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IAI RCM-GW-PR Operation Manual

Profibus gateway unit
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ProfiBus
Gateway Unit
RCM-GW-PR
Operation Manual, Second Edition

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  • Page 1: Profibus Gateway Unit

    ProfiBus Gateway Unit RCM-GW-PR Operation Manual, Second Edition...
  • Page 2 CAUTION Note on Connecting a PC or Teaching Pendant to the Gateway Unit Grounded via the Positive Terminal of Its 24-V Power Supply If the positive terminal of the gateway unit’s 24-V power supply is grounded, use a SIO converter as shown below to connect a teaching pendant or PC to the gateway unit.
  • Page 3 CAUTION If the positive terminal of the gateway unit’s 24-V power supply is grounded, the gateway unit cannot be connected directly to a teaching pendant or PC. If a teaching pendant or PC is connected directly to the gateway unit grounded in this condition, the power-supply circuit may be shorted and the PC/teaching pendant may be damaged.

  • Page 4: Table Of Contents

    PfofiBus Gateway Table of Contents 1. Overview ........................1 1.1 ProfiBus Gateway Unit ........................ 1 1.2 What Is ProfiBus?........................2 1.3 Application Example of Gateway Unit ..................3 1.4 Features and Key Functions......................4 1.4.1 Features ......................... 4 1.4.2 Key Functions ........................4 1.5 Description of Model Name ......................
  • Page 5 PfofiBus Gateway 6.4 Command Transmission......................95 7. Building Your Network System................96 7.1 Procedure ..........................96 7.2 Setting the Controller......................... 97 7.3 Setting the Gateway Unit and PLC Master................99 7.4 PLC Address Assignment......................100 8. Supported S7 Function Blocks/Functions.............. 106 8.1 GW_CTL_11..........................

  • Page 7: Overview

    PfofiBus Gateway 1. Overview 1.1 ProfiBus Gateway Unit The ProfiBus Gateway Unit (hereinafter referred to as “ProfiBus Gateway” or “Gateway Unit”) is used to connect a ProfiBus communication protocol network on which a host programmable controller (hereinafter “PLC”) operates, to a SIO communication sub-network (Modbus communication protocol) linking ROBO Cylinder controllers.

  • Page 8: What Is Profibus

    PfofiBus Gateway 1.2 What Is ProfiBus? (1) FA communication system In FA communication, each communication specification varies depending on the communicating equipment, type of information, and purpose of communication, among others. In general, however, the FA communication system is divided into the information level, controller level and field level, as shown below.

  • Page 9: Application Example Of Gateway Unit

    PfofiBus Gateway (5) ProfiBus ProfiBus is an open field network most commonly used in the world today. It was first established under DIN 19245 (German standard) in Germany in 1989, and standardized under EN 50170 (European standard) in July 1996. In January 2000, ProfiBus became an international standard under IEC 61158.

  • Page 10: Features And Key Functions

    PfofiBus Gateway 1.4 Features and Key Functions 1.4.1 Features The ProfiBus gateway unit lets you select a desired operation mode from three modes including the position number specification mode, direct numerical specification mode and command specification mode. (1) Position number specification mode In this mode, a desired position number is specified to operate the actuator.
  • Page 11 Position number Direct numerical specification Command specification mode Key function specification mode mode Positioner operation Simple direct operation Operation by position data specification X (P table specification) (P table rewriting) Direct specification of speed and X (P table specification) (P table rewriting) X (P table specification) acceleration/deceleration Direct specification of positioning band...
  • Page 12 PfofiBus Gateway Next, the relationship of the number of positions supported by each controller under each PIO pattern, and the maximum number of positions that can be stored in the gateway unit, is explained. Take note that the number of positions may become subject to restrictions. PIO pattern (Parameter No.

  • Page 13: Description Of Model Name

    PfofiBus Gateway 1.5 Description of Model Name Base model ProfiBus specification Gateway Unit 1.6 Accessories [1] Power-supply input connector plug 1 pc MC1•5/4-ST-3•5 (Phoenix Contact) [2] SIO communication connector plug 1 pc MC1•5/6-ST-3•81 (Phoenix Contact)

  • Page 14: Specifications And Name Of Each Part

    500 kbps 400 m 1.5 Mbps 200 m 3 Mbps 200 m 12 Mbps 100 m Transmission path configuration IAI’s original multi-drop differential communication Communication method Half-duplex Synchronization method Asynchronous Transmission path type EIA RS485, 2-wire type Baud rate 230.4 kbps...

  • Page 15: External Dimensions

    PfofiBus Gateway 2.2 External Dimensions Dimensions...

  • Page 16: Name And Function Of Each Part

    PfofiBus Gateway 2.3 Name and Function of Each Part [1] Gateway Status LEDs RUN: Normal G.ER: Error C.ER: ProfiBus controller error T.ER: SIO link error [6] ProfiBus communication connector [2] SIO communication status LEDs [7] Termination switch TxD: Sending data RxD: Receiving data [8] Address setting switches X10 and X1 (decimal, 2 digits)
  • Page 17 PfofiBus Gateway [1] Gateway status LEDs Indicated status Description Steady green The Gateway CPU is operating. Unlit CPU operation is stopped. If this LED does not come on after turning on the power, the Gateway is experiencing a CPU error. G.ER Steady red The Gateway is experiencing a CPU error or major shutdown failure.
  • Page 18 PfofiBus Gateway [3] Mode setting switch This switch is used to set the operation mode of the ProfiBus gateway. Before operating this switch, turn off the ProfiBus gateway power. If any position between No. 1 and No. 5 is selected, the position table settings of the controller will become invalid.
  • Page 19 PfofiBus Gateway [6] ProfiBus communication connector This connector is used to connect the ProfiBus communication lines. D-sub, 9-pin connector (female) ProfiBus communication connector Pin No. Signal name Description Not connected Not connected B-Line Communication line B (RS485) Request to send Signal ground (insulated) +5-V output (insulated) Not connected...
  • Page 20 PfofiBus Gateway [9] ProfiBus status LEDs The three LEDs of (LINE-) ON, LINE-OFF and ERR on the front face of the board indicate the node status and network status. (The remaining LED is not used.) These LEDs illuminate in one of two colors (red or green), and each LED indicates a different monitored status, as shown in the table below.
  • Page 21 PfofiBus Gateway [10] Port switch This switch is used to enable the teaching pendant/PC connector (TP) (PORT ON = Start communication). Set this switch to the OFF position when connecting/removing the communication cable connector for teaching pendant or PC software. To use the teaching pendant or PC software, plug in the connector first, and then set the switch to the OFF position.

  • Page 22: Installation And Noise Elimination Measures

    PfofiBus Gateway 3. Installation and Noise Elimination Measures Exercise due caution regarding the installation environment. 3.1 Installation Environment. The Gateway Unit is not dustproof or waterproof (oilproof). Accordingly, avoid using the Gateway Unit in a dusty place or place where the unit may come in contact with oil mist or splashed cutting fluid.
  • Page 23 PfofiBus Gateway Notes on wiring method Separate the communication lines of the Gateway Unit and ProfiBus module from lines carrying large current such as power circuits. (Do not bundle them together or place them in the same cable duct.) Noise sources and elimination of noise There are many noise sources, but the ones you should pay most attention to when building your system are solenoid valves, magnet switches and relays.

  • Page 24: Installation

    PfofiBus Gateway 3.4 Installation Examine appropriate settings for the control box size, installation position of the Gateway Unit and cooling method of the control box, so that the temperature around the Gateway Unit will remain at or below 40°C. Install the Gateway Unit vertically on a wall, as shown below, and provide a minimum clearance of 50 mm above and below the unit, with a minimum clearance of 100 mm provided on all sides for wiring access.

  • Page 25: Wiring

    PfofiBus Gateway 4. Wiring 4.1 Overall Configuration The following is an example of ProfiBus system configuration using the Gateway Unit.
  • Page 26 PfofiBus Gateway The ProfiBus network is wired as shown below. For details on ProfiBus-DP, check the operation manual for the master (PLC) or website of the Japanese PROFIBUS Organization. Master (Node address 2) Terminal Terminal resistor resistor Slave Slave Slave Slave (Node address 3) (Node address 4) (Node address 5) (Node address 6) [1] A device connected to a network and assigned an address is called a “node.”...
  • Page 27 PfofiBus Gateway [6] The ProfiBus gateway connector should be the D-sub, 9-pin (female) connector recommended by the ProfiBus DP Standard under EN 50170, as shown below. The network connectors are not supplied. Pin No. Signal name Description Not connected Not connected B-Line Communication line B (Positive side) Not connected...

  • Page 28: I/O Signals Of Gateway Unit

    PfofiBus Gateway 4.2 I/O Signals of Gateway Unit (1) Connection diagram Gateway Unit ProfiBus communication cable Teaching pendant/ Teaching pendant PC connector Emergency stop Emergency stop signal output for teaching pendant Allowable load voltage: 30 VDC Allowable load current: 1 A Gateway power supply 24 VDC ±10%, 300 mA max.
  • Page 29 PfofiBus Gateway (2) Port control and emergency stop signal output The teaching pendant/PC connector port can be operated by external signals, other than by ON/OFF r than by ON/OFF switching of the port switch on the Gateway Unit. switching of the port switch on the Gateway Unit. While the port is ON, the Gateway Unit outputs contact signals of the emergency stop pushbutton While the port is ON, the Gateway Unit outputs contact signals of the emergency stop pushbutton switch on the teaching pendant.
  • Page 30 Symbol Description Specification Connector and applicable wire Positive side of the 24-VDC 24 VDC ±10% 24 V 0.8 to 1.3 mm Gateway power supply The connection plug is a standard accessory. Negative side of the 24-VDC Power consumption: 300 mA AWG 18 to 16 Gateway power supply max.

  • Page 31: Design Of Sio Communication Network (Sio Communication)

    PfofiBus Gateway 4.3 Design of SIO Communication Network (SIO Communication) 4.3.1 Wiring (1) Basics Item Description 16 axes max. (The specific number varies depending on the operation Number of connected units mode. Refer to 1.4, “Features of Gateway Unit.”) Communication cable length Total cable length: 100 m max.
  • Page 32 PfofiBus Gateway Detail connection diagram Details of SIO link connection are illustrated below. Controller link cables are available as options, but the customer must provide the communication trunk. SIO communication trunk Gateway Unit Double shielded twisted-pair cable Recommended cable: HK-SB/20276 X L 4-way junction (5-1473574-4 by AMP) 2P X AWG22 by Taiyo Electric Wire &...
  • Page 33 PfofiBus Gateway Controller link cable (CB-RCB-CTL002) This is an optional cable for the controller. You must purchase this cable separately. Controller end e-CON connector 3-1473562-4 (Housing color: Orange) Mini DIN connector Signal Signal Yellow Orange Blue The following parts are supplied with the controller link cable. [1] 4-way junction Model: 5-1473574-4 by AMP...
  • Page 34 PfofiBus Gateway (3) SIO communication connection for ERC2-SE For details, refer to the ERC2-SE operation manual. Use 4-way junctions to connect the cables as shown below. The power-supply & I/O cable and network connection cable (including the 4-way junction and e- CON connector) are standard accessories of the ERC2-SE.
  • Page 35 PfofiBus Gateway (4) SIO communication connection for ERC2-NP/PN Use relay terminal blocks to connect the cables as shown below. Gateway unit PIO type power-supply & I/O cable Relay terminal Orange block Axis 1 (red 1) Orange (black 1) Axis 2 Pair shield cable (fabricated by the customer)
  • Page 36 PfofiBus Gateway (5) Wiring the emergency stop (EMG) circuit When designing an emergency stop circuit that incorporates the emergency stop switch on the teaching pendant connected to the Gateway Unit, emergency stop signals output from the “S1” and “S2” terminals of the Gateway Unit can be used.
  • Page 37 PfofiBus Gateway [1] Example of cutting off drive signals Teaching pendant Gateway Unit Emergency stop button TP connector Emergency stop Emergency reset switch stop button PCON, ACON controller SIO connector communication Connection detection connector Gateway signal (H) connection power supply detection Port circuit...
  • Page 38 PfofiBus Gateway [2] Example of cutting off motor drive power Teaching pendant Gateway Unit Emergency stop button TP connector Emergency stop Emergency reset switch stop button PCON, ACON controller SIO connector communication Connection detection Gateway connector signal (H) connection power supply detection Port circuit...

  • Page 39: Axis Number Setting

    PfofiBus Gateway 4.3.2 Axis Number Setting The following explanation applies to PCON, ACON and ERC2 controllers. Set an axis number as a SIO-linked slave station number. The axis number of axis 1 is “0,” while that of axis 16 is “F.” Set an appropriate axis number using a hexadecimal value between 0 and F.

  • Page 40: How To Connect The Teaching Tool When The Positive Terminal Of The 24-V Power Supply Is Grounded

    PfofiBus Gateway 4.4 How to Connect the Teaching Tool When the Positive Terminal of the 24-V Power Supply Is Grounded If the positive terminal of the 24-V power supply is grounded (= +24 V is grounded), use a SIO converter as shown below to connect a teaching pendant or PC to the gateway unit.

  • Page 41: Address Configuration Of Gateway Unit

    PfofiBus Gateway 5. Address Configuration of Gateway Unit All data exchanged between the master station and the controller are tentatively stored in the internal memory of the Gateway Unit, and then transmitted cyclically. Accordingly, the PLC program recognizes these data as remote ProfiBus I/Os. Up to 16 ROBO Cylinder controllers can be connected to the Gateway Unit, with the connected controllers assigned an axis number of 0 to 15, respectively.

  • Page 42: Overall Address Configuration

    PfofiBus Gateway 5.1.1 Overall address configuration In the position number specification mode, four bytes are used by the gateway control signals, and gnals, and also by the status signals, to be input/output. For each axis, each control signal occupies two bytes in also by the status signals, to be input/output.

  • Page 43: Gateway Control/Status Signals

    PfofiBus Gateway 5.1.2 Gateway Control/Status Signals The initial fixed area in the address configuration is used by signals that control the gateway unit, and consists of four input bytes and four output bytes. These signals are used to control the ON/OFF of SIO communication and monitor the SIO communication status and gateway unit status.
  • Page 44 PfofiBus Gateway I/O Signal List Signal Signal type Byte Description name SIO link communication will start when this signal is turned ON, and stop when it is turned OFF. Do not turn the MON signal ON when CFG15 to 0 (linked axis connection) are all OFF.
  • Page 45 PfofiBus Gateway Signal Signal type Byte Description name This signal remains ON while the Gateway Unit is operating normally. Gateway Unit normal The signal is synchronized with the output illumination of the LED (RUN) on the front face of the unit. This signal turns ON when a major shutdown failure has been detected.

  • Page 46: Assignment For Each Axis

    PfofiBus Gateway 5.1.3 Assignment for Each Axis The input signal and output signal of each axis consist of two bytes each in the PLC I/O area. Control signals and status signals are ON/OFF signals defined in units of bits. The command position number or completed position number is handled as a 1-byte (8-bit) binary data.
  • Page 47 PfofiBus Gateway I/O Signal Details Signal Signal type Description Details name Cannot be used. Cannot be used. Cannot be used. Servo on command 6.2 (7) Control signal Pause command 6.2 (5) HOME Home return command 6.2 (8) CSTR Start command 6.2 (9) Reset command 6.2 (4)
  • Page 48 PfofiBus Gateway [Alarm List] The table below summarizes the content of each alarm that may be output by PM8 to PM1 (as a binary code) while the alarm is present. For details on each alarm, refer to the operation manual for the controller.

  • Page 49: Direct Numerical Specification Mode

    PfofiBus Gateway 5.2 Direct Numerical Specification Mode In the direct numerical specification mode, the position data, speed, acceleration/deceleration, positioning band (push band) and push-current limiting value are specified directly as numerical values to operate the actuator. One of five patters can be set according to the maximum number of connected axes. (Mode setting switch SW1) Also, the current position data can be read at any time.

  • Page 50: Overall Address Configuration

    PfofiBus Gateway 5.2.1 Overall Address Configuration Four bytes are used by the gateway control signals, and also by the status signals, to be input/output. In the direct numerical specification mode, the control signals of each axis consist of 12 bytes in the PLC output area (gateway input area) and six bytes in the PLC input area (gateway output area).
  • Page 51 PfofiBus Gateway The overall address configuration is shown below. The byte address indicates the initial address of the assigned area in the master. The values in parentheses ( ) indicate axis numbers. Output from each axis ⇒ Gateway Unit ⇒ Output from PLC ⇒...

  • Page 52: Gateway Control/Status Signals

    PfofiBus Gateway 5.2.2 Gateway Control/Status Signals The initial fixed area in the address configuration is used by signals that control the gateway unit, and consists of four input bytes and four output bytes. These signals are used to control the ON/OFF of SIO communication and monitor the SIO communication status and gateway unit status.
  • Page 53 PfofiBus Gateway I/O Signal List Signal Signal type Byte Description name SIO link communication will start when this signal is turned ON, and stop when it is turned OFF. Do not turn the MON signal ON when CFG15 to 0 (linked axis connection) are all OFF.
  • Page 54 PfofiBus Gateway Signal Signal type Byte Description name This signal remains ON while the Gateway Unit is operating normally. Gateway Unit normal The signal is synchronized with the output illumination of the LED (RUN) on the front face of the unit. This signal turns ON when a major shutdown failure has been detected.

  • Page 55: Assignment For Each Axis

    PfofiBus Gateway 5.2.3 Assignment for each axis Control and status signals are set using ON (1)/OFF (0) signal bits, while current-limiting value for push-mode operation and acceleration/deceleration are set using one-byte (eight-bit) hexadecimal decimal data. Speed, target position data, in-position band and current position data are three-byte (24-bit) data.
  • Page 56 PfofiBus Gateway PLC input = Axis status signal Byte address Status signal Sign (Sign) Current position data (signed 24-bit integer) * “Byte+” indicates the Gateway head address, while n indicates an axis number (0 to 15). Caution 1. Signed 24-bit hexadecimal data output or input from/to the PLC is treated as a negative value when the most significant bit is “1.”...
  • Page 57 PfofiBus Gateway I/O Signal Details Signal Signal type Description Details name Set a signed 24-bit integer (unit: 0.01 mm) based on 6.3 (4) hexadecimal notation. Example) To specify +25.4 mm, set “0009ECH” (“2540” in decimal notation). Target 24-bit The maximum value that can be set is +9999.99 position data mm = 999999 (decimal) = 0F423FH (hexadecimal).
  • Page 58 PfofiBus Gateway Signal Signal type Description Details name Set a 24-bit integer (unit: 0.01 mm) based on 6.3 (4) hexadecimal notation. Example) To specify +25.4 mm, set “0009ECH” (“2540” in decimal notation). (Notes) In-position 24-bit Set position data within the soft stroke limits. band data Specify the direction of push-motion operation using...

  • Page 59: Command Specification Mode

    PfofiBus Gateway 5.3 Command Specification Mode In this operation mode, one of two patterns can be combined including one (simple direct operation) where only the target position data is specified as a numerical value and all other position data are specified via a position number to operate the actuator, and the other (positioner operation) where the actuator is operated only by specifying a position number.
  • Page 60 PfofiBus Gateway For all items, the top row indicates positioner operation, while the bottom row indicates simple direct operation. : Direct control Δ: Indirect control Key function Remarks X: Disabled Home return operation Δ Positioning operation Specify the position table number. *1 Specify all positioning data other than the position in the position table, and specify the Δ...

  • Page 61: Overall Address Configuration

    PfofiBus Gateway 5.3.1 Overall Address Configuration Input/output Gateway control signals consist of four bytes each. Only in this mode, PPS0 to PPS2 and NPS0 to NPS4 of control signal 0 are used to set the pattern and number of position-number specification axes.
  • Page 62 PfofiBus Gateway Example of Address Configuration Output from PLC ⇒ Gateway Unit Output from each axis ⇒ Gateway Unit ⇒ Input to each axis ⇒ Input to PLC Byte Upper byte Lower byte Upper byte Lower byte address Gateway control signal 0 Gateway status signal 0 Gateway control...

  • Page 63: Gateway Control/Status Signals

    PfofiBus Gateway 5.3.2 Gateway Control/Status Signals The initial fixed area in the address configuration is used by signals that control the gateway unit, and consists of four input bytes and four output bytes. These signals are used to control the ON/OFF of SIO communication and monitor the SIO communication status and gateway unit status.
  • Page 64 PfofiBus Gateway I/O Signal List Signal Signal type Byte Description name SIO link communication will start when this signal is turned ON, and stop when it is turned OFF. Do not turn the MON signal ON when CFG15 to 0 (linked axis connection) are all OFF.
  • Page 65 PfofiBus Gateway Signal Signal type Byte Description name This signal remains ON while the Gateway Unit is operating normally. Gateway Unit normal The signal is synchronized with the output illumination of the LED (RUN) on the front face of the unit. This signal turns ON when a major shutdown failure has been detected.

  • Page 66: Assignment For Each Axis

    PfofiBus Gateway 5.3.3 Assignment for Each Axis The I/O signals of each axis vary in terms of the size and content of each applicable area depending on whether the axis is a positioner operation axis or simple direct operation axis. (1) Control/status signals for positioner operation axis Each axis consists of two PLC output (control signal) bytes and two PLC input (status signal) bytes, as shown below.
  • Page 67 PfofiBus Gateway I/O Signal Details Signal Signal type Pattern No. Description Details name 0 to 4 Servo on command 6.2 (7) 0 to 4 Reset command 6.2 (4) CSTR 0, 2, 3 Start command 6.2 (9) PWRT Position data load command TEAC 6.2 (17) 0 to 4 Pause command...
  • Page 68 PfofiBus Gateway (2) Control/status signals for simple direct operation axis Each axis consists of eight PLC output (control signal) bytes and six PLC input (status signal) bytes, as shown below. The position data specification and current position data signals use singed 32-bit hexadecimals based on integers that are multiples of 0.01 mm.
  • Page 69 PfofiBus Gateway I/O Signal Details Signal Signal type Description Details name Set a signed 32-bit integer (unit: 0.01 mm) based on hexadecimal notation. Example) To specify +25.4 mm, set “0009ECH” (“2540” in decimal notation). Target The maximum value that can be set is +9999.99 32-bit position mm = 999999 (decimal) = 0F423FH...
  • Page 70 PfofiBus Gateway Caution The corresponding “default parameter value” will not be applied to any movement data that must be specified directly as a numerical value from the PLC. Accordingly, take note that the actuator will not operate or an alarm will generate when any such movement data is not specified as a numerical value. The table below summarizes the method for specifying movement data in each operation mode.

  • Page 71: Command Area

    PfofiBus Gateway 5.3.4 Command Area In the command specification mode, command areas are provided to let you use the various commands explained below to read/write the position table, among others. (1) Address configuration The request command area and response command area consist of 14 bytes each in the range of (Byte+ 04) to (Byte+ 17).
  • Page 72 PfofiBus Gateway (2) Command list The available commands and commands are listed below. Positioner Positioner Function category Code Description operation operation axis axis Handshake 0000H Clear a request command. Position table data 1000H Write a target position. write 1001H Write an in-position band. 1002H Write a speed.
  • Page 73 PfofiBus Gateway (3) Each command and data format [1] Position table data write commands Command name Byte+*1 PLC output (request) PLC input (response) Target position write 1000H Same as the value in the request command if normal. Position number Position data *2 Axis number 0 to FH *3 (RSV) (RSV)
  • Page 74 PfofiBus Gateway Command name Byte+*1 PLC output (request) PLC input (response) Deceleration write 1006H Same as the value in the request command if normal. Position number Deceleration data *5 Axis number 0 to FH *3 (RSV) (RSV) Push motion current- 1007H Same as the value in the limiting value write...
  • Page 75 PfofiBus Gateway [2] Position table data read commands Command name Byte+*1 PLC output (request) PLC input (response) Target position read 1040H Same as the value in the Position number request command if normal. Target position data *3 Axis number 0 to FH *2 Same as the value in the (RSV) request command if normal.
  • Page 76 PfofiBus Gateway Command name Byte+*1 PLC output (request) PLC input (response) Deceleration read 1046H Same as the value in the request command if normal. Position number Deceleration data *5 Same as the value in the request command if normal. Axis number 0 to FH *2 (RSV) (RSV) Current-limiting value...
  • Page 77 PfofiBus Gateway [3] Position table data ROM write command Command name Byte+*1 PLC output (request) PLC input (response) Position table data 0DA0H Same as the value in the ROM writing coil write request command if normal. Axis number 0 to FH *2 (RSV) (RSV) Position table data...
  • Page 78 PfofiBus Gateway [5] Current position read command Command name Byte+*1 PLC output (request) PLC input (response) Monitor the current 0440H Same as the value in the position of a specified request command if normal. axis. Current position of the specified axis*3 (32-bit signed integer) Axis number 0 to FH *2 (RSV)
  • Page 79 PfofiBus Gateway [6] Group specification broadcast command The axes specified by the group number are started simultaneously to the position specified by the position number. When this command is issued, the Gateway and each controller communicate in the broadcast mode, meaning that the controller does not return any response. The response result indicated by the PLC input only means that the command has been sent successfully to the applicable controllers;...
  • Page 80 PfofiBus Gateway (4) Error response If a command error occurs, the most significant bit (b7) of the response command will turn ON. In he response command will turn ON. In addition, one of the following error codes will be set in response data 1. addition, one of the following error codes will be set in response data 1.

  • Page 81: Communication Signal Details

    PfofiBus Gateway 6 Communication Signal Details 6.1 Overview of Communication Signal Timings When a given control signal is turned ON to operate the ROBO Cylinder using the sequence program in the PLC, the maximum response time before a response (status) signal will be received is expressed by the formula below: Maximum response time (msec) = Yt + Xt + 2 x Mt = Command processing time (operation time, etc.) Mt = 10 (msec) x (n+1): SIO link (Modbus) cycle time...
  • Page 82 PfofiBus Gateway...

  • Page 83: Communication Signals And Operation Timings

    PfofiBus Gateway 6.2 Communication Signals and Operation Timings (1) Controller ready (PWR) PLC input signal This signal turns “1” (ON) when the controller becomes ready following the power on. Function This signal turns “1” (ON) when the controller has been initialized properly following the power on and becomes ready, regardless of the alarm condition, servo status, etc.
  • Page 84 PfofiBus Gateway (5) Pause (STP) PLC output signal Turning this signal “1” (ON) causes the axis to stop temporarily (decelerate to a stop). Turning it “0” (OFF) resumes the axis movement. The relationship of the STP signal and MOVE (moving) signal is shown below. tdicm ≤...
  • Page 85 PfofiBus Gateway (8) Home return command (HOME) PLC output signal Home return complete (HEND) PLC input signal Home return operation starts at the leading edge of the HOME signal from “0” (OFF) to “1” (ON). When the home return is complete, the HEND (home return complete) signal turns “1” (ON). Turn the HOME signal “0”...
  • Page 86 PfofiBus Gateway (9) Positioning start (CSTR) PLC output signal Upon detecting the leading edge of this signal from “0” (OFF) to “1” (ON), the controller reads the target position number specified by the binary code of PC1 to PC32768 (the signal varies according to the operation mode), and then performs positioning to the target position corresponding to the applicable position data.
  • Page 87 PfofiBus Gateway (11) Command position number (PC1 to PC512) PLC output signal A command position number is read as a binary code. The number of command positions varies as follows according to the operation mode: • Position number specification mode PC1 to PC32 64 points •...
  • Page 88 PfofiBus Gateway (14) Jog+ command/jog- command (JOG+ / JOG-) PLC output signal These signals are used to operate a positioner operation axis in the command specification mode under PIO pattern 1 (teaching mode). These signals are used to start jogging or inching. When the + command is issued, the actuator moves in the direction opposite home.
  • Page 89 PfofiBus Gateway (15) Jog/inch switching (JISL) PLC output signal This signal is used to switch between jogging and inching. JISL = “0” (OFF): Jogging JISL = “1” (ON): Inching If the JISL signal switches to “1” (ON) during jogging, the accelerator will decelerate to a stop and the inching function will be enabled.
  • Page 90 PfofiBus Gateway (17) Position data read command (PWRT) PLC output signal Position data read complete (WEND) PLC input signal These signals are used when a positioner operation axis is operated in the command specification mode under PIO pattern 1 (teaching mode). The PWRT signal is effective when the MODS signal is “1”...

  • Page 91: Basic Operation Timings

    PfofiBus Gateway 6.3 Basic Operation Timings (1) Preparation After confirming that the slider or rod is not colliding with a mechanical end or the load is not contacting any surrounding equipment, start the system by following the procedure below: [1] Cancel the emergency stop or enable the motor drive power supply. [2] Turn on the 24-VDC controller power via the 24-V terminal and 0-V terminal on the power-supply terminal block.
  • Page 92 PfofiBus Gateway Warning With the ACON, excited-phase detection operation is performed when the servo is turned on for the first time following the power on. Because of this detection operation, the actuator normally moves by approx. 0.5 to 2 mm, although the specific dimension varies according to the ball screw lead. (On rare occasions, the actuator may move by up to around a half of the ball screw lead depending on the actuator position when the power is turned on.) Also note that if the power is turned on while the actuator is near a mechanical end, the actuator may...
  • Page 93 PfofiBus Gateway (2) Home return operation The controller unit uses an incremental position detector (encoder), which means that once the power is cut off, the mechanical coordinates will be lost. Accordingly, home return must be performed after the power is turned on to establish the mechanical coordinates.
  • Page 94 PfofiBus Gateway (3) Operation by position number specification Positioner operation in the position number specification mode or command specification mode is explained. Operation The actuator is operated by specifying position data in the controller’s position table beforehand, and specifying a desired position number using the link register in the PLC. The push-motion operation, speed change during movement, pitch feed by incremental coordinate specification, etc., are the same in PIO (I/O cable) operation.
  • Page 95 PfofiBus Gateway Command position number Start command Positioning complete Completed position number Moving T1: Set T1 to 0 ms or more by considering the scan time of the host controller. Yt+2Mt+Xt≤tdpf≤Yt+2Mt+Xt+7 (ms)
  • Page 96 PfofiBus Gateway (4) Operation in the direct numerical specification mode The actuator is operated not by using the position table of the controller, but by writing the target position data, acceleration/deceleration data, speed data, push-current limiting value data and positioning band data to the link registers in the PLC. All these data must be set in the case of push-motion operation.
  • Page 97 PfofiBus Gateway Set value of target position data Set value of speed and acceleration/deceleration data Set value of positioning band data Set value of push-current limiting value data Push mode Push direction Start command [13] Positioning complete/missed load in push operation [11] Current position [12]...
  • Page 98 PfofiBus Gateway The target position data, acceleration/deceleration data, speed data, positioning band data and push- current limiting value data can be changed while the actuator is moving. After a given data has been changed, turn CSTR “1” (ON) for at least tdpf. Also, after CSTR is turned “0”...
  • Page 99 PfofiBus Gateway (5) Simple direct operation (command specification mode) The actuator is operated by writing the target position data to the link register in the PLC and specifying other data such as the speed, acceleration/deceleration, positioning band and push- current limiting value in the position table. Preparation Set all position data other than the target position (speed, acceleration/deceleration, positioning band, push-current limiting value, etc.) in the position table.
  • Page 100 PfofiBus Gateway Set value of target position data Command position number Start command Positioning complete Current position Moving T1: Set T1 to 0 ms or more by considering the scan time of the host controller. Yt+2Mt+Xt≤tdpf≤Yt+2Mt+Xt+7 (ms) twcsON1≥Mt twcsOFF≥1Mt...

  • Page 101: Command Transmission

    PfofiBus Gateway 6.4 Command Transmission Commands can also be used in the command specification mode. A timing chart of command transmission is given below. Every time control/status data is exchanged for any of the connected axes in normal operations, the Gateway Unit analyzes each request command and responds to the command.

  • Page 102: Building Your Network System

    PfofiBus Gateway 7. Building Your Network System 7.1 Procedure The procedure to start a ProfiBus network using the gateway unit is explained below. (1) Installation Install the ProfiBus gateway unit, each axis controller and other necessary units in the control panel. (2) Wiring Wire the gateway unit’s 24-V power supply and field network, and also wire for SIO communication, etc.

  • Page 103: Setting The Controller

    PfofiBus Gateway 7.2 Setting the Controller For the controller to be able to communicate with the Gateway, the settings specified below must be performed. (1) Setting the axis number Set an axis number in a range of 0 to 15 by avoiding duplication. Take note that the range of settable axis numbers varies depending on the operation mode of the Gateway Unit.
  • Page 104 PfofiBus Gateway (2) Setting the SIO baud rate Set the applicable controller parameter using the PC software or teaching pendant in the same manner as in (1). [1] Set parameter No. 16, “SIO baud rate” to “230400” (230.4 kbps). SIO communication cannot be performed at any baud rate other than 230.4 kbps. [2] Set parameter No.

  • Page 105: Setting The Gateway Unit And Plc Master

    PfofiBus Gateway 7.3 Setting the Gateway Unit and PLC Master For the Gateway Unit to be able to communicate with the master station, the settings specified below must be performed. The following items must be consistent between the master station and the Gateway Unit. : ON X: OFF Item...

  • Page 106: Plc Address Assignment

    “HW Config”). Before defining the gateway, download the GSD file for the gateway. The GSD file you need is hms_1003.gsd. It can be downloaded from IAI’s website. Start the HW Config software and install the GSD file you have downloaded. Select Options from the menu bar, and then click Install New GSD from the pull-down menu.
  • Page 107 PfofiBus Gateway (2) Inserting a ProfiBus-DP mater system Select Insert from the menu bar, select Master System from the pull-down menu, and then click DP. Select the ProfiBus-DP master to insert the master system. <Master system insertion> When the ProfiBus-DP master has been inserted successfully, it will be displayed as the master system, as shown below.
  • Page 108 PfofiBus Gateway (3) Inserting a Gateway rack in the network Drag and drop “ANYBUS-S PDP” in the catalog window over to the master system and insert it as a module, as shown below. The address will be set automatically. To change the address that has been set automatically, do so in the Properties dialog box.
  • Page 109 PfofiBus Gateway Double-clicking the inserted universal module will open the Properties dialog box shown below. Select “Out-input” under I/O Type, and enter appropriate values under Output Length and Input Length according to the occupied area information in the table in 7.3. The example below applies to a 4-axis system operated in the direct numerical specification mode.
  • Page 110 PfofiBus Gateway (5) Setting for I/O data consistency With normal settings, consistency of ProfiBus I/O data is guaranteed in units of words and bytes. It is rds and bytes. It is important that each command code and related parameters in the command area are read or written important that each command code and related parameters in the command area are read or written together.
  • Page 111 PfofiBus Gateway (6) Actual assignment example If the mode setting switch SW1 on the gateway unit is turned OFF (direct numerical specification mode, 4 axes) for all axes, performing the I/O assignment explained in the preceding section would result in the actual addresses looking like those specified below. PLC output PLC input Gateway control word 0...

  • Page 112: Supported S7 Function Blocks/Functions

    PfofiBus Gateway 8. Supported S7 Function Blocks/Functions The function blocks (FB)/functions (FC) provided by IAI allow for easy programming without the need to worry about detailed I/O assignments. The basic functions provided include this addressing function and a range check function for certain input parameters.

  • Page 113: Gw_Ctl_11

    PfofiBus Gateway 8.1 GW_CTL_11 Modbus communication start Gateway status Axis link status Axis configuration definition word Number of POS mode axes POS-mode PIO pattern number Gateway head address Explanation; This is a function to access Gateway control/status words. Before calling other function block/function, communication between the Gateway and the controller must be started using this function.

  • Page 114: Rc_Nvc_11

    PfofiBus Gateway 8.2 RC_NVC_11 Controller ready Move request Servo status Servo on Home return status Home return Alarm status Push-motion operation Emergency stop status Push direction Movement complete pulse Pause Moving Alarm reset Address error Target position Current position Speed Acceleration/deceleration In-position band Push rate...

  • Page 115: Rc_Esync_00

    PfofiBus Gateway 8.3 RC_ESYNC_00 Controller ready Move request Servo on Servo status Home return Home return status Target position Alarm status Movement parameter Emergency stop status number Movement complete pulse Pause Movement start pulse Alarm reset Gateway head address Current position Axis number Address error Explanation;...

  • Page 116: Rc_Bcmovp_00

    PfofiBus Gateway 8.4 RC_BCMOVP_00 Issuance complete pulse Move request POS number Executing Group number Result code Gateway head address Explanation; The Gateway broadcasts the start command for the specified POS to the specified group at the leading edge of REQ. The execution complete pulse of this function block indicates that issuance of this command has completed, not that movement of each axis has completed.

  • Page 117: Rc_Read_00

    PfofiBus Gateway 8.5 RC_READ_00 Complete pulse Read request Executing Position number Result code Data type ID Read data Gateway head address Axis number Explanation; The data specified by POS and DATA_ID is read from the specified axis at the leading edge of REQ.

  • Page 118: Rc_Write_00

    PfofiBus Gateway 8.6 RC_WRITE_00 Complete pulse Write request Executing Position number Result code Data type ID Write data Gateway head address Axis number Explanation; The data specified by POS and DATA_ID is written to the specified axis at the leading edge of REQ.

  • Page 119: Rc_Prom_00

    PfofiBus Gateway 8.7 RC_PROM_00 Complete pulse ROM conversion request Executing Gateway head address Axis number Result code Explanation; A ROM conversion command is issued for the POS data of the specified axis at the leading edge of REQ. Parameters; Parameter Data type Explanation name...

  • Page 120: Appendix 1. Sample Programs For S7-300

    PfofiBus Gateway Appendix 1. Sample Programs for S7-300 Example of Using RC_NVC_11 and GW_CTL_11 ple of Using RC_NVC_11 and GW_CTL_11 #AnyON is always ON. GW/controller communication starts (MON). Axis 0 is configured (W#16#1). The Gateway I/O head addresses are “0.” Servo on delay timer Homing delay timer The next target position is controlled based on the movement...
  • Page 121 PfofiBus Gateway Step1 movement data set (push motion) Target position: 30.00 mm Speed: 100.00 mm/s Acceleration/deceleration: 0.2 Push band: 20.00 mm Push rate: 49% (7F / FF) Step2 movement data set (normal movement) Target position: 20.00 mm Speed: 100.00 mm/s Acceleration/deceleration: 0.2 Positioning band: 00.10 mm Push rate: 0%...
  • Page 122 PfofiBus Gateway A motion FB for axis 0 is always called. The instance name is “NC0.” Data is sent/received based on NC0.[tentative parameter]. The I/O head addresses are “0.” The axis number is “0.”...

  • Page 123: Appendix 2. Supply Format And Use Procedure Of Fb/Fct

    PfofiBus Gateway Appendix 2. Supply Format and Use Procedure of FB/FCt FBs are provided as source files ([Function block name_Version].AWL). The steps to use a provided source file in a user project are explained below. [1] Select the “Sources” folder, click Insert, and then click External Source..[2] When the following file selection window opens, select an appropriate source file, and then click Save.
  • Page 124 PfofiBus Gateway [4] Start Symbol Editor, and save the FB RC_NVC under a desired FB number. [5] Compile the source file. [6] When the compiling is complete, the registered function block will be generated in the “Blocks” folder. Now, FB1, namely RC_NVC, can be called from OB1.
  • Page 125 Home page: http://www.intelligentactuator.com Ober der Röth 4, D-65824 Schwalbach am Taunus, Germany TEL 06196-88950 FAX 06196-889524 The information contained in this document is subject to change without notice for the purpose of product improvement. Copyright © 2008.August. IAI Corporation. All rights reserved.

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