Application manual - Technology

Application manual 

PROFIBUS-DP 

Robot controller 

RobotWare 5.0

Application manual 

PROFIBUS-DP 

RobotWare 5.0 

Document ID: 3HAC023008-001 

Revision: -

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 

4.3 Workflows, PROFIBUS-DP internal slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 

4.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 

4.3.2 Internal slave configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 

4.4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

4.4.1 System parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

4.5 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 

4.5.1 Digital I/O configuration example (Non Modular station) . . . . . . . . . . . . . . . . . . . . . . 40 

4.5.2 Modular station configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 

4.5.3 Internal slave configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

3HAC023008-001 Revision: - 3

Table of Contents 

4.5.4 IRC5 master/slave configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 

4 3HAC023008-001 Revision: -

Overview 

Overview 

About this manual 

This manual is primarily a description of the PROFIBUS-DP field bus 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 

3HAC023008-001 Revision: - 5

Overview 

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 

6 3HAC023008-001 Revision: -

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 

3HAC023008-001 Revision: - 7


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 

include: 

• Operator’s manual - IRC5 with FlexPendant 

• Operator’s manual - RobotStudioOnline 

• Trouble shooting Manual for the controller and robot 

Miscellaneous 

A number of manuals provide generic descriptions of the robot and robot system. These 

include: 

• Robot fundamentals (describing the fundamental aspects, functions, concept and 

similar, of a robot system to provide a basic understanding of the robot system) 

8 3HAC023008-001 Revision: -

Safety 

Safety 

Safety of personnel 

When working inside the control cabinet 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, e.g. 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 control cabinet 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. 

3HAC023008-001 Revision: - 9

Safety 

10 3HAC023008-001 Revision: -

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. 

3HAC023008-001 Revision: - 11


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 

Operator’s manual - RobotStudio Online 3HAC 18236-1 

Product manual IRC5, M2004 3HAC 021313-001 

Technical reference manual - System parameters 3HAC 17076-1 

Other references 

References 

International standard IEC 61158 Type 3 

International standard IEC 61784 

PROFIBUS Technical Guideline 

User Manual DP Configurator 

ET200S Distributed I/O System Manual 

www.profibus.com 

Description 

The PROFIBUS fieldbus standard is 

described in the international standards. 

Installation Guideline for PROFIBUS-DP/FMS 

(Version 1.0, September 1998) 

Manual for the PROFIBUS configuration tool 

(PC software) 

Manual from Siemens 

The web site of PROFIBUS International 

12 3HAC023008-001 Revision: -

2 Overview 

2.1. PROFIBUS, general 

2 Overview 

2.1. PROFIBUS, general 

What is PROFIBUS? 

PROFIBUS is a vendor-independent open field 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 slaveto-slave 

data exchange with an isochronous bus cycle. 

3HAC023008-001 Revision: - 13

2 Overview 

2.2. PROFIBUS, IRC5 


Hardware overview 

DSQC 637 unit 

The hardware of the PROFIBUS-DP fieldbus consists of a Master/Slave unit, DSQC 637, and 

distributed I/O units (called Slave units). 

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. 

14 3HAC023008-001 Revision: -

2 Overview 


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 control cabinet 

C 

Robot 

D 

I/O unit, DP-Slave 

E DP-Slave (IRC5 - DSQC 637) 

F DP-Master (IRC5 - DSQC 637) 

Configuration program 

The configuration program PROFIBUS DP Configurator (from Softing), together with the 

RobotStudio Online , is used to configure the bus correctly. 

The configuration program must be executed on a PC according to the manual for the 

program. 

3HAC023008-001 Revision: - 15

2 Overview 


Specification overview, Master 

Item 

Fieldbus type 

Addressing 1-125 

Number of units 

connected to master 

Number of signals 

Baudrate 

PROFIBUS product ID 

Specification 

PROFIBUS-DP master with DP-V0 

The number is defined by the limitations of the general I/O 

systems, see Technical reference manual - System parameters. 



The PROFIBUS-DP master is configurable for all baudrates up to 

12 Mbit/s. 

0xB203 

Specification overview, Slave 

Item 

Specification 

Fieldbus type 

PROFIBUS-DP slave with DP-V0 

Addressing 1-125 

Number of units 

connected to slave 

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 

16 3HAC023008-001 Revision: -

2 Overview 

2.3. Definition of I/O units 


General 

The controller may be mounted with I/O units inside the control module. 

Standard configuration 

In the standard form, no field bus 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 

xx0400000846 

A 

B 

Control module 

Drive module 

3HAC023008-001 Revision: - 17

2 Overview 


Further information 

The table gives references to additional information: 

Information: 

Allowed configurations of I/O units and how 

to setup the configurations: 

How to install the software of the I/O units 

related in a new system: 

Found in: 

Technical reference manual - System 

parameters 

Product manual IRC5, M2004 

18 3HAC023008-001 Revision: -

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 control cabinet. 

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 

PROFIBUS User Organization (PNO). 

Instructions on how to configure the PROFIBUS network for the master and the slave channel 

are found in the chapter 4 PROFIBUS-DP Master/Slave configuration. 

Typical applications 

An example of how the DSQC 637 may be connected is illustrated in section The 

PROFIBUS-DP network on page 15. 

3HAC023008-001 Revision: - 19



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 

M 

Indicates the status of the Slave channel. Lit when the slave is in data exchange 

mode. 

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. 

20 3HAC023008-001 Revision: -



Technical data 

Parameter 

PROFIBUS DP master/slave, DSQC 637 

Data 

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 


RxD/TxD-N 8 Receive/Transmit data N 


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. 

3HAC023008-001 Revision: - 21



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). 

22 3HAC023008-001 Revision: -


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 

Always mounted in slot 1 as 

shown in the figure above! 

Ethernet card 3HAC 15639-1 DSQC 612 

Only used in multimove control 

applications. 

1 

2, 3, 4 or 

5 

DeviceNet master/slave 3HAC 12817-1 DSQC 603 2, 3, 4 or 

5 

PROFIBUS DP master/ 

slave 

INTERBUS master/ 

slave, copper interface 

3HAC 023047-001 DSQC 637 2, 3, 4 or 

5 

3HAC 11819-1 DSQC 529 

Two physical boards, i.e. the 

master board and the slave board 

are placed in two separate slots. 

2, 3, 4 or 

5 

3HAC023008-001 Revision: - 23



Description Art. no. Note Pos. 

INTERBUS master/ 

slave, fiber optical 

interface 

3HAC 5579-1 DSQC 512 

Two physical boards, i.e. the 

master board and the slave board 

are placed in two separate slots. 

- - Not used 6 

2, 3, 4 or 

5 

Installation of communication units 

For installation descriptions refer to Product manual IRC5, M2004, section Replacement of 

PCI cards in the Computer unit slots, IRC5. 

24 3HAC023008-001 Revision: -


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 21. 

3HAC023008-001 Revision: - 25


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 

26 3HAC023008-001 Revision: -

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 

RobotStudio Online 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 

RobotStudio Online /FlexPendant , or by loading a configuration file from RobotStudio Online . 

For information on how to work with RobotStudio Online and FlexPendant refer to, 

respectively, Operator’s manual - RobotStudio Online and Operator’s manual - IRC5 with 

FlexPendant, see References on page 12 . 

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. 

3HAC023008-001 Revision: - 27



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: 

:\Utility\fieldbus\PROFIBUS\gsd\ 

The directory contains following files: 

GSD-file 

softb203.gsd 

softb205.gsd 

abb_0600.gsd 

Description 

Softing DP-Master PROFIboard 

Softing DP-Slave PROFIboard 

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 disc. 

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. 

28 3HAC023008-001 Revision: -


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 RobotStudio Online . 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 RobotStudio Online . 

3HAC023008-001 Revision: - 29


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. 

30 3HAC023008-001 Revision: -


4.2.1. Introduction 

4.2 Workflows, PROFIBUS-DP master bus 


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 start-up is required. The robot controller will 

automatically start the communication with the DP-slaves, and the controller will report any 

errors that occur. 

3HAC023008-001 Revision: - 31


4.2.2. Configuration overview 

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 RobotStudio Online . Make sure to install the 

PROFIBUS-DP option . 

2. 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. 

3. Download the system to the IRC5 controller. 

4. Reboot the controller to start up with the new system. 

5. Add the binary configuration file to the HOME directory and configure the bus. 

See section Bus configuration on page 33. 

6. Configure the units connected to the bus, see Unit configuration on page 32. 

7. Configure the signals, see Technical reference manual - System parameters . 

8. Reboot the controller. 

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. 

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. 

32 3HAC023008-001 Revision: -


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 at the network. 

3HAC023008-001 Revision: - 33



Downloading binary configuration file to the controller 

When the binary configuration file has been created on an off-line PC, it needs to be 

transferred to the controller. There are two different ways to achieve this: 

• let RobotStudio Online perform the file transfer at the same time as the rest of a newly 

created system is transferred from the RobotStudio Online PC to the controller, or 

• use a third party FTP client and download the configuration file directly to the 

controller. 

Downloading via third party FTP client 

Using a third party FTP client is the easiest way to download a new or modified binary 

configuration file to a software system that already has been downloaded to the robot 

controller. While creating the system, put the binary configuration file in the home directory 

of the created robot system by using the Add files to Home Directory in the RobotStudio Online 

system builder. 

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. 

34 3HAC023008-001 Revision: -



4.3 Workflows, PROFIBUS-DP internal slave 


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. 

3HAC023008-001 Revision: - 35


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 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 

DP_SLAVE is not suited, edit the 

Internal Slave Output Size and/or 

Internal Slave Input Size for the 

unit type DP_SLAVE. 

Note! The internal slave is special in its 

behaviour since outputs from the 

master/PLC will become inputs to the 

controller and vice versa. 

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: 

:\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). 

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 

36 3HAC023008-001 Revision: -



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. 

3HAC023008-001 Revision: - 37


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 

Profibus Address 

Description 

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 

38 3HAC023008-001 Revision: -



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 

Product ID 

Internal Slave 

Internal Slave Output Size 

Internal Slave Input Size 

Description 

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. 

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 

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. 

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. 

3HAC023008-001 Revision: - 39


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. 

(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. 

40 3HAC023008-001 Revision: -



Step 

Action 

5. In the Master Selection List, double-click on the PROFIboard. 

en0400000888 

3HAC023008-001 Revision: - 41



Step 

Action 

6. In the DP-Master-Configuration window, set Station Address to 2 and Baudrate to 

12 MBaud. Click OK. 

en0400000892 

42 3HAC023008-001 Revision: -



Step 

Action 

7. In the Slave Selection List, double-click on the B-16DI/16DO. 

en0400000889 

3HAC023008-001 Revision: - 43



Step 

Action 

8. In the DP Slave Configuration window, click the Basic tab and set Station Address 

to 10. 

en0400000890 

9. In the DP Slave Configuration window, click the Settings tab and set Watchdog 

Time to 100 ms. Click OK. 

en0400000891 

44 3HAC023008-001 Revision: -



Step 

Action 

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 

RobotStudio Online or a third-party FTP client. 

For description of how to download the file, see Operator’s manual - 

RobotStudio Online . 


3HAC023008-001 Revision: - 45


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 46. 

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 48. 


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. 

(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.) 

46 3HAC023008-001 Revision: -



Step 

Action 


5. In the Master Selection List, double-click on the Profiboard. 

See figure in step 5, in section PROFIBUS DP configurator setup on page 40(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 40 (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 49 . 

3HAC023008-001 Revision: - 47



Step 

Action 








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. 

48 3HAC023008-001 Revision: -



The table shows an example of unit mapping: 

Signal Unit map Description 

DO_1 0 Digital output signal 




DI_1 0 Digital input signal 




AO_1 24-31, 16-23 Analog output signal 

Byte swap is needed 

AO_2 40-47, 32-39 Analog output signal 


AI_1 24-31, 16-23 Analog input signal 


AI_2 40-47, 32-39 Analog input signal 


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. 

3HAC023008-001 Revision: - 49



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. 

50 3HAC023008-001 Revision: -



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- 


3HAC023008-001 Revision: - 51


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 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. 

52 3HAC023008-001 Revision: -


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 

according to section Internal slave 

configuration example on page 52. 

2. Configure the master system with one 

unit at address 12 of type 

EXT_DP_SLAVE. 

The slave system will be set up as an 

ordinary PROFIBUS-DP slave unit with 

128 DI and 128 DO. The address is 12. 

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. 

3HAC023008-001 Revision: - 53




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 

54 3HAC023008-001 Revision: -



Step 

Action 


12 MBaud. Click OK. 

en0400000892 

3HAC023008-001 Revision: - 55



Step 

Action 

5. In the Slave Selection List, double-click on the PROFIboard/PROFI104. 

en0400000903 

56 3HAC023008-001 Revision: -



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 

3HAC023008-001 Revision: - 57



Step 

Action 







9. Restart the controller. 

58 3HAC023008-001 Revision: -

Index 

B 

Bus termination 22 

C 

Cable parameters 26 

D 

DSQC 637 19 

DSQC 637, Master and Slave connector 21 

E 

Example, ET200B unit 40 

Example, ET200S unit 46 

F 

FlexPendant, I/O configuration 32 

FlexPendant, unit configuration 32 

G 

GSD-files 28 

I 

Internal Slave Input Size 39 

S 

Softing PROFIBUS DP Configurator 15, 27, 30 

System parameters, Internal Slave 39 

System parameters, Internal Slave Input Size 39 

System parameters, Internal Slave Output Size 39 

System parameters, Product ID 39 

System parameters, Profibus Address 38 

System parameters, Unit 38 

System parameters, Unit Type 39 

3HAC023008-001 Revision: - 59

3HAC023008-001, Revision - -en 

 

ABB Automation Technologies AB 

Robotics 

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SWEDEN 

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