32989175 profibustoethernetip v10 en - siemens · application description ethernet/ip...

Automation Integration

Allen-Bradley EtherNet/IP to PROFIBUS Communications

Third-Party Integration

Application Description

EtherNet/IP Communications to PROFIBUS Nodes

EtherNet/IP to PROFIBUS Communications Item-Number: 32989175

A&D Safety Integrated Seite 2/56 as_fe_i_003_v10_de

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Note The application examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The application examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used. These application examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these application examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these application examples at any time without prior notice. If there are any deviations between the recommendations provided in these application examples and other Siemens publications - e.g. Catalogs - then the contents of the other documents have priority.

Warranty, liability and support We do not accept any liability for the information contained in this document.

Any claims against us - based on whatever legal reason - resulting from the use of the examples, information, programs, engineering and performance data etc., described in this application example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (“wesentliche Vertragspflichten”). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health The above provisions does not imply a change in the burden of proof to your detriment.

Copyright© 2008 Siemens A&D. It is not permissible to transfer or copy these application examples or excerpts of them without first having prior authorization from Siemens A&D in writing.

For questions about this document please use the following e-mail address:

mailto:[email protected]





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Foreword

Objective of the application Siemens designs and sells automation products to meet the needs of customers around the globe. It is common to find automation equipment from a multitude of vendors in plants around the world.

This application shows how to integrate a Siemens PROFIBUS node with a Rockwell Allen Bradley ControlLogix controller that is using EtherNet/IP as the communication protocol. This integration is made possible by the use of an EtherNet/IP to PROFIBUS gateway from ProSoft Technology, Inc. located in Bakersfield, CA USA.

Main contents of this application This application deals with the following key elements:

• Configuration of the PROFIBUS network of the gateway

• Configuration of the Ethernet parameters of the gateway

• Configuration of the Rockwell/Allen Bradley ControlLogix CPU

• Basic programming requirements of the ControlLogix CPU

• Configuration of data/diagnostics transfers

Delimitation This application does not include a complete functional description of the configuration tools used in the application example nor does it include all communication possibilities for the gateway. Additional information should be obtained from appropriate technical training sources.

Structure of the document The documentation of this application is divided into the following main parts.

Part Description Application Description This section contains a general overview of the

application example. It also provides an overview of the development architecture.

Principles of Operation and Program Structures

This section explains the functional concepts along with the required hardware and software components of this example.

Operation This section contains installation, startup, and test for this application example.

Appendix This section contains includes further information, e.g. bibliographic references, glossaries, etc.





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Reference to Automation and Drives Service & Support This entry is from the internet application portal of Automation and Drives Service & Support. Clicking the link below directly displays the download page of this document.

http://support.automation.siemens.com/WW/view/en/32989175





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Table of Contents

Table of Contents ......................................................................................................... 5

Table of Contents ......................................................................................................... 5

1 EtherNet/IP-to-PROFIBUS Communications ........................................... 8

1.1 Overview.......................................................................................................... 8

1.2 Requirements.................................................................................................. 8

2 Automation Solution.................................................................................. 9

2.1 Overview of the overall solution ................................................................... 9

2.2 Functional Description................................................................................... 9

2.3 Required hardware and software components.......................................... 11

2.4 Verification .................................................................................................... 14

3 Functional Overview ................................................................................ 15

3.1 Gateway Functionality.................................................................................. 16

3.2 PLC Functionality ......................................................................................... 16

4 Data Structures ........................................................................................ 18

4.1 Gateway Data Structure ............................................................................... 18

4.2 ControlLogix PLC Tag Database................................................................. 18

5 Technical Details...................................................................................... 20

5.1 ET200S Configuration .................................................................................. 20

5.2 Ethernet Configuration................................................................................. 21

5.3 Gateway PROFIBUS Configuration............................................................. 21 5.3.1 Gateway PROFIBUS Master Configuration.................................................... 22 5.3.2 Gateway PROFIBUS Slave Configuration...................................................... 22

5.4 ControlLogix Configuration......................................................................... 27 5.4.1 ControlLogix Hardware Configuration............................................................. 27 5.4.2 ControlLogix Logic Program ........................................................................... 31 5.4.3 ControlLogix Data mapping ............................................................................ 42

5.5 Gateway EtherNet/IP Configuration ............................................................ 43 5.5.1 Gateway Ethernet Configuration..................................................................... 43 5.5.2 Gateway PROFIBUS Watchdog Configuration............................................... 43 5.5.3 Gateway PROFIBUS Diagnostic Configuration .............................................. 44 5.5.4 Gateway Unsolicited Read/Write Configuration.............................................. 44

6 Installation, Startup, and Test................................................................. 48





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6.1 Installation and Startup................................................................................ 48 6.1.1 Hardware Installation ...................................................................................... 48 6.1.2 Configuration Software Installation ................................................................. 49 6.1.3 Application Software Installation..................................................................... 49

6.2 Testing the Application Software................................................................ 51

7 Flash animations...................................................................................... 53

8 Literature................................................................................................... 54

8.1 Bibliographic references.............................................................................. 54

8.2 Internet links ................................................................................................. 54

9 History....................................................................................................... 56





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Content This application provides a list of components and step by step instructions for communicating between Siemens PROFIBUS devices and a Rockwell/Allen Bradley ControlLogix PLC using the EtherNet/IP protocol.





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1 EtherNet/IP-to-PROFIBUS Communications

1.1 Overview

Introduction It is common for a production plant to have products from several vendors. In order to automate the plant, it is sometimes necessary to have communications between the different equipment for coordination or to add best in class technology to an existing production line. This example shows how to communicate between PROFIBUS nodes and PLCs that use the EtherNet/IP protocol.

Overview of the automation problem The figure below shows an overview of the configuration. Figure 1-1

PLCwith Ethernet/IPCommunications

Ethernet SIMATICET200S

PROFIBUS I/O

PROFIBUS?

In the diagram, the PLC communicates with the ET200S I/O which using PROFIBUS DP communications. A gateway is required which translates the data between the two protocols.

1.2 Requirements

The requirements for this application are:

• Read and write to the ET200S I/O using a ControlLogix PLC

• Read and write the ControlLogix PLC without using a ControlLogix program

• Implement watchdog functionality to disable I/O on a communications fault

• Send the diagnostic information from a PROFIBUS slave to the ControlLogix PLC





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2 Automation Solution

The solution to the problem involves using an EtherNet/IP-to-PROFIBUS gateway to translate between the two protocols.

2.1 Overview of the overall solution

Schematic layout The following figure shows the most important components of the solution. Figure 2-1

PLCwith Ethernet/IPCommunications

Ethernet SIMATICET200S

PROFIBUS I/O

PROFIBUSProSoftTechnology

GatewaySwitch

Configuration In Figure 2-1, the ControlLogix PLC communicates with the ProSoft Technology gateway using the EtherNet/IP protocol through an Ethernet cable (Ethernet switches can be configured as well). The ProSoft Technology gateway communicates with the ET200S I/O using PROFIBUS DP communications. The gateway translates the data between the two protocols.

2.2 Functional Description

The ProSoft Technology gateway (“gateway”) contains three essential functions:

1. PROFIBUS DP master communications

2. EtherNet/IP communications

3. A database table that is shared between the two protocols

The functionality of the gateway is to map registers of the database table to inputs and outputs of PROFIBUS DP slaves. The EtherNet/IP communications read and write the same registers in the database table. This sharing of the same database table results in data exchange between the two protocols.

Sequence Functionality Table 2-1 contains a list of configuration steps and operations during the configuration.





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Table 2-1

Action Note 1. The hardware is assembled and

power is applied. Ensure that all the hardware powers up.

2. Configure the PROFIBUS network and download the configuration to the gateway.

After download the gateway will begin exchanging data with the PROFIBUS node. None of the red Bus Fault (BF) and System Fault (SF) lights should be illuminated.

3. Configure the PLC hardware and program and download it to the ControlLogix PLC. Put the PLC into RUN mode.

4. Configure network, diagnostics, watchdog, and data transfers, and download the configuration to the gateway.

Ensure that the gateway's ERR light is off the. In this case, data should be exchanged.

Advantages of this solution The two primary advantages of this solution are that it provides

• control of PROFIBUS I/O as well as

• peer communications between EtherNet/IP PLCs and PROFIBUS PLCs which configured as slave devices.

Alternative solutions The Siemens Automation Customer Support portal offers a number of other suggestions to connect SIMATIC components to Allen-Bradley/Rockwell networks. For more details, see ref. \5\.





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2.3 Required hardware and software components

Hardware components Table 2-2 contains the hardware components used in this application example. Table 2-2

Component No. MLFB Note ControlLogix 4-slot Chassis

1 1756-A4 Any suitable chassis can be used.

ControlLogix Power Supply

1 1756-PA72/C Any ControlLogix power supply suitable for the selected chassis and power source can be used.

ControlLogix Controller (CPU)

1 1756-L55 Any suitable Controller (CPU) can be used.

ControlLogix Input Module

1 1756-IB16 Not required for communications. Used in this demo as a command for the PROFIBUS motor starter.

ControlLogix Output Module

1 1756-OB8 Not required for communications. Used in this example to indicate that a motor has started.

ControlLogix EtherNet/IP Module

1 1756-ENBT/A EtherNet/IP communications module

RJ45 Ethernet Cable

1 Any PLC to gateway

ET200S PROFIBUS IM

1 6ES7 151-1AA02-0AB0

PROFIBUS Interface Module

ET200S Power Module

1 6ES7 138-4CB10-0AB0

PM-E (use the appropriate terminal module for your application)

ET200S Digital Input

1 6ES7 131-4BD01-0AB0

4 DI (use the appropriate terminal module for your application)

ET200S Digital Output

1 6ES7 132-4BB01-0AB0

2 DO (use the appropriate terminal module for your application)

ET200S Power Module

1 3RK1903-0BA00 PM-D (use the appropriate terminal module for your application)

ET200S Motor Starter

1 3RK1301-0AB10-0AA4

DS1e-x HF (use the appropriate terminal module for your application)

PROFIBUS Cable

1 Any Gateway to ET200S





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Component No. MLFB Note ProSoft Technology Gateway

1 5204-DFNT-PDPM DPV0 – The supplier also has a DPV1 version of the gateway.

Null Modem RS232 Cable

1 Siemens Simatic-TI programming cable 2601090-0001C

This cable is for programming the ControlLogix PLC. Use a Rockwell Automation cable or the Siemens cable that is listed.

Null Modem RS232 Cable

1 Supplied with Gateway

9-pin to mini-din serial cable

1 Supplied with Gateway

This cable connects to the RS232 cable supplied with the gateway.

Configuration PC

1 Any Any operating system that meets the configuration software requirements. One Ethernet port and one serial port is needed. Windows XP SP2 was used in the development of the application note.

Standard software components Table 2-3

Component No. Version (or higher)

Note

Rockwell RSLinx Classic Lite communications software

1 V2.50.00.20 Any version may be used as long as it supports communications to the EtherNet/IP network.

RSLogix 5000 Programming Software

1 V15.01.00 Any version that supports the hardware components (CPU and EtherNet/IP network card) can be used.

SYCON PROFIBUS Configuration Software

1 V2.6.5.3

Prosoft Configuration Builder Software

1 V2.0.13.18

Supplied with the gateway. (Check www.prosoft-technology.com for more recent versions)





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Example files and projects Tabel 2-4 is a list of all files and projects used in this example. Table 2-4

Component Note PROFIBUSToEthernetIP.doc This document. Application_Files.zip The application files used for

this application example. Refer to chapter 6 of this document.

Video_Files.zip The video files for this application example. Refer to the appendix section of this document.





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2.4 Verification

Chapter 6 identifies the verification steps.





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The following diagram is a more detailed diagram of the configuration used in the application example. The functional descriptions are based on this diagram.

Figure 2-2

ProSoftTechnology

Ethernet/IP to PROFIBUS

Gateway

IM 151

PM-E 4 DI 2 DO

PWRCON

SF

PM-D

31

11

21

DS1e-x

2 T1 4 T2 6 T3

1 L1 3 L2 5 L3

ET200

S

Power

Module

Digital

Inpu

ts

Digital

Outp

uts

Power

Module

Motor S

tarter

Push ButtonSwitch

Light

Push ButtonSwitch

Light

Contro

lLogix

Power

Supply

CPUInp

ut Mod

ule

Output

Module

Etherne

t/IP M

odule

RS232

EthernetPR

OFI

BUS

RS232

3 Functional Overview

This application consists of three major components; the ET200S PROFIBUS I/O, the EtherNet/IP to PROFIBUS gateway, and the ControlLogix PLC. The ET200S PROFIBUS I/O functions in the same manner as it does in all PROFIBUS applications. The gateway and the PLC require the majority of effort for this application and an overview of their functionality will be described here.





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3.1 Gateway Functionality

The gateway used in this application is a DPV0 gateway. The manufacturer also provides a DPV1 version that provides additional functionality and flexibility.

At the heart of the gateway is a data table. Both protocols, EtherNet/IP and PROFIBUS, have access to the data table making it a shared memory area for both. The data table for the gateway used in this application contains a user area of 4000 registers (0-3999).

The inputs of PROFIBUS slaves are mapped into the data table beginning at location 0. The data table is mapped to PROFIBUS outputs beginning at location 300. When the PLC reads locations 0-299 (integer form) it receives the status of the PROFIBUS inputs. When the PLC writes to locations 300-599, the written values are sent to the PROFIBUS outputs. Any data table location that is not directly mapped to I/O can be used for other purposes (such as a watchdog register). The engineer must manage the use of the data table.

The gateway provides a watchdog feature to disable outputs in the event of communications loss with the PLC (The watchdog feature of the I/O manages this in the event of PROFIBUS communications loss). A register in the gateway’s data table is assigned to the watchdog function. A watchdog timeout value is also assigned in 1/10th second units (the value 10 equals 1 second). The watchdog function is activated if the value in the watchdog register does not change within the configured time period. In other words, the PROFIBUS outputs will turn off if the watchdog register value does not change during the configured time period.

The gateway provides the ability to read the diagnostic information from each PROFIBUS slave. The user can choose the location in the gateway’s data table where the diagnostic data will be stored.

Finally, the gateway provides a feature to perform unsolicited read and write commands from/to the PLC. This allows data exchange without any data transfer logic in the PLC (no MSG instructions). Note that the reading and writing of PROFIBUS data will not be synchronized with the PLC program scan if this method is used.

3.2 PLC Functionality

The PLC program is written to operate with the functionality of the gateway. This section defines the basic requirements of the PLC program.

A startup routine is written to eliminate user intervention in the event of power loss while the PLC is in run mode.

A startup timer is used to allow the gateway and the PLC’s EtherNet/IP card to initialize after power up. This start delay is not required but it eliminates errors from the MSG instructions until all components are ready for operation.





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Watchdog logic is used to continuously change a watchdog value that is sent to the watchdog register in the gateway. The value ranges between 0-32000.

Additional watchdog logic is used to clear the PROFIBUS inputs in the event of communications loss with the gateway.

Application logic is used to manage the application (motor starter operation).

In order for the gateway’s unsolicited read/write functionality to work, a controller tag must be mapped to an integer file (like the “N” files used in the PLC5, and SLC families of Rockwell/Allen Bradley PLCs).





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4 Data Structures

Both the gateway and the ControlLogix PLC contain data structures that are used for the sharing of information. This section details these data structures.

4.1 Gateway Data Structure

As previously mentioned, the gateway contains a data table with an image of the PROFIBUS I/O and additional user defined registers. The structure of the gateway’s data table used in this application is in Table 4-1. Note that some of the registers used fall within the I/O map of the gateway but can be used because no I/O is being mapped to them. Table 4-1

Register Number

Function

0 Data from the ET200S input module (6ES7 131-4BD01-0AB0) 1 Data from the ET200S motor starter (3RK1 301-0AB10-0AA4)

300 Data to the ET200S output module (6ES7 132-4BB01-0AB0) 301 Data to the ET200S motor starter (3RK1 301-0AB10-0AA4) 399 Watchdog register

1000 Unsolicited read of PLC watchdog value 3100-3122 Diagnostic data from the ET200S PROFIBUS node

4.2 ControlLogix PLC Tag Database

Table 4-2 contains a list of the tags used in the PLC program. Table 4-2

Tag Function FaultData PLC fault information Light Alias tag representing the light connected to the

output module of the ET200S PROFIBUS node Local 1:C Internal PLC tag representing the configuration of

the input module in slot 1 of the ControlLogix rack Local 1:I Internal PLC tag representing the fault status and

data values of the input module in slot 1 of the ControlLogix rack

Local 2:C Internal PLC tag representing the configuration of the output module in slot 2 of the ControlLogix rack

Local 2:I Internal PLC tag representing the fault status and data values of the output module in slot 2 of the ControlLogix rack

Local 2:O Internal PLC tag representing the commanded data values of the output module in slot 2 of the





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Tag Function ControlLogix rack

Motor_Run_Command Alias tag used to energize the ET200S motor starter Motor_Running Alias tag used to turn on the first output of the

ControlLogix output module Motor_Running_Feedback Alias tag that receives the energized feedback from

the ET200S motor starter Motor_Start Status of the pushbutton that is connected to the

input module of the ControlLogix PLC Motor_Stop Status of the pushbutton that is connected to the

input module of the ET200S PROFIBUS node PROFIBUSdata Data array that is an image of the gateway data table ReadData Flag used to enable the read data MSG instruction

for reading data from the gateway ReadSlave3 MSG instance tag used for reading the ET200S data

from the gateway StartTimer Timer instance tag used to delay the read and write

MSG instructions until the hardware has time to initialize

Watchdog_Timeout Register used to store the previous watchdog value send back from the gateway

WatchdogRegister Alias tag used to write the watchdog value to the gateway

WatchdogTimerPLC Timer instance tag used by the PLC to determine loss of communications with the gateway so the PROFIBUS input values can be cleared

WriteData Flag used to enable the write data MSG instruction for writing data to the gateway

WriteSlave3 MSG instance tag used for writing the ET200S data to the gateway





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5 Technical Details

This section describes the technical details of the configuration and logic program.

5.1 ET200S Configuration

The ET200S requires no configuration other than assembly, wiring, and setting the PROFIBUS address using the dip switches on the interface module. Refer to the appropriate Siemens documentation for assembly and wiring. The PROFIBUS address is set to 3 for this application. The switch settings for address 3 are shown in Table 5-1. The switch position is indicated by the green shading in the table. Table 5-1

Switch OFF (switch position left)

ON (switch position right)

64 32 16 8 4 2 1

Unused

Figure 5-1 shows the module positions in the ET200S PROFIBUS node. Figure 5-1

ET200SIM151

PROFIBUSInterfaceModule

ET200SPower ModulePM-E

Slot 1

ET200SDigitalInput

Module

Slot 2

ET200SDigitalOutput Module

Slot 3

ET200SPower ModulePM-D

Slot 4

ET200SMotorStarter

HF

Slot 5





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5.2 Ethernet Configuration

Figure 5-2 shows the Ethernet network components.

Figure 5-2

ProSoftTechnology

Ethernet/IP to PROFIBUS

Gateway

Contro

lLogix

Etherne

t/IP M

odule

Ethernet

Table 5-2 contains the settings for each Ethernet device used in this application. Table 5-2

Device IP Address Subnet Mask ControlLogix

Ethernet Card 192.168.0.120 255.255.255.0

Prosoft Technology

Gateway

192.168.0.36 255.255.255.0

5.3 Gateway PROFIBUS Configuration

Figure 5-3 shows the PROFIBUS topology for this application.





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Figure 5-3

5.3.1 Gateway PROFIBUS Master Configuration

The gateway PROFIBUS master configuration involves configuring the PROFIBUS address, assigning a descriptive name, and selecting automatic or manual I/O addressing. In this example, automatic addressing is used and the PROFIBUS address for the master is zero (0). Figure 5-4 shows the configuration screen. Figure 5-4

5.3.2 Gateway PROFIBUS Slave Configuration

The gateway PROFIBUS slave configuration involves --

Device Description

Auto Address Selection

PROFIBUS Address





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1. configuring the PROFIBUS address,

2. assigning a descriptive name,

3. enabling the activation mode and watchdog,

4. configuring the I/O modules,

5. disabling DPV1, and

6. configuring parameters for the I/O modules.

Figure 5-5 shows the configuration screen. Figure 5-5

Once the initial configuration is made, parameters need to be assigned. Figures 5-6 through 5-14 show the parameter settings for DPV1, Common Parameters, the power modules, the digital input module, the digital output module, and the motor starter.

2.) Device Description

1.) PROFIBUS Address

3.) Activation and

Watchdog

4.) Module Configuration

5.) DPV1 and 6.) Module

Settings





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Figure 5-6 DPV1 Parameter Settings

Figure 5-7 Common Parameter Settings Screen 1

Deactivate DPV1

Common parameters set

for the application





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Figure 5-8 Common Parameter Settings Screen 2

Figure 5-9 Power Module Settings

Common parameters set

for the application

Parameters for Power Module





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Figure 5-10 Digital Input Module Settings

Figure 5-11 Digital Output Module Settings

Figure 5-12 Power Module Settings

Parameters for Digital Input

Module

Parameters for Power Module

Parameters for Digital Output

Module





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Figure 5-13 Motor Starter Settings Screen 1

Figure 5-14 Motor Starter Settings Screen 2

5.4 ControlLogix Configuration

The ControlLogix PLC requires hardware configuration and software programming. This section describes both.

5.4.1 ControlLogix Hardware Configuration

Table 5-1 shows the hardware component layout in the ControlLogix rack.

Parameters for Motor Starter

Parameters for Motor Starter





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Table 5-1

Control Logix

Slot 0 Slot 1 Slot 2 Slot 3

Power Supply

CPU Digital Input Card

Digital Output Card

Ethernet Comm. Card

When configuring the hardware of the ControlLogix PLC, most of the default values can be used. Figures 5-15 through 5-20 show the configuration settings for the application.

Figure 5-15 CPU “General” Settings

Symbolic Name

Chassis Type

Slot





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Figure 5-16 CPU “Advanced” Settings

Figure 5-17 Digital Input Module Settings

Select logic routines. This must be done after the logic is programmed.

Symbolic Name

Slot

Firmware Revision





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Figure 5-18 Digital Output Module Settings

Figure 5-19 Ethernet Module “General” Settings

Symbolic Name

Slot

Firmware Revision

Symbolic Name

IP Address

Slot

Firmware Revision





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Figure 5-20 Ethernet Module “Port Configuration” Settings

5.4.2 ControlLogix Logic Program

The ControlLogix logic has been programmed in Ladder for this application. The program consists of multiple logic routines and ladder rungs. This identifies the logic routines and explains the functionality of each ladder rung. The tags used in the logic are defined in chapter 4.2 (p. 18) of this document.

IP Address

Subnet Mask

Port Mode





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Figure 5-21 Ladder Logic in the ControlLogix configuration environment

5.4.2.1 Power-Up Handler Logic Routine “Start”

The power-up handler routine executes when the PLC is powered up. The routine must be identified to the CPU (Figure 5-16, p. 29).

For this application, the power-up handler has the symbolic name of “Start”. The functionality provided by “Start” is to clear power up faults, such as Power-off in Run Mode”, so the CPU will transition to run mode without user intervention. Figure 5-22 contains the “Start” logic.





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Figure 5-22 “Start” Logic

Technical Detail

• Ladder rung 0: the GSV instruction stores the current value of the CPU’s fault data into the user define FaultData array tag.

• Ladder rung 1: The fault code in the FaultData tag is cleared by setting it to zero.

• Ladder rung 2: The cleared fault code is written back to the CPU allowing the CPU to start error free.

5.4.2.2 Fault Handler Logic Routine “Fault”

When a fault occurs, the fault handling routine is called by the ControlLogix CPU. The routine must be identified to the CPU (Figure 5-16).

For this application, the fault handler has the symbolic name of “Fault”. The functionality provided by “Fault” is to store the fault data record. For this application, no attempt is made to recover from the fault. The CPU will operate in its default mode when the fault occurs. Figure 5-23 contains the “Fault” logic.





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Figure 5-23 “Fault” Logic

Technical Detail

• Ladder rung 0: The GSV instruction stores the current value of the CPU’s fault data into the user define FaultData array tag.

5.4.2.3 Main Logic Routine “MainRoutine”

All of the application logic is contain in the main logic routine for the CPU. The routine, by default, is called “MainRoutine”. Figures 5-24 through 5-38 contain the “MainRoutine” logic. Figure 5-24 “MainRoutine” Logic Rungs 0-1

Technical Detail

• Ladder rung 0: On power up the delay timer will begin to run. Once the timer expires it is latched on by the done bit.

• Ladder rung 1: The watchdog register value is kept between 0 and 32000. This is not a requirement of the gateway but is used to avoid a CPU non-fatal error in certain start up instances.





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Figure 5-25 “MainRoutine” Logic Rungs 2-3

Technical Detail

• Ladder rung 2: The watchdog register is incremented by one each time the CPU scans the logic. The watchdog value is maintained between 0 and 32000 by rung 1.

• Ladder rung 3: The start up timer’s done bit is sent continuously to the first output point on the ET200S output module (6ES7 132-4BB01-0AB0). Once the timer expires, the output point remains set unless there is a loss of communications.

Figure 5-26 “MainRoutine” Logic Rung 4

Technical Detail

• Ladder rung 4: When the start up timer expires and a write is not in progress, the MSG command is used to write output data to the gateway. The write command tag, WriteData, and the MSG enable bit are cleared once the instruction begins execution. This allows the instruction to run to completion before it runs again. The configuration of the MSG instruction follows below.





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Figure 5-27 “MainRoutine” Write MSG Configuration Tab

Technical Detail

• The Message Type of the MSG instruction is “CIP Data Table Write”. This means that data will be written from a table in the ControlLogix CPU to a data table in the gateway. From the configuration shown, 100 integer data values will be written from the PROFIBUSData tag beginning at array location 300. The data will be written into the gateway’s data table whose symbolic name in “Int_data” beginning at location 300 (the start of the PROFIBUS output data area). This one write instruction will write the PROFIBUS outputs and the watchdog register, register 399, which was defined purposely to allow the I/O and watchdog to be written with a single instruction.





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Figure 5-28 “MainRoutine” Write MSG Communication Tab

Technical Detail

• The communication path for the write MSG instruction is to use the EtherNet/IP card, symbolic name of EthernetIP (Figure 5-20), the port identified as 2 (EtherNet/IP port), to the IP address of the gateway.

Figure 5-29 “MainRoutine” Write MSG Tag Tab

Technical Detail

• The MSG instance tag WriteSlave3 is used for the instruction.





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Technical Detail

• Ladder rung 5: A new gateway write request is made when the write MSG instruction completes or receives an error.


Technical Detail

• Ladder rung 6: When the start up timer expires and a read is not in progress, the MSG command is used to read input data from the gateway. The read command tag, ReadData, and the MSG enable bit are cleared once the instruction begins execution. This allows the instruction to run to completion before it runs again. The configuration of the MSG instruction follows below.





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Figure 5-32 “MainRoutine” Read MSG Configuration Tab

Technical Detail

• The Message Type of the MSG instruction is “CIP Data Table Read”. This means that 100 data locations will be read from the gateways data table, Int_data, beginning at location zero (the start of the PROFIBUS input data area). The data will be put into the ControlLogix CPU’s PROFIBUSData tag beginning at array location zero. This instruction reads the PROFIBUS inputs into the CPU.

Figure 5-33 “MainRoutine” Read MSG Communication Tab

Technical Detail





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• The communication path for the read MSG instruction is to use the EtherNet/IP card, symbolic name of EthernetIP (Figure 5-20), the port identified as 2 (EtherNet/IP port), to the IP address of the gateway.

Figure 5-34 “MainRoutine” Read MSG Tag Tab

Technical Detail

• The MSG instance tag ReadSlave3 is used for the instruction. Figure 5-35 “MainRoutine” Logic Rung 7

Technical Detail

• Ladder rung 7: A new gateway read request is made when the read MSG instruction completes or receives an error.





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Technical Detail

• Ladder rung 8: When the motor start push button is pressed, the pushbutton that is connected to the digital input module in the ControlLogix rack, and the motor stop pushbutton is not pressed, a start command is sent to the ET200S motor starter and the command is latched on. When the motor stop pushbutton is pressed, the pushbutton that is connected to the input module of the ET200S node, the latched circuit is broken and the motor starter is de-energized.

• Ladder rung 9: The motor starter running feedback is sent to the output module in the ControlLogix rack.


Technical Detail





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• Ladder rung 10: A gateway watchdog timer runs if the watchdog value that is returned from the gateway does not change. This indicates a loss of Ethernet communications with the gateway.

• Ladder rung 11: If the gateway watchdog timer expires, clear the PROFIBUS input and diagnostic data from the gateway.


Technical Detail

• Ladder rung 12: Save the value of the last watchdog value from the gateway for the compare on the next scan.

5.4.3 ControlLogix Data mapping

The gateway offers the ability to read and write data registers in the ControlLogix CPU without the need for logic in CPU. The data from the gateway will not be synchronized with the application logic scan but may not be required in all cases. In order to support this functionality, a ControlLogix tag needs to be mapped as a file. The file concept is the same concept used in earlier Rockwell/Allen Bradley PLCs, such as the PLC 5. In this application example, the PROFIBUSData tag is being mapped to an integer file, N7. Figure 5-39 shows the data mapping. Figure 5-39 File data mapping





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Technical Detail

• Mapping: File number 7 is mapped to the ControlLogix tag “PROFIBUSData”. This means that file N7 (integer file in Rockwell/ Allen Bradley PLCs) overlays the data being read/written from/to the gateway. As an example, register N7:399 is the watchdog register that is written in the ControlLogix “MainRoutine”.

5.5 Gateway EtherNet/IP Configuration

The gateway does not require programming (logic code) but does require configuration. This section defines the configuration information.

5.5.1 Gateway Ethernet Configuration

Figure 5-40 shows the Ethernet configuration for the gateway. Figure 5-40

5.5.2 Gateway PROFIBUS Watchdog Configuration

Figure 5-41 shows the PROFIBUS watchdog configuration for the gateway. The watchdog register is location 399 in the data table of the gateway.





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Figure 5-41

5.5.3 Gateway PROFIBUS Diagnostic Configuration

Figure 5-42 shows the gateway configuration for reading PROFIBUS diagnostics for slave address 3, the ET200S PROFIBUS node. The diagnostic information is read into the gateway’s data table beginning at address 3100. Figure 5-42

5.5.4 Gateway Unsolicited Read/Write Configuration

As mentioned previously, the gateway provides client functions that can read/write directly to data locations in the ControlLogix CPU without the need for logic in the CPU. The data is written to the data files that were mapped in the CPU (N7 in this example). The configuration for these read/write functions is performed in the “Commands PLC 5 ASCII” section





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for client commands. Figure 5-43 shows the area of the configuration screen where the commands are added and Figure 5-44 shows a list of the commands used in this application. Figure 5-43 Read/Write Command Configuration

Figure 5-44 Commands used in the application

5.5.4.1 Write Diagnostic Data to ControlLogix CPU

As stated previously, the PROFIBUS diagnostic information for the ET200S node is read and put into the gateway’s data table beginning at location 3100. A command has been configured to write this information continuously to the ControlLogix CPU. The data, starting at the gateway data table location 3100, is written to location 100 in the N7 data file that was mapped in the ControlLogix CPU (address N7:100). Twenty-two (22)

Commands are addressed using PLC 5 ASCII addressing





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data bytes are written since this is the size of the diagnostic data for the ET200S. Since the N7 file is an overlay of the “PROFIBUSData” tag in the ControlLogix CPU, the data is actually written to “PROFIBUSData[100-121]”. The IP address is the address of the ControlLogix PLC (192.168.0.120). The Byte Swap option has been chosen so the data in the PLC will match the Siemens ET200S documentation. Figure 5-45 shows the configuration. Figure 5-45 Write PROFIBUS Diagnostics to PLC

5.5.4.2 Read Watchdog Data from ControlLogix CPU

The second command used is an example of reading data directly from the ControlLogix CPU. The command reads the watchdog register, PROFIBUSData[399] (mapped as N7:399) and puts the data in the gateway’s data table at address 1000. The gateway data table can be viewed using the diagnostic functions of the gateway’s configuration tool (Prosoft Configuration Builder). Figure 5-46 show the configuration of the command.





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Figure 5-46 Read Data from PLC

5.5.4.3 Write Watchdog Data back to the ControlLogix CPU

The third command returns the watchdog data that the PLC writes to the gateway back to the PLC. The data is used by the PLC code to detect a loss of communications with the gateway. The data is written back to the “PROFIBUSData” tag at location 125 via the N7:125 mapping. Figure 5-47 shows the configuration of the command. Figure 5-46 Write Watchdog Data to PLC

Operation




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Operation

6 Installation, Startup, and Test

6.1 Installation and Startup

This chapter describes the hardware and software installation.

6.1.1 Hardware Installation

For the hardware components, please refer to the manufacturer’s instructions for installation and wiring for power. Table 6-1 identifies the major tasks.

Table 6-1

No. Instruction Comment 1. Configure and install the ControlLogix hardware. Configure per section 5.4.1 of

this document. 2. Connect a pushbutton switch to the first input of the

digital input card in the ControlLogix rack. This pushbutton is used to energize the motor starter.

3. Connect a light to the first output of the digital output card in the ControlLogix rack.

This light is feedback from the motor started indicating its energized status.

4. Configure and install the ET200S hardware. Configure per section 5.1 of this document.

5. Connect a pushbutton switch to the first input of the digital input card in the ET200 node.

This pushbutton is used to de-energize the motor starter.

6. Connect a light to the first output of the digital output card in the ET200 node.

This light is indicates that gateway is transferring data from the ControlLogix PLC and the Et200S PROFIBUS node.

7. Configure and install the Prosoft gateway hardware. Install per the manufacturer’s documentation.

8. Connect a PROFIBUS cable between the gateway and the ET200S PROFIBUS node.

Observe the PROFIBUS cabling rules for distance and termination.

9. Connect an RJ45 Ethernet cable between the gateway and the EtherNet/IP card in the PLC.

Ethernet switches may be used in the configuration as well.

10. Connect serial cables between the configuration PC and the gateway.

This application shows serial cables for configuring both the PLC and the gateway. Any communication means that the PLC supports may be used.

Operation




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Note In general, the hardware manufacturer’s installation guidelines need to be observed.

6.1.2 Configuration Software Installation

There are four configuration software packages that are used for this application note. Table 6-2 lists these packages. The configuration software packages should be installed per the manufacturer’s instructions.

Table 6-2

No. Software Package Comment 1. RSLinx – Communication software from Rockwell

Software This package is needed to communicate with the ControlLogix PLC.

2. RSLogix 5000 –Configuration and programming software from Rockwell Software

This package is used to configure and program the ControlLogix PLC.

3. SyCon – Software for configuring the PROFIBUS network of the gateway.

This software is supplied with the gateway.

4. Prosoft Configuration Builder – Software for configuring the EtherNet/IP and data transfer commands of the gateway.

This software is supplied with the gateway.

Note In general, the software manufacturer’s installation guidelines need to be observed.

6.1.3 Application Software Installation

The application files are supplied in a compressed (zip) file named “Application Files”. Figure 6-1 contains the file structure once the archive is unzipped. The yellow background indicates a directory and the green background indicates a file name. Figure 6-1 File Structure

Application Files

Gateway Config Files

PLC Config Files

PROFIBUS Config Files

EthernetIP-ET200S.ppf

EthernetIPtoProfibusET200S.ACD

EthernetIPtoProfibus-ProfibusConfiguration.pb

IM151-1AA0x_Std-CU siem806a_n.bmp

siem806a_s.bmp

siem806a.gse

siem806a.gss

siem806a.gsi

siem806a.gsg

siem806a.gsf

Operation




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6.1.3.1 Download PROFIBUS Configuration

Table 6-3 contains the steps for downloading the files for the PROFIBUS configuration.

Table 6-3

No. Activity Comment 1. Unzip the “Application Files” zip file to a directory on the

configuration PC. The directory structure should be created when the file is unzipped.

2. Connect the serial cable that was supplied with the gateway to the serial port of the PC and to the port on the front of the gateway labeled “CONFIG”.

3. Start the SYCON application. Select the File->Copy GSD menu item and browse to the IM151-1AA0x_Std-CU directory and select the PROFIBUS GSD file for the language that you are using (for English use siem806a.gse). Select "No" when asked to import the bitmap files.

4. Using the File-> Open menu item of SYCON, browse and open the file EthernetIPtoPROFIBUS-PROFIBUSConfiguration.pb.

5. Select the Online->Download menu item of SYCON. When the “Device Assignment CIF Serial Driver” configuration box appears, select the check box for the serial port of the configuration PC that will be used for downloading and then select "OK". The “Name” column in the configuration box should indicate “DPM” for the correct serial port.

6. Once the download completes the Bus Fault light should go out on the ET200S PROFIBUS node. All the lights on the ET200S node should be green.

The video clip “Download PROFIBUS Configuration” is a video of these instructions, see section 7..

6.1.3.2 Download EtherNet/IP Configuration

Table 6-4 contains the steps for downloading the file for the EtherNet/IP configuration.

Table 6-4

No. Activity Comment 1. Connect the serial cable that was supplied with the gateway

to the serial port of the PC and to the port on the front of the gateway labeled “DEBUG”.

Operation




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No. Activity Comment 2. Using the File-> Open menu, browse and open the file

EthernetIP-ET200S.ppf.

3. Select the Project->Module->Download from PC to Device menu item. Select the appropriate serial port and then select the "Download" button.

4. Once the download completes, all the lights on the gateway should be green.

The video clip “Download EtherNetIP Configuration” is a video of these instructions, see section 7.

6.1.3.3 Download ControlLogix PLC Configuration and Program

Table 6-5 the steps to downloading the configuration and program file for the ControlLogix PLC.

Table 6-5

No. Activity Comment 1. Connect the serial cable for downloading the ControlLogix

PLC to the appropriate serial port of the PC and to the RS232 port on the front of the ControlLogix CPU.

2. Start the RSLinx application and configure the serial port driver.

3. Start RSLogix 5000 and select the Communications->Who Active menu item. Select the "1756-L55/A" item and then select the “Go Online” button.

4. Once the “Connected To Go Online” window appears, select the “Select File” button. Browse to the EthernetIPtoPROFIBUSET200S.ACD file. When the “Connected To Go Online” window changes, select the “Download” button. When the “Download” window appears, select the “Download” button.

5. Once the download completes, put the PLC into Run mode. The video clip “Download ControlLogix Configuration” is a video of these instructions, see section 7.

6.2 Testing the Application Software

Table 6-6 is a test procedure to ensure the application is working correctly.

Operation




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Table 6-2

No. Test Comment 1. Verify that the light connected to the output module of

the ET200S PROFIBUS node is on and not blinking.

2. Press the pushbutton that is connected to the input module in the ControlLogix rack. The motor starter in the ET200S PROFIBUS node should energize and latch in the energized state.

3. Verify the light that is connected to the output module in the ControlLogix rack is on while the motor starter is in the energized state. The light should illuminate in approximately one second after the motor starter energizes.

4. Press the pushbutton that is connected to the input module of the ET200S PROFIBUS node. Verify the motor starter de-energizes and the light connected to the ControlLogix output module goes off.

5. Verify the gateway is sending the PROFIBUS diagnostic information by looking at the online values of the PROFIBUSData tag in the ControlLogix CPU. The data will be in locations 100-121. The first 9 locations, in hexadecimal format, should be: PROFIBUSData[100] – 0x000c PROFIBUSData[101] – 0x0000 PROFIBUSData[102] – 0x806a PROFIBUSData[103] – 0x4900 PROFIBUSData[104] – 0x0000 PROFIBUSData[105] – 0x0000 PROFIBUSData[106] – 0x0000 PROFIBUSData[107] – 0x0014 PROFIBUSData[108] – 0x8200

The video clip “Verify ControlLogix Data” is a video of these instructions, see section 7.

6. Verify the gateway is sending the watchdog value back to the ControlLogix PLC. The value of the PROFIBUSData[125] tag should be changing.

The video clip “Verify ControlLogix Data” is a video of these instructions, see section 7

7. Verify the gateway is reading the watchdog value and putting it into its data table at location 1000. Verify this by using the diagnostic tools of the ProSoft Configuration Builder.

The video clip “Verify Gateway Address 1000” is a video of these instructions, see section 7.

Appendix and Literature




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7 Flash animations

A selection of Flash animations has been supplied with this application to assist in the explanation of the application. Extract the Zip archive into any directory, and start the Framework by double-clicking Start.exe:: Figure 7-1

To watch any clip from within the framework, simply click on the respective menu entry.

Table 7-1 contains a list of the animations. Table 7-1

Animation Content 1. Download ControlLogix

Configuration This video shows how to set the RSLinx driver and download the PLC project to the ControlLogix PLC.

2. Download EtherNetIP Configuration This video shows how to download the EtherNet/IP and network configuration data to the gateway.

3. Download PROFIBUS Configuration

This video shows how to download the PROFIBUS configuration data to the gateway.





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Animation Content 4. Verify ControlLogix Data This video shows how to verify that

the PROFIBUS diagnostics and the watchdog data is being sent to the ControlLogix PLC from the gateway.

5. Verify Gateway Address 1000 This video shows how to verify that the gateway is reading the watchdog data from the ControlLogix PLC.

8 Literature

8.1 Bibliographic references

This list is by no means complete and only provides a selection of appropriate sources.

Table 8-1

Topic Title /1/ STEP7 Automating with STEP7 in STL and SCL

Hans Berger Publicis MCD Verlag ISBN 3-89578-113-4

/2/ ControlLogix System

ControlLogix Controllers Publication 1756-UM001G-EN-P http://literature.rockwellautomation.com/

/3/ Prosoft Technology Gateway

PROFIBUS DP Master Driver Manual http://www.prosoft-technology.com/

/4/ Prosoft Technology Gateway

EtherNet/IP Explicit Messaging Client/Server Driver Manual http://www.prosoft-technology.com/

8.2 Internet links

This list is by no means complete and only provides a selection of appropriate sources.

Topic Title \1\ Reference to the entry http://support.automation.siemens.com/WW/vie

w/en/32989175 \2\ Siemens A&D Customer

Support http://www.ad.siemens.de/support

\3\ Prosoft Technology, Inc. http://www.prosoft-technology.com





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Topic Title \4\ Rockwell Automation, Inc. http://www.ra.rockwell.com \5\ Reference to a collection

of articles regarding the connection of Rockwell components

http://support.automation.siemens.com/WW/view/en/32989862





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9 History Table 9-1 History

Version Date Modification

V1.0 03/21/08 First edition V1.1 30/10/08 Adaptation to CS Design Guidelines

32989175 profibustoethernetip v10 en - siemens · application description ethernet/ip...

Documents