Example - AC500+S500FDP
Example - AC500+S500FDP
On principle, the configuration of decentralized systems connected by network is done in two steps:
• The CPU has to be informed about which couplers are assigned to it (internal and/or external
couplers).
• The couplers have to be informed about which peripheral devices are connected to them.
This is done using the tool SYCON.net (opened via the tab Resources -> Tools -> SYCON.net). This tool
is also used to create the variables lists for the individual peripheral devices. The symbolic names
created therein are directly (online) made available for the programming software. Thus, these created
variables are located in the Global Variables folder.
PDA11-FBP.050
+ 24 V DC
–
from COM2/PLC to PC
+/– 24 V DC +/– 24 V DC
PDP22
-FBP
+ 24 V DC
–
DC505-FBP + DC532 + AX522
PDR11-FBP.150
Figure: Example with an AC500 CPU as PROFIBUS DP master and a DC505-FBP as PROFIBUS DP
slave. Note: “to PC” – either COM1 interface of PC, directly, or corresponding COM interface of PC,
allocated via USB RS-232 converter.
The following example will guide you through the installation and the configuration of a small PROFIBUS
DP fieldbus using an AC500 PLC as PROFIBUS DP master and a S500-FBP remote I/O station with a
modular FBP.
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This example could be used as starting point to develop your own application.
Needed products
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Starting the programming software
Start the AC500 Control Builder programming software. Select "File/New" to create a new project.
Select the desired CPU in the appearing window. In our example, select PM581.
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A window appears where you can select the POU name, type and language. For the name and the type
keep the settings "PLC_PRG" and "Program". Select "ST" for the language and confirm with "OK".
First, save the project under a specific name. Select the menu item "File/Save as".
Select the desired directory and enter the project name (in our example: "Test3"). Complete your input
with "Save".
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Specifying the hardware configuration
The software has to be informed about the hardware configuration, i.e. the hardware configuration has to
be specified in the software. Click on .
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Double click the object "PLC Configuration". If the AC500 folder in the PLC configuration tree is closed,
click on the symbol.
First the I/O devices connected directly to the I/O bus of the CPU will be entered: Click on "I/O-Bus[FIX]"
and then press the right mouse button.
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Select "Append Subelement" -> "DC532".
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Now we are going to append the PROFIBUS DP communication module. In the configuration tree, click
on "Couplers[FIX]" and then press the right mouse button. Select Append Subelement -> CM572 and
then click to append the element.
The coupler is appended to the tree. As the CPU also comprises an integrated Ethernet coupler we are
going to replace ‘Couplers – Internal none’ by an Ethernet coupler.
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Configuring the decentralized S500-FBP I/O station using the SYCON.net fieldbus
configurator
Now we are going to configure the decentralized S500-FBP I/O station. Proceed as follows:
• In the left-hand window, click on the symbol in front of the Tools entry. Then double click the
entry SYCON.net.
• The SYCON.net fieldbus configurator is opened. Using this configurator, you can configure the
decentralized I/O station.
In the "Fieldbus" tab, open the folder 'PROFIBUS DPV 0' by clicking on the symbol. Do the same with
file "Master". With the left mouse button, click on CM572-DPM. Keep the left mouse button pressed and
drag the object into the left window to append it to the green line (this line represents the connection to
the CPU). Release the left mouse button.
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In the appearing window, leave the "Board No. 1" unchanged (counting mode: CPU-internal coupler =
Board No. 0, first coupler left of the CPU = Board No. 1, second coupler = Board No. 2).
Recommendation: You can choose the symbolic coupler name according to your plant (mark coupler
with left mouse button; the coupler is displayed with a blue rectangle; press right mouse button ->
symbolic name. Example for symbolic name: DPM1_AC500).
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The parameter settings of the communication coupler can be easily modified by double clicking on the
coupler symbol (surrounded by a blue line). A window opens - click on "Configuration -> Bus
Parameters". With that you can change the parameters.
The same procedure is used to append a slave to the PROFIBUS DP master CM572-DPM. Open the
"Slave" folder in the "Fieldbus" tab. Drag the PROFIBUS DP FieldBusPlug PDP22-FBP (DPV1 modular)
into the left-hand window to append it to the purple line (this line represents the PROFIBUS DP fieldbus).
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The FieldBusPlug slave is now appended to the PROFIBUS DP line. The symbolic name has been
changed to DPS2_FBP_S500.
The slave has to be correctly software configured and mapped to precisely match the true hardware
configuration. Double click on the PDP22-FBP symbol to open a new configuration window. In this
window the hardware configuration is described and some parameter settings can be defined.
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The slave station has to be set up. Click on "Configuration -> Modules" in the 'Pages Tree View'. First
select the FBP interface module DC505-FBP from the list of available modules. Click on "Append". Thus
the selected module is added to the list of configured modules.
The order of the modules in the list of configured modules must match the actual
ATTENTION order of hardware modules. Otherwise, the decentralized station and the
network cannot work properly!
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Repeat this procedure to append the modules DC532 and AX522. Then, the list of configured modules
looks as follows:
Proceed as follows to configure the module parameters. Click on "Configuration -> Parameters". Select
the corresponding module from the list.
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The available parameters are displayed.
Highlight the line of the desired parameter: move the cursor to that line and press the left mouse button.
Double click with the left mouse button onto the highlighted line. Click with the left mouse button on
to display the values available. Select the desired value by clicking with the left mouse button on that
value. Click with the left mouse button into the area with the empty lines. Thus the change has been
adopted.
After you have changed all the desired parameters, click on OK to exit the parameter configuration.
The configuration of the fieldbus modules is finished. Now the names of the communication variables
used for data exchange between coupler and CPU program have to be specified. Proceed as follows to
specify the variables (these variables are automatically forwarded to the AC500 Control Builder software
in order to have them available there):
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The upper part of the netConnect area contains a tree structure showing the master communication
coupler CM572-DPM and the slave PDP22-FBP (DPV1 modular) with the sorted list appended. Click on
the symbol in front of the entry PDP22-FBP to open this branch of the tree. For each I/O module, a
separate folder is displayed containing the corresponding data exchange variables.
Click on the first folder 2 byte input. This folder represents the digital inputs of the DC505-FBP module
(8 DI + 8 DC as input). The corresponding variables are listed in the appended list (with Name of signal,
Data type, I/O identifier (I = input, O = output) and Name of variable (can be entered)).
Enter a corresponding “Name of variable“ for each “Name of signal” .To do this, double click into the
Name of variable field of the corresponding signal. Enter the desired variable name and press the
<Enter> key to complete your entry. These names are used in the AC500 Control Builder software. In
our example, we use the following system for the variable name:
bytePROFIBUSDpslaveAddress2_S500(system)_DC505(device)_Input8_to15 (by - byte; b - bit; w -
word).
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Recommendation: For the planning of your plant we recommend to use symbolic names according to
your plant.
Assign a name to each variable. For the 8 DC (as outputs) of the DC505-FBP module:
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For the 16 DC (as outputs) of the DC532 module:
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For the 8 analog outputs of the analog module AX522:
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Double click on the coupler icon and select "Settings -> Driver -> 3S Gateway Driver".
In the Communication Parameters window, you can set the parameters for the communication between
the PC and the PLC (port: serial interface of the PC).
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Confirm the settings with "OK". Select "Settings -> Driver -> Device Assignment" and click on "Scan".
The configuration tool SYCON.net searches for PROFIBUS couplers connected to the stated interface.
Select the device "CM572-DP" and confirm with "OK". Then press the right mouse button and select
"Connect".
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The coupler entry CM572-DPM is now highlighted in green, indicating that the connection is established:
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This downloads the configuration to the coupler. Progress of data transfer is displayed.
After the download is completed, SYCON.net has to be disconnected. Press the right mouse button and
select "Disconnect".
In SYCON.net, the configuration has to be saved to a file. The system adopts the project name (in our
example: "Test3"). Select "File/Save".
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Return to the AC500 Control Builder by clicking on the button in the Windows task bar on
the bottom of the screen.
The AC500 Control Builder software is opened again and the fieldbus variables are automatically
transferred to the Global Variables list of the programming software.
Open the Global Variables in the "Resources" tab. Double click on Slot 1 <R>. The previously
configured variables are displayed and available in the programming software.
The input byte with the variable name byDps1_S500_DC505_In0_7 (signals I0 to I7 at DC505) is read
and applied to the output byte by_AC500_DC532_Out16_23 (signals C16 to 23 at DC532).
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New GSD file(s)
If you install additional GSD files to the installation of the Control Builder CD's
Note GSD files they have to be added to the device catalog of SYCON.net. To do
this apply subsequent procedure.
The GSD files have to be copied to the corresponding directory beforehand
(\ProgramFiles\HilscherGmbH\SYCONnet\ABBPBGenericSlaveDTM\GSD).
Attention: Handling of GSD files only works that way in case of an empty
project!
Click on . Open the 'Tools' folder. Double click on the entry SYCON.net.
Click into the window next to netDevice and select "Network/Device Catalog…" from the menu.
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Click on . This integrates the new GSD file. Click on OK and close SYCON.net.
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For AC1131 experts –
connection S500-FBP I/O module to series 90
Example with an AC31 Series 90 CPU as PROFIBUS DP Master and a DC505-FBP as
remote I/Os
+/– 24 V DC
PDA11-FBP.050
RUN
STOP
COM2
07 KT 98
AdvantController31
BasicUnit
COM1
PC
07 KT 97/98 DP
+
24 V DC
DC505 DC532 AX522
PDP22-FBP
+ 24 V DC
–
DC505-FBP + DC532 + AX522
PDR11-FBP.150
Figure: Example with an AC31 series 90 CPU as PROFIBUS DP master and a DC505-FBP as remote
I/Os
The following example will guide you through the installation and the configuration of a small PROFIBUS
DP fieldbus using an AC31 PLC as PROFIBUS DP Master and a S500-FBP remote I/O station with a
modular FBP.
This example could be used as starting point to realize your own application.
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Needed products
Before starting:
• Use the previous installation instructions to assemble and mount the system, also refer to the
dedicated User's manual of the PROFIBUS DP FBP and AC31 series 90 PLC.
• Make the wiring and provide power supply to the system (process supply) and to the FieldBusPlug
(use dedicated accessory, e.g. PDA11-FBP.050 which allows to connect a PROFIBUS DP master
with a 9-pin D-Sub and provide power supply for the FBP through an M12 connector).
• Set the slave address of the FBP to 1 with the front rotary switches of the S500-FBP module (see
Getting Started with S500-FBP, "Setting the FBP slave address").
• Install the AC1131 programming software for AC31 PLCs
• If you want to configure the fieldbus using the fieldbus configurator software 907 FB 1131, install this
software. As an alternative, you can also use the fieldbus configurator included in the programming
software.
• If you want to use the fieldbus configurator 907 AC 1131 for configuration, copy the PROFIBUS GSD
file ABB_091F.GSD to the folder \Program Files\AC1131\FB1131\Fieldbus\PROFIBUS\GSD. If you
want to configure the fieldbus using the fieldbus configurator included in the programming software,
copy the GSD file to the folder \Program Files\AC1131\Library\PLCConf.
• Connect the PC (COM1) to the AC31 CPU (COM1) using the programming cable 07 SK 90.
• Connect the CPU to the DC505-FBP module via the FieldBusPlug.
• Switch on voltage.
• Perform the steps given in the following instructions.
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Variant A: Configuration using the fieldbus configurator included in the
programming software
First, we have to specify the hardware. Click on . Double click the object "PLC
Configuration". Click on "Hardware Configuration". Press the right mouse button. Select "Append
Subelement/DP Master…".
Set the "Card number" in the appearing window. The following rule applies: The slot number (= card
number) can be gathered from the identification number of the CPU. Furthermore, we can also
determine the coupler form the identification number. The following applies:
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Press the right mouse button and select "Append DP Slave".
In the appearing window, select "PDP22-FBP (DPV1 modular) (Default)" in the File Name list box.
Click on the entry "PDP22-FBP (DPV1 modular). Press the right mouse button and select "Properties".
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Select "Input/Output". Click on the entry DC505-FBP in the left-hand window and then click on
"Select >>". Proceed in the same way for DC532 and AX522.
When a user program is loaded to the CPU, the configuration data of the coupler (the data are a definite
element of a project) are loaded as well. The operating system of the PLC transfers the configuration
data to the coupler. In addition, the configuration data can be saved together with the user program in
the Flash memory of the controller. The configuration data stored in the Flash memory are automatically
loaded the next time the power is switched on.
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Variant B: Configuration using the fieldbus configurator software FB1131
Start the fieldbus configurator software 907 FB 1131 and select "File -> New". A window appears where
you can select a fieldbus system.
Select PROFIBUS and click on OK. Now you have to configure the master.
Select Insert -> Master from the menu bar. The mouse pointer changes to an arrow with an 'M'. Left
click with the mouse on that position on the screen where you want to place the DP Master. Another
window appears.
In this window, select 07KT97 DPM and click on Add >> to add the selected master to the network. The
selected master is now displayed on the right-hand side of the window. You can change the default
address of the master and enter a comment in the 'Description' field.
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Now append a slave to the PROFIBUS DP line. Click below the master surrounded by a frame. A
rectangle indicates the area where the slave will be inserted.
The mouse pointer changes to an arrow with an 'S'. Proceed as already described for the master in
order to place the slave. A new window appears.
Left click with the mouse on that position on the screen where you want to place the Slave. Another
window appears. Scroll down in the left-hand area and select PDP22-FBP (DPV1 modular) as the
slave. Then click on ADD >>. Your selection is displayed on the right-hand side of the window.
In this window, you can also change the default station address and enter a description for the device.
Then click on OK.
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The configured fieldbus is displayed.
Double click inside of the rectangle surrounding the slave in order to configure the slave. A new window
named Slave Configuration appears.
The modular station has to be configured in order to specify the used hardware. First, select the FBP
interface module DC505-FBP (list of available modules ('Module' column) in the window shown above;
the selected module is highlighted by a rectangle). Click on Append Module to insert it into the list of
configured modules.
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The following information is given for the selected modules: Slot number (Slot), module type (Module)
and definition of the input bytes/words IB/IW and the output bytes/words QB/QW. Then we have to
specify the expansion modules of the used hardware. In our example this is a digital input/output module
DC532 and an analog input/output module AX522.
After you have added all required modules into the configuration list, click on OK to apply the
configuration.
Call the address table before you specify the parameter data (via View -> Address Table) in order to
update the addresses of the input/output variables.
If you want to change the device parameters of the slave, select the device entry to highlight it by a
rectangle. Press the right mouse button and select Parameter Data from the context menu.
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A new window appears, showing all PROFIBUS DP parameters:
For instance, click on Module if you want to change the delay time of all inputs of the module DC532.
Select dc532 1sap240100r0001 and click on OK. The corresponding module parameters are displayed
and can be changed now.
Example: In order to change the delay time of the inputs, double click on Input Delay.
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A new window appears, showing all available values. Select the desired value, e.g. 1 ms, and click on
OK.
After you have changed all the desired parameters, click on OK to exit the parameter configuration. The
following configuration is displayed:
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In order to test the configured fieldbus, the configuration has to be downloaded to the master. Select the
master (click on the master to highlight it by a surrounding rectangle). Select the menu item Online ->
Download.
Select 3S Gateway Driver as gateway for the download to the CPU coupler and click on OK.
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A new window named 3S Gateway Driver Assignment is opened for setting the gateway parameters
for the address assignment of the DP coupler in the CPU (this is only done when the gateway is used
the first time).
Click on Gateway Configuration and then select the default channel COM1_PC in the appearing
window.
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The window is closed and the software tries to establish the connection via the gateway. If the
connection establishment is successful, the couplers are displayed in the Device Information area.
Click into the field next to the coupler name to select the desired coupler (DPM) and confirm with OK.
To perform the download, select the menu item Online -> Download. A safety inquiry is displayed.
Answer with Yes. The configuration is then transferred to the controller.
The address data used can be displayed using the menu item View -> Address Table.
The digital inputs can be accessed via IB0 to IB5, the digital outputs via QB0 to QB2 and the analog
outputs via QW3 to QW11.
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Testing the system
In order to test the system, we are going to create a small user program. We are using the programming
language FBD. The program should read an input of the decentralized station (DC505-FBP) and output
the value at the CPU. The program looks as follows:
The first byte on the DC505-FBP is read at address %IB2.0 and output at the CPU via the address
%QB124 (outputs A62,00 to A62,07).
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