HIMA Training

Ethernet-Communication

Contents
1

Protocols HIPRO-S / HIPRO-S-DIRECT............................................................ 2

Creating a project with 3 resources (example) ............................................... 3

Definition of bus and subscribers.................................................................... 4

Properties of the Resource............................................................................... 9

Assigning the variables for the communication ........................................... 13

5.1

Notes regarding variable definition: .......................................................................................13

Compiling PES - Master (for communication control only) ......................... 19

Communication monitoring............................................................................ 22
7.1
For ELOP-II NT V3.0 / operating system up to V7.0-7 (0114)...............................................22
7.2
For ELOP II V3.5 / operating system V7.0-8 (0214) / F8625 with OS V1.14 and function block
HK-COM-3......................................................................................................................................23

General notes, error sources, system limits ................................................. 25

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1 Protocols HIPRO-S / HIPRO-S-DIRECT

There are two protocols existing for safety relate data transmission (safeethernet).
The protocols and according preconditions are explained in the actual data sheet of module F8627.

Here an extract of the data sheet:

Conclusion:
In new installations the preconditions for HIPRO-S DIRECT are normally fulfilled.
Comparing the two protocols there are only advantages for HIPRO-S DIRECT (faster, easy to
configure, more flexible)
Recommendation:
If possible on some way, adjust at communication module F8627 HIPRO-S DIRECT mode (Dipswitch).
In ELOP-II there is no need anymore to define dummy communication from each PES with each
other PES.

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2 Creating a project with 3 resources (example)

Example: Configuration with 3 resources:
PESxxx01
PESxxx02
PESxxx03

with Program-Instance Program_PES1

with Program-Instance Program_PES2
with Program-Instance Program_PES3

The programs are already assigned as program-instances to the resources.

The name of a resource must be exactly 8 characters long, the last two characters must be
numbers (from 01 to 64). With this numbers the IP addresses of the F8625 modules are calculated
automatically (see data sheet F8625).
The following bus (Type HIBUS) has two tasks:
1. By using the Ethernet module F8625 and according settings the HIPRO-S data is transferred via
this bus. In this network the IP addresses defined via the resource names are valid.
2. If an additional RS-485 bus is used as programming bus for ELOP II the bus addresses set on the
Central units are valid in this network. ELOP II cannot be connected via Ethernet!
That means, that the bus which was once defined in ELOP-II may exist twice physically. A definition of
two busses is possible but not necessary.

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3 Definition of bus and subscribers

Step 1: Open context menu of the configuration and select properties

Step 2: Add a new bus.

Select the tab "Buses", button "Add" and define a name for the bus e. g. "NETWORK".
Confirm with OK.

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Step 3:

Ethernet-Communication

Add the stations of the bus

Click on the button: "Add"

Step 4: Define the slaves

Select a resource out of existing list.
BSN (bus station number) must be the same as set with the dip switches on the Central unit.
Repeat this step for each resource!

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Step 5: Add ELOP II PC

Select the bus name, click on the button "Edit"

In the window "Edit HIBUS bus name" : click on Add

Type: select PADT (PC)
Insert name for PC
Define BSN, No. 31 for PC !
Confirm with OK.

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Step 6: Add PES-Master

Note: A real master does not exist when using Ethernet communication. However, a PES master has
to be defined!
Click on Add
Select the type "PES-Master"
Insert name e. g. "Master"
Parameter for BSN and PES-Master can be free selected, entries are not evaluated!

Result after 6 Steps:

Confirm entries with OK.

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Step 7: Check parameter, valid for RS485 ELOP-II programming bus:

Recommendation: keep standard setting

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4 Properties of the Resource

Step 1: Select context menu of the resource, properties, PADT (PC):

Select bus out of existing bus list.
Select PADT (PC) out of existing PADT list.
Note: Do not insert own new names here!

Take entries with Apply and confirm with button "OK".

Repeat Step 1 for each resource!

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Step 2: Edit cabinet layout, checking the interfaces of the Central unit
Click the right mouse button on the Central unit e. g. F8652, > Edit or double click:
The properties of the Central unit are shown
It is recommended to "use bus settings". By this the parameters can be defined central for all
resources belonging to a defined bus.
HW-settings means, the baud rate set with the Dip switches on the Central unit is active.
It is also possible to set the parameters manually (for special applications).
The setting can be different for both interfaces (left SIO1, right SIO2)

Inserting the Ethernet -modules F8625 (left) and F8625x (right) is required for a complete
documentation. This has no effect to the system.
Repeat Step 2 for each resource!

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Step 3: Introduce the communication partner in the resource:

Select context menu of the resource, > properties, > HIPRO-S
Select the resources, with which data shall be exchanged:
Example: If you opened the properties of PES___01, you can select PES___02 and/or PES___03 as
partners.
Select the Master(s) responsible for organisation of the communication.
Define the Monitoring time: If there is no data exchange with the resource within the monitoring time,
the values of the variables are reset if the setting "Reset imported variables" is marked. (Required for
safety related communication)

Repeat Step 3 for each resource!

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Result for PES___01:

Result for PES___02:

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5 Assigning the variables for the communication

5.1

Notes regarding variable definition:

Each HIPRO-S variable is defined twice. In the sender as "Export to Resource" and in minimum one
receiver as "Import from Resource". The variable name must be the same in all resources where the
variable is defined.
One variable can be transferred to several receivers.
To ensure correct spelling it is recommended to define the variable one time at the sender and to copy
it using "drag and drop" to the receiver (keep left mouse key pressed)
Another possibility: using EXCEL to define the variables and import them afterwards.
Example: AN02_PES01to PES02 will be created in PES01 and send to PES02 to read it there.
So the variable must exist in both program instances.
Open both program instances and copy it by "drag and drop":

HIPRO-S (standard):
For a Safe-Ethernet-communication each BUS-subscriber must know the other BUS-subscribers. To
ensure this requirement, dummy-variables must be defined and exchanged. Following matrix shall be
observed.
Principle: There must be a communication from each PLC with each other PLC (unidirectional)
Example: 3 PES (PES___01 PES___03)
PES___01
Export

Import

PES___02
Export

Import

Dummy_PES1toPES2

PES___03
Export

Import

Dummy_PES1toPES2

Dummy_PES1toPES3

Dummy_PES1toPES3
Dummy_PES2toPES3

Dummy_PES2toPES3

In principle the definition of dummy-variables is only required, if no other variables are exchanged
between the corresponding subscribers.
For a systematic way of working it is strictly recommended, to define all required dummy-variables
which are needed to ensure a reliable Safe-Ethernet-communication.
HIPRO-S DIRECT: No dummy communication from each PES to each other PES required!
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The definition of communication variables must be done for all resources according to the steps 1-6 in
this chapter.

Example: Variable Var01_PES01toPES02

should be transmitted from PES___01 to PES___02.

Step 1 Export:
Open program instance PES___01, > Variable declaration
Right mouse button, > New

Step 2 Export:
Enter variable name in PES___01 e.g. Var01_PES01toPES02, declaration "BOOL"

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Step 3 Export :
Open folder "HIPRO-N/_S"
Mark other resource (PES___02)

Step 4 Export :
Select with double-arrow Export to Resource

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Step 5 Import
Open program instance in PES___02 to define the corresponding Import:
Create a new Variable in PES___02 with the same Name like in PES___01 used for Export or copy
the variable from program instance PES___01 to program instance PES___02, refer to 5.1
(e.g. Var01_PES01toPES02)

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Step 6 Import :
Open folder "HIPRO-N/_S"
Mark other resource

Step 7 Import :
Select with double-arrow Import from Resource

Repeat steps 1 to 7 till all variables are defined.

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Step 8 Start code generator for all resources

The code generator must be started for all modified resources!
It is not possible to generate reloadable code.

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Compiling PES - Master (for communication control only)

Step 1 Edit PES-Master

Configuration, right mouse button > PES-Master

Step 2 Compiling PES-Master

Mark the PES-Master
Button "Execute"

Then press button "Cross-Reference"

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Step 3 Cross-Reference
With the cross-reference the defined communication variables can be checked. (button CrossReference in the PES-Master window.
Example without errors:

You can see the variables which will be exchanged between the resources. If there is no error shown
in the column Error, all variables are defined correctly.
If there are any errors shown they must be eliminated before you can proceed to the next step!

Example with errors:

The variables with indication "no source" or "no target" must be checked again in the program
instances .
The indication "different data blocks" will sometimes appear additional, can be ignored.
In example the definition for Export in PES___01 is missing.

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Please note: Window PES-Master CRF-Docu Configuration must be closed!

Otherwise code generation in a resource in not possible any more
Reaction:

Step 4 Download of the resources

If there is no error in the Cross-Reference, each resource can be downloaded.
Right mouse button on the resource, > Control panel
> Download
Remember: There is no need to download the master because the Master is not existing physically.

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7 Communication monitoring
7.1

For ELOP-II NT V3.0 / operating system up to V7.0-7 (0114)

Example: Logic for communication monitoring in PES___03:

The system variables "HIBUS.Resoucename.Receive counter" and "HIBUS.Resourcename.Fault" are

created automatically during installing a HIPRO-S communication.
The system variables must be assigned to normal variables to use them in logic.
Please take care:
Communication monitoring is only possible, if there is an installed "Import" from the other resources,
means e.g. there must be an active data transmission from PES___02 (Export) to PES___03 (Import)
to see "HIBUS.PES___02.Fault" as "FALSE" and a running "HIBUS.PES___02.Receive counter".
Advice:
In example both system variables are used, in practice it is ok to use only
"HIBUS.Resourcename.Fault"

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7.2

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For ELOP II V3.5 / operating system V7.0-8 (0214) / F8625 with OS V1.14
and function block HK-COM-3

Example:
Using function block Ethernet_Diag (e.g. copy from Application project)

Please note: In redundant operation one PES is using in minimum two different nodes in two different
segments !
Settings:
Setup Slot with location of communication module (1,2,3,4,5)
Setup Nb_OPC-Server_SegmentX with the number of used OPC-Servers in segment.
HIPRO-S:
Function block HK-COM3 will look always for 4 OPC-Server, means if no OPC-Server available, 4
stations are indicated as not connected.
To avoid wrong indication, the number of existing OPC-Servers must be set.
HIPRO-S-DIRECT:
The maximum number of OPC-Server must be set by dip switch on the module F8627. This number
must be set also in the logic of function block Ethernet_Diag.
The number of really existing OPC-Server must be set as a parameter Nb_OPCServer_SegmentX
Example: if no OPC-Server is used, Nb_OPC-Server_SegmentX will be 0 !

Diagnostic:
Error_Redundancy is indicated if one segment is OK and in the other segment at least one node is
disconnected or module error is active.
Error_Communication is indicated if nodes in both segments are disconnected or module error.
Regarding only safety related communication, Error_Communication can also mean
Error_Redundancy if nodes in different PES are disconnected or the missing node is an OPCServer.

Advice:
Function block Ethernet_Diag should only used additional to the evaluation of system
variable HIBUS.Resourcename.Fault .
Not in every case , Error_Communication is indicating also a problem in safety related
communication !

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Logic of function block Ethernet_Diag :

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8 General notes, error sources, system limits

Bus configuration, Hardware:
Please refer to the H41q/H51q catalogue where you find the data sheet of the module F 8625 with
comprehensive explanations regarding the bus configuration.
Take care: Using SafeEthernet (F8625) and PES-Master (F8621A) is only possible with special
settings of function block HK-COM-3 !
Dip-switches on the module F 8625
Please refer to the H41q/H51q catalogue where you find the data sheet of the module F 8625. Please
take care of to the settings if using redundant modules!
For interpretation of LED's on F8625 please refer to datasheet F8625 page 2/12
Error sources:
wrong name for the resource

Result: RUN-LED on F 8625 is flashing, no communication

between Central unit and F8625.
wrong cable connection
If using a HUB the standard Ethernet cables have to be used.
In case of direct connection of two devices so called Cross-Over
cables have to be used.
no dummy-variables (HIPRO-S) Several token are started at the same time which causes collisions
on the bus.
Exchange of module F8625/F8627:

Don't withdraw module while RUN-LED = Off and ERR-LED = flashing

In a redundant system first withdraw according Central unit (CU) !

If modules are working in redundant mode, withdraw a module only with connected
HSR cable to ensure a defined disconnection from the Ethernet segment.
Otherwise communication will not jump over to other module properly and
communication may be interrupted. (see Catalogue H41q/h51q page 108)

After the new exchanged module is in, it may take up to two minutes until the
communication is working again.
(Reason: The ARP-Timeout on the module of communication partner can be two minutes in
worst case. During this time the communication partner still tries to contact the old MACAddress. Then an ARP-Request is used to figure out the new MAC-Address of the exchanged
module)
Now first check whether the exchanged communication module is working again, using
ELOP-II Block HK-COM3 or service tool ComEth.
If there are not yet all nodes connected properly, exchanging of other (redundant)
communication modules or executing a reload can be risky.

System limits:

Number of variables for HIPRO-S:

Max.505 Bytes from one resources to another one, means in one transmission.
"Word" will be counted as two Bytes, 8 "Bool" will be counted as one Byte (round up).

Data memory:
Max.64KB can be used in a Central unit for safety related data exchange with HIPRO-S

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Note: "Word" will be counted as two Bytes, "Bool" will be counted as one Byte.

Max.64 communication partners (limit never reached in practice).

Estimation of bus cycle time (n = number of F8625 at the segment, without OPC-server):
[n] x 10ms + [n x (n - 1) /2] x 6ms
Example: n = 3 means: 3 x 10ms + 3 x 6ms = 48ms

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