on the Profiboard.
en0400000888
Continued
Step Action
12 MBaud. Click OK.
en0400000892
5. In the Slave Selection List, double-click on the PROFIboard/PROFI104.
en0400000903
Continued
Step Action
to 12.
en0400000904
7. In the DP Slave Configuration window, click the Modules tab.

In the Available Modules list, select 8 Word Out, 8 Word In and click Add.
en0400000905

For description of how to download the file, see
Operator’s manual - RobotStudioOnline.
9. Restart the controller.
Continued
Index
B
Bus termination 22
C
Cable parameters 26
D
DSQC 637 19
DSQC 637, Master and Slave connector 21
E
Example, ET200B unit 43
Example, ET200S unit 47
G
GSD-files 28
GSD-files, importing 33
I
I/O configuration 32
Internal Slave Input Size 42
S
Softing PROFIBUS DP Configurator 16, 28, 30
System parameters, Internal Slave 42
System parameters, Internal Slave Input Size 42
System parameters, Internal Slave Output Size 42
System parameters, Product ID 42
System parameters, Profibus Address 41
System parameters, Unit 41
System parameters, Unit Type 42
U
Unit configuration 33
59
Index
60
3HAC023008-001, Revision A, en
ABB Automation Technologies AB

Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

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1 Reference information, PROFIBUS 11

3 PROFIBUS-DP Master/Slave hardware 19

4 PROFIBUS-DP Master/Slave configuration 27

4.5.3 Internal slave configuration example ............................................................................ 53

About this manual

Who should read this manual?

Continues on next page

Product documentation, M2004

Continues on next page

1 Reference information, PROFIBUS

2.1. PROFIBUS, general

2.2. PROFIBUS, IRC5

DSQC 637 unit

Continues on next page

The PROFIBUS-DP network

A Line PLC, DP-Master

Continues on next page

Specification overview, Master

Specification overview, Slave

2.3. Definition of I/O units

Configuration of the controller

A Control module of the dual cabinet

Continues on next page

Information: Found in:

3 PROFIBUS-DP Master/Slave hardware

3.1 Hardware description

3.1.1. DSQC 637 PROFIBUS-DP master/slave

Installation and configuration

Continues on next page

Continues on next page

Description Art. number

Connections, Master and Slave connector

Signal name Master/Slave channel pin Function

Continues on next page

Cables and connectors

3.1.2. Definition of communication units, IRC5

Description Art. no. Note Pos.

Continues on next page

Description Art. no. Note Pos.

Installation of communication units

3.2.1. Connections, general

3.2.2. Selecting cables

Cable parameters, PROFIBUS-DP

Data rate in kbit/s Max. segment length in m

4 PROFIBUS-DP Master/Slave configuration

4.1.1. Software overview

Predefined master bus and I/O unit types

Continues on next page

Updating DSQC 637 firmware

4.1.2. Software, how to start

4.1.3. PROFIBUS-DP configuration software

Installing PROFIBUS-DP configurator

Bus parameter set - changing parameters

Slave parameter set - changing parameters

4.2 Workflows, PROFIBUS-DP master bus

4.2.2. Configuration overview

Continues on next page

Continues on next page

5. Now the imported GSD-file appears in the Imported DDB list.

4.2.3. Bus configuration