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1. f Program Function Block Function Return Type You have now opened a new project Note All necessary libraries are loaded automatically h File Edit Project Insert Extras Online Window Help aca Gee ea e fie ROGRAM PLC_PRG ae A PLC_PRG PRG Saving the project to the PC First of all save the project by selecting the menu item File Save as File Edit Project Insert Extras Online Window Help Mew Mew From template OpEN Close Save Ctrl o Ctrl 5 SavelMail Archive Print Printer Setup Exit 1 C Program Files35 SoftwarelCobesys Y2 3Projects Test ora Ctrl F Alt F4 G1 Introduction to AC500 1 79 AC500 Issued 07 2006 Select the desired directory and enter the project name Complete your input with Save Save in E Projects a fe File name First_Steps nave as type CoD eSys Project pro Cancel Edit license mto In our example the project is saved under the name First_Steps to the folder Projects The file extension pro is automatically created by the software 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 e g the I O devices Click on fm Resources EH Fie Edit Project Insert Extras Online Window Help tm Reso WICeS I Global Variables H E library lecste lb 26 11 02 10 23 26
2. Insertion replacement of the Lithium battery The CPU is shipped without a battery Please order the TA521 lithium battery separately The battery is used to retain data stored in the user s RAM and in the Real Time Clock Although the CPU can be used without any battery it is recommended to install it to avoid process data loss The CPU monitors the battery status A low battery error is output before the battery condition becomes critical about 2 weeks before After the error message appears the battery should be replaced as soon as possible ANY The TA521 Lithium Battery is the only one which can be used with AC500 CPUs ATTENTION The following procedures describe the insertion replacement of the Lithium battery G1 gt WARNING Use of incorrect battery may cause fire or explosion Cc WARNING Use of incorrect battery may cause fire or explosion WARNING Use of incorrect battery may cause fire or explosion Introduction to AC500 AC500 Issued 07 2006 Insertion of the battery 1 Open the battery compartment by inserting a fingernail in the small locking mechanism press it down and slip down the door The door is attached to the front face of the CPU and cannot be removed 2 Remove the TA521 battery from its package and hold it by the small cable 3 Insert the battery connector into the small connector port The connector is keyed to find the correct polarity red plus pole
3. G1 Introduction to AC500 1 88 AC500 Issued 07 2006 Click on the entry COM2 Online access SLOT in order to display the default values of the PLC s COM2 interface 11 Haudrate Parity 13 Data bits 14 Stop bits Then we have to define the PC interface settings Select the menu item Online Communication Parameters G1 Logout SOE G Download LTT sop sihe HEG PL Reset icady Reset LOrginaly loggie Breakpoint erearpaimt Dialog m Wer l l phat L SLED I ra simge Cayce SoHE S vrte valles trey Farce talles ry Release Force Shihb ey White Ronee alo She ShittHey Sha Gell STACK e Display Flow Control Communication Parameters Introduction to AC500 1 89 AC500 Issued 07 2006 In the Communication Parameters dialog click on the Gateway button and then select the entry Local from the Connection list box in the appearing dialog Then confirm your settings with OK Communication Parameters a Channels E Local aia Cancel Cancel Mew Communication Parameters Gateway x Remov Gateway Password hi Port pao Connector Now the Communication Parameters dialog displays the PC interface Press the New button Enter any name for the new channel e g COM1_PC and select Serial RS232 for the Device driver Communication Parameters po aa OK C l sales Communication Parameters New Channel f
4. Decentralized expansion Using the DC505 FBP interface module for fieldbus systems PROFIBUS DP CANopen DeviceNet Modbus RTU up to seven S500 FBP system I O devices can be connected with a maximum of four analog modules Mechanical mounting of the electronic modules is done using CPU terminal bases for the CPU and the couplers and I O terminal units for the I O modules designed for snap on mounting on a DIN rail or for screw mounting on a mounting panel G1 Introduction to AC500 1 3 AC500 Issued 07 2006 AC500 system overview AC500 is a complex state of the art system providing extensive automation potential for your plant Figure AC500 system The following pages provide a summary of all devices available for the AC500 system For detailed information about the individual devices please refer to the respective hardware description G1 Introduction to AC500 1 4 AC500 Issued 07 2006 Overview of available CPUs PM571 1SAP 130 100 R0100 PM571 CPU 64kB 24 V DC Memory Card Slot 2x RS 232 485 Programming MODBUS CS31 1x FBP Display PM571 ETH 1SAP 130 100 R0170 PM571 ETH CPU 64kB 24 V DC Memory Card Slot 2x RS 232 485 Programming MODBUS CS31 1x FBP Display integrated Ethernet TCP IP 1SAP 140 100 R0100 PM581 CPU 256kB 24 V DC Memory Card Slot 2x RS 232 485 Programming MODBUS CS31 1x FBP Display PM581 1SAP 140 100 R0160 PM581 ARCNET CPU memory 256 kB 24 V DC ARCNET Memory Card Slot i
5. lt Remove Wl In this window you can also change the default station address and enter a description for the device Then click on OK G1 Introduction to AC500 1 128 AC500 Issued 07 2006 The configured fieldbus is displayed os File Edit View Insert Online Settings Tools Window Help Oea 2 a ia a POD 7 k ar Master ee ciation address O OF Master OF KT 9Y DPM O Slave Station address DP Slave POP 2 FBP OP 1 modular Double click inside of the rectangle surrounding the slave in order to configure the slave A new window named Slave Configuration appears Slave Configuration x General Device FOF22 FBP DPY1 modular Station address f Lk Description Is lave Cancel IW Activate device in actual configuration M Enable watchdog control GSD file ABB_OSIF GSD _ Parameter Data A Mae length of in output data 488 Byte Length of in output data 3 Byte DPYT Settings Max length of input data 244 Byte Length of input data Byte Assigned master Mas length of output data 244 Byte Length of output data 1 Byte Station address O Mas number of modules E Number of modules Masterl o 07 ET 37 DFPM Actual slave Station address 1 foaile inputs e Raensities a DCSOS FEP amp Byte 1 Byte Oxll xz 154F220000R0001 DPis 4d LSaPe40000R0001 4 Byte Oxls PCSs2 LSAPSa40L00RO000L 4 Byte z Byte Oxls Oxel Clavel fi POP22 FBP DPV m
6. All types of external communication couplers can be used together in the same time but only up to 4 external couplers in total e g a mix of coupler types like Ethernet Ethernet Profibus DP CANopen etc The total number of communication couplers internal external is limited to 5 The CPU terminal base is always the left most device in the system An external 24 Vdc power supply has to be provided to the CPU Cluster the additional I O modules have to be installed to the right of the PLC module The AC500 PLC module supports as many as 7 local I O expansion modules An additional process power supply has to be provided for the I Os of each module Each I O expansion module can be powered with its own power supply for isolation purposes or the same power supply can also be used One FieldBusPlug can be plugged directly into an AC500 PLC cluster Introduction to AC500 1 34 AC500 Issued 07 2006 Steps for installation y Installation step Further information 1 Snap the AC500 PLC Terminal Base onto DIN Rail or wall mount with screws 2 Snap the additional Terminal Units for I O modules onto DIN Rail optional or screw them wall mounting 3 Make the sensor actuator wire connections according to the dedicated Electronic module you want to use Provide external process power supply as required 4 If required make the fieldbus connections according to the dedicated master coupler module you want to use Plug the
7. DIN VDE 0113 Part 1 lt EN 60204 Part 1 DIN VDE 0660 Part 500 EN 60439 1 lt IEC 439 1 All rights reserved to change design size weight etc VDE stands for Association of German Electrical Engineers Safety technical instructions Please read General Completely safe installation and starting up and problemfree functioning of the devices at their work location can be ensured by observing the following instructions Qualified personnel Both the control system AC500 and other componenis in the vicinity are operated with dangerous contact voltages Touching parts which are under such voltages can cause grave damage to health In order to avoid such risks and the occurrence of material damage everyone involved with the assembly starting up and servicing must possess pertinent Knowledge of the following e the automation technology sector e dealing with dangerous voltages e using standards and regulations in particular VDE accident prevention regulations and regulations concerning special ambient conditions e g areas potentially endangered by explosive materials heavy pollution or corrosive influences G1 Introduction to AC500 1 29 AC500 Issued 07 2006 Use as directed Properly installed systems that are used as directed and properly conform with the applicable codes regulations and sound engineering principles pose no risks or dangers to health Used as directed implies that the devices are inst
8. Device Cancel Mame Channels El Local id x Hew Remove Gateway HEE Senal AS232 35 SenalAS232 driv Senal AS232 8 bit 35 Seral AS232 driv Tcpylp Level 2 35 Topvlp level 2 dri Update Seral Modem 35 Modern driver Pipe 35 Pipe driver LAN open DSPS02 35 CANopen OSP3 AS Controller 35 451 Controller m q F Confirm your settings with OK G1 Introduction to AC500 1 90 AC500 Issued 07 2006 Now we have to specify the corresponding parameters in the Communication Parameters dialog Specify the serial interface of the PC with the parameter Port double click on the value of Port possibly several times Click on the Baudrate value and then double click the value until 19200 is displayed Proceed in the same way to change the Motorola byteorder setting from No to Yes Confirm your settings with OK Channels i eral AS2s2 El Local COMI COM1_PC Baudrate 19200 Parity Ho New Stop bits Ix Cancel Gateway FEE EE Testing the program with PLC hardware connected Proceed as follows to test the program with PLC hardware connected Downloading the program to the PLC First we have to load the program to the controller To do this select the menu item Online Login online Window Help J Login a Logout atri tFa The software checks whether the project on the PLC is identical to the project on th
9. Phone 49 6221 701 1202 or 1205 Telefax 49 6221 701 1361 E mail Dieter Druschke de abb com or Heinrich Happle de abb com If desired we also offer seminars at the customer s facility Please find detailed information in our seminar brochure You can order this brochure from the address given above or from every ABB STOTZ KONTAKT GmbH office or you can download it from our Internet website PDF file see the following link Please send your enrolment directly to ABB STOTZ KONTAKT GmbH using the address given above or via Internet http www abb de stotzkontakt gt Schulungen und Seminare gt Seminare If necessary it is also possible to arrange the seminar contents according to the customer s wishes Depending on the special requirements the training can be held in Heidelberg or at any other location favored by the customer We are pleased to prepare an individual offer for you according to your special requirements G1 Introduction to AC500 1 27 AC500 Issued 07 2006 Addresses G1 ABB STOTZ KONTAKT GmbH P O Box 10 16 80 D 69006 Heidelberg Telephone 49 62 21 701 0 Telefax 49 62 21 701 729 http www abb de stotz kontakt ABB Entrelec Control Division 184 rue L on Blum F 69100 Villeurbanne France Telephone 33 0 4 72 35 35 Telefax 33 0 4 72 35 12 http www abb com lowvoltage Introduction to AC500 AC500 Issued 07 2006 Regulations concerning the appropriate and safe setup
10. WORD wOps1_ S500_A 522 Out AT SOWV1 3 WORD Wg PLC Configuration 0021 wDps1_S500_A522 Out AT O 1 4 WORD ee E Sampling Trace wOpst_S500_Ax522 Outd AT W 0W1 5 WORD glide Target Settings wOps1_ SS500_A 52 Outi AT SOW WORD A Task configuration wDps1_5500_AX522_0ut6 AT 01 7 WORD ME Watch and Reciee iManage wOps1_ SS500_A 522 Out AT SOWV1 9 WORD C026 wOps1_5500_4x522_0ut8 AT SOV1 9 WORD a 37 Workspace UOU2 END VAR Testing the system In order to test the system we are going to create a small user program according to the procedure used in the Getting Started example We are using the ST programming language structured text The program should read an input of the decentralized station DC505 FBP and output the value to the DC532 device located next to the CPU The output byte QB0 at DC532 located next to the CPU is named with the symbolic name by_AC500_DC532_Out16_23 The program looks as follows PROGRAM PLO_PRG OOO The input byte with the variable name byDps1_S500_DC505_In0_7 signals 10 to I7 at DC505 is read and applied to the output byte by_AC500_DC532_Out16_23 signals C16 to 23 at DC532 by ACSOO DCSS2 Outlb_ 23 byOps1_ ssdgd_ 0C505_Ind_ G1 Introduction to AC500 1 119 AC500 Issued 07 2006 New GSD file s If you install additional GSD files to the installation of the Control Builder CD s GSD files they have to be added to the device catalog of SY
11. voltage is present 24V DC power supply is provided voltage is missing n a activity status green error indication Working activity of the beneath described device e g top right of the display ETH communication line Indicates the selected device to be read or configured Acts as a cursor moving with the arrow F7 keys Introduction to AC500 CPU is in RUN mode An error has occurred The error type and code is displayed in the LC Display The error codes can be shown by means of the DIAG and OK keys Device is present and OK e g the battery is present and OK Points out the selected device of which the name is written beneath e g top right of the display ETH communication line CPU is in STOP mode No errors are encountered or only warnings E4 errors This is configurable by error 2 4 the LED behaviour is configurable No activity or device not present No device selected If flashes fast 4 Hz The CPU is reading writing the SD card indicates together with the blinking error LED that the CPU is writing the internal Flash EEPROM If flashes slow 1 Hz The firmware update from the SD card is finished without errors Flashing fast 4 Hz Indicates together with RUN a firmware update process and a Flash EEPROM write Flashing according to the device activity e g when data exchange on ETH COM1 etc communication l
12. CHANNEL c as AT W 80 6 BOOL Input 6 CHANNEL lt eon AT SISO BOOL Input CHANNEL 3 ee Fal AT 151 BYTE Input 8 15 CHANNEL gH 0 aa AT 181 0 BOOL Inputs CHANNEL 3 aii AT 181 1 BOOL Input 9 CHANNEL 3 i AT 81 BOOL Input i CHANNEL l ae AT 181 3 BOOL Input 11 CHANNEL 1 sore AT Sls 4 BOOL Input 12 CHANNEL l aca AT 181 5 BOOL Input 13 CHANNEL l a LI a al AT 181 6 BOOL Input 14 CHANNEL il T BOOL Input 15 CHANNEL l AN a AT S611 i ome cE AT WWO WORD Guiput 16 31 CHANNEL 2 256 cca AT W080 BYTE Output 16 23 CHANNEL li 1 aaa OOdig AT SOs0 0 BOOL amp Output 16 CHANNEL ga aaa AT W080 1 BOOL Output 17 CHANMEL 24 oe AT W080 2 BOOL Output 18 CHANNEL 24 poe AT W080 3 BOOL Output 19 CHANNEL 24 G1 Introduction to AC500 1 94 AC500 Issued 07 2006 Using Online Logout the connection to the PLC is disconnected and the Force function is canceled To exit the CoDeSys software select the menu item File Exit Saye a ni Sawe ARCHIVE s AHIT trite ShIGbEh SERIE r Exit Alt F4 G1 Introduction to AC500 1 95 AC500 Issued 07 2006 Examples for decentralized systems connected by network On principle the configuration of decentralized systems connected by network is done in two steps e The CPU has to be informed a
13. DP Master UF KT 97 OFP Slave1 Station address 1 DP Slave POP 22 FBP DP 1 modular G1 Introduction to AC500 1 132 AC500 Issued 07 2006 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 gt Download Online Settings Tools Window Help Download Start Debug Mode Device Diagnostic EMS Diagnostic Firmware Download Firmware Reset Extended Device Diagnostic Ctrl T Global State Field Live List EMS Monitor Automatic Webwork Scan Geb Object dictionary Seb Slave fddress Skart Communication Stop Communication Device Info Read Project Information Select 3S Gateway Driver as gateway for the download to the CPU coupler and click on OK Driver Select i X Jo Gateway Driver OK CIF TCP IP Driver a Cancel Vendor 35 GmbH Version Y2 0n Date 18 07 2002 Functions 5 G1 Introduction to AC500 1 133 AC500 Issued 07 2006 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 35 Gateway Driver Assignment S l xj Gateway Configuration Channel Gateway Configuration Cancel Driver Hame Device Information Name Type Vers
14. New A window appears where you can select a fieldbus system Select fieldbus X LAN open K DeviceNet Ethernet Protocol Cancel InterBus Select PROFIBUS and click on OK Now you have to configure the master Select Insert gt 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 Insert Master D p x Available masters Selected masters EL OF ET 97 DPM ddd gt Cancel OF ET 9 OPM OF KET 98 DPM 07 KT 98 DPM Add All gt gt OF KT 98 DPHM 07 SL 97 DPM Remove All OF SL 9 DPM OF SL 9 DPM g Remove CIFEO FE Vendor name ABB STOTZ KONTAKT GmbH Station address Ident number Oe F505 Description GSD file name KT37_DFPM GSO In this window select O7KT97 DPM and click on Add gt gt 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 Insert Master x Available masters Selected masters OK OF ET 97 DPM 07 KT 97 DPM Cancel OF ET 9 OPM OF KT 98 DPM D7 KT 98 DPM Add All gt gt OF KT 98 DPM 07 SL 97 DPM Remove All OF SL 9 DPM OF SL 9 DPM g Remove CIFEO FE Vendor name ABB STOTZ KONTAKT GmbH Station address lo Ident number Oe 05 Description Master GSD
15. Shitt F amp In order to test the program we are going to force input lOdig to TRUE Double click to the input lOdig G1 Introduction to AC500 AC500 Issued 07 2006 In order to set this value permanently the Force function has to be used With this function the user defined value is set in the runtime system each time at the beginning and at the end of the program cycle online Window Help Login Altta Logout Ctr F8 Download Run FS Stop Shift F amp Reset Reset cold Reset original Toggle Breakpoint Fo Breakpoint Dialog Step OVEF FIG Step ini med Single Cycle Cbrl F5 Write values Ctrl FF Force Values Release Force Shift F Write Force Dialog Ctrl Shift FF This way the input is assigned to the output i e set to TRUE in each program cycle The CoDeSys software displays the TRUE state in blue color the FALSE state is displayed in black a _oodig This way the input lOdig is assigned to output OOdig G1 Introduction to AC500 1 93 AC500 Issued 07 2006 Note The status of the I Os can also be displayed in the PLC configuration Click on fm Resources Double click on PLC configuration ae H INdig AT 1s0 0 BOOL ff Input do CHANNEL cI oa AT 180 1 BOOL Input CHANNEL c ee AT W80 BOOL Input 2 CHANNEL i ae AT SISO BOOL Inputs CHANNEL c a AT W80 BOOL Input 4 CHANNEL 3 acai AT W 180 5 BOOL Inputs
16. _ Master _ Slave E OF KT 97 DPS fan E 07 KT 98 DP5 A PDP22 FER YL Fieldbus O7M Class G1 Introduction to AC500 1 106 AC500 Issued 07 2006 The FieldBusPlug slave is now appended to the PROFIBUS DP line The symbolic name has been changed to DPS2_FBP_S500 DPM1_ACSOO0 CMS72 DPM J lt 1l gt 1 pe DPS2 FBP_S500 POF22 FBP DPW 1 modular lt 2 gt d i E 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 JnetDevice Configuration DPS _FBP_S5O00 PDP22 FBP DP 1 modular lt 2 gt y TO Device POP22 FeP DPY1 Device ID Vendor ABE Vendor ID Station Address 2 Modules Parameters I Watchdog control Groups Extensions OPW I a Device Description Device G50 Interval 200 ms G1 Introduction to AC500 1 107 AC500 Issued 07 2006 The slave station has to be set up Click on Configuration gt 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 Available Modules Module Configuration Identifier al Or_S05 FEP Ox11 0 20 DIS24 Ox13 DESA 0xiz 0x21 Daoa 0x10 0x20 Deoe
17. above 4 Bend the cable and insert first the cable and then the battery into the compartment push it until it reaches the bottom of the compartment 5 Arrange the cable in order not to inhibit the door to close 6 Pull up the door and press until the locking mechanism snaps AN In order to prevent data losses or problems the battery should be replaced after 3 NOTICE years of utilisation or at least as soon as possible after receiving the Low battery Warning indication Don t use a battery older than 3 years for replacement Do not keep batteries too long in stock Replacement of the battery In order to avoid any data losses if needed the battery replacement should be done with the system under power Without battery and power supply there is no data buffering possible AN ATTENTION 1 Open the battery compartment by inserting a fingernail in the small locking mechanism press it down and slip down the door The door is attached to the front face of the CPU and cannot be removed 2 Remove the old TA521 battery from the battery compartment by pulling it by the small cable Remove then the small connector from the socket do this best by lifting it out with a screwdriver see photo 3 Follow the previous instructions to insert a new battery AN Lithium batteries must not be re charged not be disassembled and not be ATTENTION disposed of in fire They must be stored in a dry place Exhausted batteri
18. Commands for importing blocks and variables from Siemens STEPS files DDE communication Using the DDE interface Dynamic Data Exchange Keywords in CoDeSys Reserved keywords in CoDeSys ABS ACOS ADD CoDeSys files Files generated by CoDeSys Compiler errors and warnings Information about possible error and warning messages displayed in the message window during project compilation Documentation for the AC500 system Section oomme SOS Introduction Overview Here you can gain an overview of the AC500 system This section provides further useful information First steps when working with AC500 and S500 FBP examples For AC1131 experts Your tasks Documentation from the user s Engineering company point of view Sales and export Control cabinet building and construction Commissioning Program creation Operation service and maintenance Training and education Callcenter helpline AC500 hardware System data CPU terminal bases and terminal units CPUs Communication modules CS31 modules FBP interface modules Digital input and output modules Analog input and output modules Accessories S500 FBP hardware system description System data and system structure G1 Terminal units FBP interface modules Digital input and output modules Analog input and output modules Accessories Introduction to AC500 1 16 AC500 Issued 07 2006 Section O Com
19. DC505 TTT ET Figure S500 I O modules connected to an FBP Interface Module DC505 FBP with an FBP decentralized expansion AC500 Issued 07 2006 Introduction to AC500 1 63 G1 Minimum spacing SS eS ee ABB DC505_ ABB DC532_ ABB O O W B m ajj m B OO DIN rail a a o earthed Oo O O Oo Oo o o o O E A Mounting o o O plate o o O earthed Cable duct 20 mm minimum distance between the modules and the cable duct DC505 ABB O32 ABE O O a a o COCO a DIN rail Oo Oo o o E E earted Oo Oo o T T O Oo Oo o E A Mounting Oo Oo O s A z plate T T O earthed Figure AC500 S500 module mounting into cabinets Maintain spacing from enclosure walls wireways adjacent equipment etc Allow minimum 20 mm 1 in of space on all sides as shown This provides ventilation and electrical isolation G1 Introduction to AC500 1 64 AC500 Issued 07 2006 AN Important Horizontal mounting is highly recommended Vertical mounting is possible however derating consideration should be made to avoid problems with poor air circulation and the potential for excessive temperatures see also the AC500 system data operating and ambient conditions for reduction of ambient temperature my Note By vertical mounting always place an end stop terminal block e g type BADL P N 1SNA399903R0200 at the bottom and on the top of the modules to properly secure the modules By high vibration appl
20. FBP 0 25 m modular FieldBusPlug PDP22 FBP 050 1SAJ 2401 00 R1005 PDP22 FBP 050 PROFIBUS DP V0 V1 FBP 0 5 m modular FieldBusPlug PDP22 FBP 100 1SAJ 2401 00 R1010 PDP22 FBP 100 PROFIBUS DP V0 V1 FBP 1m modular FieldBusPlug PDP22 FBP 200 1SAJ 2401 00 R1020 PDP22 FBP 200 PROFIBUS DP V0 V1 FBP 2 m modular FieldBusPlug PDP22 FBP 500 1SAJ 2401 00 R1050 PDP22 FBP 500 PROFIBUS DP V0 V1 FBP 5 m modular FieldBusPlug Overview of available accessories TA524 1SAP 180 600 R0001 TA524 Dummy Coupler Module TA525 1SAP 180 700 R0001 TA525 Set of 10 white Plastic Markers TA526 1SAP 180 700 R2001 TA526 Wall mounting accessory 10 pcs PS501 PROG 1SAP 190 100 R0001 PS501 PROG Control Builder AC500 Programming Software German English French CD ROM incl Online Help and PDF Docs G1 Introduction to AC500 1 7 AC500 Issued 07 2006 Bus systems overview Bus System Short information Web Links Block Libraries ARCNET www arcnet com ARCNET Trade Association USA gt Literature gt Other Puplications gt ARCNET Tutorial and Product Guide CANopen www odva org gt DEVICENET www modbus org PROFIBUS www profibus com gt Web Based Training The PROFIBUS DP Library gt see Function Block Libraries AC500 www ethermanage com The Ethernet Library gt see Function Block Libraries AC500 G1 Introduction to AC500 1 8 AC500 Issued 07 2006 Brief information about ARCNET ARCNET Attached
21. MODBUS CS31 COM1 1 x FBP e PM581 or PM582 256kB or 512kB memory 2 RS 232 485 interfaces programming MODBUS CS31 COM1 1 x FBP e PM591 4MB memory 2 RS 232 485 interfaces programming MODBUS CS31 COM1 1 x FBP All three types are also available with an integrated Ethernet coupler TCP IP Communication modules For connection to standard field bus systems and integration into existing networks Ethernet coupler supporting the protocols TCP IP UDP IP and Modbus TCP Coupler for fieldbus systems PROFIBUS DP DeviceNet and CANopen Up to four communication modules in any desired combination are allowed at one CPU The CPU terminal base For easy plug in mounting of a CPU and one two or four communication modules three types available accordingly The I O modules Digital and analog in different versions Can be simply plugged onto the terminal units for local expansion of the CPU max seven modules and decentralized expansion via the FBP interface max seven modules thereof max four analog modules Flexible use thanks to configurable channels The I O terminal units Multi purpose usage for both digital and analog I Os for 1 2 and 3 wire designs Enable simple prewiring without electronics For 24 V DC and 230 V AC optionally for spring or screw type terminals The FBP interface module G1 Introduction to AC500 1 19 AC500 Issued 07 2006 With embedded digital I Os and a field bus neutral interface
22. Rear view Front view Figure Fastening with screws of the Terminal Unit TU516 as an example 1 The Wall Mounting Accessory TA526 is snapped on the rear side of the Terminal Unit like a DIN rail The arrow points to the right side 2 Accessory for wall mounting inserted 3 Terminal Unit fastened with screws Use two screws per module Use M4 or 8 pan head screws Mounting screws are required on every module By wall mounting the Terminal Unit is earthed through the screws It is necessary that e the screws have a conductive surface e g steel zinc plated or brass nickel plated e the mounting plate is earthed e the screws have a good electrical contact to the mounting plate The following procedure allows you to use the assembled modules as a template for drilling holes in the panel Due to module mounting hole tolerance it is important to follow these procedures 1 On a clean work surface assemble no more than three modules 2 Using the assembled modules as a template carefully mark the center of all module mounting holes on the panel 3 Return the assembled modules to the clean work surface including any previously mounted modules 4 Drill and tap the mounting holes for the recommended M4 or 8 screw 5 Place the modules back on the panel and check for proper hole alignment 6 Attach the modules to the panel using the mounting screws TIP If mounting more modules mount only the last one of this group and put
23. Trunk cable Max cable length of 100 m 328 ft 100 m 328 ft 100 m 328 a trunk line Drop cable Max cable length per m 20 ft m 20 ft m 20 See branch line Trunk cable Drop cable Max cable length total 156 m 512 ft 78 m 256 ft 39 m 128 ft branch line Trunk cable Drop cable Diagnostics Detailed diagnostic messages for rapid trouble shooting are shown on the CPU display or can be called using the programming tool In addition the device status is indicated at the communication module by four LEDs G1 Introduction to AC500 1 10 AC500 Issued 07 2006 Brief information about CS31 field bus CS31 Communication Serial Field Bus developed by ABB in 1989 for continuity and migration CS31 is a proprietary master slave field bus It is characterized by simple handling easy configuration and inexpensive installation The COM1 interface of the AC500 can be configured as a CS31 field bus master Communication Is handled using polling i e the master sends a request to the slave and then receives the response The CS31 operating mode of COM1 is set using the engineering tool Topology Multi point line RS485 approved without branch lines A system consists of one master and up to 31 slaves The maximum cable length is 500 m or 2 km with an amplifier Slaves are primarily decentralized input output modules with integrated CS31 bus connection Data transmission Is performed at 187 5 kB s Each telegram has an 8 bi
24. Use two screws per module three for the TB Use M4 or 8 pan head screws Mounting screws are required on every module By wall mounting the CPU Terminal Base is earthed through the screws It is necessary that e the screws have a conductive surface e g steel zinc plated or brass nickel plated e the mounting plate is earthed e the screws have a good electrical contact to the mounting plate G1 Introduction to AC500 1 47 AC500 Issued 07 2006 The following procedure allows you to use the assembled modules as a template for drilling holes in the panel Due to module mounting hole tolerance it is important to follow these procedures On a clean work surface assemble no more than three modules e g one TB two TUs 2 Using the assembled modules as a template carefully mark the center of all module mounting holes on the panel 3 Return the assembled modules to the clean work surface including any previously mounted modules Drill and tap the mounting holes for the recommended M4 or 8 screw 5 Place the modules back on the panel and check for proper hole alignment 6 Attach the modules to the panel using the mounting screws TIP If mounting more modules mount only the last one of this group and put the others aside This reduces remounting time during drilling and tapping of the next group 7 Repeat steps 1 to 6 for any remaining modules Grounding considerations This product is designed to be mounted to a well gro
25. VORU position of the display beside the ETH in scription and the already configured ad dress is displayed sys Press one time more the CFG key to move BATT the triangle to the position below FBP I O Bus The FBP is then selected and the current address is shown Press then the arrow keys UP or DOWN to increase or decrease the address the mo SYS dified value blinks to indicate that it differs O Bus from the previously stored one Once the desired address is reached press OK to accept and quit or only ESC to sys exit the menu without saving the changes BATT The CPU status is then displayed I O Bus run StoP A If the FBP address set on the AC500 CPU module is different from those ATTENTION assigned into the Fieldbus configurator software of the Master device for that station the station could not be accessed and the complete Fieldbus could not work properly or be completely down AA The modified address will only be valid after a Power OFF Power ON ATTENTION A AC500 CPU equipped with a FieldBusPlug is always a slave device on the bus To act as a master a AC500 CPU should be equipped with master couplers e g CM572 DP for PROFIBUS DP Make the Connection of the FieldBusPlug to the Fieldbus Master Device The FieldBusPlug module has to be connected to the master device and the power supply has to be provided Please use the dedicated accessories to the FBP used for the desired Fieldbus Refer to the
26. a Technical Support Center to assist with even the most difficult of problems e Consultation by phone Helpline e Failure analysis and removal at the machine installation In order to provide the customer with qualified assistance customers are requested to provide the following e Provide all required application documentation and information e Provide access if required to the system being examined e Assign key individuals to assist as required For inquiries and orders please contact ABB STOTZ KONTAKT GmbH Dept STO CPT Control Engineering Helpline Eppelheimer StraBe 82 D 69123 Heidelberg Postfach 10 16 80 D 69006 Heidelberg Phone 49 6221 701 1444 Telefax 49 6221 701 1382 E mail desst helpline desto de abb com For further information about control engineering please also refer to our Internet Website http www abb de stotzkontakt Repair services and replacement devices The following services are also covered by our activities e Delivery of replacement devices e Repair of defective devices and systems Please contact your responsible sales office for your inquiry G1 Introduction to AC500 1 26 AC500 Issued 07 2006 Seminars Workshops We also offer seminars and workshops to support you in planning commissioning and operation of Advant Controller AC500 controls Please contact ABB STOTZ KONTAKT GmbH Dept STO VPS Eppelheimer StraBe 82 Postfach 10 16 80 D 69123 Heidelberg D 69006 Heidelberg
27. and requirements associated with any particular installation ABB cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by ABB with respect to use of information circuits equipment or software described in this manual Throughout this manual we use notes to make you aware of safety considerations A Identifies information about practices or circumstances that can cause an WARNING explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss A Identifies information that is critical for successful application and IMPORTANT understanding of the product AA Identifies information about practices or circumstances that can lead to ATTENTION personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid a hazard e recognize the consequence SHOCK HAZARD Labels may be located on or inside the device to alert people that dangerous voltage may be present SHOCK HAZARD Labels may be located on or inside the device to alert people that surfaces may have dangerous temperatures Environment and Enclosure Information A Environment and Enclosure ATTENTION This equipment is intended for use in a Pollution Degree 2 industrial environment in overvoltage Category II applications as defined in IEC publication 60664 1 at altitudes up to 2000 meters without derating This equipmen
28. channel of the corresponding group e g one output short circuited Module Error r error within the I O module All of the LEDs CH ERR1 to CH ERR4 as far as they exist light up together For the meaning of the different LEDs and their behaviour when the system is running please refer to the S500 System Data of the S500 User s manual for further information AC500 Issued 07 2006 G1 Introduction to AC500 FBP LEDs PROFIBUS DP H1 and H2 display the PROFIBUS status H3 and H4 display the device status Label for writing down the address setting Fastening screw provided on delivery Meaning of the LEDs PROFIBUS status FIB US status iii G1 ee status Module status Status Cause Power supply is missing Possible errors No connection to the bus master e g PROFIBUS not operating The PODF21 PDP22 has a slave address that is not configured in the bus master Parameter length and slave address are correct but 0 aE of the slave does not meet the configuration The ace carers received from The bus master are formal Incorrect e g of other length Connection to the bus master lis interrupted longer than the time out set at me master saili Sen Phuc is waiting for e Jaia to be sent from the device number of input output bytes number of parameter bytes Internal baud rate ete Note If no data has been sent by the terminal device within lug switches to the p
29. contacts are visible on the left side bevelled edge below 3 Push on the card until it moves forward then release your pressure the SD card comes slightly backward and it locks into the SD card slot Removing the SD Memory Card To remove the card first push on the card until it moves forward that unlocks the card then release your pressure the card will go forward out of the slot and can be easily removed The technical data sheet for the SD Memory Card can be found in the chapter Hardware Accessories SD Memory Card MC502 G1 Introduction to AC500 1 41 AC500 Issued 07 2006 Mounting the System iN During panel or DIN rail mounting of all devices be sure that all debris metal ATTENTION chips wire strands etc is kept from falling into the controller Debris that falls into the controller could cause damage while the controller is energized Mounting and Demounting of the Terminal Base the Terminal Unit and the Electronic Modules Mounting on DIN rail Step 1 Install the 7 5 mm or 15 mm DIN Rail Step 2 Snap the AC500 Terminal Base TB5xx Figure Mounting of the AC500 Terminal Base TB5xx The AC500 Terminal Base will be placed on top of the DIN Rail and then snapped on the bottom Follow the reverse order to disassembly G1 Introduction to AC500 1 42 AC500 Issued 07 2006 Step 3 Mounting of the I O Terminal Unit TU515 TU516 TU531 or TU532 to the CPU Terminal Base ggggggogogoao OOOOO
30. for connecting the chosen FBP connector For decentralized expansion by up to seven I O modules The SD card The SD memory card is used for the following purposes Backup of user data storage of the user program storage of the project s source code update of the internal CPU firmware Short description of the software Programming in conformity with IEC 61131 3 AC500 Control Builder provides the following functionalities m Five standardized programming languages Function Block Diagram FBD Instruction List IL Ladder Diagram LD Structured Text ST Sequential Function Chart SFC m Free graphical function chart CFC m Debugging functions for the program test Single step Single cycle Breakpoint Offline simulation IEC 61131 3 commands can be simulated without a PLC being connected including the relevant malfunctions After the program test the application can be downloaded to the control system Sampling trace Timing diagrams for process variables and storage of data in a ring buffer with event trigger Recipe management and watch lists Values of selected variables are displayed Pre defined values can be assigned to variables which can then be downloaded to the control system all at once Write recipe Ongoing values from the control G1 Introduction to AC500 1 20 AC500 Issued 07 2006 system can also be pre assigned for reading into the Watch and Recipe Manager and stored in memory there
31. lb 29 8 02 16 12 58 global variables library SyeT asklnfo lb 29 86 02 16 12 58 global variables library Util Ib 12 2 04 12 39 58 global variables E ay Tools e A Alarm configuration pen Til Library Manager ae EH Log M PLC Browser FEE PLC Configuration cml Sampling Trace Sampling aa Target Settings l a Task configuration a Watch and Recipe Manager ss a Workspace 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 vo m Interfaces F Ix _ E Couplers Flx Insert Element ppend Subelement d Replace element Calculate addresses Export module Import module ut Etrit Copy Ctrl C Paste Etrit Delete Del G1 Introduction to AC500 1 101 AC500 Issued 07 2006 Select Append Subelement gt DC532 vo Interfaces F Ix a F Couplers Ix Run on config fault Insert Element DIS 4 32 digital Input Replace element D532 16 digital Input and 16 digital Inoutput D522 6 digital Input and 6 digital Qutput FR D531 6 digital Input and 4 digital Qutpuk FR A522 8 analog Input and 6 analog Output ppend Subelement Calculate addresses Export module Import module ijr orl Copy Ctrl C Paste oor Delete Del Repeat this procedure to append the analog module AX522 Module paramete m Interfaces F i oe Couple
32. libraries Storage of visualizations in libraries System variables within the visualization Implicitly created system variables for programming visualizations Possible key combinations For operation by keyboard G1 Introduction to AC500 1 17 AC500 Issued 07 2006 CoDeSys HMI seton o commen Overview Runtime system for execution of visualizations Installation starting and operation Program which has to be purchased and installed separately Notes regarding start from command line Operation by keyboard mouse via visualization elements CoDeSys license management not available Section CCCs Comment Overview License management using the tool Creating a module which is subject to licensing Using the command File gt Save as gt Edit License Information dialog G1 Introduction to AC500 1 18 AC500 Issued 07 2006 Short description of the hardware Example of an AC500 system 1 Back lighted LCD display and keypad 2 SD card slot 3 Plug in communication modules 1 to max 4 4 Optionally with integrated Ethernet or ARCNET 5 FBP interface for slave 6 Two serial interfaces for programming ASCII Modbus or CS31 field bus master 7 Expandable by up to seven local I O modules Figure AC500 system module arrangement beginning from the left communication module CPU I O module CPUs Available in three performance classes e PM571 64kKB memory 2 RS 232 485 interfaces programming
33. required for this example e One basic unit e g PM581 and one terminal base e g TB511 ETH e One digital I O module DC532 DX522 or DX531 as an alternative and one I O terminal unit e g TU516 e One 24 VDC power supply eA PC with the programming software PS501 installed e One cable TK501 to connect the PC to the basic unit G1 Introduction to AC500 1 76 AC500 Issued 07 2006 Task Assign an input signal to an output In this example we are using the programming language FBD Preparations e Connect the PM581 controller to 24 V DC Connect the DC532 I O module to 24 V DC Connect the COM2 interface of the controller to the COM1 interface of the PC or use an USB RS 232 converter and connect it to the USB interface of the PC e Start the PS501 software The project last edited is opened If necessary close this project by selecting File Close e Familiarize yourself with the main window of the software Object organizer Menu bar Tool bar CoDeSys First_Steps pre File Edit Project Insert Extras Online windo Help SIAE alela Sx G db Eg Ca EN A 100 At EE ree mel F 3 POUs ya PLC_PRG PRG FED DOOWPROGRAM PLO_PRG o002 AR O003 END_VAR POW indices 238 23 Size of used data 603 of 262144 bytes 0 45 Size of used retain data 0 of 32768 bytes ii 0 Errorisi 0 Warningisi POUs MA Data types Visualizations Resources Work space Mes
34. that no malfunctions due to capacitive and inductive interference can occur EMC AN Precautions against wiring short circuits and breakages Connection plans and user software must be created so that all technical safety aspects legal regulations and standards are observed In practice possible shortcircuits and breakages must not be able to lead to dangerous situations The extent of resulting errors must be kept to a minimum AN Use only ABB approved lithium battery modules At the end of the battery s lifetime always replace it only with a genuine battery module AN Never short circuit or operate lithium batteries with the polarities reversed They are likely to overheat and explode Avoid chance short circuiting and therefore do not store batteries in metal containers and do not place them on metallic surfaces Escaping lithium is a health hazard AN Never charge lithium batteries Lithium batteries are primary cells and cannot be recharged Attempts to charge lithium batteries lead to overheating and possible explosions A Dispose of lithium batteries environmentally consciously Do not open lithium batteries and never throw them into fires risk of explosion Do not dispose of along with the household rubbish but in an environmentally conscious manner in accordance to local authority regulations Additional notes Avoidance of electrostatic charging AN ATTENTION Electrostatic charging can cause internal defects o
35. the equipment in appropriate static safe packaging Make sure that you have all the components you need To use the S500 FBP Interface Module you should use at least the following parts Part Number 1SAP220000R0001 DC505 FBP Interface Module with 8DI 8DC 24 V DC 1SAP210000R0001 or TU505 FBP Terminal Unit with screw or TU506 FBP Terminal Unit with 1SAP212000R0001 spring See the FBP Catalog FieldBusPlug module with desired Fieldbus protocol You may also use these components with the S500 FBP Interface If you want to Then use this component e connect a 24 V dc digital sensor or DI524 32 DI DC522 16DC DC523 24DC actuator to the device DC532 16DI 16DC or DX522 8DI 8 DO R with the corresponding terminal unit with screw type or spring connection TU515 516 or TU531 532 e connect a 115 230 V AC digital sensor or DX531 8DI 115 230 V AC 4 DO R actuator to the device corresponding Terminal Unit TU531 532 with screw or spring technology e connect a 24 V DC analog sensor or Al523 16Al U I PT100 AO523 16A0 actuator to the device AX521 4Al 4A0 U I PT100 or AX522 8Al BAO U I PT100 corresponding Terminal Unit TU515 516 e Label the I O Channels TA523 Pluggable marking holder TA525 Markers for marking holder G1 Introduction to AC500 1 60 AC500 Issued 07 2006 System planning Consider the following when planning your S500 FBP system e The S500 FBP controller is always the left most module in
36. the following instructions G1 Introduction to AC500 1 123 AC500 Issued 07 2006 Variant A Configuration using the fieldbus configurator included in the programming software First we have to specify the hardware Click on im Resources Double click the object PLC Configuration Click on Hardware Configuration Press the right mouse button Select Append Subelement DP Master File Edit Project Insert Extras Online Window Help 2a Ml 2 ee H 2 2qq Resources tS Insert Element Global Variables ppend Subelenent library IEC S90 V47 LIB 11 4 0 Properties Til Library Manager ut br s Copy Ctrl Paste Gtr fee PLC Configuration Fie glad elit Pelete Bel pen a Sampling Trace a Task configuration a a Watch and Receipt Manager OFCR41 a OFCT41 UE inne OFERSL OFETS1L OFET95 OFET96 OFET9Y OFKT9S OFSL9y OP Master DP Slave 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 e GJR5 253x 00 Rxxyz with y slot number card number 1 Zz slot number card number 2 e Furthermore the following code applies to y and z 2 PROFIBUS DP 5 DeviceNet 6 ARCNET 7 Ethernet 8 CANopen 9 Interbus e For our exampl
37. the system e The FieldBusPlug delivers the power supply for the FBP interface module DC505 and the connected I O bus the additional I O modules have to be installed to the right of the FBP Interface Module e The DC505 FBP Interface module supports as many as 7 I O expansion modules e An additional process power supply has to be provided for the I Os of each module Each I O expansion module can be powered with its own power supply isolation purpose or the same power supply can also be used e One FieldBusPlug can be used in a S500 FBP cluster Installation steps ar Snap the FBP Terminal Unit onto DIN Rail or screw it wall mounting on the additional Terminal Units for I O modules onto DIN Rail oon or screw them wall mounting Make the sensor actuator wire connections according to the dedicated Electronic module you want to use see dedicated pages connect also a Process Power supply to the modules the different Electronic modules in the right place FBP Interface module on TU and eventually also I O modules onto dedicated TUs Make the FBP fieldbus connection acc to the chosen FBP and use the dedicated FBP accessories cables pe cable to M12 line termination power supply connector etc Plug the FBP Plug on the M12 connector er on the Terminal Unit of the S500 FBP Interface Module Set the correct address onto the FBP Interface Module rotary i Install the appropriate EDS GSD files into the Fieldb
38. 0 AO523 16AO0 AX521 actuator to the CPU 4Al 4A0 U I PT100 or AX522 8AI 8AO U I PT 100 corresponding Terminal Unit TU515 516 e to label the I O channels TA523 Pluggable Marking Holder TA525 Set of Plastic Markers The following components are recommended for fieldbus communication If you want use the following component s the system to act as a master on PROFIBUS DP DeviceNet or CANopen fieldbuses CM572 DP for PROFIBUS DP CM575 DN for DeviceNet or CM578 CN for CANopen the system to act as a slave on FieldBusPlug standard plugs like PDP22 FBP PROFIBUS DP DeviceNet or CANopen PROFIBUS DP slave or DNP21 FBP fieldbuses DeviceNet or other one s e to exchange data via the network CM577 ETH to achieve Ethernet TCP IP communication with integrated 2 ports switch System planning Consider the following when planning your AC500 system G1 The AC500 PLC consists of a CPU Terminal Base TB5xx from 1 to 4 coupler slots and a pluggable CPU Three different CPU classes are offered from PM571 with 64KB memory up to PM591 with 4MB memory available also with integrated Ethernet coupler Proper CPU Terminal Base selection requires that sufficient slots are available for all current or future network and fieldbus communication modules e g Ethernet ARCNET PROFIBUS etc if required Up to 4 communication couplers can be connected to the CPU through the dedicated CPU terminal base
39. 2 5500 DCS32 Inz4 31 Li ili mm meti All signals Unconnected signals 5 Connected signals G1 Introduction to AC500 1 112 AC500 Issued 07 2006 G1 For the 16 DC as outputs of the DC532 module onnmect mete o a Project Tests DPM _ACSOOLCMS72 DPM lt 1 1 Slot 1 ERAY DPS2_FEP_5500 POP22 FBFP OPW 1 modular lt 2 gt el 2 byte input 8 4 byte input 8 word input E 1 byte output a Z byte output 8 word output IjO Name of variable Qutput_1 BYTE E byDps2_S500_DC532_Outi6_23 BYTE a byDps2_s500 pcs32 outed 31 All signals Unconnected signals Connected signals For the 8 analog inputs of the AX522 module Le Ll mi Cc nett g a Project Tests e DPM ACSOO CMS72 DPM lt 1 gt 1 Slot 1 Sey DPS2_FBP_SS00 POP22 FeP DP 1 modular lt 2 gt ll 2 byte input S 1 byte output 8 2 byte output 6 word output 10 Name of variable Input_1 woos SSOU0 Axssee nl Input 2 wops2 S500 4 522 nz Inputs WwOos2 S500 Assee Ins Input 4 wops2 S500 Ax522 In4 Input 5 woos SSO Assee Ind Input 6 wops2 S500 Ax522 n6 Inpuk_ woos SSO Asses In WORD woos 5500 4x52 Ing All signals Unconnected signals 5 Connected signals Introduction to AC500 1 113 AC500 Issued 07 2006 For the 8 analog outputs of the analog module AX522 g Project Tests DPMI_ACSOOLCMS72 DPM lt 1 gt 81 Slot 1 Sey DPS2_FBP_SS00 POP22 FeP DP 1 m
40. 5 2070 00 R0102 Before starting e 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 e 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 e 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 e Install the AC1131 programming software for AC31 PLCs e f 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 e f 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
41. CON net To do this apply subsequent procedure The GSD files have to be copied to the corresponding directory beforehand ProgramFiles HilscherGmbH S Y CONnet ABBPBGenericSlaveDTM GSD Attention Handling of GSD files only works that way in case of an empty project Click on ia Resources Open the Tools folder Double click on the entry SYCON net kA Resources T Global Variables H E library lecste lib 26 77 02 10 23 26 global variable library standard lib 22 11 02 11 08 30 global varia library SYSLIBCALLBEACK LIB 29 8 02 16 12 56 g library SysLibMem lb 29 8 02 16 72 56 global var library SwsLibT ime lib 29 8 02 16 72 58 global var library Sus T asklnfo lib 29 68 02 16 72 58 global va library Uhhlib 12 2 04 12 39 58 global variables aa Tools IE contig lt A gt vl Notepad lt A gt sy Device Catalog G1 Introduction to AC500 1 120 AC500 Issued 07 2006 a netDevice Device Catalog m AEE H ABE STOTZ KONTAKT GmbH select a device to show information dlk Yendor Click on Reload This integrates the new GSD file Click on OK and close SYCON net G1 Introduction to AC500 1 121 AC500 Issued 07 2006 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 S lt gt 24V DC lt PDA11 FBP 050 A 07 KT 98 AdvantController31 asicUnit i O re DOOOO G2S
42. FBP documentation for the installation instructions G1 Introduction to AC500 1 51 AC500 Issued 07 2006 Status display and error indication on the AC500 CPU All AC500 CPUs have LEDs and a LC Display for indicating operating statuses and errors The following drawing shows the front face of a AC500 CPU ADD The CPU statuses are displayed on the CPU front face with 3 LEDs PWR RUN ERR and by means of a background lighted display The display contains the following indications E small black squares indications acting as a LED status for the device written beneath WARNING a ae ke eco gt small black arrows used for indication by incorrect pointing the selected device to be con arate figured or read explosion etch 6x 7 segment displays for plain text or error codes display 24V DC 10W Figure Front face of a AC500 CPU The display s background lighting is normally switched off The status of the CPU is shown as plain text run or Stop which reflects the operating status of the CPU program By pressing one of the dialog keys RUN DIAG CFG or VAL the background lighting is turned ON and the desired function is performed In case of a function error the display background lighting is also switched on and an error code is displayed G1 Introduction to AC500 1 52 AC500 Issued 07 2006 The meanings of the LEDs and the LCD display are listed in the following table AC500 CPU module LEDs
43. IK3 3 BOOL Input 27 CHANNEL 1 a AT 3 4 BOOL Input 23 CHANNEL y AT IX3 5 BOOL amp Input 29 CHANNEL hy AT IM3 6 BOOL Input 30 CHANNEL i AT IX3 7 BOOL Input 34 CHANNEL th Introduction to AC500 1 84 AC500 Issued 07 2006 The I Os will have the following CPU addresses in the CPU mapping table Channels Address in Comment the mapping programming software Digital inputs 0 15 YoIWO All the 16 digital inputs combined as Word from the DC532 module Digital inputs 0 7 BO All the 8 first digital inputs combined as Byte Digital inputs 8 15 lB1 All the 8 following digital inputs combined as Byte Single digital input O Single digital input as a bit for the input O to the input 7 to single digital input 7 Single digital input 8 Single digital input as a bit for the input 8 to the input 15 to single digital input 15 Digital configurable YolW 1 All the 16 digital configurable I Os as inputs in combined inputs 16 31 as Word from the DC532 module Digital configurable IB2 All the 8 following digital configurable I Os as inputs inputs 16 23 combined as Byte Digital configurable IB3 All the 8 following digital configurable I Os as inputs inputs 24 31 combined as Byte Single digital Single digital configurable I Os as input as a bit for the configurable input 16 input 16 to the input 23 to single digital configurable input 23 Single digital Single digital configurable I Os as input a
44. IX jees ai acsoo In the line of input O click twice on AT Then enter the symbolic name e g lOdig Pal Digital Inputs 0 1 5 F i Complete your input by pressing the lt Enter gt key displayed entry lOdig AT IX0 0 Now the program can access this input by its symbolic name Using the same procedure we then have to label the digital output with a symbolic name Click on the H symbol in front of the entry Digital In Outputs outputs 16 31 FIX oe E So GIB BYTE p Output 16 23 CHANNEL li eae ST SOGLAO O BOOL amp Output 16 CHANNEL 00 a AT W0890 1 POOL Output 1 CHANNEL 2 ais AT SOls0 2 BOOL amp Output 18 CHANNEL on G1 Introduction to AC500 1 86 AC500 Issued 07 2006 In the line of output 16 click twice on AT Then enter the symbolic name e g OOdig and complete your input by pressing lt Enter gt Fl pes Digital nvfQutputs outputs 16 31 FL 3 esp AT 00 WORD Output 16 31 CHANNEL 2 Opening the Function Block Diagram editor From the Resources we now want to switch to the Function Block Diagram editor Click on the POUs tab and then double click on the entry PLC_PRG PRG The Function Block Diagram editor is opened DOOWPROGRAM PLO PRG button Select Assign Cut Cret Copy Chrl 0 Paste Ctrl V Delete Del Metwork before Network after Ckrl T Input artO Qutput Box Ckr B Assign Jump CErl L Return Ctrl F The display is as fo
45. OFIBUS not operating The POP 21 POP22 has a slave address that is not configured in the bus master Parameter length and slave address are correct but 0 configuration of the slave does not meet the configuration The deica anie received from The bus master are formal Incerrect e g of other length Connection to the bus master lis interrupted longer than the time out set by the bus master before ntarmuptien ott Normal data RS ang eto the anal In a cers Plug is under self test during power up flashes off Plug is waiting for configuration data to be sent from the device number of input output bytes number of parameter bytes ami Internal baud rate ete Note If no data has been sent by the terminal device within lug switches to the parallel mode _ flashes Error can be remedied e g connection to the terminal device is Error cannot be remedied e g Incorrect checksum in the flash Exchange plug G1 Introduction to AC500 1 74 AC500 Issued 07 2006 500 FBP Modules Specifications Please refer to the S500 User s Manual chapter System Data S500 FBP Modules Certifications Please refer to the S500 User s Manual chapter System Data G1 Introduction to AC500 1 75 AC500 Issued 07 2006 Examples Examples for introduction Getting started We will introduce you to the system using a simple example 24 V DC 24 V DC OV OV FE Functional Earth The following components are
46. OOOOO Figure I O Terminal Unit assembly TU515 TU516 TU531 or TU532 The I O Terminal Unit is snapped into the DIN rail in the same way as the Terminal Base Once secured to the DIN rail slide the I O unit to the left until it fully locks into place creating a solid mechanical and electrical connection Up to 7 I O Terminal Units could be combined with a CPU Terminal Base A When attaching the CPU Terminal Base and I O modules make sure the bus ATTENTION connectors are securely locked together to ensure proper electrical connection 0O 0O 0O 0O 0 0 0O 0O 0O 0O 0 0 0 0 0O 0O 0 0 0 0 Figure Maximum configuration 1 CPU Terminal Base plus 7 I O Terminal Units G1 Introduction to AC500 1 43 AC500 Issued 07 2006 Disassembly of a Terminal Unit Figure CPU Terminal Base TB5xx or I O Terminal Unit disassembly TUxx A screwdriver is inserted in the indicated place to separate the Terminal Units Step 4 CPU or Electronic Module assembly OJ Ts Ol Ol O OJ OJ Ol OJ OJ OJJ OJ Te OJ fe Figure Mounting of the CPU PM5xx on a Terminal Base TB5xx in the same way as I O modules on Terminal Units The CPU or I O module will be plugged on the dedicated Terminal Base Terminal Unit And will be locked in place The disassembly is done in reverse order G1 Introduction to AC500 1 44 AC500 Issued 07 2006 Figure CPU I O Module disassembly For disassembly press top and bottom then p
47. Read recipe These functions are also helpful for example for setting and entering control parameters Visualization Includes color change moving elements bitmaps text display allows input of setpoint values and display of process variables read from the PLC dynamic bar diagrams alarm and event management function keys and ActiveX elements Configurators of the communication interfaces Integrated field bus configurator SYCON net for PROFIBUS DP CANopen DeviceNet Ethernet Modbus and CS31 Open interfaces DDE and OPC Programming Serial or via Ethernet or ARCNET networks Engineering interface Provides access from the programming system to an external project database in which the program source code of one or several automation projects is managed Optionally a version control system such as Visual Source Safe can be used in order to ensure data consistency of the program code for several different users and projects e Comprehensive libraries e Windows 32 bit standard e Operating systems Windows 2000 and XP G1 Introduction to AC500 1 21 AC500 Issued 07 2006 Operating and displaying The AC500 offers as well an extensive range of products for communication between operator and machine There are many different displays to choose from which satisfy application specific demands regarding required operator actions and information density Users can communicate with the AC500s CPUs via the various opera
48. Resource Computer NETwork ARCNET is an open multi purpose field bus solution with real time capability It can be used for multi master networking and for programming the AC500 and AC31 controller series but also for connecting additional ARCNET subscribers e g PCs via an appropriate interface card see catalog Topology ARCNET is one of the few networks that can be operated in every conceivable topology Options include bus star or tree topologies or mixtures of these This means that ARCNET can be used for a broad field of different applications Bus assignments ARCNET operates on the token passing procedure where each subscriber has equal rights Configuration mechanisms ARCNET subscribers can freely join and leave during an active runtime session The system will automatically configure the available user database Security mechanisms A 16 bit CRC is appended to every data packet and checked by the recipient If the token is lost a reconfiguration routine will be initiated and the network will automatically be restructured Additionally diagnostic registers are available Physical characteristics ABB recommends coaxial cables as transmission medium for direct connection to the CPU But also twisted pair cables or glass plastic fiber optic cables can be connected via bus converters The line lengths that can be achieved without any intermediate amplifiers depend not only on the used medium but also on the selecte
49. SSSSSSE SSSOSSSSOSS 029SSSSSSOO oaoa 24V DC DC505 FBP DC532 AX522 lt 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 1 O station with a modular FBP This example could be used as starting point to realize your own application ANY Refer to the dedicated User s manuals or Installation guides of the ATTENTION FieldBusPlug and the AC31 PLCs and programming software G1 Introduction to AC500 1 122 AC500 Issued 07 2006 Needed products fd Quantity Product description 1 CPU 07 KT 97 98 with PROFIBUS DP here 07 KT 97 with Ethernet and PROFIBUS DP GJR5 2530 00 R0272 coupler e Programming cable 07 SK90 cable 07 SK 90 GJRS 2502 00 R0001 2502 00 R0001 be d AA PDA11 FBP 050 adapter for FBP power supply and era 9240 09 R0005 field bus PDP22 FBP 050 PROFIBUS DP V0 V1 FBP 0 5 m 1SAJ 2401 00 R1005 modular field bus plug a PDR11 FBP 150 terminating resistor 1SAJ 9240 07 R0001 DC505 FBP with 8DI 8BDC SAP 2200 00 R0001 DC532 with 16DI 16DC TONER YORE AX522 with 8Al 8AO E COON TU506 FBP terminal unit for FBP interface 4SAP 2100 00 R0001 TU516 I O terminal unit for I O modules 1SAP 2120 00 R0001 GSD file for FBP modules ABB 091F GSD Programming software 907 AC 1131 GJP
50. System Description AC500 Scalable PLC for Individual Automation Introduction Contents Introduction SULVEY gain aM OVEN VICW sciana a A R eine EEEE eee 1 3 System structure o1 AG 500 S500 FBP ssis a eee a ae 1 3 AC5SOO SVSICIM OVENI W oust e a a ese a A eee 1 4 BUS SYSIOMS OVEIVIOW reena a a a a e a A ees 1 8 DOCUMENTATION OVeMVEWensienera e e a a seas e e r a ee ae ee eee 1 15 SHO description or Ne NardWalG snina e Oe et eed a eee a 1 19 Short description of THE SOMWAN e iscsi a Ea i aa 1 20 Operating and diS playing osesspa n E iE O EA 1 22 GEIGE S issa a E a a e E 1 26 SENICE Control ENGINEENN G eseria o Ea eE Ea AOA E E a 1 26 Repair services and replacement AeVICES c ccccceeccceeeeceeecceeeceuceceucesueecsueesaueeseuseseeesseeecsueessusenanes 1 26 Seminars WorkShoDS eacscsasunsaa a a a a aG 1 27 Addresses Ganen a a E O ee 1 28 Regulations concerning the appropriate and safe setup of systems and installations cc cce 1 29 Getting SUCCEED FC OO oriin anea cts edd ects eae dca edicts an esas eames easel AN 1 32 IMPOKMANT user Mormaer sneha tedaaueeGensantelnsacauetceialosentecaan a 1 32 BEOOG SIAM ING rx ctereecstetinst see anete a hasta ced santesiatastatacunahesishonudasemumocekactssssaneGenuches 1 33 ASSEMDIING ING SY SION nestor cscekocchacnatsananGssuatnstencesaetc iiehocu a A R 1 36 Insertion replacement of the Lithium battery ceeccccceeccecsesseeceeseeecseeeeeceaaseeeee
51. a 2440 Byte Length of input data 22 Bue Max length of output data 244 Bute Length of output data 19 Byte Max length of in output data 468 Byte Length of tn oukput 4 Byte Max number of modules a Number of modules 4 El Input Modules selected Modules D524 1S4P240000R0001 DCSO5 FBP 154P220000R0001 PSs 16 byte input DES32 154P2401 0OR 0001 PMSe1 4 byte input n A1522 1 SAPP5O000R0001 os PMSx1 16 word input PMSx1 4 word input E Dutput Modules lt lt Welete In utput Modules DCSO5 FBP 15 4P220000R 000 DCS 15 4P2401 OR 000 D531 15 4P245000R 0007 He D522 TSAP245200R 0001 _ Properties Axa 15 4P250000R 0001 PMS 16 bye word inv output Pe5s1 16 byte in output Pe5s1 16 word in output Properties OF Cancel AAg22 TSAPZSOOOOROO01 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 G1 Introduction to AC500 1 126 AC500 Issued 07 2006 Variant B Configuration using the fieldbus configurator software FB1131 Start the fieldbus configurator software 907 FB 1131 and select File gt
52. alled maintained and operated in accordance with appropriate ABB manuals amp documents No liability is assumed for the direct or indirect consequences of the improper use improper application or inadequate maintenance of these devices Risk reduction instructions Protect the devices from dampness dirt and damage during transport storage and operation Do not operate devices outside of the specified technical data Trouble free functioning cannot be guaranteed outside of the specified data Operate the control system only in an enclosed housing switch cabinet Due to their construction degree of protection IP 20 according to EN 60529 and their connection technology the devices are suitable only for operation in enclosed housings switch cabinets AN Earth the devices The earthing switch cabinet earthing PE is supplied both by the mains connection or 24 V supply voltage and via DIN rail The DIN rail must be connected to the earth before the device is subjected to any power The earthing may be removed only if it is certain that no more power is being supplied to the control system In the description for the devices operating manual or AC500 system description reference is made at several points to earthing electrical isolation and EMC measures One of the EMC measures consists of discharging interference voltages into the earthing via Y type capacitors Capacitor discharge currents must basically be able to
53. and text Display size 320 x 240 Pixel 320 x 240 Pixel 320 x 240 Pixel 320 x 240 Pixel Display area 115 2 x 86 4 78 0 x 58 5 115 2 x 86 4 115 2 x 86 4 W x H mm Text height variable variable variable variable mm eoo Function keys 16 8 with labeling strip Alarm 16 groups 4 groups 5 groups management Buzzer Trend curves developing of developing of developing of developing of values values values values Recipe management Report printing Password 8 levels 8 levels 8 levels 8 levels protection Multilanguage support Application 400 kB Flash 400 kB Flash 400 kB Flash 400 kB Flash memory Power supply 24 V DC 24 V DC 24 V DC 24 V DC Current 550 mA 450 mA 400 mA 450 mA consumption Ambient 0 50 C 0 50 C 0 50 C 0 50 C temperature RS232 RS422 RS232 RS422 RS232 RS422 RS232 RS422 RS485 RS485 RS485 640 x 480 Pixel 211 2 x 158 4 variable 5 groups 11 groups developing of values 8 levels 1600 kB Flash 24V DC 0 50 C RS232 RS422 Communication interfaces Ethernet of which 2 at of which 2 at of which 2 at the same time the same time the same time Expansion slots i Degree of IP65 IP65 IP65 IP65 IP65 protection front cover Dimensions 276 x 198 x 89 138 x 100 x 30 200 x 150 x 69 200 x 150 x 69 W x H x D mm Weight kg 7 T5 290 x 250 x 105 a 0 G1 Introduction to AC500 1 25 AC500 Issued 07 2006 Services Service Control Engineering ABB operates
54. anteed collision free data transmission guaranteed response times and real time capability thanks to token passing e Large network dimensions network length 300 m with amplifier max 16 km e Secure thanks to checksums in the data packet and handshake protocol between transmitter and receiver e Variable network structure bus tree and star topologies are possible plus any desired mixtures of them e Variable networking media coaxial cables twisted pair cables and fiber optic cables can be mixed e Automatic subscriber log on and log off the network automatically incorporates new stations in the ring and cancels them as well e Master master access the subscriber that holds the token is the master With up to 255 masters at the same network e Data transmission rate of max 2 5 MBit s e ARCNET is configured and programmed using the AC500 Control Builder engineering tool G1 Introduction to AC500 1 9 AC500 Issued 07 2006 Brief information about CANopen and DeviceNet CANopen Controller Area Network and DeviceNet The CANopen protocol was originally developed for the European automotive industry to replace expensive cabling with an affordable system Today it is also used in the field of automation for transmitting process data between control systems decentralized I O modules drives valves etc CAN features a high level of transmission security since large portions of the monitoring mechanisms have been implemented directly in th
55. application ty Refer to the dedicated User s manuals or Installation guides of the ATTENTION FieldBusPlug and the AC500 PLCs and programming software Needed products amount product description PM581 ETH CPU 1SAP 1401 00 R0170 1 CM572 DP Communication Module PROFIBUS DP 1SAP 170 200 R0001 Master 12 Mb s 1 TB521 ETH CPU Terminal Base AC500 1x CPU Slot 1SAP 1121 00 R0170 2x Coupler Slots Ethernet RJ45 Connector TA524 Dummy Coupler Module 1SAP 1806 00 R0001 TK501 Programming Cable D Sub D Sub 1SAP 1802 00 R0001 1 PDA11 FBP 050 Adapter M12 Dsub9 M12 cable length 1SAJ 9240 09 R0005 a 0 50 m field bus power supply 1 PDP22 FBP 050 PROFIBUS DP V0 V1 FBP 0 5 m 1SAJ 2401 00 R1005 7 modular FieldBusPlug PDR11 FBP 150 Terminating resistor 150 Ohm 1SAJ 9240 07 R0001 DC505 FBP with 8DI 8DC 1SAP 2200 00 R0001 DC532 with 16DI 16DC 1SAP 2401 00 R0001 AX522 with 8AI 8AO 1SAP 2500 00 R0001 TU506 FBP Terminal Unit Spring Terminals 1SAP 2100 00 R0001 ype TU516 I O Terminal Unit 24 V DC Spring Terminals 1SAP 2120 00 R0001 oe Ee GSD file for FBP module file for FBP module ABB_091F ABB_091F GSD PS501 PROG Control Builder AC500 Programming Faria 1901 00 R0001 Software Before starting with the following example please e Use the previous installation instructions to assemble and mount the system also refer to the dedicated Users manual of the PROFIBUS DP FBP S500 FBP and AC500 PLCs e Make the wi
56. appropriate electronic and I O modules in the correct locations CPU module communication couplers on TB and eventually also I O modules onto dedicated TUs Install the battery and the memory SD card this is optional and the CPU is able to run without them lf required make the FBP fieldbus slave connection according to the chosen FBP and use the dedicated FBP accessories oes master cable to M12 line termination power supply connector etc If required plug the FBP Plug on the M12 connector oe on the CPU Terminal Base of the AC500 PLC Connect a programming cable e g TK501 in COM2 PLC and COM1 PC TK502 is necessary for COM1 PLC on the PC and on the AC500 PLC mp Set the power on process power supply first and PLC power supply SS 11 If required set the an address for the integrated Ethernet communication interface by using the front face LCD Display keyboard of the CPU module see the dedicated chapter of the user s manual 12 Install the AC500 Control Builder programming software on your PC If required also copy the appropriate EDS GSD files into the Fieldbus configurator AC500 Control Builder to manage the possible fieldbus slave modules connected to the AC500 master couplers Ly 3 Program the hardware configuration 4 Refer to the AC500 hardware description for proper wiring and addressing information Refer to the Installation Instructions for the particular FBP devices Follow appropriate
57. arallel mode flashes Snor can be remedied e g connection to the terminal device is Eror cennel be remedied e g incorrect checksum in the flash Exchange plug Introduction to AC500 1 57 AC500 Issued 07 2006 AC500 Modules Specifications Please refer to the AC500 User s Manual chapter System Data AC500 Modules Certifications Please refer to the AC500 User s Manual chapter System Data G1 Introduction to AC500 1 58 AC500 Issued 07 2006 Getting Started with S500 FBP Important user information Solid state equipment has operational characteristics differing from those of electromechanical equipment Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will ABB be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variants and requirements associated with any particular installation ABB cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by ABB with respect to use of information circuits equipment or software described in this manual Throughout this manual we use notes t
58. battery is The user should decide the reaction to exhausted or not inserted provide n Note The error messages are displayed as error codes using the Control Builder software via PLC browser Errors are displayed as text in the status line of the Control Builder software or with function blocks for diagnosis G1 Introduction to AC500 1 54 AC500 Issued 07 2006 How an error message is built up in the display An error always consists of an Error Class E1 to E4 see the previous table and a number 0 to 63 which indicates the identifier of the error for direct error recognition Moreover there are further four detailed error codes from d1 to d4 which define the error in detail E1 E4 00 63 error identifier e g wrong value checksum error short circuit exhausted or missing battery etc which is directly displayed in the LCD d1 000 015 indicates the component which has sent the error coupler CPU COM1 FBP IO Bus etc d3 000 030 defines the part of the module with an error slot d4 000 031 defines the channel within the module Example of an error display for an exhausted battery a d2 000 255 defines the faulty device within the component To display the complete error codes please follow the procedure described below The CPU is running The display only shows the RUN status and the background lighting is OFF When an error occurs the red ERR LED goes on An error message is outpu
59. bout which couplers are assigned to it internal and or external couplers e 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 gt Tools gt 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 Example with an AC500 CPU PM581 as PROFIBUS DP Master and a DC505 FBP as PROFIBUS DP slave with a FieldBusPlug PDP22 FBP AC500 PM581 ETH CM572 DP as master DC532 AX522 TT ooooooo0ooo0o PDA11 FBP 050 BROoOoOoOoOoooo from COM2 PLC to PC 24 V DC DC505 ABB DC532 ABB ie a o_o TTT OSC DC505 FBP DC532 AX522 lt 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 O station with a modular FBP G1 Introduction to AC500 1 96 AC500 Issued 07 2006 This example could be used as starting point to develop your own
60. cation Module CANopen Master G1 Introduction to AC500 1 5 AC500 Issued 07 2006 Overview of available CPU terminal bases TB511 1SAP111 100 R0160 TB511 ARCNET CPU Terminal Base AC500 1x CPU ARCNET Slot 1x Coupler Slot ARCNET COAX Connector TB511 ETH 1SAP 111 100 RO170 TB511 ETH CPU Terminal Base AC500 1x CPU Slot 1x Coupler Slot Ethernet RJ45 Connector TB521 1SAP 112 100 RO160 TB521 ARCNET Terminal Base AC500 1x CPU Slot 2x ARCNET Coupler Slots ARCNET COAX Connector TB521 ETH 1SAP 112 100 R0170 TB521 ETH CPU Terminal Base AC500 1x CPU Slot 2x Coupler Slots Ethernet RJ45 Connector TB541 ETH 1SAP 114 100 RO170 TB541 ETH CPU Terminal Base AC500 1x CPU Slot 4x Coupler Slots Ethernet RJ45 Connector Overview of available I O modules Order Number 1SAP 240 000 R0001 DI524 Digital Input Module 32 DI 24 V DC 1 wire DC522 1SAP 240 600 R0001 DC522 Digital input output module 16 DC 24 V DC 0 5 A 2 wire DC523 1SAP 240 500 R0001 DC523 Digital input output module 24 DC 24 V DC 0 5 A 1 wire DC532 1SAP 240 100 R0001 DC532 Digital Input Output Module 16 DI 16 DC 24 V DC 0 5 A 1 wire DX522 1SAP 245 200 R0001 DX522 Digital Input Output Module 8 DI 24 V DC 8 DO Relay 2 wire DX531 1SAP 245 000 R0001 DX531 Digital Input Output Module 8 DI 230 V AC 4 DO Relay 2 wire 1SAP 250 300 R0001 Al523 Analog input module 16 Al U I Pt100 12 Bit sign 2 wires 1SAP 250 200 R0001 AQ0523 Analog output mo
61. ceting stane Recmeee meee teerr see tare eet trier sie ee otc r Draenor ee ee Oe ern ee fore eee eo ene ee eee 1 76 Examples for decentralized systems connected by network cccccseeeeeeeeeeeeeeeesaeeeseeeenees 1 96 Example AC500 CPU PM581 as PROFIBUS DP master and coupler DC505 FBP as PROFIBUS DP slave with FieldBusPlug PDP22 FBP cccccccccsseeeeeeeeeeeeeseeeeeesaeeeeeens 1 96 For AC1131 experts connection of S500 FBP I O module to series 90 1 122 Example AC31 Series 90 CPU as PROFIBUS DP master and decentralized I O expansion using a DC505 FBP cccceccccccceeeeeeeeeceeeeeeeessaeseeeeeesaaeeeeess 1 122 G1 Introduction to AC500 1 1 AC500 Issued 07 2006 G1 Introduction to AC500 1 2 AC500 Issued 07 2006 Survey gain an overview System structure of AC500 S500 FBP The principle system structure is shown in the following figure AC500 External CPU S500 FBP I Os couplers max 7 modules max 4 internal couplers 500 FBP DC505 FBP S500 FBP I Os 7 modules max with a maximum of 4 analog modules Explanation The following electronic modules are the basic components of the AC500 system e CPUs of three different performance classes e Couplers for various bus systems Fieldbus systems PROFIBUS DP CANopen DeviceNet Ethernet couplers Central expansion One CPU supports direct connection of up to seven S500 FBP system I O devices
62. ck Parameter Diagnosis Format Click on the corresponding module G1 Use Block Parameters DPVO Diagnosis Format Introduction to AC500 AC500 Issued 07 2006 The available parameters are displayed Module pcs32 Display mode Hexadecimal Parameters Check Supply On Input Delay 6 ms Detect short circuit at outputs Cpl Behaviour outputs at Stop GFF Substitute value outputs Ox0000 Example Changing the input delay of the module DC5382 Module pcs32 Display mode Hexadecimal Parameters Check Supply On Input Delay ms Detect short circuit at outputs Cpl Behaviour outputs at Stop GFF Substitute value outputs Ox0000 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 E 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
63. d baud rate and the number of subscribers The ranges per segment vary from approximately 120 m for a simple two wire bus up to 3 km for fiber optics in each case at 2 5 MBit s By providing appropriate hubs different topologies and transmission media can be combined with each other and the transmission distance can be increased The coaxial cables used are a type with 93 Ohm e g RG 62 The permissible twisted pair cables are specified in IEEE 802 3i 1990 At 2 5 MBit s and with coaxial cables for example the maximum length of a bus segment is 300 m with eight subscribers and without a hub With twisted pair cables under the same conditions a maximum length of approximately 120 m can be achieved The maximum transmis sion length depends on the number of connected subscribers With coaxial cables a maximum of 16 km can be achieved with twisted pair cables approximately 6 km in each case at 2 5 MBit s The fiber optic link provides the highest degree of interference immunity With glass fiber optics distances of up to 3 km are possible at 2 5 MBit s with plastic fiber optic cables only small distances of up to approximately 100 m The baud rate plays no significant role in fiber optic cable transmission Here the range can as well be extended using hubs Diagnostics Detailed diagnostic messages for rapid trouble shooting are shown on the CPU display or can be called using the programming tool ARCNET the functionality at a glance e Guar
64. diagram and free graphic function block diagram editor The resources PLC configuration Global variables Alarm configuration Library manager Logging chronological recording of actions during online session Task configuration Watch and recipe manager Workspace image of the project options set Target system settings Target specific resources ENI revision control ENI engineering interface for accessing an external project database from the programming system IEC operators and additional norm Arithmetic operators ADD MUL SUB extending functions Bitstring operators AND OR XOR NOT Bitshift operators SHL SHR ROL ROR Selection operators SEL MAX MIN LIMIT MUX Comparison operators GT LT LE GE EQ NE Address operators ADR ADRINST BITADR content operator Calling operator CAL Type conversions Numeric operators ABS SQRT LN LOG Initialization operator INI G1 Introduction to AC500 1 15 AC500 Issued 07 2006 Section come Operands in CoDeSys Constants Variables Addresses Functions Data types in CoDeSys Standard data types Defined data types Overview of operators andiibrarybloks Command line command file commands Commands provided when CoDe Sys is started Command set for building a command file Cmdfile Use of keyboard Operating CoDeSys using the keyboard only Key combinations Siemens import not available
65. dress Table station address U fo SOF ET 97 DPM Uk Description Masteri i z P22 FBP CF E FEF TIE DCS05 FBP Module DLSs2 Module DCS32 Module Ane Modules Ane Modules Sort according ta station addresses Sort according to data addresses Address Overview G1 Introduction to AC500 1 135 AC500 Issued 07 2006 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 182 0 aB124 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 G1 Introduction to AC500 1 136 AC500 Issued 07 2006
66. dule 16 AO U I 12 Bit sign 2 wires AX521 1SAP 250 100 R0001 AX521 Analog input output module 4 Al 4 AO U I Pt100 12 Bit sign 2 wires AX522 1SAP 250 000 R0001 AX522 Analog Input Output Module 8 Al 8 AO U I Pt100 12 Bit sign 2 wire Overview of available terminal units Order Number TU515 1SAP 212 200 R0001 TU515 I O Terminal Unit 24 V DC Screw Terminals TU516 1SAP 212 000 R0001 TU516 I O Terminal Unit 24 V DC Spring Terminals TU531 1SAP 217 200 R0001 TU531 I O Terminal Unit 230 V AC Relay Screw Terminals TU532 1SAP 217 000 ROOO1 TU532 I O Terminal Unit 230 V AC Relay Spring Terminals TU551 CS31 1SAP 210 600 R0001 TU551 CS31 Bus l O Terminal Unit 24 V DC Screw Terminals TU552 CS31 1SAP 210 400 ROOO1 TU552 CS31 Bus l O Terminal Unit 24 V DC Spring Terminals G1 Introduction to AC500 1 6 AC500 Issued 07 2006 Overview of available FBP interface modules Order Number DC505 FBP 1SAP 220 000 R0001 DC505 FBP FBP Interface Module 8 DI 8 DC 24 V DC 0 5 A 1 wire DC551 CS31 1SAP 220 500 R0001 DC551 CS31 Digital Inout Output Bus Module 8DI 16DC 24 V DC 0 5 A 1 wire Overview of available FBP terminal units Order Number TU505 1SAP 210 200 R0001 TU505 FBP Terminal Unit Screw Terminals TU506 1SAP 210 000 R0001 TU506 FBP Terminal Unit Spring Terminals Overview of available FieldBusPlugs and accessories PDP22 FBP 025 1SAJ 2401 00 R1003 PDP22 FBP 025 PROFIBUS DP V0 V1
67. e CPU with identification number R0272 gt slot number 1 gt Ethernet slot number 2 gt PROFIBUS DP e Since we are using the PROFIBUS coupler in our example the resulting card number is 2 Select a PROFIBUS DP master BE ST TZ KONTAKT GmbH Ident r 1 000 Hi Release 0s7505 Sw Release E Manutacturer 4 15 KTI DPM ged File Hame Card number o7 KT 37 DOPM Default 2 Cancel Confirm with OK G1 Introduction to AC500 1 124 AC500 Issued 07 2006 Press the right mouse button and select Append DP Slave El Hardware Configuration Insert Element ppend DP Slave Properties Cuk Ctrl Copy Chrl C Paste brit Del Delete In the appearing window select PDP22 FBP DPV1 modular Default in the File Name list box x Ident HMr 1 1 Cancel Hw Release 0091F Dw Release W 1 0 Manufacturer W 1 0 ABB O91F G50 File Hame POUR22 FBP DPY1 modular Default ha Confirm with OK EE Insert DP Slavwe ppend Subelememt Properties Cut Ctrl Copy ctrl E Faste Ctrl Del Delete G1 Introduction to AC500 1 125 AC500 Issued 07 2006 Select Input Output Click on the entry DC505 FBP in the left hand window and then click on Select gt gt Proceed in the same way for DC532 and AX522 PDP22 FBP DP 1 modular l x Base Parameters Input Output Parameter Groups Max length of input dat
68. e 0x10 0x20 n 0x57 0x67 ALGAZ 0x57 Oxe ATS 23 0x5F Insert Configured Modules Module Configuration Identitier 1 D S05 FBP 0x11 0x20 Length of inputfoutput data 3 bytes max 488 bytes EUe Length of input data z bytes max 244 bytes Length of output data 1 bytes max 244 bytes Number of modules 1 rex 8 The order of the modules in the list of configured modules must match the actual order of hardware modules Otherwise the decentralized station and the network cannot work properly AN ATTENTION G1 Introduction to AC500 1 108 AC500 Issued 07 2006 Repeat this procedure to append the modules DC532 and AX522 Then the list of configured modules looks as follows Available Modules Module Configuration Identitier al O S0S FBF DIs24 D S32 Daal Drozg Anodi ALIZ AlS23 Configured Modules 0x11 020 013 0x13 0x21 0x10 0x20 0x10 020 0x57 ixir 0x57 0x67 0x5F E Insert Append Module Configuration Identitier 0x11 0x20 0x13 0x21 1 O 505 FBF 2 D 532 3 sodA Length of inputfoutput data Length of input data Length of output data Humber of modules 0x57 0x67 41 bytes max 488 bytes 22 bytes max 244 bytes 19 bytes max 244 bytes 3 imax 8 Remove Proceed as follows to configure the module parameters Click on Configuration gt Parameters Select the corresponding module from the list Module Common Display mode Hexadecimal Blo
69. e CAN chip DeviceNet and CANopen utilize the physical structure and the data transport mechanisms of CAN Controller Area Network The difference lies in the transmission protocols DeviceNet and CANopen can be used correspondingly for the AC500 and AC31 controller series and for field bus neutral FBP devices decentralized I Os and intelligent switching devices via the CANopen FBP plug connector Data transmission Two types of message have been defined I O data transfer and direct link I O data transfer is used for time critical process data while the direct link can be for example used for diagnostic messages Bus access for subscribers The connection ID with the lower address has higher priority on the bus Data is transmitted by the source while the sinks i e receivers of the data have likewise been specified during the configuration phase CANopen The bus operates on the master slave principle with one master and up to 127 slaves A shielded twisted pair cable is used according to ISO 11898 Cable lengths and transmission rates from max 40 m at 1 MBit s to 1000 m at 20 kBit s DeviceNet The bus operates on the multi master and or the master slave principle with up to 64 bus subscribers Two types of shielded twisted pair cables are used trunk cable for the main line and drop cable for the branch line 125 Kbit s 250 Kbit s 500 Kbit s Max cable length of 500 m 1610 ft 250 m 820 ft 100 m 328 ft trunk line
70. e FBP plug onto the AC500 CPU if needed but not recommended Normally the FBP slave address is set using the AC500 Control Builder Neverthless it is possible to set this address using the CPU The FieldBusPlug must have a properly assigned slave module address The AC500 CPU gives them an address at system power up The address can be set with the use of the display and the pushbutton on the top of the module AN Attention The local setting of an FBP address by means of pushbuttons and display has a higher priority than an FBP address configured by the AC500 Control Builder The locally set address replaces the address configured by the software It is highly recommended to be extremely careful when modifying the address locally because it has high influence on the behaviour of the application Up to 99 addresses can be then set with the display By using the CFG the ar row keys and the OK pusbutton some parame ters of the CPU can be configured GS QW C Figure Configuration on the CPU WARNING Use of incorrect battery may cause fire or MC INSERT explosion c PUSH 24V DC 10W G1 Introduction to AC500 1 50 AC500 Issued 07 2006 To configure the FBP address please follow the procedure described below 1 First select the item to be configured by pressing the CFG key the CPU changes to SYS configuration mode and a small triangle is BATT displayed on the LCD on the first right up
71. e PC If the PLC does not yet contain a user program the message No program available in the controller Should the new program be loaded is displayed If the project on the PLC differs from the project on the PC the following message is displayed CobeSy s The program has changed Download the new program Mo Cancel Details gt gt Select Yes Then the program is downloaded from the PC to the PLC When starting the download process the PLC changes to the STOP mode G1 Introduction to AC500 1 91 AC500 Issued 07 2006 Now we are going to store our program in the Flash memory of the PLC to protect it against voltage breakdown To do so select Online Create boot project online Window Help Starting the program Now we want to run the program Select the menu item Online Run online Window Help Lagin Logout Downoad Run Stop Reset Reset cold Reset Coriginall Toggle Breakpoint Breakpoint Dialog Step over step ini Single Cycle Write Values Force Values Release Force Wirite Force Dialog Show Call Stack Display Flow Control Simulation Mode GonimuUnication Parameter S Sourcecode download Create boot project write File bo PLE Read File From PLE Login Logout Download stap Reset Reset cold Reset foriginall Alt FE Ctr F amp F5 Shift F amp FY HiG Fe Ctrl FS Chrl F FY Shift F Ctrl Shifk F Ait FS Ctril F
72. e mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts The interior of the enclosure must be accessible only by the use of a tool Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications See NEMA Standards publication 250 and IEC publication 60529 as applicable for explanations of the degrees of protection provided by different types of enclosure Also see the appropriate sections in this publication as G1 Introduction to AC500 1 59 AC500 Issued 07 2006 Before starting Use this document as a guide for installing and powering up your S500 FBP Interface Module You should already be familiar with the system components How to handle S 500 FBP components AA Preventing Electrostatic Discharge ATTENTION This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these guidelines when you handle this equipment e Touch a grounded object to discharge potential static Wear an approved grounding wrist strap Do not touch connectors or pins on component boards Do not touch circuit components inside the equipment If available use a static safe workstation When not in use store
73. en Til Library Manager ian EH Log a Fa PLC Browser bas FEE PLC Configuration lina Sampling Trace am Target Settings l a Task configuration a Watch and Recipe Manager i q Workspace Click on I O Bus FIX and then press the right mouse button vo m Interfaces F ix _ E Couplers Flx Insert Element ppend Subelement d Replace element Calculate addresses Export module Import module ut Etrit Copy Ctrl c Paste Etrit Delete Del G1 Introduction to AC500 1 81 AC500 Issued 07 2006 Select Append Subelement gt DC532 or the I O module You use vo m Interfaces FIX _ Couplers Flx Run an config fault Insert Element ppend Subelement DIS 4 32 digital Input Replace element D532 16 digital Input and 16 digital Inoutput Calculate addresses D522 6 digital Input and 6 digital Qutput FR SSL 8 digital Input and 4 digital Output FR A522 8 analog Input and 6 analog Output Export module Import module faut orl Copy Ctrl C Paste oor Delete Del Configuring the digital I O module DC 532 Configuring the I O parameters Click ondas Resources Double click the object PLC Configuration By clicking on the I O symbol the module parameters are displayed and can be changed Example for DC532 The input delay is changed from 8 ms default to 1 ms oo Interfaces F IM Ignore module oa E Couplers Flx Chec
74. er we are going to replace Couplers Internal none by an Ethernet coupler om E CPU parameters F Ix Fl Fy Wio Bus F g Insert Blement DP Master AR Append subelement Replace element Internal none Calculate addresses PMS 1 ETH Internal Ekhernet PRSx1 4R0C Internal 4RCNET Export module Import module aut Etrit Copy Ctrl C Paste oor Delete Del eo CPU parameters FIx By VO Bus F i n DC532 16 digital Input and 16 digital Inoutputi AF pie fay AMS 22 8 analog Input and 8 analog OQutpui VAR di Interfaces F IH ee E Couplers FIx 5 EA PMSKI ETH gt InternakEthemetfSLOT i H CMS572 External PROFIBUS DF Masteri AR G1 Introduction to AC500 1 103 AC500 Issued 07 2006 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 e ln the left hand window click on the H symbol in front of the Tools entry Then double click the entry SYCON net e The SYCON net fieldbus configurator is opened Using this configurator you can configure the decentralized I O station Resources JJ Global Variables H E library lecsfc lib 26 77 02 10 23 26 global variable library standard lib 22 11 02 11 08 30 global varia library S4 SLIBCALLBACE LIB 29 68 02 16 12 56 g library SysLibMem lb 29 38 02 16 72 56 global var library SwsLibT ime lib 29 8 02 16 72 58
75. es must be recycled to respect the environment Please refer to chapter Hardware Accessories TA521 for the technical data sheet of the Lithium battery TA521 G1 Introduction to AC500 1 40 AC500 Issued 07 2006 Insertion of the SD memory card AC500 CPUs are supplied without an SD Memory Card It therefore must be ordered separately The SD Memory Card is used to back up user data and store user programs or project Source codes as well as to update the internal CPU firmware AC500 CPUs can be operated with and without SD Memory Cards The CPU uses a standard file system which allows the MC502 SD Memory card to be read with a standard memory card reader AN The use of memory cards other than the MC502 SD Memory Card is prohibited ATTENTION ABB is not responsible nor liable for consequences resulting from use of unapproved memory cards AN In operation the plugged in SD Memory Card withstands vibrations up to 1 g ATTENTION Without using an SD Memory Card the CPU itself withstands vibrations up to 4 g AA ED ED FPRIEIDIEIP SD Memory Card MC502 WARNING Use of incorrect battery may cause fire or MC lt INSERT explosion a CPU 24V DC 10W Figure Insertion of the SD Memory Card To insert the SD Memory Card follow the procedure shown below 1 Remove the SD Memory Card from its package 2 Insert the memory card into the opening of the front face of the CPU with the memory card aligned as shown above
76. f the devices and impair the proper function Observe the following rules when handling the system Touch an earthed object in order to discharge the electrostatic charging Wear a suitable earthed strap around your wrist Do not touch any connections or pins on the printed circuit boards Do not touch any circuits inside the devices If available use a work place which is equipped with suitable electrostatic discharge In order to avoid electrostatic charging the devices must only be stored when packed in suitable packaging material Minimum clearances Refer to target system AC500 S500 FBP gt Introduction gt Getting Started gt Getting Started with AC500 gt Assembling the system ABB STOTZ KONTAKT GmbH Heidelberg G1 Introduction to AC500 1 31 AC500 Issued 07 2006 Getting started with AC500 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will ABB be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variants
77. fieldbus practices outline by the conventions and standards of each protocol used in the system G1 Introduction to AC500 1 35 AC500 Issued 07 2006 Assembling the system AA The AC500 modules are not designed for removal or insertion under power WARNING Because of unforeseeable consequences it is not allowed to plug or unplug modules with the power being ON Disconnecting the FBP or any powered modules while energized in a hazardous location could result in an arc which could create a flammable ignition resulting in a fire or explosion Be sure that power is removed and that an area has been thoroughly checked to insure that flammable materials are not present prior to proceeding Using S500 I O Modules The S500 I O modules could be used either directly connected to an AC500 CPU central expansion or together with an FBP Interface Module DC505 FBP an FBP PROFIBUS DP DeviceNet etc as decentralized expansion Ge sie E Abi CM572 Amis CM577 AAi DC532_ ABD or 0O 0O OT H Oj SE o z z fa O 0O 0 0 OoOO ee Figure S500 I O modules directly connected to an AC500 CPU central I O expansion G1 Introduction to AC500 1 36 AC500 Issued 07 2006 AA EDE FREIPEIP DC532 A IPED MPI DC505 TTT ET Figure S500 I O modules connected to an FBP Interface Module DC505 FBP with an FBP decentralized expansion AC500 Issued 07 2006 Introduction to AC500 1 37 G1 Mini
78. flow off to the earthing in this respect see also VBG 4 and the relevant VDE regulations In the description special attention must be paid to designs using electrical isolation earthing and EMC measures for the reasons stated For more information see Target System gt AC500 S500 FBP gt Hardware AC500 gt System data gt General considerations for EMC conforming assembly and construction The earthing concept of these busses apply to the connection to external bus systems AN Connection of the supply voltage The supply voltage or mains connection terminal block must only be plugged in or withdrawn with the power off The same applies to the terminal blocks of input or output channels e g relay outputs if they are operated with dangerous contact voltages AY Do not open live devices The devices work with voltages with which contact must be avoided under all circumstances Therefore they must not be opened when live The same applies to the networking interfaces Lifting up the cover of the battery compartment to exchange the battery module is not construed as opening in this context G1 Introduction to AC500 1 30 AC500 Issued 07 2006 AN Do not obstruct the ventilation for cooling The ventilation slots on the upper and lower side of the devices must not be covered by wiring cable ducts and things like that AN Run signal and power wiring separately Signal and supply lines power cables must be laid out so
79. global var library Sus asklnfo lib 29 68 02 16 72 58 global va library Util lib 12 2 04 12 39 58 global variables J fa Tools l File wiew Device Metwork Help am 2 3 CANopen Devicehet Ethernet H E PROFIBUS DPW 0 netProjeck 1 i za e i Cc alll LE Wendor Fieldbus EE Network In the Fieldbus tab open the folder PROFIBUS DPV 0 by clicking on the H 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 G1 Introduction to AC500 1 104 AC500 Issued 07 2006 In the appearing window leave the Board No 1 unchanged counting mode CPU internal coupler Board No O first coupler left of the CPU Board No 1 second coupler Board No 2 CA Mopen DeviceMet Ethernet PROFIBUS OPW 0 CM572 DPM Ch netConnect Driver Parameter Device CM Br 2 DPM CM572 DOPM 1 1 Slot Board No Conca Click on Accept The coupler is now connected to the CPU Fieldbus netbeyice DPM1 ACSOO CMS72 DPM J lt 1 gt 1 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 gt symbol
80. global variables library standard jib 22 11 02 11 08 30 global varnables library Sy SLIBCALLBACE LIB 29 68 02 16 72 56 global variables library SuslLibMern lib 29 5 02 16 12 56 global variables brary SuslibT ime lb 29 8 02 16 12 58 global varnables library Sus asklnfo lib 29 8 02 16 12 58 global variables library Util lib 12 2 04 12 39 58 global variables E sa Tools A Alarm configuration Til Library Manager fa PLC Browser eo 28 PLC Configuration pe Sampling Trace l am T arget Settings E Task configuration oy Watch and Recipe Manager q workspace POUs MA Data types T Visualizations m Resources G1 Introduction to AC500 1 80 AC500 Issued 07 2006 Double click the object PLC Configuration If the AC500 folder in the PLC configuration tree is closed click on the H symbol File Edit Project Insert Extras Online Window Help aan aSa nA Saal Resouces Le T Global Variables library lecstc lib 26 77 02 10 23 26 global variables aay WO Bus F ls library standard lib 22 11 02 11 08 30 global variables f PR Intertaces FIs library SYSLIBCALLBACK LIB 29 8 02 16 12 56 global variables 9 I El Couplers FIx library SvsLibMern lib 29 8 02 16 12 56 global variables library SysLibTime lb 29 8 02 16 12 58 global variables library SyeT asklnfo lb 29 86 02 16 12 58 global variables library Util Ib 12 2 04 12 39 58 global variables E ay Tools tie A Alarm configuration p
81. ic name Example for symbolic name DPM1_AC500 G1 Introduction to AC500 1 105 AC500 Issued 07 2006 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 gt Bus Parameters With that you can change the parameters Profile PROFIBUS OF wi Bus Parameters Baud Rate 12000 Slot Time 1000 Min Station Delay Time pou Max Station Delay Time 800 Quiet Time Setup Time 16 Bus Monitoring Data Control Time 120 Min Slave Interval 2000 Calculated Timing Tid1 76 ms Tid B00 ms 4 kits Station Address l tBit Target Rotation Time Ky 33430 EBit tBit edad m5 tBit GAP ctualization Factor 10 EBit Max Retry Limit 4 EBit Highest Station Address H54 1276 ms Override slave specific Watchdog Control Time us Watchdog Control Time ae co ms Auto Clear ON Values marked with this symbol should be Adjust adjusted to changes in the topology Cancel yp i Help Change the desired parameters and then click OK 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 CANopen DeviceNet Ethernet PROFIBUS DPW O
82. ications and horizontal mounting we also recommend to place end stop terminals at the right and left side of the device to properly secure the modules e g type BADL P N 1SNA399903R0200 Mounting the System During panel or DIN rail mounting of all devices be sure that all debris metal chips wire strands etc is kept from falling into the controller Debris that falls into the controller could cause damage while the controller is energized AN ATTENTION Mounting and Demounting of the Terminal Unit and Electronic Module Mounting on DIN rail Step 1 Install the 7 5 mm or 15 mm DIN Rail Step 2 Snap the FBP Terminal Unit TU505 or TU506 OO OU OO oO OO oO OO OU OO oO OO O OO oO OO oO OO O OO a Figure Mounting of the FBP Terminal Unit TU505 or TU506 The FBP Terminal Unit will be placed on top of the DIN Rail and then snapped on the bottom Follow the reverse order to disassembly G1 Introduction to AC500 1 65 AC500 Issued 07 2006 Figure Disassembly of the FBP Terminal Unit TU505 or TU506 Step 3 Mounting of the I O Terminal Unit TU515 TU516 TU531 or TU532 l onooonnnoooonoononon OO OO oO OO OO O OO OO O OO Oo U OO OO OU OO ONO oO OO OVO O OO OO OU OO OO oO Oo Oo O Figure I O Terminal Unit assembly TU515 TU516 TU531 or TU532 The I O Terminal Unit is installed on the DIN rail in the same way as the FBP Terminal Unit Once secured on the DIN rail slide the I O unit to the
83. idelines when you handle this equipment e Touch a grounded object to discharge potential static Wear an approved grounding wrist strap Do not touch connectors or pins on component boards Do not touch circuit components inside the equipment If available use a static safe workstation When not in use store the equipment in appropriate static safe packaging Make sure that you have all the components you need To use the AC500 PLC in our example CPU PM581 ETH you should use at least the following parts TB521 ETH Terminal Base for CPU with 2 coupler slots PM581 ETH CPU TA524 Dummy coupler module to cover the unused coupler slots 1SAP 1802 00 R0001 TK501 Programming Cable D Sub D Sub Optional Part Number 1SAP 1803 00 ROOO1 TA521 Lithium Battery 1SAP 1801 00 R0001 MC502 Memory SD Card G1 Introduction to AC500 1 33 AC500 Issued 07 2006 You can use the following components to add additional I O modules If you want use the following component s to connect a digital 24 VDC sensor or DI524 32 DI DC522 16DC DC523 24DC actuator to the CPU DC532 16DI 16DC or DX522 8DI 8 DO R with the corresponding terminal unit with screw or spring connection TU515 516 or TU531 532 e to connect a 115 230 VAC sensor or DX531 8DI 115 230 V AC 4 DO R actuator to the CPU corresponding Terminal Unit TU531 532 with screw or spring technology to connect an analog 24 VDC sensor or Al523 16Al U I PT10
84. igital nfGutputs outputs 16 31 Fs _ i Fast counterfF i In our example it is possible to access the digital inputs of the DC532 module as word using the address IWO simultaneous access to the 16 inputs l0 inputs l8 I7 or 1X1 0 to IX1 7 for the inputs 18 115 A ATTENTION 115 or as bytes inputs 0 7 using the address IBO 115 using the address IB1 or as individual bits addresses IX0 0 to IX0O 7 for inputs l0 In our example the DC532 I O expansion module used has digital inputs and also digital configurable inputs outputs These configurable I Os are displayed in the I O mapping either as inputs or as outputs according to G1 how the channel will be used by the user Introduction to AC500 1 83 AC500 Issued 07 2006 eee Ay acsoag G1 fz CPU parameters F lx fa WO Bus F is IB2 BYTE Input 16 335 CHANNEL AT IK2 0 BOOL Input 16 CHANNEL AT IK2 1 BOOL Input 17 CHANNEL AT IK2 2 BOOL amp Input18 CHANNEL hy a AT IK2 3 BOOL Input 19 CHANNEL i AT IK2 4 BOOL Input 20 CHANNEL hy al AT IX2 5 BOOL Input 21 CHANNEL 1 AT IX2 6 BOOL amp Input 22 CHANNEL hy al AT IX2 7 BOOL amp Input 23 CHANNEL hy va AT IB3 BYTE Input 24 31 CHANNEL th a AT IX3 0 BOOL Input 24 CHANNEL iy al AT 31 FOOL amp Input 25 CHANNEL ciy AT IK3 2 BOOL Input 26 CHANNEL th a AT
85. ilder by clicking on the CoDeS s 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 lt R gt The previously configured variables are displayed and available in the programming software DOTAR GLOBAL is Resources byDps1_S500_0C505_In0_7 AT IB1 0 BYTE ES Global Variables byDps1_ 500_DC5045_In8_15 AT IB1 1 BYTE ef Global_Variables 0004 byOps1_5500_DC532_n0_7 AT IB1 2 BYTE byDps1_S500_DC532_In8_15 AT 181 3 BYTE ae Variable Configuration M amp A CON 0006 wOps1_5500_A8522_n1 AT Sos WWORD ibrary lecsfc lib 26 11 02 10 23 26 glo EP E ere eles wOps1_S500_AK522 In AT IV1 4 WORD ibrary standard lib 22 11 02 11 08 30 o Vagggl byDps1_SS00_DC532_In24_31 AT IB1 5 BYTE library SyslibMern lib 23 6 02 16 196 pooti wDps1_8500_A8522_n4 AT WI WORD library SysLibT ime lib 29 8 02 16 12 58 wOps1_ S500_A522 nd AT 17 WORD JF library SysT ask nfo lib 29 8 02 16 12 58 wWDOpST S500 AKS22 nb AT fyi 2 WORD library Util lib 12 2 04 12 39 59 global v inten eget n ae g pian Fy wos a in 10 i i ee ndon 0016 byOps1_8500_DC505_0ut8_15 AT G81 0 BYTE byDpsi1_S4500_DC532_Outi6_23 AT 0B1 1 BYTE byDps1_S4500_DC532_Out 4_31 AT 0B1 2 BYTE wOps1_S500_A 522 Outl AT SOWV1 2
86. imensions are in mm in Hole spacing tolerance 0 4 mm 0 016 in G1 Introduction to AC500 1 71 AC500 Issued 07 2006 Setting of the slave address of the FBP plug onto the S500 FBP interface module The FieldBusPlug needs to get an address to be used into a fieldbus as a slave module The S500 FBP Interface Module gives them an address at power up of the system The address should be set according to 2 rotary switches located on the top of the module Up to 99 addresses can be then set with the switches 5 PWR f FBP f S ERR M 1 O Bus Jj k caz ADDR Rotary switch for setting asra x10 the FBP slave address SS ololNijolo alo i fi SA en ee free es UVUIN I Oa IJN Boo ooo See ADDRU Po L x1 o A screwdriver with a FBP 8DI 8 DC 16 DI 16 DC Input 24 V DC Input 24 V DC width of 2 5 mm to 3 mm O Output 24 V DC 0 5A O Output 24 V DC 0 5A E m is required Figure Setting the FBP slave address The two rotary switches labelled ADDR x 1 and ADDR x 10 are used to assign an address to the FieldBusPlug For example to assign the address 25 to the station turn the rotary switch ADDRx10 to the position 2 and the ADDRx1 to the position 5 then the resulting address is 2x10 5x1 25 Same example but for the address 6 turn the ADDRx10 to 0 and the ADDRx1 to 6 then the resulting address is 0x10 6x1 6 A If the address set on the FBP Interface Module is differen
87. ines AC500 Issued 07 2006 Displaying error messages error codes on the AC500 CPU When an error occurs the red error LED goes on and an error message is displayed in the LC Display By pressing the DIAG key the complete error code can be shown and an acknowledgement of the error can be performed By using the DIAG and the OK or the ESC push buttons the error mes Ne sage code can be dis incorrect played and the error can battery may cause fire or be acknowledged explosion 24V DC 10W Figure Error display on the CPU The AC500 CPU can display various errors according to the error classes The following error classes are possible The reaction of the CPU is different for each type of error Error class Type Meaning Example E1 Fatal error A safe function of the operating system Checksum error in the is no longer guaranteed system Flash or RAM error E2 Severe error The operating system is functioning Checksum error in the without problems but the error free user Flash independent of processing of the user program is no the task duration longer guaranteed E3 Light error It depends on the application if the user Flash could not be program should be stopped by the programmed I O module operating system or not The user has failed should decide which reaction is necessary E4 Warning Error in the periphery e g I O which Short circuit at an I O only can have influence in the future module the
88. ion ed no communication between FBP Interface Module and the I O modules communication between FBP Interface Module and the I O modules is running green ed serious error within ed ed the corresponding group Channel Error no error error messages in groups digital or analog inputs and outputs combined into the groups 1 2 3 4 r r r r Module Error red error within the I O module All of the LEDs CH ERR1 to CH ERR4 as far as they exist light up together no error Meaning Color LED ON LED OFF LED flashes digital input input ON input OFF error e g error on one channel data exchange is not stopped during initialization error on one I O expansion module e g one output short circuited error on one channel of the corresponding group e g one output short circuited For the meaning of the different LEDs and their behaviour when the system is running please refer to the S500 System Data of the S500 User s manual for further information G1 Introduction to AC500 AC500 Issued 07 2006 FBP LEDs PROFIBUS DP H1 and H2 display the PROFIBUS status H and H4 display the device status Label for writing down the address setting Fastening screw provided on delivery Module status Meaning of the LEDs PROFIBUS status Seine status Status Cause Power supply is missing flashes Possible errors No connection to the bus master e g PR
89. ion Date Error P a nie a ee ee es a ee ey ees es ee Sb et ial i Click on Gateway Configuration and then select the default channel COM1_PC in the appearing window Communication Parameters E x fa J OK BB RS232 a Fort COM Baudrate 19200 Parity No EIN Stop bits 1 Channels EI Lokal ge OMI PC Remove Gateway ALTE EE Update Apply the selection by clicking on OK G1 Introduction to AC500 1 134 AC500 Issued 07 2006 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 Device Information Name Type Version Date Error Slat 1 Pm em5720P To1 og7 24 02 05 jo sar Pat sot ff fas sot f Fa 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 gt 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 gt Address Table View Insert Online Device Table 4ddress Table GAL Table OE Table Toolbars b w Status Bar The digital inputs can be accessed via IBO to IB5 the digital outputs via QBO to QB2 and the analog outputs via QW3 to QW11 Ad
90. k supply Input delay Fast counter Detection short circuit at outputs Behaviour outputs at communication Substitute Value Mo Oo oo on Fe bo This way you can also configure the inputs and outputs of the S500 FBP interface module DC505 FBP in order to use them as decentralized inputs and outputs G1 Introduction to AC500 1 82 AC500 Issued 07 2006 First click on the El symbol in front of the entry DC532 and then click on this symbol in front of the entry Digital Inputs O 15 FIX The I O address mapping in the CPU is displayed Eer gi acsoo om E CPU parameters F i F Je opuso oe a AT IB0 BYTE Input 0 7 CHANNEL i ae AT IKO 0 BOOL amp Input 0 CHANNEL m AT 180 1 BOOL Input 1 CHANNEL ane al AT SIMO 2 BOOL Input 2 CHANNEL ui AT 180 3 BOOL amp Input 3 CHANNEL aia AT IA0 4 BOOL Input 4 CHANNEL ees AT IA0 5 BOOL Input 5 CHANNEL ee AT SIA0 6 BOOL Input 6 CHANNEL ae AT 180 7 BOOL Input 7 CHANNEL i 4 AT IBV BYTE Input 8 15 CHANNEL ae AT 187 0 BOOL Input CHANNEL ace AT 187 7 BOOL Input 9 CHANNEL ae AT Sol87 2 BOOL Input 10 CHANNEL ee AT 187 3 BOOL Input 11 CHANNEL aa AT Sol87 4 BOOL Input 12 CHANNEL one AT 6187 5 BOOL Input 13 CHANNEL a AT 187 6 BOOL Input 14 CHANNEL T AT 11 BOOL Input 15 CHANNEL ae t Digital InfOutputs Inputs 16 331 Fis pee D
91. left until it fully locks into place creating a solid mechanical and electrical connection Up to 7 I O Terminal Units could be combined with a FBP Terminal Unit A When attaching the FBP FBP Interface and I O modules make sure the bus ATTENTION connectors are securely locked together to ensure proper electrical connection G1 Introduction to AC500 1 66 AC500 Issued 07 2006 S S a ee a OQOQOOQOOO00O a QQOQOOOOOO0O a QQOQOOOOOO00O Figure Maximum configuration 1 FBP Terminal Unit plus 7 I O Terminal Units Disassembly of a Terminal Unit Bee a QQQOOOOO O00 TU531 or TU532 TU515 TU516 Figure I O Terminal Unit disassembly A screwdriver is inserted in the indicated place to separate the Terminal Units AC500 Issued 07 2006 Introduction to AC500 1 67 G1 Step 4 Module assembly Figure Mounting of the module The module will be plugged on the Terminal Unit And will be locked in place The disassembly is done in reverse order Figure Module disassembly For disassembly press top and bottom then pull out the module G1 Introduction to AC500 1 68 AC500 Issued 07 2006 Panel mounting If the Terminal Unit should be mounted with screws a Wall Mounting Accessory TA526 must be inserted at the rear side first This plastic part prevents bending of the Terminal Unit while screwing on Holes for wall mounting O 0O 0O 0O O O O 0 0O 0O O 0O 0O 0O O O O 0O 0 0
92. llows Now we have to enter the symbolic names previously assigned to the input and the output Click on the left hand question marks and press lt F2 gt The Help Manager appears Select System Variables G1 Introduction to AC500 1 87 AC500 Issued 07 2006 x Local Variables ky E Global Yariables O0dig covetem Warlables Cancel Select IOdig and confirm with OK Proceed in the same way for the output At the end click into the free area of network 0001 Compiling the project The definition of the project is now completed and the project can be built For this purpose select the menu item Project Rebuild all Project Insert Extras Online Window Build a Rebuild all Clean all Load download information If no errors were detected the message 0 errors O warnings is displayed in the message box Setting the communication parameters In order to establish the connection between the PLC and the PC the communication parameters have to be set We are using the COM2 interface of the PLC and the COM1 interface of the PC or the COM interface of the PC assigned by the USB RS 232 converter Switch to the tay Resources tab Double click the object PLC Configuration In the configuration tree click on the H symbol in front of the Interfaces FIX element A e Interfaces F Ix ee COMI Online access SLOT m E COM2 Online access SLOT a E FEF none SLoT a Couplers F
93. ment SSCS Block libraries System libraries Modbus library Series 90 AC500 library ASCII communication library CS31 library Ethernet library PROFIBUS DP library CANopen library DeviceNet library DC541 library System technology Basic units Couplers O modules OPC Object Linking and Embedding for Project Control a standardized interface for accessing process data CoDeSys libraries semon o o foom SS SSS SSS SS Standard lib library Standard library util lib library Various blocks e g for BCD conversion bit byte functions etc AnalyzationNew lib library Analysis of expressions CoDeSys system libraries Depends on the target system CoDeSys visualization Section SOS ooe Creating a visualization object A CoDeSys project block The project block contains a set of visualization elements and can have specific properties as one complete object Inserting visualization elements E g rectangle curve button etc Positioning visualization elements Selecting copying modifying etc of visualization elements Configuring the visualization visualization Configuring the visualization Overview elements or visualization objects Configuring selected elements using configuration dialogs Summarizing graphical elements to one visualization object which can have specific parameters assigned Visualization in online mode With operation by keyboard configurable Visualizations in
94. mum spacing FAD DC532 aa r PM581 ABB CM577 ABB CM572 AA EED PRAIPIP 189 1893 q i O h a 4 od n A Sa a ina 753 zy O ED T z y O O o gt OIOICIOICIOIOISIOIOIOIO ICO plate earthed Cable duct 20 mm minimum distance between the modules and the cable duct AA aD ED AED ID N ce lo oO m AA EDID FRIPID DC505 O Mounting Figure AC500 S500 module mounting into cabinets 1 in wireways adjacent equipment etc Allow minimum 20 mm 1 38 AC500 Issued 07 2006 of space on all sides as shown This provides ventilation and electrical isolation Introduction to AC500 Maintain spacing from enclosure walls G1 A Important Horizontal mounting is highly recommended Vertical mounting is possible however derating consideration should be made to avoid problems with poor air circulation and the potential for excessive temperatures see also the AC500 system data operating and ambient conditions for reduction of ambient temperature my Note By vertical mounting always place an end stop terminal block e g type BADL P N 1SNA399903R0200 at the bottom and on the top of the modules to properly secure the modules By high vibration applications and horizontal mounting we also recommend to place end stop terminals at the right and left side of the device to properly secure the modules e g type BADL P N 1SNA399903R0200
95. nction keys 3 Web functions Buzzer E e E e E e Eem values O o l lr a e 8 levels 8 levels O 64 kB Flash 64 kB Flash 400 kB Flash 400 kB Flash 24V DC 24V DC 24V DC 24V DC 150 mA 150 mA 450 mA 450 mA 0 50 C 0 50 C 0 50 C 0 50 C G1 Introduction to AC500 1 23 AC500 Issued 07 2006 Alarm management Time channel Real time clock Trend curves Data logger Recipe management Report printing Password protection Multilanguage support Application 16 kB Flash memory Power supply 24 V DC Current 200 mA consumption Ambient temperature 0 50 C CP501 CP502 CP503 CP511 CP512 Communication interfaces Expansion slots Degree of protection front cover Dimensions WxHxD mm Weight kg G1 RS232 or RS232 RS422 RS422 RS485 of which 2 at the same time RS232 RS422 RS232 RS422 RS232 RS422 a a mae aA 104 x 69 x 38 142 x 100 x 29 147 x 163 5 x 211 x 198 x 69 214 x 232 x 87 38 Introduction to AC500 AC500 Issued 07 2006 CP555 CP513 CP551 CP552 CP554 Order Number 1SBP 260175 1SBP 260176 1SBP 260177 1SBP 260178 1SBP 260179 R0101 R0101 R0101 R0101 R0101 Display type TFT 256 Color Touch B W 16 grey levels TFT 256 Color TFT 256 Color LCD with STN Touch LCD touch LCD touch LCD backlight with backlight with backlight Grafic and text Representation Grafic and text Grafic and text Grafic and text Grafic
96. nnected signals 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 lt Enter gt 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 byteP ROFIBUSDpslaveAddress2_S500 system _DC505 device _Input8_to15 by byte b bit w word G1 Introduction to AC500 1 111 AC500 Issued 07 2006 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 Project Tests DPM ACSOOLCMS72 DPM lt 1 414 Slot 1 Ff DPS FEP_SSOO PDP22 FBP DPY1 modulary lt 2 gt ol 2 byte input 4 byte input 8 word Lon 3 ae acre 6 word output 10 Name of variable ES Bee ck netlonn All signals Unconnected signals Connected signals For the 16 DI 16 DC as inputs of the DC532 module cea Project Tests eS DPM1_ACSOO CMS72 OPM lt 1 gt 4 1 Slot 1 DPS2_FBP_SSOO PDP22 FBP DPV1 modular lt 2 gt a 2 ae _ f word m 8 1 byte output J 2 byte output Sword output 10 Name of variable Input_1 BYTE byDps2 S500 DC5352 In0_ Inpuk_ BYTE byDps2 S500 C532 Ind 15 Input 3 BYTE byDos _S500_DCS32_Ini6_23 ie ET byDps
97. nterfaces 2 x RS 232 485 programming Modbus CS31 1 x FBP Display integrated coupler ARCNET PM581 ETH 1SAP 140 100 RO170 PM581 ETH CPU 256kB 24 V DC Memory Card Slot 2x RS 232 485 Programming MODBUS CS31 1x FBP Display with integrated Ethernet TCP IP coupler 1SAP 140 200 R0100 PM582 CPU memory 512 kB 24 V DC Memory Card Slot interfaces 2 x RS 232 485 programming Modbus CS31 1 x FBP Display PM582 ETH 1SAP 140 200 RO170 PM582 ETH CPU memory 512 kB 24 V DC Memory Card Slot interfaces 2 x RS 232 485 programming Modbus CS31 1 x FBP Display integrated coupler Ethernet TCP IP 1SAP 150 100 R0100 PM591 CPU 4MB 24 V DC Memory Card slot 2x RS 232 485 Programming MODBUS CS31 1x FBP Display PM591 1SAP 150 100 R0160 PM591 ARCNET CPU memory 4 MB 24 V DC Memory ARCNET Card Slot interfaces 2 x RS 232 485 programming Modbus CS31 1 x FBP Display integrated coupler ARCNET PM591 ETH 1SAP 150 100 RO170 PM591 ETH CPU 4MB 24 V DC Memory Card Slot 2x RS 232 485 Programming MODBUS CS31 1x FBP Display with integrated Ethernet TCP IP Coupler Overview of available couplers CM572 DP 1SAP 170 200 R0001 CM572 DP Communication Module PROFIBUS DP Master 12 Mb s CM575 DN 1SAP 170 500 ROOO1 CM575 DN Communication Module DeviceNet Master CM577 ETH 1SAP 170 700 R0001 CM577 ETH Communication Module Ethernet TCP IP with integrated 2 port switch CM578 CN 1SAP 170 800 R0001 CM578 CN Communi
98. o make you aware of safety considerations A Identifies information about practices or circumstances that can cause an WARNING explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss A Identifies information that is critical for successful application and IMPORTANT understanding of the product A Identifies information about practices or circumstances that can lead to ATTENTION personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid a hazard e recognize the consequence SHOCK HAZARD Labels may be located on or inside the device to alert people that dangerous voltage may be present SHOCK HAZARD Labels may be located on or inside the device to alert people that surfaces may have dangerous temperatures Environment and Enclosure Information A Environment and Enclosure ATTENTION This equipment is intended for use in a Pollution Degree 2 industrial environment in overvoltage Category II applications as defined in IEC publication 60664 1 at altitudes up to 2000 meters without derating This equipment is considered Group 1 Class A industrial equipment according to IEC CISPR Publication 11 Without appropriate precautions there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance This equipment is supplied as open type equipment It must b
99. oc ae EEN ee DPCSOS FE Modulel IE j DCSOS FE Modulel Remove Module Insert Module Predefined Modules Symbolic Names 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 D531 LSAPZ4S000R0001 l Byte 1 Byte OxlO Oxe o G1 Introduction to AC500 1 129 AC500 Issued 07 2006 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 Slave Configuration X General Device FOF22 FBP DPY1 modular Station address li Uk Description lavel Cancel M Activate device in actual configuration M Enable watchdog control GSD file ABB_D91F GSO _ Parameter Data Jala Max length of in output data 488 Bute Length of in outout data 4 Bute DPYT Settings Max length of input data 244 Byte Length of input data de Byte Assigned maste
100. odular lt 2 gt 2 byte input 4 byte input 8 word input S 1 byte output 10 Name of variable Output 1 wOps _ 5500 Ax522 Outi Output 2 wOps S500 AxS22 Cut Output 3 wOps S500 Ax522 Ouk3 Output 4 wOps S500 AxS22 Cuk4 Output 5 wOps S500 AX522 Ouk5 Output 6 wOps S500 AxS22 Cuk Qutput_ wOps _S500_Ax522_Out7 WORD INMece nett ali All signals Unconnected signals Connected signals After completion of the variables configuration the fieldbus configuration is finished Store the project via File gt Safe Loading the configuration from SYCON net to the coupler Now the configuration has to be loaded from SYCON net to the coupler CM572 DP Proceed as follows In the netDevice window click on the coupler to highlight it with a blue frame D G1 Introduction to AC500 1 114 AC500 Issued 07 2006 G1 Double click on the coupler icon and select Settings gt Driver gt 3S Gateway Driver JnetDevice Configuration DPM1_AC500 CM5 2 0 Ea il Device ID 150x069E Ra Vendor ID iB oy Setti ka Current Configuration Eg Driver Device Assignment Channel COM1_PC Firmware Download l Driver name 5 ial RS License Codes erial C Configuration Read Configuration Bus Parameters Station Table Gateway Configuration Address Table Cancel Apply Help Select Gateway Configuration In the Communication Parameters window you can set the pa
101. of systems and installations Apart from the basic Regulations for the Setting up of Power Installations DIN VDE 0100 and for The Rating of Creepage Distances and Clearances DIN VDE 0110 Part 1 and Part 2 the regulations The Equipment of Power Installations with Electrical Components DIN VDE 0160 in conjunction with DIN VDE 0660 Part 500 have to be taken into due consideration To insure project success and to insure that all systems are properly and safely installed the customer must be familiar and proficient with the following standards and must comply with their directives e Working amp Process Machinery DIN VDE 0113 Part 1 amp Part 200 e Close proximity to dangerous voltages DIN VDE 0106 Part 100 e Protection against direct contact DIN VDE 0160 DIN VDE 0110 Part 1 The user has to guarantee that the devices and the components belonging to them are mounted following these regulations For operating the machines and installations other national and international relevant regulations concerning prevention of accidents and using technical working means also have to be met Advant Controller Devices are designed according to IEC 1131 Part 2 under overvoltage category II per DIN VDE 0110 Part 2 For direct connection of AC Category Ill overvoltages provide protection measures for overvoltage category Il according to IEC Report 664 1980 and DIN VDE 0110 Part 1 Equivalent standards DIN VDE 0110 Part 1 lt IEC 664
102. pecified in the software Click on ta Resources Eh Fie Edit Project Insert Extras Online Window Help BAECRHCEHHRAFMEAARNA to Resources Global Yanables library lecste lib 26 11 02 10 23 26 global variables library standard jib 22 11 02 11 08 30 global varnables library SYSLIBCALLBEACK LIE 29 68 02 16 72 56 global vanables library SusLibMern lib 29 5 02 16 12 56 global variables brary SuslibT ime lb 29 8 02 16 12 58 global variables library SusTaskinito lib 29 8 02 16 12 58 global variables library Util ib 12 2 04 12 39 58 global variables E Sy Tools F Alarm configuration Til Library Manager fa PLC Browser l s REE FPLC Configuration lina Sampling Trace am Target Settings ea Pe Task configuration a Watch and Recipe Manager q7 workspace Visualizations we Resources G1 Introduction to AC500 AC500 Issued 07 2006 Double click the object PLC Configuration If the AC500 folder in the PLC configuration tree is closed click on the H symbol File Edit Project Insert Extras Online Window Help aan aSa nA Saal Resources Be A E E AA _ Global Variables library lecstc lib 26 77 02 10 23 26 global variables aay WO Bus F ls library standard lib 22 11 02 11 08 30 global variables f PR Intertaces FIs library SYSLIBCALLBACK LIB 29 8 02 16 12 56 global variables 9 I El Couplers FIx library SvsLibMern lib 29 8 02 16 12 56 global variables library SysLibTime
103. perate simultaneously as Modbus interfaces The Modbus operating mode of an interface is set using the engineering tool Topology Point to point via RS232 or multi point via RS485 With RS232 a maximum of one master and one slave is possible while with RS485 one master and a maximum of 31 slaves can be operated The maximum cable length is 15 m with RS232 and 1 2 km with RS485 Data transfer Max 187 5 kB s Each telegram has a 16 bit CRC appended The telegrams permit process data input output data to be written and read either individually or in groups The data are packed in the RTU format Transmission media May vary One widely used option is the RS485 bus physics a twisted pair shielded cable with terminators Diagnostics Detailed diagnostic messages for rapid trouble shoot ing are shown on the CPU display or can be called using the programming tool G1 Introduction to AC500 1 13 AC500 Issued 07 2006 Brief information about PROFIBUS DP PROFIBUS DP Process Field Bus Decentral Periphery PROFIBUS DP is an open high speed and widely used field bus It provides multi master and master slave communication in the field area This field bus can accordingly be used for AC500 and AC31 control system series and for field bus neutral FBP devices decentralized I Os and intelligent switching devices via the PROFIBUS FBP connector Communication The masters rule data traffic on the bus When in possession of the bus acces
104. r Max length of output data 244 Byte Length of output data 19 Byte Station address 0 Mas number of modules E Number of modules 4 Ss Ts aaa T C531 LEAP445000R0001 l Byte 1 Byte OxlO xz a Master o 07 ET 37 OPM Actual slave Station address 1 DNS22 lSaPpedsS400R0001 l Byte 1 Byte OxlO Oxe o Slave fi POP22 FBP DPV moc a E DPCSOS FB Modulel DCSOS FB Modulel Remove Module DCS32 Modulez LC532 Module Insert Module o a Predefined Modules ae oe Modules Symbolic Names Call the address table before you specify the parameter data via View gt 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 AMS22 LEAPSSOO00R0001 2 Word 8 Word Oxo Oxe paca Master0 es I Station address 0 DP Master UF KT ODPM A Slave Station address DOP Stave POP 2 FBP DPY modular Cut Ctrl Copy ctrl E Paste Chri Delete Ctrl Lb Replace Ctrl F Slave Configuration Parameter Data G1 Introduction to AC500 1 130 AC500 Issued 07 2006 A new window appears showing all PROFIBUS DP parameters x Description All Parameter Data in hex description O iparameterdata byte 030 0x00 0x00 0x00 0x00 0x00 E 7 parameter data byte O00 0x00 B 9 paramete
105. r data byte DX 3 10 parameter data byte Dx Ox 12 parameter data byte UxF 4 3 parameter data bute 00A Cancel Parameter Data Common Module Hi h For instance click on Module if you want to change the delay time of all inputs of the module DC532 x DCS05 FEF 154P220000R0001 Ok OC532 15AP2401 00R 0001 o A522 15AP250000R0001 Cancel Select dc532 1sap240100r0001 and click on OK The corresponding module parameters are displayed and can be changed now Parameter Data q x Description Indes Parameter Data Ok Cancel 2 IO Parameter Length Check Supply 4 Input Dely o Fast counter No counter Common Detect short circuit at outputs ON aa Behaviour outputs at Stop Ott Substitute value outputs 0 Example In order to change the delay time of the inputs double click on Input Delay G1 Introduction to AC500 1 131 AC500 Issued 07 2006 A new window appears showing all available values Select the desired value e g 1 ms and click on OK xl o mg 29 tr Cancel The new value is applied Parameter Data X Description Index Parameter Data Cancel WIS 2 Bytes 4 Input Delw o No counter E Detect short circuit at outputs ON Dii 0 After you have changed all the desired parameters click on OK to exit the parameter configuration The following configuration is displayed oe File Edit View Insert Online Settings Tools Window Help Masterd station address 0
106. ral Network functionality Visualization Elathan PowerPl i First parameter register lintegerl Last parameter register lintegerl Register for retum value Integer R3 E AI F H3 P Floating point processor F Intel byte order G1 Introduction to AC500 1 98 AC500 Issued 07 2006 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 New POU ee xi Name of the new POU FLC_PRG Type of POU Cancel f Program Language of the POL tL Function Block C LD Function C FBD Return Type C SFC BOOL aa a o The ST editor is opened DOOTPROGRAM PLO PRG OO04 VAR DUOSIENMD VAR _ El First save the project under a specific name Select the menu item File Save as File Edit Project Insert Extras Online Window Help New New From template Open Chrl 0 Close Save Chrl 5 SavelMail Archive Print Ctrl F Printer Setup Exit Alt F4 1 C Program Files 35 SoftwarelCobesys V2 3 1Projects Test ora Select the desired directory and enter the project name in our example Test3 Complete your input with Save G1 Introduction to AC500 1 99 AC500 Issued 07 2006 Specifying the hardware configuration The software has to be informed about the hardware configuration i e the hardware configuration has to be s
107. rameters for the communication between the PC and the PLC port serial interface of the PC Communication Parameters Channels El Local i enal A5232 ABB AS232 COM m Fort LOM Baudrate 19200 Parity Mo Stop bits Motorola byteorder es Introduction to AC500 1 115 AC500 Issued 07 2006 Confirm the settings with OK Select Settings gt Driver gt Device Assignment and click on Scan The configuration tool SYCON net searches for PROFIBUS couplers connected to the stated interface Device Assignt nent Scan progress 2 2 Devices Current device oe a Device Serial number Driver Access path ra CMS72 DP 00000136 35 Gateway Driver VS5lotl Access path 4135CSF6E9 EF6D 41CB 85FB E0EFS9ED2B7E Slot Cancel Apply Help Select the device CM572 DP and confirm with OK Then press the right mouse button and select Connect DPR ACSOOLCMS72 DPM amr Connect Wisconnmeck Download Upload Configuration Measured Value Simulation Diagnostic Additional Functions Delete Symbolic Mame Device Properties G1 Introduction to AC500 1 116 AC500 Issued 07 2006 The coupler entry CM572 DPM is now highlighted in green indicating that the connection is established DPS2_FEP_S500 PDP22 FaP DPYL modular J lt 1 gt Press the right mouse button and select Download ATTENTION To do thi
108. ring and provide supply power to the system process supply and to the FieldBusPlug use dedicated accessory e g PDA11 FBP 050 which allows connecting a PROFIBUS DP master with a 9 pins D Sub and provides power supply for the FBP through a M12 connector e Set the slave address of the FBP to 2 with the front rotary switches of the S500 FBP Interface module chosen for this example see also S500 FBP Getting started Install the AC500 Control Builder programming software for AC500 PLCs Install the SYCON net fieldbus configurator Install GSD and EDS files Connect the programming cable TK501 from the PC to the AC500 PLC Review all of the hardware instructions for your specific system to be sure you have completed all of the required preliminary steps prior to beginning the system configuration with the AC500 Control Builder programming software e Power up the system G1 Introduction to AC500 1 97 AC500 Issued 07 2006 Starting the programming software Start the AC500 Control Builder programming software Select File New to create a new project File Edit Project Insert Extras Online Window Help New From template Open Chrl a Close Select the desired CPU in the appearing window In our example select PM581 Target Settings Configurations None x Mone ACSOO PMS ACSO PMS In the appearing window confirm with OK Target Settings Configuration Target Plattorm Memory Layout Gene
109. rs Insert Element 4opend Subelement Replace element Calculate addresses Export module Import module faut Girls Copy Ctrl C Paste Corl Delete Del DIS 4 32 digital Input D532 16 digital Input and 16 digital Inoutput D522 6 digital Input and 6 digital Qutput R D531 8 digital Input and 4 digital Qutpuk PR ee DSS 16 digital Input and 16 digital InoutputVvAR _ faLAxS 22 8 analog Input and 8 analog Output AF m Interfaces FIX _ E Couplers F i G1 Introduction to AC500 AC500 Issued 07 2006 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 gt CM572 and then click to append the element CPU parameters F Iis F VO Bus F i T BE D532 16 digital Input and 16 digital Inoutput ARF Den fy AMS 22 analog Input and 8 analog Output ARF E Interfaces F i 7 J Corer T A E E E E E AE T ae meee Insert Element External none Append Subelement Replace element CMS72 External PROFIBUS DP Master Calculate addresses CMS External Ekhernet CMS78 External CANopen E t module xport modue CMS75 External DeviceNet Import module Gut bri Copy Chrl Paste arit pelete Del The coupler is appended to the tree As the CPU also comprises an integrated Ethernet coupl
110. s a bit for the configurable input 24 input 24 to the input 31 to single digital configurable input 31 Digital configurable YQWO All the 16 digital configurable I Os as outputs combined outputs 16 31 as Word from the DC532 module Digital configurable QBO All the 8 following digital configurable I Os as outputs outputs 16 23 combined as Byte Digital configurable QB1 All the 8 following digital configurable I Os as outputs outputs 24 31 combined as Byte Single digital Single digital configurable I Os as output as a bit for the configurable output 16 output 16 to the output 23 to single digital configurable output 23 Single digital Single digital configurable I Os as output as a bit for the configurable output 24 output 24 to the output 31 to single digital configurable output 31 For more details concerning the I O mapping please refer to the AC500 User s manual G1 Introduction to AC500 1 85 AC500 Issued 07 2006 Symbolic names for I Os In our example we use one digital input and one digital output We want to label them with symbolic names Proceed as follows Click on the H symbol in front of DC532 in order to display the I O configuration nae Digital InfQutputs outputs 16 317 FL _ 4 Fast counter Fig A ee eg Intertaces F Is cee H Couplers FIx Now define a symbolic name for the digital input digital input 0 as follows First click on the H symbol in front of Digital Inputs O 15 F
111. s authorization token the masters can transmit data without an external request The passive devices known as slaves do not receive any bus access rights they acknowledge messages received or respond to a query from a master Baud rates from 9 6 kBaud to 12 MBaud are supported A maximum of 126 devices can be operated on the bus Data exchange This is handled predominantly in cyclical mode be tween master and slave The requisite communication functions have been specified by the PROFIBUS DP basic functions in accordance with EN 50170 Each master has full write and read access to its assigned slaves but only read access to the slaves assigned to other bus masters There is no direct data exchange between masters Acyclical services DP V1 for parameterization and diagnostics between master and slave are also available This is performed in parallel to the master s cyclical user data traffic PROFIBUS DP the functionality at a glance e Max 126 subscribers via amplifier and max 32 subscribers master slaves per bus segment e Data transmission rate from max 12 MBit s with a cable length of 100 m up to 93 75 kBit s with 1200 m e Multi master or master slave communication Bus access of the masters using token e Connection of the master CPU and the associated communication module via a 9 pole SUB D plug connector Connection of slaves CPU I Os and intelligent switching devices via FieldBusPlug e The system cable is a shielded twi
112. s the CPU must be in Stop state Gonmect Disconnect Download Upload Configuration Measured Value Simulation Diagnostic Additional Functions Delete Symbolic Mame Device Properties A safety inquiry is displayed Confirm with Yes netDevice DPM1_AC500 CM572 DPM lt 0 gt 1 x 2 IF download is done during bus operation communication between master and slaves is stopped Do you really wank to download Ves flo G1 Introduction to AC500 1 117 AC500 Issued 07 2006 This downloads the configuration to the coupler Progress of data transfer is displayed netDevice Device DPM1_ACSO0 CM5 2 0PM lt 0 gt 1 Download inning fy complete Sh Lancel After the download is completed SYCON net has to be disconnected Press the right mouse button and select Disconnect ohhech Disconnect 22 FRP OPW modular J lt 1 gt Download Upload Configuration Measured walut Simulation Diagnostic Additional Functions Delete Symbolic Mame Device Properties 1 i a 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 SYCOM net Test3 spj FET Network Help a eT View Device Network Help eo wa er G1 Introduction to AC500 1 118 AC500 Issued 07 2006 Return to the AC500 Control Bu
113. sage window AN For a correct operation of the system it is important to completely specify ATTENTION configure the device configuration in the programming software Otherwise the system will bring up corresponding error messages In case of errors please refer to the chapter System Technology Diagnosis System in AC500 for required information G1 Introduction to AC500 1 77 AC500 Issued 07 2006 Creating a new project Select File New File Edit Project Insert Extras Online Window Help New From template Open Chrl 0 Clase Select the desired CPU in the appearing window In our example select PM581 Target Settings Configurations None b Mone ACS00 PMS AC500 PM531 ACSOO PM531 In the appearing window confirm with OK Target Settings Configuration Target Platform Memory Layout General Network functionality Visualization Elathan PowerPl f First parameter register lintegerl Last parameter register integer Register for retum value integer R3 Z R10 Fis Floating point processor F Intel byte order G1 Introduction to AC500 1 78 AC500 Issued 07 2006 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 FBD for the language and confirm with OK Newpou O O OOOO Oo x Cancel Name of the new POU Type of POU Language of the POU
114. sted pair line or a fiber optic cable transmission standard EIA RS485 Diagnostics Detailed diagnostic messages for rapid trouble shooting are shown on the CPU display or can be called using the programming tool In addition the device status is indicated at the communica tion module by four LEDs G1 Introduction to AC500 1 14 AC500 Issued 07 2006 Documentation overview The documentation consists of six parts CoDeSys programming system Describes the functionality of the programming software Target system Documentation of the AC500 system CoDeSys libraries CoDeSys visualization CoDeSys HMI CoDeSys license management CoDeSys programming system Section SCS Comment SOS A brief introduction to CoDeSys Explanation of the acronym CoDeSys Software functionality Components of a project Programming languages Debugging We write a little program Controlling a traffic signal unit Visualizing a traffic signal unit The individual components Main window and functions Options for project organization Object handling blocks data types visualizations resources Editing functions Online functions Explanation of the help system Editors in CoDeSys General Declaration editor for the variables Pragma instructions for controlling the compilation process Text editor for instruction list and structured text Graphical editors for sequential function chart ladder diagram function block
115. t CRC appended The telegrams enable process data input output data to be written and read Transmission medium Primarily a twisted pair shielded cable with terminators Other transmission media fiber optic cables via a converter glass fibers max 3 km plastic max 100 m contact lines slip rings bus length max 50 m and data photocells Diagnostics Detailed diagnostic messages for rapid trouble shooting are shown on the CPU display or can be called using the programming tool G1 Introduction to AC500 1 11 AC500 Issued 07 2006 Brief information about Ethernet Ethernet Ethernet operates with a data rate of 10 MBit s and as Fast Ethernet with 100 MBit s Ethernet utilizes the producer consumer model This means that every station possesses equal rights While it is transmitting all other stations listen in and accept the data directed to them Bus access is regulated by the CSMA CD procedure Carrier Sense Multiple Access with Collision Detection where each station may autonomously transmit when the bus is free If a collision occurs if two stations begin to transmit simultaneously both of them will stop transmission and wait for a randomly determined time before they transmit again Ethernet defines the Layers 1 Physical Link and 2 Data Link of the OSI model The AC500 supports transmission and reception of data using TCP IP and or UDP IP Further application layers can be implemented by subsequent loading Simultaneo
116. t after pressing the DIAG key and for example the screen shown to the right displays E4 008 Accor ding to the error level E1 to E4 can be dis played In this example E4 008 is a warning E4 and 008 means Empty Missing By pressing on the DIAG button the LCD background lighting is turned ON the error codes can be displayed to achieve more dea SYS per diagnostic The display shows d1 009 BATT detail level 1 and 009 indicates that the O Bus CPU has sent the error By pressing DIAG one more time the display shows d2 022 detail level 2 and 022 indi cates that the device type battery SYS BATT O Bus By pressing DIAG one more time the display shows d3 031 detail level 3 and 031 means no module type device itself SYS BATT O Bus By pressing DIAG one more time the display shows d4 031 detail level 4 and 031 means no channel device itself SYS BATT l O Bus YO By pressing OK the error is acknowledged and the display returns to the normal state ESC returns to the normal state without ack nowledging the error SYS BATT O Bus O Figure Example of an error display for an exhausted battery Please refer to the Error Code list for further information See the AC500 user manual G1 Introduction to AC500 1 55 AC500 Issued 07 2006 LEDs on S500 FBP modules All S500 mod
117. t from those assigned ATTENTION into the Fieldbus configurator software of the Master device for that station the station could not be accessed and the complete fieldbus could not work properly or be completely down Make the Connection of the FieldBusPlug to the Fieldbus Master Device The FieldBusPlug module has to be connected to the master device and the power supply has to be provided Please use the dedicated accessories to the FBP used for the desired Fieldbus Refer to the FBP documentation for the installation instructions G1 Introduction to AC500 1 72 AC500 Issued 07 2006 LEDs on S 500 FBP modules All S500 modules have LEDs for the display of operating statuses and error messages They indicate LED Input Output C 5 PWR S ERR FBP O Bus CH ERR1 CH ERR2 CH ERR3 CH ERR4 CH ERR analog input digital output output ON output OFF analog output o brightness depends on the value of the analog signal brightness depends on the value of the analog signal process voltage 24 V voltage is present voltage is missing DC via terminal green 24 V DC via voltage is present voltage is missing FBP serious error data exchange is stopped depends on the behaviour of the master FBP communication communication between FBP and FBP Interface Module is broken communication between FBP and FBP Interface Module is running ed O Bus communicat
118. t is considered Group 1 Class A industrial equipment according to IEC CISPR Publication 11 Without appropriate precautions there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance This equipment is supplied as open type equipment It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts The interior of the enclosure must be accessible only by the use of a tool Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications See NEMA Standards publication 250 and IEC publication 60529 as applicable for explanations of the degrees of protection provided by different types of enclosure Also see the appropriate sections in this publication as G1 Introduction to AC500 1 32 AC500 Issued 07 2006 Before starting Use this document as a guide for installing and powering up your AC500 PLC You should already be familiar with the system components How to handle AC500 components AA Preventing Electrostatic Discharge ATTENTION This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these gu
119. the AC500 Control Builder software in order to have them available there G1 Introduction to AC500 1 110 AC500 Issued 07 2006 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 H 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 od DPM foc OPM lt 1 gt 13 Slot 1 iG DP52_FEP_SS00 PDP22 FeP DP 1 modular lt 2 gt 2 byte input 4 byte input 6 word input 1 byte output 2 byte output 8 word output T a Name of variable net onneck EA All signals Unconnected signals Connected signals 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 E H Project Test3 z Ef DPM1_ACSO0 CM572 DPM lt 1 gt 1 Slot 1 a DPS2_FBP 5500 PDP22 FBF DPV1 modulart lt 2 gt 4 4 byte ae 8 word input 1 byte output z byte output Sword output 10 Name of variable Input 1 BYTE by Bos 5500 OC505 Ind 7 vo Dps2_5500 DCS0S Ind 15 m L mi L m meki All signals Unconnected signals 5 Co
120. the others aside This reduces remounting time during drilling and tapping of the next group 7 Repeat steps 1 to 6 for any remaining modules G1 Introduction to AC500 1 69 AC500 Issued 07 2006 Grounding considerations This product is designed to be mounted to a well grounded mounting surface such as a metal panel Additional grounding connections from the S500 mounting tabs or DIN rail if used are not required unless the mounting surface cannot be grounded Refer to appropriate Chapter of the S500 FBP User s Manual for additional information This product is grounded through the DIN rail to chassis ground Use zinc plated yellow chromate stell DIN rail to assure proper grounding The use of other DIN rail materials e g aluminium plastic etc that can corrode oxidize or are poor conductors can result in improper or intermittent grounding AN ATTENTION 500 system dimensions AA OP ED FNEDID 0O O 0O O O O O 0O 0O O 0O O 0O O 0O O 0O O 0O O OOOOOOOOOO OOOOOOOOOO 67 5 2 66 67 5 2 66 Dimensions 135 mm TU505 506 TU515 516 531 532 5 31 inches Figure Dimensions of the Terminal Unit front view G1 Introduction to AC500 1 70 AC500 Issued 07 2006 84 5 3 33 77 3 03 75 2 95 DIN rail 15 mm DIN rail 7 5 mm Dimensions 135 mm 28 1 10 5 31 inches View on the left side View on the right side Figure Dimensions of the Terminal Unit with module lateral view Note All d
121. tle name TS DPM GS0 Click on OK and continue G1 Introduction to AC500 1 127 AC500 Issued 07 2006 os File Edit View Insert Online Settings Tools Window Help Deal 2 Hi in POD MasterO0 Station address 0 OP Master 07 KT 97 OF fl 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 Select Insert gt Slave from the menu bar Insert Online Settings Tools Window He Master Communication Reference connection Predefined Slave 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 gt gt Your selection is displayed on the right hand side of the window Insert Slave x Slave Filter Vendor All Master fo POF ET 9 DPM OF Slave type all gt Cancel Available slaves Selected slaves Deo POPZ2 FBP LPW modular Doo 050 D502 Deol Add gt gt Add All gt gt 0o02 Remove All POP21 FBP PDP22 FBF POP22 FBP DPW modular Vendor name ABE station address fi Ident number 0091F Description Slave GSU file name ABB_OS1F G50 G50 Revision WT
122. tor panels read and write access on device data is possible Configuration is quick and easy to perform using the same software for all devices programming software CPsoft 1SBS 260 283 R1001 Commands and programming languages are identical for all devices With regard to frequently harsh conditions at the place of installation all operator panels fulfill IP65 protection at the front Operator panels and automation devices are linked either simply via serial interfaces or in case of complex applications via Ethernet Modbus or PROFIBUS DP G1 Introduction to AC500 1 22 AC500 Issued 07 2006 O lt lt O i O D QI O Ee O O Q D I O Q ms h k k A Taa E tt pE g ssseee iri i i si coe MEPS p i LEDs Type CP501 CP502 CP503 CP511 CP512 Order Number 1SBP 260 170 1SBP 260 171 1SBP 260 172 1SBP 260 173 1SBP 260 174 R0101 R0101 R0101 R0101 R0101 Display type STN LCD STN LCD STN LCD STN LCD B W STN LCD with backlight with backlight with backlight with backlight with backlight Representation Text Text Grafic and text Grafic and text Display size 2 lines x 16 2 lines x 20 4 lines x 20 240 x 64 pixels 240 x 128 characters characters characters 5 2 pixels 5 3 Display area 55 7 x 11 0 73 5 x 11 5 70 4 x 20 8 127 2 x 33 9 120 0 x 64 0 W x H mm Text height 5 5 variable variable mm 5 2 colors 16 2 colors 16 2 colors 16 8 with labeling strip Fu
123. ules have LEDs for the display of operating statuses and error messages They indicate LED Input digital input input OFF analog input brightness depends on the value of the analog signal digital output output ON output OFF brightness depends on the value of the analog signal Output analog output process voltage 24 V C 5 voltage is present voltage is missing DC via terminal green PWR 24 V DC via voltage is present voltage is missing FBP serious error data exchange is stopped depends on the behaviour of S ERR the master i communication green r r r no error communication between FBP and FBP Interface Module is broken FBP communication between FBP and FBP Interface Module is running O Bus I O Bus communication no communication between FBP Interface Module and the I O modules communication between FBP Interface Module and the I O modules is running CH ERR1 CH ERR2 CH ERR3 CH ERR4 serious error within the corresponding group Channel Error no error error messages in groups digital or analog inputs and outputs combined into the groups 1 2 3 4 ed ed ed ed ed ed CH ERR Meaning Color LED ON LED OFF LED flashes error e g error on one channel data exchange is not stopped during initialization error on one I O expansion module e g one output short circuited error on one
124. ull out the CPU I O module Step 5 Communication Couplers on Terminal Base assembly lt Figure Mounting of a communication coupler CM5xx on a CPU Terminal Base TB5xx First insert the bottom nose of the communication Coupler module into the dedicated holes of the Terminal Base and then rotate the coupler until it will be plugged on the dedicated Terminal Base slot push to be sure that the connection is well done It will be locked in place The disassembly is done in reverse order G1 Introduction to AC500 1 45 AC500 Issued 07 2006 Figure Communication coupler module disassembly Disassembly Press Top and Bottom then rotate the coupler module and pull it out G1 Introduction to AC500 1 46 AC500 Issued 07 2006 Panel mounting If the CPU Terminal Base should be mounted with screws Wall Mounting Accessories TA526 must be inserted at the rear side first These plastic parts prevent bending of the Terminal Base while screwing on TB511 needs one TA526 TB521 and TB541 need two TA526 Rear view Holes for wall mounting Rear view Front view Figure Fastening with screws of the Terminal Base TB521 ETH as an example 1 The two Wall Mounting Accessories TA526 are snapped on the rear side of the CPU Terminal Base like DIN rails The arrows point to the middle of the CPU Terminal Base One TA526 is turned by 180 2 Two accessories for wall mounting inserted 3 CPU Terminal Base fastened with screws
125. unded mounting surface such as a metal panel Additional grounding connections from the AC500 mounting tabs or DIN rail if used are not required unless the mounting surface cannot be grounded Refer to appropriate Chapter of the S500 FBP User s Manual for additional information This product is grounded through the DIN rail to chassis ground Use zinc plated yellow chromate steel DIN rail to assure proper grounding The use of other DIN rail materials e g aluminium plastic etc that can corrode oxidize or are poor conductors can result in improper or intermittent grounding AN ATTENTION AC500 System dimensions 28 28 28 28 1 10 1 10 1 10 1 10 67 5 2 66 Dimensions 135 mm TB511 95 5 3 76 5 31 inches TB521 123 5 4 86 TB541 179 5 7 07 Figure Dimensions of the CPU Terminal Bases front view G1 Introduction to AC500 1 48 AC500 Issued 07 2006 AA ED ID PREDID gggggggaggi OOOOOOOOOO gggggggogog Yt a et a 67 5 2 66 67 5 2 66 Ma e 135 mm TU505 506 TU515 516 531 532 5 31 Zoll Figure Dimensions of the Terminal Unit front view 84 5 3 33 77 3 03 75 2 95 DIN rail 15 mm DIN rail 7 5 mm Dimensions 135 mm 28 1 10 5 31 inches View on the left side View on the right side Note All dimensions are in mm in Hole spacing tolerance 0 4 mm 0 016 in G1 Introduction to AC500 1 49 AC500 Issued 07 2006 Setting of the Slave Address of th
126. us configurator for use with AC31 or AC500 Control Builder or use a dedicated Fieldbus Configurator tool using GSD EDS configuration files of your Master device Set the power on process power supply first and FBP power supply LF EEDS Start the communication i Refer to the Installation Instructions of the used FBP device G1 Introduction to AC500 1 61 AC500 Issued 07 2006 Assembling the System AA The S500 FBP modules are not designed for removal or insertion under power WARNING Because of unforeseeable consequences it is not allowed to plug or unplug modules with the power being ON If you connect or disconnect the FBP plug while power is applied to this module or the wiring while the process power supply is on an electrical arc can occur This could cause an explosion in hazardous location installations Be sure that power is removed or area is non hazardous before proceeding Using 500 I O Modules The S500 I O modules could be used either directly connected to an AC500 CPU central expansion or together with an FBP Interface Module DC505 FBP an FBP PROFIBUS DP DeviceNet etc as decentralized expansion Tee a Ee ed ee a a ee Abi CM572 Amis CM577 stone DC532_ ABD 0O 0O O O O O 0O 0 O O 0O O 0O 0O O O 0O 0O O O Figure S500 I O modules directly connected to an AC500 CPU central I O expansion G1 Introduction to AC500 1 62 AC500 Issued 07 2006 AA EDE FREIPEIP DC532 A IPED MPI
127. us operation of TCP IP UDP IP and application layer is also assured The IP TCP UDP ARP RP BOOTP and DHCP protocols are supported as a standard feature as application layer Modbus TCP Topology Star or ring shaped using Ethernet hub or switch Data transmission Max 10 MB s with 10 Base T and max 100 MB s with Fast Ethernet Transmission media Twisted pair cables with RJ45 connector The maximum cable length is 100 m for 100 MB s Diagnostics Detailed diagnostic messages for rapid trouble shooting are shown on the CPU display or can be called using the programming tool In addition the device status is indicated at the communication module by four LEDs G1 Introduction to AC500 1 12 AC500 Issued 07 2006 Brief information about Modbus Modbus RTU developed by Modicon in 1979 Modbus RTU is an open master slave protocol and can be easily implemented on serial interfaces Numerous automation systems have Modbus RTU interfaces as standard or optional features and are thus easily able to communicate with the AC500 via its integrated COM1 and COM2 interfaces RS232 or RS485 The Modbus is used not only in industrial applications but also in building installations in energy optimization systems for long distance data transmission and for linking up operator panels Communication By polling i e the master transmits a request to the slave and then receives the response Both interfaces COM1 and COM2 can o
128. useeessaseeessseesssaaeees 1 39 Insertion of the SD Memory Card cs cnceisaccceraneactaeindnaveyansesuetesscbuetiaila vesunecsetanas tuyere dsueriaivencmiaiaetensaateeaiea 1 41 Mounting tnes yS ie Maca a a teasanemanaen manetentues mencweaanen 1 42 AC5O0 System dimensions erien a nea nees Reaat ecb ontlaes iedanecnenceiusteeiuaiases 1 48 Setting the FBP Slave address sscan searetaa tions diuskos an bunndd E de manateacent 1 50 Status display and error indication on the AC500 CPU cccccceeeceeeeeeeeeeeeeeeeeeeeeeeeseaaaeeeeesaeeeeeeesaaaees 1 52 LEDS ONS 500 F BP MOGUES carct a a A cute men derianebaen 1 56 SPECITICATIONS AMG CEMINICATONS siecex iosscniheceesodidetectice dads tien ai ie aaiae a aa oiii 1 58 Getting started with S500 FBP succs 22ers er ee ees 1 59 IMPG Mant USEF INTO GM AUOM eese E E E 1 59 BE ClOlG Soni ea aden saacccsoanveacaniaeaaetonmnansenccunanesesecnes eett os netacsaupesancn aacacamnbusamia ata yemaecnsaebensaamageeacee 1 60 ASSCMDIING INE SVS Msro nE O O 1 62 Mounting the Systemes weet onetecsauessancestandedes tcp sanbes eet when iessaunesmnanosunacees 1 65 9500 System GIMENSIONS 2 sce a cecec nce cesnnsesentnsa a a 1 70 seting Ihe FBP Slave address essiensa a a a a e aaa e iia 1 72 LEDS OMS900 FBP MOQUE S anad ia e a a a a a 1 73 Speciealions and COMINCAUNOWMS neis ia a i a E E i 1 75 BRITS ices cece ree eee ee 1 76 EXamples for IMIPOGUCIION c5i ci ses sic cei dnt en ciee ie nie cela bani e a ii i ase 1 76

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