Application Example AC500 & IRC5

Fieldbus Connection
IRC5 <-> S500 IOs

IRC5 with PN-SW as master

connected to CI50x-PNIO
cluster with S500 IO-Modules

IRC5 +
PN-SW
<->
CI50x-PNIO
+ S500 IOs
abb
Content
1 Disclaimer .................................................................................................................. 3

1.1 For customers domiciled outside Germany/

Für Kunden mit Sitz außerhalb Deutschlands........................................................................ 3

1.2 Nur für Kunden mit Sitz in Deutschland ........................................................................ 3

2 Overview of this manual ........................................................................................... 4

3 Workflow overview .................................................................................................... 5

4 Hardware setup ......................................................................................................... 6

4.1 IRC5 with PROFINET SW stack ...................................................................................... 6

4.2 CI50x-PNIO devices with IO modules ............................................................................ 6

4.2.1 Products .................................................................................................................... 6

4.2.2 S500 components documentation .............................................................................. 7

5 PROFINET Configurator............................................................................................ 8

5.1 Preparation of the PROFINET Configurator .................................................................. 8

5.1.1 Installation ................................................................................................................. 8

5.1.2 Import ABB S500 FDCML files................................................................................... 8

5.2 Configuration of the PROFINET Bus............................................................................ 10

5.2.1 Adding PROFINET master for IRC5 SW Stack ........................................................ 10

5.2.2 Adding CI50x-PNIO devices .................................................................................... 10
5.2.3 Configuration of CI50x devices ................................................................................ 11
5.2.4 Configuration of IO channels and parameters .......................................................... 13
5.2.5 Address mapping of the process data ...................................................................... 13
5.2.6 Adding more IO Modules ......................................................................................... 16
5.2.7 Creation of Profinet Bus configuration file ................................................................ 16

6 Bus and IO Configuration in IRC5 .......................................................................... 18

6.1 Bus Configuration setup............................................................................................... 18

6.1.1 Copy the IPPNIO.xml file to the IRC5 controller ....................................................... 18

6.1.2 Adapt the Bus configuration in the IRC5 .................................................................. 18

6.2 IO-Signal Configuration setup ...................................................................................... 19

6.2.1 Renaming signals .................................................................................................... 19

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 6.2.2 Understand the automaticlly generated signal names. ............................................. 20
6.2.3 Meaningfull definitions of the signals........................................................................ 22
6.2.4 Warmstart of the IRC5 controller.............................................................................. 23

7 Compatibility Hints .................................................................................................. 24

8 Related documents ................................................................................................. 25

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 1 Disclaimer

1.1 For customers domiciled outside Germany/

Für Kunden mit Sitz außerhalb Deutschlands
"Warranty, Liability:
The user shall be solely responsible for the use of this application example described within this file.
ABB shall be under no warranty whatsoever. ABB's liability in connection with this application example or the
files included within this file, irrespective of the legal ground, shall be excluded. The exclusion of liability shall
not apply in the case of intention or gross negligence. The present declaration shall be governed by and
construed in accordance with the laws of Switzerland under exclusion of its conflict of laws rules and of the
Vienna Convention on the International Sale of Goods (CISG)."
"Gewährleistung und Haftung:
Der Nutzer ist allein für die Verwendung des in dieser Datei beschriebenen Anwendungsbeispiels
verantwortlich.
ABB unterliegt keiner Gewährleistung. Die Haftung von ABB im Zusammenhang mit diesem
Anwendungsbeispiel oder den in dieser Datei enthaltenen Dateien - gleich aus welchem Rechtsgrund - ist
ausgeschlossen. Dieser Ausschluß gilt nicht im Falle von Vorsatz oder grober Fahrlässigkeit. Diese
Erklärung unterliegt Schweizer Recht unter Ausschluß der Verweisungsnormen und des UN-Kaufrechts
(CISG)."

1.2 Nur für Kunden mit Sitz in Deutschland

"Gewährleistung und Haftung:
Die in diesem Anwendungsbeispiel enthaltenen Dateien beschreiben eine mögliche Anwendung der
Steuerung AC500 bzw. zeigen eine mögliche Einsatzart der Steuerung. Sie stellen nur Beispiele für
Programmierungen dar, sind aber keine fertigen Lösungen. Eine Gewähr kann nicht übernommen werden.
Der Nutzer ist für die ordnungsgemäße, insbesondere vollständige und fehlerfreie Programmierung der
Steuerungen selbst verantwortlich. Im Falle der teilweisen oder ganzen Übernahme der
Programmierbeispiele können gegen ABB keine Ansprüche geltend gemacht werden.
Die Haftung von ABB, gleich aus welchem Rechtsgrund, im Zusammenhang mit den Anwendungsbeispielen
oder den in dieser Datei enthaltenen Dateien wird ausgeschlossen. Der Haftungsausschluß gilt jedoch nicht
in Fällen des Vorsatzes, der groben Fahrlässigkeit, bei Ansprüchen nach dem Produkthaftungsgesetz, im
Falle der Verletzung des Lebens, des Körpers oder der Gesundheit oder bei schuldhafter Verletzung einer
wesentlichen Vertragspflicht. Im Falle der Verletzung einer wesentlichen Vertragspflicht ist die Haftung
jedoch auf den vertragstypischen, vorhersehbaren Schaden begrenzt, soweit nicht zugleich ein anderer der
in Satz 2 dieses Unterabsatzes erwähnten Fälle gegeben ist. Eine Änderung der Beweislast zum Nachteil
des Nutzers ist hiermit nicht verbunden.
Es gilt materielles deutsches Recht unter Ausschluß des UN-Kaufrechts."
Only for customers with seat in Germany
"Warranties and Liability:
The files contained in this application sample are only describing a possible use of the AC 500 control
system showing a possible kind of operation of it. These are only examples of the programming features and
in no way working solutions. No warranty can be accepted.
Each user himself is exclusively responsible for the correct, i.e. complete and faultless programming of the
control system. In case of a partial or complete adoption of programming samples no resulting claims may be
asserted against ABB.
In connection with the application examples or the files contained therein any liability of ABB regardless of
the legal cause shall be excluded. The exclusion of liability does not apply in the case of willful misconduct or
gross negligence by ABB, claims under product liability law, in case of damage to life, body or health or
breach of an essential contractual obligation. In case of breach of an essential contractual obligation the
liability will, however, be limited to compensation for the foreseeable damage, that is typical for this type of
contract in as far as no other exceptions are listed under sentence 2 of this subparagraph is present at the
same time. An amendment of the burden of proof to the disadvantage of the user shall not be associated
with this.
German substantive law shall apply excluding the UN Convention on the International Sale of Goods."

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2 Overview of this manual
About this manual

This application manual describes the preconditions, tools and configuration steps to connect S500 IO
clusters to an IRC5 Profinet master.
The S500 IOs will be connected to either a CI501-PNIO or CI502-PNIO module.

Usage

This application manual should be used during design of an IRC5 system with attached S500 IO to
Profinet as well as during configuration and commissioning of the S500 IO clusters.

Who should read this manual?

This manual is intended for:

· Personnel that are responsible for installations and configurations of fieldbus hardware/software
of IRC5 system
· Personnel that make the configurations of the IRC5 I/O system

· System integrators

Prerequisites

The reader should have the required knowledge of:

· Mechanical installation work

· Electrical installation work

· System and fieldbus parameter configuration of IRC5 systems

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3 Workflow overview
The following chapter gives a short overview of the steps that have to be performed to setup and
commission the connection from an IRC5 Profnet master to a S500 IO cluster and where to find the
detailed information in this manual.

1. Hardware configuration and installation:

- IRC5 with Profinet master option PN-SW (chap 4.1., page 6)

- CI501 or CI502 + S500 IOs installation and documentation (chap. 4.2 Page 6)

2. Prepare the PROFINET Configurator

- Installation of PROFINET Configurator (chap.5.1.1 , page 8)

- Import of ABB S500 FDCML files (chap 5.1.2,.page 8)

3. Create IPPNIO.xml file of S500 IO cluster with Profinet Configurator

- Add and configure Profinet master (chap. 5.2.2, page 10)

- Add and configure CI50x modules: Device name, IO channels (chap. 5.2.4, page 13)

- Add and configure more S500 IO modules (chap. 5.2.6 page 16)

- Create final IPPNIO.xml (chap. 5.2.7 ,page 16

4. Copy the IPPNIO.xml file into the IRC5 configuration (chap. 6.1.1, page 18)

5. Adapt bus configuration and create or scan for EIO UNITS and IO Signals (chap 6.1.2, page.18)

6. Adapt the IO Signal mappings (chap.6.2, page 19)

7. Warmstart the IRC5 controller (twice) (chap. 6.2.4, page 23)

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4 Hardware setup

4.1 IRC5 with PROFINET SW stack

The PROFINET SW stack is part of the ordered IRC5 controller. See related documents.

4.2 CI50x-PNIO devices with IO modules

4.2.1 Products
Product Description Order code Version

CI501-PNIO CI501-PNIO Interface- 1SAP220600R0001 C1

Modul for Profinet IO
Protocol,

CI502-PNIO CI502-PNIO I Interface- 1SAP220700R0001 C2

Modul for Profinet IO
Protocol,

TU507-ETH TU507-ETH 1SAP214200R0001 Choose needed

S500-Bus Terminal Unit, terminal type
Screw

oder
TU508-ETH 1SAP214000R0001
TU508-ETH
S500,Bus Terminal Unit
Spring

Several S500 IO- See AC500/S500

Modules documentation

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 4.2.2 S500 components documentation
The documentation of the S500 IO modules is part of the AC500 PLC documentation of the PS501
Automation Builder (Control Builder Plus)
It can be downloaded and installed separately as described here:

4.2.2.1 Download the PS501 Online Help

Try this Link or follow the next steps:

è Goto www.abb.com/PLC
è Select English as language and doubleclick on
Downloads \ Programmable Logic Controllers PLCs

è Search for “Online Help”

è Select the AC500 control Builder Plus PS501 Documentation and download this
3ADR025078M0203.ZIP file.
è Unzip the file to a local folder on your Windows PC

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

Notice

è Doubleclick the file CAA-Merger-2.chm. The Online Help Chapter for AC500 / S500 Hardware will
open.
è In the chapter Hardware S500 the documentation of Bus Modules and IO-Moduls can be found.

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5 PROFINET Configurator
To configure the Profinet bus for IRC5 controller the tool “PROFINET Configurator” from KW-Soft has to be
used.

5.1 Preparation of the PROFINET Configurator

5.1.1 Installation
The installation files for the PROFINET Configuator can be found on the IRC5 or Automation Builder
installation media in following folder:
“Robot Controller \ IRC5 \ RoboWare XY \ Utility \ Fieldbus \ Profinet”

Unzip the “PROFINET-IO Configurator Express.zip” file and start the setup with the “setup.exe” file. Then
follow the instructions of the Setup routine.

5.1.2 Import ABB S500 FDCML files

To import the FDCML-files from Automation Products (including CI50x-PNIO) into the Profinet Configurator
please proceed as follows:

1. Extract the archive “ABB Automation Products GmbH.zip” into the FDCML directory for PROFINET
devices
a) On Windows 7 this directory is usually called
“C:\Users\Public\Documents\FDCML10\Profinet”
b) On Windows XP this directory is usually called
“C:\Documents and Settings\All Users\Documents\FDCML10\ Profinet”

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2. In the device catalog of the PROFINET Configurator choose
“Import Device…” (Not “Import GSD File…”!) from the context menu and
select all 4 XML files simultaneously.

After the import the folder “ABB Automation Products” will be selectable in the Device Catalog section.

The XC-versions of CI50x-PNIO are constructed for extrem conditions and therefore have
a separat order code.
There is no diffrence in configuration for the XC versions
NOTICE

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5.2 Configuration of the PROFINET Bus
5.2.1 Adding PROFINET master for IRC5 SW Stack
Create a new project,
open the folder “KW-Software \ IO \ PLC “ folder.
double click on the “KW-Software PROFINET IO Rev >= 3.50” device in the Device Catalog section.

5.2.2 Adding CI50x-PNIO devices

Activate the PROFINET node in the Bus Structure section by a click on it.
Double click on the IO device to be added to the bus in the Device Catalog section.

The CI50x-PNIO module will be placed beneath the PROFINET node.

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 5.2.3 Configuration of CI50x devices
5.2.3.1 Device name

Malfunctions due to wrong device name settings!

Each device name can only be used once in a network to be explicit.
Make sure that each device has an unique device name.
CAUTION!

The Device name of the CI50x-PNIO devices has to be set according the one of the following rules.

5.2.3.1.1 Automatic device name via Address Switches

The AC500 PROFINET® IO RT Devices (CI50x-PNIO) are equipped with 2 rotary switches to set an
explicit name to the IO Devices before commissioning. No engineering tool is needed.
The device gets its name (including the fixed part of the device name) directly from the setting of the
switches (01h...FFh). This name has to be set in the device configuration as DNS/PROFINET Device
Name.

This name is for example: ci501-pn-xx

"ci501-pn“ is the fixed part of the device name and “xx” represents the position of the rotary switch
(0..255d or 00..FFh).
See number 10 in the figure below:

If the first rotary switch is set to 2 and the second to 0 the Device Name must be: ci501-pn-20

The last number of the device name must not have leading zeros.

Only two digits must be used.

Note

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 5.2.3.1.2 Free configuration of the device name
The allocation of the device name can also be free selected. For this possibility of naming, it is necessary
to set both address switches to "00".
Then a device name can be set manually.

If the address switches are not set to "00", the device name set via configuration
tool is also stored permanently. But after a restart, the stored device name is not
used; the device's behaviour is like described in section 5.2.3.1.1
Note

5.2.3.1.3 Set the device name in Profinet Configurator

The name for the device name must be set according the following picture in the Profinet Configurator.

5.2.3.2 Configuration parameters of CI50x modules

Check the other configuration parameters and adapt them to your needs.
E.g. the check of the power supply of the IO cluster can be disabled in the section Device parameters of
CI501 Input/Output.

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 5.2.4 Configuration of IO channels and parameters
Select the “CI50x Input/Output” module in the Bus Structure section and select the “Device Parameter”
tab in the Device Details section to edit the IO parameters of the module.
E.g. the configuration of the analogue channels

5.2.5 Address mapping of the process data

To later find the process data in the (group) signals of the IRC5 configuration, the IO addresses of the
inputs and outputs should be “stored” to look-up later on.
Open the Process Data tab to see how (many of) the input and output bytes and bits are mapped within
the module.
e.g. for CI501-PNIO inputs

and outputs:

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 The next attached IO module will send and receive data to and in IRC5 on addresses which have an
offset to the last device before.

5.2.5.1 Information about the internal data usage per module

To allocate the data within the whole IO-cluster including several IO moduls it is important to know how
many data each IO module occupies.
This information can be found in the S500 Hardware chapter of the PS501 Online Help for each IO
module under the subchapter “Internal Data exchange”.
Open the CAA-Merger-2.chm file as described in chapter 4.2.2 and check the following chapters

5.2.5.1.1 For CI50x devices:

“Hardware S500 (System description) \ Bus modules \ PROFINET”
e.g. for a CI501 (V3)

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 5.2.5.1.2 For IO modules:
“S500 \ Hardware S500 (System description) \ Digital Input/Output Modules”
or
“S500 \ Hardware S500 (System description) \ Analog Input/Output Modules”
or
“S500 \ Hardware S500 (System description) \ Digital/Analog Input/Output Modules”
e.g. for a DC532

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 5.2.6 Adding more IO Modules
To add more IO-Modules click on the last IO module in the Bus Structur section.
Double click on the new IO-Module to be added in the Module Catalog section.

Do not select the IO-Modules “With Fast Counter” as the Fast Counter mostly is
only working with AC500 as the Profinet master.

NOTICE Please check in the S500 documentation (Online Help) if the Fast Counter is
available only for AC500 Profinet master.
This can be found in the Hardware documentation of the according IO Module in
the section “Internal Data Exchange”
See chapter 5.2.5.1.2

E.g: DAO501, DI524, DC522, DC523, DC532, DX522

5.2.7 Creation of Profinet Bus configuration file

1. Save the project
2. Click on the Profinet master node in the Bus Structur section
3. Check the configuration: Edit \ Check
4. Parametrize: Edit \ Parametrize

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The IPPNIO.xml configuration file is generated and saved in the project folder.

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6 Bus and IO Configuration in IRC5

6.1 Bus Configuration setup

6.1.1 Copy the IPPNIO.xml file to the IRC5 controller
Use FTP or USB Stick to copy the IPPNIO.xml file into the HOME directory of the robot system to be
used.

6.1.2 Adapt the Bus configuration in the IRC5

While being connected to the robot which is to be used as master, navigate to the Bus configuration page
in Robot Studio according the figure below for the selected robot and its bus to adapt.

Request write permission from the connected controller by clicking the “Request Write Access” button in
menu. If the robto is in manual mode, answer the request for mastership at the FlexPendant.
Double click the Profinet_SW bus:

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 1 Enter the name of the bus configuration file “IPPNIO.xml”
2 Enter the IP-Address and subnet mask for the PROFINET master
3 Enter the name of the PROFINET master (must be the same as used in the bus
configuration)
4 If you want an automatic definition of the untis defined in the bus configuration you can use
the Auto Configuration parameter to select the way how the unit shall be defined.

Restart the IRC5 controller twice.

The first restart will detect and define the found units from the IPPNIO.xml bus configuration file.
With the second restart the new found units will be activated in the IRC5 system.

If you need to adapt signal naming or other settings, this has to be done after the first restart as described in
the following chapters.

6.2 IO-Signal Configuration setup

The following subchapters apply as well to input as well as to output signals.
The examples are made for inputs signals only.

6.2.1 Renaming signals

To verify the signals in the IRC5 program it is helpful to rename the signal according their meaning and or
use.
Navigate to the signal list in the configuration of the IRC5 according the following screenshot:

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 Find the signal you want to adapte and double click it´s entry.

Here you can edit the name of the signal.

6.2.2 Understand the automaticlly generated signal names.

If the auto configuration for the units on the bus is used, the IRC5 signal names are generated using the
following rule:
“device name + In/Out indication + index”.
The index is starting at zero and automatically increased by steps of one overall slots of the device.
If the auto configuration is set to use group signals, the step will be one for each byte.
If single signals is selected, the step will be one for each channel (bit).

In the PROFINET Configurator you can find the meaning of the signals and their slot-internal address as
described in chapter 5.2.5

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 Example:
The unit consisting of CI501-PNIO + DC522 + AX522

The CI501 itself has the following Inputs:

This corresponds to the IRC5 group signals in the green frame.

e.g ci501_pn_20_IN2 = Analog Input Channel 1.

The last entry + 1 gives the starting address for the next device.
DC522 itself has the following inputs:

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 This results in a numbering of 18+1 = 19 for the first input byte of the DC522 in IRC5 mapping:

This mechanism applies for all following slots.

E.g. the third module (AX522) input numbering will start with byte number 21 (19 + 2).

6.2.3 Meaningfull definitions of the signals

All the automatically defined groups are 8 bit group.
The analog values from the IO-devices are managed word wise.
E.g.
ci501_pn_20_IN2 = HighByte of Analog Input Channel 1
ci501_pn_20_IN3 = LowByte of Analog Input Channel 1.
Therefore it´s sensefull to adapt the definition of the group signals.
Change the group signal ci501_pn_20_IN2 to a 16 bit input group,
change the Unit Mapping to channel 16 – 31 and
rename it to “Analog_Input_Channel_1”.
The remaining group ci501_pn_20_IN3 can be deleted now.

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 In the following screenshot you will see the needed changes for the signal ci501_pn_20_IN2.
After the changes have been applied the signal “Analog_Input_Channel_1” will be a input group with 16
bits, reflecting the second analog input value of AX522.

6.2.4 Warmstart of the IRC5 controller

To activate the configured changes the IRC5 controller has to be restarted.
At least once after changing parameters manually.
Twice if automatic bus scan is used. Because the first restart will scan the bus. The second warmstart will
activate the found units.

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7 Compatibility Hints
The functionality described in this application note was originally tested with the following components and
software versions:

Component Hardware Firmware Remark

IRC5 Controller RW 5.15.04, RW 5.60.00

CI501-PNIO Index: C1
CI502-PNIO Index: C2
DC532 Index B4
DC522 Index:B0
AX522 Index: B8

KW-Soft
1.10 Express (File version 1.10.22)
PROFINET Configurator
S500-CI501-PNIO_20121120_ci501-pn-00_DIM 1.xml
S500-CI501-PNIO_20121120_ci501-pn-00_DIM 2.xml
Xml-files for CI50x
S500-CI502-PNIO_20121120_ci502-pn-00_DIM 1.xml
S500-CI502-PNIO_20121120_ci502-pn-00_DIM 2.xml

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8 Related documents
Titel Doc ID Revision

Technical Reference manual Revision: R (RW 5.15)

Document ID: 3HAC17076-1
System parameters IRC5 Revision: S (RW 5.60)
Application manual
Document ID: 3HAC039906-001 Revision: D (RW 5.15)
PROFINET Master and Slave SW
IRC5
Application manual Document ID: 3HAC047133-001 Revision: - (RW 5.60)
PROFINET IRC5
AC500 / S500 Online Help V2.3.0,
Document ID 3ADR025078M0203
CAA-Merger-2.chm Issue Date 2013-04-30

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Doc. kind: No. o. p.:

Application Note 28
Title: Lang.:

AC500 communication with a MySQL server English

Doc. No

3ADR025200M0201

HISTORY
History Page (P) Description Date
Index Chapter (C) Dept./Initials
A First version March 2014
DEAPR/ACM2

Manual No. 3ADR 025 200 M0201

abb
ABB Automation Products GmbH
Wallstadter Str. 59
D-68526 Ladenburg
Tel. : +49 62 21 / 701-1444
Fax : +49 62 21 / 701-1382
E-Mail : [email protected]

www.abb.com/plc