3HAC031975 en

Application manual
PROFINET Master/Slave
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Application manual
PROFINET Master/Slave
RobotWare 5.15
Document ID: 3HAC031975-001

Revision: K
© Copyright 2008-2015 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of contents
Table of contents
Manual overview ............................................................................................................................... 7
Product documentation, M2004 ....................................................................................................... 10
Safety ................................................................................................................................................ 12
1 Introduction to PROFINET 13
1.1 PROFINET, general ........................................................................................... 13
1.2 PROFINET, IRC5 ............................................................................................... 14
1.3 Definition of I/O units ......................................................................................... 17
2 Hardware description 19
2.1 PROFINET master/slave, DSQC 678 ..................................................................... 19
2.2 LAN connection ................................................................................................ 22
2.3 Connections, general ......................................................................................... 23
2.4 PROFINET-IO Routing ....................................................................................... 24
3 PROFINET Master/Slave configuration 27

3.1 Introduction ...................................................................................................... 27
3.1.1 Software overview ................................................................................... 27
3.2 Configuration overview ....................................................................................... 28
3.2.1 PROFINET master ................................................................................... 28
3.2.2 IRC5 internal PROFINET slave .................................................................. 29
3.2.3 Step 7 Configuration files .......................................................................... 32
3.2.4 Upgrade or downgrade firmware using Step7 ............................................... 33
3.2.5 Automatic firmware upgrade ..................................................................... 39
3.2.6 Using Fast Unit Startup ............................................................................ 40
3.3 Workflows ........................................................................................................ 42
3.3.1 Configuring PROFINET master .................................................................. 42
3.3.2 Configuring IRC5 internal PROFINET slave .................................................. 43
3.3.3 Configuring PROFINET-IO Routing ............................................................. 44
3.4 Examples ........................................................................................................ 46
3.4.1 Overview ............................................................................................... 46
3.4.2 Configuring digital I/O, example ................................................................. 47
3.4.3 Configuring IRC5 internal PROFINET slave, example ..................................... 57
3.4.4 Configuring PROFINET-IO Routing, example ................................................ 63
4 System parameters 67
4.1 Introduction ...................................................................................................... 67
4.2 Type Bus ......................................................................................................... 68
4.2.1 Path to Bus Configuration File ................................................................... 68
4.2.2 Automatic Firmware Upgrade .................................................................... 69
4.2.3 Connector ID .......................................................................................... 70
4.3 Unit ................................................................................................................ 71
4.3.1 PROFINET Address ................................................................................. 71
4.3.2 Fast Unit Startup ..................................................................................... 72
4.4 Unit Type ......................................................................................................... 73
4.4.1 Input Size .............................................................................................. 73
4.4.2 Output Size ............................................................................................ 75
5 Trouble shooting 77
5.1 Scenarios ........................................................................................................ 77
Index 83
Application manual - PROFINET Master/Slave 5

3HAC031975-001 Revision: K
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Manual overview
Manual overview
About this manual
This manual describes the PROFINET IO Master/Slave option and contains
instructions how to configure the PROFINET Master/Slave in an IRC5 system.
Usage
This manual should be used during installation and configuration of the PROFINET
fieldbus.
Who should read this manual?

This manual is intended for:
• Personnel that are responsible for installations and configurations of fieldbus
hardware/software.
• Personnel that make the configurations of the I/O system.
• System integrators.
Prerequisites
The reader should have the required knowledge of
• the PROFINET system
• I/O system configuration
• IRC5 Controller
• Robot Studio
References
Reference Document ID
Technical reference manual - System parameters 3HAC17076-001
Product manual - IRC5 3HAC021313-001
Operating manual - IRC5 with FlexPendant 3HAC16590-001
Operating manual - RobotStudio 3HAC032104-001
Other references
Reference Description
International standard IEC 61158 Type 3 In- The PROFINET fieldbus standard is described
ternational standard IEC 61784 in the international standards.
PROFINET Cabling and Interconnection Installation Guideline for PROFINET (Version
Technology 2.00, September 1998)
Commissioning PC Stations - Manual and Release 12/2006 C79000-G8976-C156-08
Quick Start
ET200S Distributed I/O System Manual from Siemens
www.profinet.com The web site of PROFINET International
Operating instructions CP1616 Manual from Siemens
Continues on next page

Manual overview
Continued
Revisions
Revision Description
- First edition. RobotWare 5.11
A Released with RobotWare 5.12.
PROFINET version changed to 2.2. Updated examples of PROFINET
Master/Slave configuration.
B Added two new scenarios in the Trouble Shooting chapter.
Information about the PROFINET Version V2.2 is added in the Specifica-
tion Overview section.
Added a NOTE in the Prerequisites section about the Robotware version
and firmware version in the Hardware Description chapter.
C Updated the section Specification overview, Slave on page 16.
Added the RobotWare version compatability information in the NOTE that
is available in the section Prerequisites on page 19.
Added information about Step 7 configuration files in the Configuration
subsection in the section PROFINET master on page 28.
Updated the Input and output size subsection in the section IRC5 internal
PROFINET slave on page 29.
Updated the Communication status subsection in the section Configuring
IRC5 internal PROFINET slave on page 43.
Added the new Type Bus system parameters Path to Bus Configuration
File on page 68 and Automatic Firmware Upgrade on page 69.
Updated the Addition information section for the Type Unit Type system
parameters Input Size on page 73 and Output Size on page 75.
Added the new sections Step 7 Configuration files on page 32 and Auto-
matic firmware upgrade on page 39in the PROFINET Master/Slave Con-
figuration chapter.
D Added the new section Upgrade or downgrade firmware using Step7 on
page 33.
E Updated for the RW 5.14 release.
The section Configuration program on page 15 is updated.
Updated the Number of I/O signals entry in the table in the section Spe-
cification overview, Slave on page 16.
Information about the location of the GSDML files in the RobotWare DVD,
PC, and IRC5 Controller is added in the following section:
• GSDML files on page 28
The following sections are updated for the change to increase the number
of I/O signals on I/O units:
• Specification overview, Slave on page 16
• IRC5 internal PROFINET slave on page 29
• Input Size on page 73
• Output Size on page 75
F Updated for the RW 5.14.02 release.
• Added the new system parameter Connector ID.
• Updated the Description and Usage sections for the system para-
meter PROFINET Address.
• In the Trouble Shooting chapter, answer for the Scenario How do
I upgrade/downgrade the firmware on DSQC 678? is updated.
G The section GSDML files on page 28 is updated for the RW 5.14.03 re-
lease.

8 Application manual - PROFINET Master/Slave
Manual overview
Continued
Revision Description
H Updated for the RW 5.15 release.
• Updated the section Introduction section in the chapter System
parameters on page 67.
• Firmware versions usage made consistent through-out the manual.
• Updated the firmware versions details for all the releases starting
from 5.11 till 5.14 in Upgrade or downgrade firmware using Step7
on page 33.
• Added the steps to verify that the bus is not running before starting
the upgrade or downgrade procedure in Upgrade or downgrade
firmware using Step7 on page 33.
J Updated for the RW 5.15.01 release.
• Updated the Overview and firmware file table in Upgrade or
downgrade firmware using Step7 on page 33.
• Updated the section How to reset a DSQC 678 (CP1616) on
page 77.
K Updated for the RW 5.15.06 release.
• Added Fast Unit Startup section. See Using Fast Unit Startup on
page 40 and Fast Unit Startup on page 72.

Product documentation, M2004

Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing
is based on the type of information in the documents, regardless of whether the
products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for M2004 manipulator systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools ).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals

The technical reference manuals describe reference information for robotics
products.
• Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
• Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
• Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
• Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

Continued
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
• Operating manual - Emergency safety information
• Operating manual - General safety information
• Operating manual - Getting started, IRC5 and RobotStudio
• Operating manual - Introduction to RAPID
• Operating manual - IRC5 with FlexPendant
• Operating manual - RobotStudio
• Operating manual - Trouble shooting IRC5, for the controller and manipulator.

Safety
Safety
Safety of personnel
When working inside the robot controller it is necessary to be aware of
voltage-related risks.
A danger of high voltage is associated with the following parts:
• Units inside the controller, for example I/O units, can be supplied with power
from an external source.
• The mains supply/mains switch.
• The power unit.
• The power supply unit for the computer system (230 VAC).
• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!
• The drive unit (700 VDC).
• The service outlets (115/230 VAC).
• The power supply unit for tools, or special power supply units for the
machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Therefore, it is important that all safety regulations are followed when doing
mechanical and electrical installation work.
Safety regulations
Before beginning mechanical and/or electrical installations, ensure you are familiar
with the safety regulations described in Product manual - IRC5.

1 Introduction to PROFINET
1.1 PROFINET, general
1.1 PROFINET, general
What is PROFINET?
PROFINET is an open standard for Industrial Ethernet. PROFINET satisfies
requirements for automation technology. PROFINET solutions can be implemented
for factory and process automation, for safety applications, and for the entire range
of drive technology right up to clock-synchronized motion control.
PROFINET standardization
The use of open standards, simple operation, and the integration of existing system
segments have driven the definition of PROFINET from the beginning. PROFINET
is standardized in IEC 61158 and IEC 61784. The continual further development
of PROFINET offers users a long term perspective for the implementation of their
automation tasks.
PROFINET versions
PROFINET has a modular design and different PROFINET versions are all
combinations of modular elements from the groups transmission technology,
communication protocol, and application profiles.
Here are some examples of PROFINET versions:
• PROFINET-IO - Distributed I/O (Remote I/O). Here, the familiar I/O view of
PROFIBUS is retained, in which the user data from the field devices are
periodically transmitted into the process model of the control system.
• PROFINET-CBA - Based on the object-oriented modelling of technological
modules. Based on the object model, machines and installations are
structured in PROFINET in the form of technological modules.
• PROFIsafe - Defines how safety-oriented devices (emergency shutoff
switches, light grids, overfill protection systems, etc.) can communicate
safety control information over a network securely enough that they can be
used in safety-oriented automation tasks up to EN954's KAT4, AK6, or SIL3
(Safety Integrity Level).
• PROFIdrive - The PROFIdrive profile covers application scenarios from simple
frequency converters to highly dynamic servo drivers.
• PROFIenergy - A profile of the PROFINET communications protocol that
allows the power consumption of automation equipment in manufacturing
(such as robot assembly cells, laser cutters and sub-systems such as paint
lines) to be managed over a PROFINET network. It offers an open and
standardized means of controlling energy usage during planned and
unplanned breaks in production.

1.2 PROFINET, IRC5
1.2 PROFINET, IRC5
Hardware overview
The hardware of the PROFINET fieldbus consists of a master/slave board, DSQC
678, and distributed I/O units.
DSQC 678
The DSQC 678 is connected to the PCI bus of the IRC5 robot controller. The I/O
units are attached to the fieldbus network. The slave part of the master/slave unit
is normally controlled by an external master on the same physical PROFINET
network. The DSQC 678 can act as a master and a slave simultaneously.
The DSQC 678 has a built-in switch with four ports. The built-in switch can be
powered by external power supply. This allows the switch to be used even if the
IRC5 controller is powered down, see Operating instructions CP1616 for details.
I/O units
The I/O units can have digital and/or analog signals. They are all controlled via the
master part of the DSQC 678.
Main computer
The DSQC 678 requires the main computer DSQC 639.
Note
If the IRC5 controller is powered down, the DSQC 678 built-in switch will not
work without external power supply.
PROFINET version compatibility

DSQC 678 supports the PROFINET version PROFINET-IO (see PROFINET versions
on page 13).

1.2 PROFINET, IRC5
Continued
PROFINET network
The following illustration is an example of a PROFINET network.
xx0800000131
A Line PLC, PROFINET-master

B IRC5 controller
C I/O unit
D DSQC 678
E Ethernet switch
Configuration program
An external PROFINET configuration tool such as Step 7 or NCM PC from Siemens,
together with RobotStudio is needed for the configuration of DSQC 678. The NCM
PC program can be downloaded from the Siemens hompage for free. The external
PROFINET configuration tool should be used according to the manual for the
program.

1.2 PROFINET, IRC5
Continued
Specification overview, Master
Item Specification
GSDML ID 6GK1 161-6AA00
Number of I/O units connected to master Maximum 30 I/O units
Number of I/O signals Maximum 8192 I/O signals
Specification overview, Slave
Item Specification
GSDML ID 6GK1 161-6AA00
PROFINET Version V2.2 or V 2.4 Migration
Slot configuration Slot 1-4: Digital input or output modules of variable size
PROFINET-IO Routing Supported
Number of I/O signals Maximum 1024 digital in
Maximum 1024 digital out
Expressions
Expressions Specification
DSQC 678 Siemens CP1616 PCI-card
Master PROFINET controller
Slave, I/O unit PROFINET device
External PROFINET configuration tool Siemens Step7, V5.4, Service pack 5 and above

1.3 Definition of I/O units
1.3 Definition of I/O units
General
It is possible to connect any type of PROFINET-IO compliant I/O unit on the
PROFINET master bus. All I/O units should comply with the PROFINET standard
and be conformance tested by PROFINET international. I/O units may be mounted
inside the controller. There are no PROFINET compliant I/O units installed in a
standard version controller.
Further information
The table gives references to additional information:
Information See
Allowed configurations of I/O units and how Technical reference manual - System para-
to setup the configurations. meters.

2 Hardware description
2.1 PROFINET master/slave, DSQC 678
Description
The DSQC 678 is a PCI card mounted in the computer module. The card has both
master and slave functionality. The master functionality is used to communicate
with I/O units and the slave functionality is used to communicate with the IRC5
controller from a master, e.g PLC.
Prerequisites
RobotWare 5.11 or later version and the PROFINET IO Master/Slave option are
required to run the PROFINET master/slave board.
Note
Robotware 5.11 is compatible only with DSQC 678 firmware version 2.1.
Robotware 5.12 is compatible only with DSQC 678 firmware version 2.2.
RobotWare 5.13 is compatible with DSQC 678 firmware version 2.2 or 2.4.
Installation of DSQC 678

For installation instructions for PROFINET, see the PROFINET specification, IEC
61158 Type 3. See also the Commissioning PC Stations - Manual and Quick Start,
chapter 6 from SIEMENS. For hardware installation refer to Product manual -IRC5,
section Replacement of PCI cards in the computer unit slots.
xx0700000432
A,B,C, and D Possible slot for DSQC 678

Continued
Illustration
The following figure shows the DSQC 678 PCI card.
xx0800000132
A LED, SF (collective error), red

B LED, BF (bus error), red
C External power connections
D Link LED, green
E Activity LED, yellow
F Port 1-4, RJ-45 connectors

Continued
Technical data
LED Meaning State Remarks

B (red) Bus error (BF) Off Communications connection established.
On Link status error occurred.
Flashing I/O device cannot be addressed or duplicate
slowly IP address on the network.
A (red) Collective error Off No error occurred or loading is in progress.
(SF)
On Diagnostic information is available.
A and B Bus error (BF) Flashing Flash test for visual identifying of boards.
Collective error slowly.
(SF)
Flashing Exception error occurred.
quickly
E (yellow) Activity LED On Send and Receive.
D (green) Link LED On Connection exists.
Article number and firmware version
Article number Firmware version Description

3HAC030327-001 2.1.4 PROFINET master/slave, DSQC 678
3HAC033556-001 2.2.1 PROFINET master/slave, DSQC 678
Connections, RJ-45 connectors

The DSQC 678 board has four standard Ethernet RJ-45 connectors. Each connector
is a port to a built in switch on the DSQC 678 board.
Cables and connectors

Cables used to connect the PROFINET network must comply with Cat 5 balanced
LAN requirements or better according to ISO/IEC 11801. For details see PROFINET
Cabling and Interconnection Technology available from www.profinet.com.

2.2 LAN connection
2.2 LAN connection
Ethernet cable between DSQC 678 and LAN port

DSQC 678 is connected with an ethernet cable to the LAN port of the main
computer. The other three ethernet ports on DSQC 678 can be used for network
connections such as factory LAN and PROFINET fieldbus.
xx0900000141
PROFINET in combination with option 707-1

Option 707-1 offers an ethernet port on the connection plate of the controller
cabinet. A cable normally connects this ethernet port on the connection plate with
the LAN port on the main computer.
If both option 707-1 and 888-1 (PROFINET) are used, the ethernet cable from the
connection plate is instead connected to a port on DSQC 678.
xx0900000145
A Main computer
B LAN port
C DSQC 678 (option 888-1)
D Connection plate
E Ethernet connection on connection plate (option 707-1)

2.3 Connections, general
2.3 Connections, general
General
All I/O units are connected to Industrial Ethernet switches in a tree structure. Some
I/O units have built-in ehernet switches allowing I/O units to be connected in a
cascade structure.
xx0800000133
A Switch
B I/O unit

2.4 PROFINET-IO Routing
General
The DSQC 678 has a built in functionality called PROFINET-IO Routing. This
functionality makes it possible for a PLC that is connected to the internal slave of
the DSQC 678 to read and write I/O signals on I/O units that operates as slaves
under the DSQC 678 master.
Note
In the IRC5 I/O configuration it is possible to configure digital output signals on

signal bits controlled by the PLC. These output signals will not affect the digital
outputs on the I/O unit, but can still be used to monitor the actual value of the
digital outputs on that I/O unit. It is recommended to name these kind of output
signals to reflect the fact that they are controlled by the PLC, or configure a
proper access level on the signals to prevent the RAPID program to write to
these kind of signals. For more information see Technical reference
manual - System parameters.

Continued
Example
The figure below shows a setup where the IRC5 Controller is connected to a PLC
as a slave and an I/O unit as a master.
xx0800000137
A PLC
B DSQC 678
C IRC5 controller
D I/O units
With the PROFINET-IO Routing functionality it is possible to configure:

• Some of the I/O signals on the I/O unit to be controlled by the IRC5 controller
and some by the PLC.
• Some I/O signals to be read both by the PLC and the IRC5 controller.

3 PROFINET Master/Slave configuration
3.1.1 Software overview

3.1 Introduction
3.1.1 Software overview
Controller software
The IRC5 controller must be installed with software that supports the PROFINET
IO Master/Slave option (that is, RobotWare 5.11 or later).
Note
The PROFINET IO Master/Slave option must be installed on the IRC5 controller.
PC software
The PROFINET communication is configured manually using RobotStudio or
FlexPendant. For more information on:
• RobotStudio, refer to Operating manual - RobotStudio
• FlexPendant, refer to Operating manual - IRC5 with FlexPendant
An external PROFINET configuration tool, such as Step7 or NCM PC from Siemens,
is needed to configure the DSQC 678. The NCM PC program can be downloaded
from the Siemens hompage for free. Refer to the respective manual for the external
PROFINET configuration tools.

3.2.1 PROFINET master
3.2 Configuration overview
3.2.1 PROFINET master
Configuration
To configure the PROFINET network in the IRC5 controller, a configuration file
needs to be downloaded to DSQC 678 using an external PROFINET configuration
tool.
It is also possible to create a configuration file (an .XDB file) in Step 7, that holds
all the configuration data. This file can be downloaded directly to DSQC 678 from
the IRC5 controller at the system startup. For more information see, Step 7
Configuration files on page 32.
The maximum number of I/O units that can be defined in an IRC5 controller with
PROFINET IO Master/Slave option is described in the section PROFINET, IRC5
on page 14.
The following are counted I/O units:
• All PROFINET I/O units connected to the IRC5 PROFINET master.
• The IRC5 internal PROFINET slave.
• Simulated I/O units and other I/O units connected to other IRC5 fieldbuses.
Predefined Bus
When the system is installed with the PROFINET IO Master/Slave option, a
predefined Bus Profinet1 is created.
Predefined Unit Type

predefined Unit Type PN_GENERIC is created. This I/O Unit Type is used for all
I/O units except the IRC5 internal PROFINET slave.
GSDML files
In order to configure a PROFINET network with an external PROFINET configuration
tool, GSDML files need to be imported into the tool. These files contains vital
information about the PROFINET I/O units and they shall be supplied by the
vendor/manufacturer of the specific PROFINET module.
The GSDML file, GSDML-Vz.z-Siemens-CP16xx-YYYYMMDD.xml (for example
GSDML-V2.2-Siemens-CP16xx-20100709.xml), for PROFINET master is available
in the RobotWare DVD, PC, or IRC5 controller at the following locations:
• On the RobotWare DVD: <DVD-drive>:\utility\fieldbus\PROFINET\GSDML\
• On the PC where the RobotWare is installed: ...\ABBIndustrialIT\
RoboticsIT\Mediapool\<RobotWare_xx.xx.xxxx>\utility\service\GSDML\
• On the IRC5 Controller:
\hd0a\<RobotWare_xx.xx.xxxx>\utility\service\GSDML\

3.2.2 IRC5 internal PROFINET slave
Configuration
The DSQC 678 unit has an internal slave with maximum 1024 digital input signals
and 1024 digital output signals. This can, for example, be used:
• To connect the IRC5 controller to a PLC.
• To connect the IRC5 controller to another IRC5 controller which acts as a
master.
Predefined Unit Type

predefined Unit Type PN_INTERNAL_SLAVE is available. This Unit Type is used
to define the internal slave in the IRC5 controller, which will enable a PLC to connect
to the IRC5 controller. There can only be one I/O unit with this Unit Type defined
in the IRC5 controller.
GSDML files
The GSDML file for DSQC 678 (alias CP1616), that is included in the Step 7 software
package, is needed to operate the DSQC 678 PCI board.
Input and output size

The Unit Type PN_INTERNAL_SLAVE has two Unit Type parameters, Input Size
and Output Size. Input Size is used to configure the input size of the IRC5 internal
PROFINET slave and Output Size configures the output size. A connecting PLC
needs to have a slot configuration created in the external PROFINET configuration
tool that matches the configuration of the IRC5 internal PROFINET slave.
The available module sizes of DSQC 678 are dependent on the firmware version
of DSQC 678.
If firmware V2.2.X.X is used the supported module sizes are: 4 byte, 16 byte, 20
byte, and 64 byte.
If firmware V2.4.X.X is used the supported module sizes are: 4 byte, 8 byte, 16
byte, 20 byte, 32 byte, 64 byte, and 128 byte.
The IRC5 internal PROFINET slave uses a maximum of 2 input and 2 output slots
to configure the input and output size of the IRC5 internal PROFINET slave.
Input Size and Output Size can be set to the values 4, 8, 16, 20, 32, 64, and 128
(other values will be rounded up to one of these values).
If firmware V2.2.X.X is used, the value 8 results in two slots with 4 bytes each. The
value 32 will result in two slots with 16 bytes each. Other values will result in one
slot with 4, 16, 20, or 64 bytes.
If firmware V2.4.X.X is used, all values results in one slot with 4, 8,16, 20, 32, 64,
or 128 bytes.
Note
The Input Size sets the size on digital outputs and Output size sets the size on
digital inputs, seen from the PLC’s point of view.

Continued
The following table shows a few examples of how the Input Size and Output Size
Unit Type parameters can be used to create different slot configurations of a
connecting PLC when firmware V2.2.X.X is used:
Input Size Output Size Step 7 Configuration
4 bytes 4 bytes Slot 1: DI 4 bytes
Slot 2: DO 4 bytes
Slot 2: DI 4 bytes
Slot 3: DO 4 bytes
Slot 2: DO 16 bytes
1 byte 20 bytes Slot 1: DI 20 bytes
Slot 2: DO 4 bytes
Slot 2: DO 16 bytes
Slot 2: DO 16 bytes
Slot 3: DO 16 bytes
Slot 2: DI 16 bytes
Slot 3: DO 16 bytes
Slot 4: DO 16 bytes
Slot 2: DO 64 bytes
If firmware V2.4.X.X is used the above table will differ in the following cases:
Input Size Output Size Step 7 Configuration
Slot 2: DO 4 bytes
Slot 2: DO 32bytes
Slot 2: DO 32 bytes
Slot 2: DO 128 bytes
If a configuration mismatch between the connecting PLC and the IRC5 internal
PROFINET slave occurs, the event message 71437 is generated. This event
message informs the user of the present slot configuration of the IRC5 internal
PROFINET slave.

Continued
Note
The System Info menu in FlexPendant or RobotStudio can be used to view the
current slot configuration of the IRC5 internal PROFINET slave. On the
FlexPendant, the System Info path is: "System Info/Hardware
devices/Controller/Computer system/PCI bus/Profinet board".

3.2.3 Step 7 Configuration files
3.2.3 Step 7 Configuration files
Configuration
There are two ways to download the Step 7 configuration to DSQC 678. The most
common way is to download the configuration directly from within Step 7 to DSQC
678. An alternate way is to create an .xdb configuration file in Step 7 and place this
file in the HOME directory of the IRC5 controller.
By specifying the configuration file name using the bus type parameter Path to
Bus Configuration File (see Path to Bus Configuration File on page 68), the IRC5
controller will open and read the file at startup and send the configuration to the
DSQC 678 board. This means that the current configuration in DSQC 678 is replaced
by the one specified in the configuration file.
Configuration File Type

The configuration file of type .xdb is created by default every time a Step 7 project
is compiled. The .xdb file is placed in the current project folder under the directory
XDBs. By default, this file is named as pcst_1.xdb.
It is recommended to place the configuration file in the HOME directory of the
current system. If the configuration file is placed in the HOME directory it is only
necessary to specify the name of the file in the Path to Bus Configuration File
parameter and not the complete file path. All files in the HOME directory are included
in a backup of the system.
en0900001024

3.2.4 Upgrade or downgrade firmware using Step7
Overview
You can upgrade or downgrade firmware versions using the Firmware Loader
program which is included in the Step7 package. RobotWare 5.13 supports firmware
upgrade of the DSQC 678 board from within RobotWare itself (but no support for
downgrade).
The firmware files (for example DSQC678_2425.fwl), for the DSQC 678 board is
available in the PC or IRC5 controller at the following locations:
• On the PC where the RobotWare is installed:
...\ABBIndustrialIT\RoboticsIT\Mediapool\<RobotWare_xx.xx.xxxx>\firmware\
• On the IRC5 Controller: \hd0a\<RobotWare_xx.xx.xxxx>\firmware\
Compatability limitations of RobotWare versions and firmware versions

Different releases of RobotWare are compatible only with specific firmware versions
in the DSQC 678 board, as shown in the following table. Therefore, an upgrade or
downgrade of RobotWare requires a change of firmware in the board.
RobotWare version Firmware version Firmware file
RW 5.14.03 2.4.XX or 2.2.1.24 DSQC678_2425.fwl included
in RW
in RW
in RW
RW 5.14 2.4.XX or 2.2.1.24 DSQC678_2423.fwl included
in RW
RW 5.13.04 2.4.XX or 2.2.1.24 DSQC678_242.fwl included in
RW
RW
RW
RW
RW 5.13 2.4.XX or 2.2.1.24 DSQC678_241.fwl included in
RW
RW 5.12 2.2.1.24 fw16xx-2.2.1.24.1.fwl *
RW 5.11 2.1.4.0 vxworks.fwl *
Note
The system generates error messages if firmware 2.2.1.24 is used with RW5.11.
*
Firmware file delivered by Siemens.

Continued
Checking the firmware version

You can check the version number of the firmware loaded in the DSQC 678 board
in one of the following ways.
• Using FlexPendant: Select ABB -> System Info -> Hardware devices ->
Controller -> Computer system -> PCI bus -> Profinet board.
• Using RobotStudio: Right click on the controller in the Online view and select
Properties -> Device Browser -> Devices -> Hardware devices -> Controller
-> Computer system -> PCI bus -> Profinet board.
Note
The PROFINET bus must be available in the I/O configuration to display the
firmware information.
Upgrading or downgrading firmware using step7

Perform the steps 1 – 4 to verify that the bus is not running before starting the
upgrade or downgrade procedure.
1 Open the hardware configuration window of a project and set the project
“Online” with the menu View, Online.

Continued
2 Right click Station and choose Open Object.
3 Right click CP1616 and choose Operating Mode.
If the Current Operating Mode displays RUN, click STOP button to stop the
bus.
4 Click Close.

Continued
Perform the steps 5 - 14 to upgrade or downgrade firmware version.

5 Open SIMATIC Manager (Step7) and check Options -> Set PG/PC Interface.
Note
The TCP/IP address should be the IP address of your network card.
6 Go to PLC -> Edit Ethernet Node.

The Edit Ethernet Node dialog box appears.
7 Click Browse, select the appropriate DSQC 678 (CP1616) board, and click
OK.
en1000000521
Note
To identify the DSQC 678 board click the Flash button. The LED of the
selected board start flashing until you press Stop button.

Continued
8 Click the Reset button in the Reset to factory settings section.
en1000000522
Note
Before downloading the firmware, reset the board to factory settings using
steps 1 to 4. If a reset is not carried out before performing an upgrade or
downgrade of the firmware, the DSQC 678 board might end up in an error
state which cannot be recovered.
9 Click Browse, select the appropriate DSQC 678 board, and click OK. It might
take some time for the board to appear in the list after the reset.
10 Type the desired IP address and Subnet mask and click Assign IP
Configuration.
11 Close SIMATIC Manager and open SIMATIC NET Firmware - Loader.

Continued
12 Click Browse, select the firmware according to the RobotWare version, and
click Next.
en1000000523
13 Select IP protocol, type the IP address that was set from SIMATIC Manager,
and click Next.
14 Follow PG/PC Interface instructions and load the firmware.

3.2.5 Automatic firmware upgrade
3.2.5 Automatic firmware upgrade
Overview
It is possible to upgrade the firmware directly from within the IRC5 controller, if the
current version of RobotWare is compatible with more than one firmware versions
of DSQC 678.
Configuration
The bus type parameter Automatic Firmware Upgrade on page 69 activates the
upgrade function. After activation, the IRC5 controller upgrades the firmware during
the next system startup.
Note
On some systems the automatic firmware upgrade can take several minutes to
complete. Since this is performed at system startup, it might appear as if the
IRC5 controller has stopped responding.
Firmware version
The firmware version is important in the Step 7 projects. A PLC configured to
communicate with a V2.2.X.X firmware might not accept that the communication
partner suddenly appears as a V2.4 device.
To view the current firmware version available for upgrade in the current RobotWare
release, refer to‘System Info/Hardware devices/Controller/Computer system/PCI
bus/Profinet board’ on the FlexPendant.
Note
The current configuration data in DSQC 678 is not destroyed when performing
a firmware upgrade operation. If the current configuration is not compatible with
the new firmware, DSQC 678 might perform illegal address operations against
the IRC5 controller. This might cause a system failure. It is therefore
recommended to clear the DSQC 678 configuration data before upgrading the
firmware.

3.2.6 Using Fast Unit Startup
About Fast Unit Startup

The Fast Unit Startup functionality is used in tool changing applications to shorten
the connection time between the PROFINET master and an I/O unit. To be able to
use this functionality, the I/O unit needs to support this functionality. Some
manufacturers also call this functionality Fast Start Up (FSU) or Prioritized Startup.
To activate Fast Unit Startup against an I/O unit, activate the system parameter
Fast Unit Startup and select the corresponding port(s) to be configured. See Fast
Unit Startup on page 72.
Three alternative connections

I/O unit connected via a switch
xx1100000093
A IRC5 controller acting as PROFINET master

B Switch
C Connection point
D I/O unit
F Port 1 on the I/O unit
G Port 2 on the I/O unit
In this alternative, the PROFINET master connects to the I/O unit via a switch.
Enable fast unit startup and select 100 MBit (full duplex) on port 1. The port number
is usually displayed upon the I/O unit itself.

Continued
Two I/O units connected in serial via a switch
xx1100000094

B Switch
C Connection point
D I/O unit
E I/O unit
In this alternative, both I/O units are disconnected at the connection point. Both
port 1 and port 2 on the first I/O unit (D) and port 1 on the second I/O unit (E) needs
to be configured to support Fast Unit Startup.
I/O unit connected without a switch
C
A
D
xx1100000095

C Connection point
D I/O unit
E I/O unit
In this alternative there is a direct cable between the PROFINET master and the
I/O unit. Enable fast unit startup and select 100 MBit (full duplex) on the port. A
crossed Ethernet cable needs to be used.

3.3.1 Configuring PROFINET master
3.3 Workflows
3.3.1 Configuring PROFINET master
Description
The PROFINET master configuration is set according to the I/O units and I/O signals
definitions.
Configuration
Action Note
1 Create a new system using RobotStudio. Make sure the See Operating manu-
PROFINET IO Master/Slave option is installed. al - RobotStudio.
2 Download the system to the IRC5 controller and restart.
3 Use the external PROFINET configuration tool to create a Described in section
project that contains the configuration of the PROFINET Configuring digital I/O,
network. If the I/O units are not available in the configuration example on page 47.
tool, import the GSDML files.
Note
This step is always unique depending on the type of I/O unit

to configure.
4 Download the configuration to the DSQC 678.

5 Restart the IRC5 controller to start up with the new system.
6 Configure the I/O units connected to the Profinet1 bus using
RobotStudio or FlexPendant.
7 Configure the I/O signals. See Technical reference
manual - System para-
meters.
8 Restart the IRC5 controller.

3.3.2 Configuring IRC5 internal PROFINET slave
3.3.2 Configuring IRC5 internal PROFINET slave
Description
When the IRC5 controller is connected, for example, to an external PLC, the IRC5
controller acts as an ordinary slave unit on the PROFINET network. The PLC
connects to the IRC5 internal PROFINET slave to exchange data.
Configuration
Action Note
1 Use the external PROFINET configuration tool to Described in section Configuring
create a project for the master, for example a PLC, IRC5 internal PROFINET slave,
that contains the configuration of the PROFINET example on page 57.
network.
2 In the tool, configure the master to connect to the Described in section Configuring
DSQC 678 internal slave that represents the IRC5 IRC5 internal PROFINET slave,
controller. example on page 57.
3 Configure the IRC5 internal PROFINET slave unit See Configuring IRC5 internal
in the IRC5 controller using RobotStudio or Flex- PROFINET slave, example on
Pendant. page 57 and Operating manu-
al - RobotStudio.
4 Configure the I/O signals. See Technical reference manu-
al - System parameters.
5 Restart the IRC5 controller. See Operating manual - IRC5 with
FlexPendant.
6 Download the configuration in the external Described in section Configuring
PROFINET configuration tool to the master. IRC5 internal PROFINET slave,
example on page 57.
Communication status
To control the communication status between the master (for example a PLC) and
the IRC5 internal PROFINET slave, the following scheme is used:
1 Configure the master to set a signal during the startup or within the controller
loop.
2 Configure the internal PROFINET slave to attach the signal to a RAPID trap
function in the robot controller. The signal then functions as a communication
supervision signal.
If the communication between the master and the internal PROFINET slave is
interrupted, all the inputs of the internal slave will go to the fail safe state (that is,
input value will be zero). This means that the user defined communication
supervision signal will also have the value zero.

3.3.3 Configuring PROFINET-IO Routing
General
The PROFINET-IO Routing functionality is configured entirely using an external
PROFINET configuration tool. It is important to remember that the PROFINET-IO
Routing functionality also connects different projects in the configuration tools with
each other. A configuration change in one of the projects might also change the
configuration in the connected project. In order to execute changes regarding
PROFINET-IO Routing, all affected projects must be downloaded to respective
hardware, even if a change in configuration only was made in one of the connected
projects.
Prerequisites
The PROFINET master and the PROFINET internal slave has to be configured,
see section Configuring PROFINET master on page 42, and section Configuring
IRC5 internal PROFINET slave on page 43.
Master configuration
Use this procedure to configure the master.
Action
1 Configure the master functionality as described in Configuring PROFINET master on
page 42.
2 Use an external PROFINET configuration tool to create a project and add a Simatic
PC station with a CP1616 device and a network with the devices that shall be slaves
to the IRC5 controller.
3 Configure the IRC5 controller I/O system and define the slave devices as I/O units.
4 Configure the IRC5 controller I/O system and define the I/O signals that shall be ac-
cessible from the IRC5 controller.
Slave configuration
Use this procedure to configure the slave.
Action
1 Configure the IRC5 internal PROFINET slave functionality as described in Configuring
IRC5 internal PROFINET slave on page 43
2 Add a PLC station to the project created in Configuring PROFINET master on page 42
step 1 using an external PROFINET configuration tool.
3 Add a Simatic PC Station as a slave to the PLC, make sure the name and IP address
is the same as in the master configuration.
4 Configure the IRC5 controller I/O system and define a unit of type PN_INTERN-
AL_SLAVE to activate the IRC5 internal PROFINET slave functionality.

Continued
PROFINET-IO Routing configuration

Configure PROFINET-IO Routing in the external PROFINET configuration tool.
Action
1 In the PLC configuration select the CP1616 device and add transfer modules to slot
3 and above, as described in Configuring PROFINET-IO Routing, example on page 63.
Note
In the IRC5 I/O configuration it is still possible to configure digital output signals
on signal bits controlled by the PLC. These output signals will not affect the
digital outputs on the I/O unit, but can still be used to monitor the actual value
of the digital outputs on that I/O unit. It is recommended to name these kind of
output signals to reflect the fact that they are controlled by the PLC, or configure
a proper access level on the signals to prevent RAPID programs to write to these
kind of signals. For more information, see Technical reference manual - System
parameters.

3.4.1 Overview
3.4 Examples
3.4.1 Overview
About the examples

All the examples in this section are based on the Robotware 5.11 or 5.12 systems
with DSQC 678 firmware version V2.1.4.0 or V2.2.1.24. If you are using Robotware
5.12 or above, you need to use the corresponding DSQC 678 (alias CP1616) module
type that corresponds to the current firmware version of your DSQC 678 board.
Robotware 5.12 uses CP1616 V2.2 module type. Robotware 5.13 or above uses
CP1616 V2.2 or V2.4 module type.

3.4.2 Configuring digital I/O, example
Description
This is an example of how to configure an I/O unit with four input signals and four
output signals.
The I/O unit used in this example is an ET200S I/O unit with five submodules
attached to it:
• One power module.
• Two modules with two DO in each module.
• Two modules with two DI in each module.
The network is configured using Siemens Step7.
PROFINET configuration setup

Use this procedure to set the configuration in Siemens Step7.
Action
1 Create a new empty project.
2 On the Insert menu, point to Station, and then click SIMATIC PC Station.
3 In SIMATIC Manager, expand the project tree and select the created station. Right-
click the station and select Open Object to open the HW Config window.
xx0800000138
4 Expand the SIMATIC PC Station on the right-hand side catalog tree. Expand further
in the tree, find SIMATIC PC Station\CP Industrial Ethernet\CP 1616\V2.2.
5 Double-click or drag the V2.2 device from the catalog tree to slot 1 of the PC rack.

Continued
Action
6 Enter the IP address used for the DSQC 678, and then click New to create a PROFINET
network.
xx0800000139
7 Click OK on the Industrial Ethernet dialog and OK in the Properties-Ethernet interface

PN-IO dialog.
xx0800000140

Continued
Action
8 Double-click the X1 slot in PC rack to open the PN-IO dialog.
xx0800000141
9 Enter Robot1 in the Device Name text box and click OK.
xx0800000142

Continued
Action
10 Expand the catalog tree view and locate the correct ET200S device,
PROFINET IO\I/O\ET 200S\IMI151-3 PN ST V6.0.
xx0800000143
11 Drag the device from the catalog and drop it on the Ethernet PROFINET-IO-System.
12 Continue expanding the catalog tree to locate the modules that are connected in the
hardware device.
xx0800000144
13 For each module double-click or drag it to the appropriate slots of the ET200S device.
Note
Make sure the catalog number matches the catalog number printed on the hardware.
Continued
Action
14 If the feature prioritized startup is desired for the ET200S, double-click on slot X1 and
select Prioritized startup. This will shorten the time it takes for the device to start data
exchange with the controller after losing and regaining power or after disconnection
and reconnection on the bus.
en0900000001
Note
Prioritized startup is available with PROFINET IO board firmware version 2.2.1.24 or

later.
15 On the File menu, click Save and compile.
xx0800000145
16 Make sure that you have an ethernet connection between the PC and the DSQC 678.

Continued
Action
17 On the PLC menu, click Download and then click OK.
xx0800000146
18 Click View to search the network for the DSQC 678.
xx0800000147

Continued
Action
19 Select the appropriate DSQC 678 card and click OK.
xx0800000148
20 Click OK to stop the card. This finishes the setup in the Siemens tool.
Continue with configuring the IRC5 controller I/O system.
xx0800000149

Continued
IRC5 controller I/O configuration setup

Use this procedure to setup the configuration in the IRC5 controller, using
RobotStudio.
Action
1 Start RobotStudio and connect to the IRC5 controller. Request write access.
2 Click Configuration Editor and select I/O.
3 In the type list, click Unit and then right-click in the workspace and select Add Unit.
4 Enter the parameter values for the unit and click OK.
• Name.
• Type of Unit should be PN_GENERIC.
• Profinet Address should be 1, same as the device number in the Step7 project.
xx0800000152
xx0800000155
Note
Device number 1 in the Siemens project.
5 In the type list, click Signal and then right-click in the workspace and select Add Signal.

Continued
Action
6 Enter the parameter values for the signal and click OK.
• Name
• Type of signal
• Assign to unit
• Unit mapping
xx0800000156
The lower panel in Step7 can be a guide when specifying the parameter Unit Mapping.
Select the device in the project and use the lower panel. See settings explanation in
Signal mapping example on page 56.
xx0800000158

8 After the restart, start RobotStudio and make sure the configured I/O signals are ac-
cessible.

Continued
Signal mapping example
xx0800000158
The panel shows that the signals are mapped to:

Slot Module type Module mapping in Step7 Unit mapping in IRC5 con-
troller
2 2DO Out 0.0..0.1 Out 0,1
3 2DO Out 1.0..1.1 Out 8,9
4 2DI In 0.0..0.1 In 0,1
5 2DI In 1.0..1.1 In 8,9
The I/O signals in the IRC5 controller should be mapped as:

Name Type of signal Assigned to Unit Unit mapping
DI1 Digital Input IM151 0
DO1 Digital Output IM151 0
This example shows that even if a 2 bit module type is used, every slot occupies
atleast 1 byte. If an 8 bit module type is used, all signal bits (unit map 0-7) would
have valid data.

3.4.3 Configuring IRC5 internal PROFINET slave, example
Description
This is a configuration example for an IRC5 internal PROFINET slave with 64 byte
input and 64 byte output size. The example also shows how to configure a PLC
that connects against the IRC5 internal PROFINET slave.
This example comes from the Step7 project in section Configuring digital I/O,
example on page 47
Configuring IRC5 internal PROFINET slave

Use this procedure to configure the configuring IRC5 internal PROFINET slave
using Siemens Step 7.
Action
1 Start Simatic Manager and open the project containing the Simatic PC Station that
represents the IRC5 controller with DSQC 678.
This project was created in section Configuring digital I/O, example on page 47
2 Expand the project tree and select the Simatic PC station that represents the IRC5
controller with the DSQC 678. Right-click the station and select Open Object to open
the HW Config window.
3 Double-click slot 1 in the PC Station rack to open the object properties and then select
the PROFINET tab.
Make sure the Enable IO device mode is selected, if not select Enable IO device
mode and download the updated configuration to the DSQC 678.
Click OK.
xx0800000159

Continued
Action
4 Click OK and add a PLC station to the project.
Note
If using the PROFINET-IO Routing functionality, make sure that the PLC station and
the Simatic PC station are located in the same project.
5 Open the HW Config window for the PLC hardware configuration.
xx0800000160
6 Make sure the PROFINET network connected to the PLC is the same as the network
connected to the Simatic PC station representing the IRC5 controller with DSQC 678.
7 Expand PROFINET IO\I/O\SIMATIC PC-CP\CP1616\6GK1 161-6AA00 (Migration) in
the catalog view to the right, to find the V2.2 device.

Continued
Action
8 Drag the V2.2 device to the PROFINET network workspace.
xx0800000161
9 Double-click the added CP1616 icon.
xx0800000162

Continued
Action
10 Make sure the device name is the same as the name selected for slot X1 in the config-
uration of the Simatic PC Station configuration and that Assign IP address via IO
controller is cleared.
Click OK.
xx0800000163
Note
Before clearing the Assign IP address via IO controller box, make sure the IP address
is set to the IP address of the CP1616 card in the Simatic PC Station configuration.
11 Click OK in the Properties-CP-1616 dialog and then click Yes to confirm the warning
xx0800000164

Continued
Action
12 Make sure the CP1616 icon is selected, expand the catalog view further to find the
input modules, PROFINET IO\I/O\SIMATIC PC-CP\CD1616\6GK1 161-6AA00 (Migra-
tion)\ V2.2\DI. Double-click the 64 bytes module to insert it into slot 1 of the CP1616
card.
13 Expand the output modules in the catalog tree and double-click or drag the 64 bytes
module to slot 2 of the CP1616 card.
xx0800000165
14 On the Station menu, click Save and Compile.

15 Make sure that you have an Ethernet connection between the PC and the PLC.
16 On the PLC menu, click Download.
IRC5 controller I/O configuration setup

Use this procedure to configure the slave in the IRC5 controller, using Robot Studio.
Action
1 Start RobotStudio and connect to the IRC5 controller. Request write access.
2 Click Configuration Editor and select I/O.
3 In the type list, click Unit and then right-click in the workspace and select Add Unit.

Continued
Action
4 Enter the parameter values for the unit and click OK.
• Name.
• Type of Unit should be PN_INTERNAL_SLAVE.
• Connected to Bus should be Profinet1.
• Profinet Address must be 0. (Not needed in Robotware 5.12 or above).
xx0800000166

3.4.4 Configuring PROFINET-IO Routing, example
Description
This is an example of how to configure the DSQC 678, PROFINET-IO Routing
functionality.
Note
This example requires both configurations described in example Configuring

digital I/O, example on page 47, and Configuring IRC5 internal PROFINET slave,
example on page 57.
PROFINET configuration setup

Use this procedure to setup the configuration in Step7 (Siemens PROFINET
configuration tool).
Action
1 Use Siemens Simatic Manager and open the PLC configuration made in example
PROFINET configuration setup on page 47.
2 Select the CP1616 icon representing the IRC5 internal PROFINET slave.
3 In SIMATIC Manager, expand the catalog tree to the right of the window. Right-click
the window and find PROFINET IO\I/O\SIMATIC PC-CP\CP1616\6GK1 161-6AA00
(Migration)\V2.2\Transfer Module.
4 Drag one DI 1 byte transfer module to slot 3 of the CP1616 device.
5 Drag one DO 1 byte transfer module to slot 4 of the CP1616 device.
xx0800000167

Continued
Action
6 Double-click DI 1 byte transfer module in slot 3 to open the Properties dialog.
xx0800000168
7 In the column Device name click the first cell named Empty to open a list of devices
that are controlled by the PROFINET master in the IRC5 controller.
8 Click to select the IM151 device.
9 Click the Module (slot) cell with white background to open a list of available slot
modules. This will show a list of all slot modules that the PLC can read.
Then select the input module in slot 4.

Continued
Action
10 Click the next cell labeled Empty and select the IM151 module, then select the output
module in slot 2. As seen in this example, it is possible to also choose to read outputs.
This is generally not needed by the PLC, but shown here to illustrate that it's possible.
With this configuration, the PLC can read the input signals 0 and 1, and read back the
output signals 0 and 1.
xx0800000170
11 Click OK to close the Properties dialog.

12 Double-click the DO 1 byte transfer module in slot 4 of the CP1616device.

Continued
Action
13 Configure the transfer module so that the PLC will be able to control the output signals
0 and 1 of the output module in slot 3 of the IM151 device.
xx0800000171
14 Click OK to close the Properties dialog.

15 On the Station menu, click Save and compile.
16 Open the SIMATIC PC Station configuration.
17 On the Station menu, click Save and compile.
18 Download the PLC configuration to the PLC.
19 Download the Simatic PC Station configuration to the DSQC 678.
Note
In the IRC5 I/O configuration it is still possible to configure digital output signals
on signal bits controlled by the PLC. These output signals will not affect the
digital outputs on the I/O unit, but can still be used to monitor the actual value
of the digital outputs on that I/O unit. It is recommended to name these kind of
output signals to reflect the fact that they are controlled by the PLC, or configure
a proper access level on the signals to prevent RAPID programs to write to these
kind of signals. For more information, see Technical reference manual - System
parameters.

4 System parameters
4.1 Introduction
4 System parameters
4.1 Introduction
About the system parameters

There are both PROFINET specific parameters and more general parameters. This
chapter describes all PROFINET specific system parameters. The parameters are
divided into the type they belong to. For information about other parameters, see
Technical reference manual - System parameters.
PROFINET system parameters

Bus
These parameters belong to the type Bus in the topic I/O.
Parameter For more information, see ...
Name Technical reference manual - System parameters
Type of Bus Technical reference manual - System parameters
Connector ID Connector ID on page 70
Label of Fieldbus Connect- Technical reference manual - System parameters
or
Unit Recovery Time Technical reference manual - System parameters
Path to Bus Configuration Path to Bus Configuration File on page 68
File
Automatic Firmware Up- Automatic Firmware Upgrade on page 69
grade
Unit Type
These parameters belong to the type Unit Type in the topic I/O.
Parameter For more information, see ...
Name Technical reference manual - System parameters
Type of Bus Technical reference manual - System parameters
Vendor Name Technical reference manual - System parameters
Product Name Technical reference manual - System parameters
Internal Slave Technical reference manual - System parameters
Input Size Input Size on page 73
Output Size Output Size on page 75

4 System parameters
4.2.1 Path to Bus Configuration File
4.2 Type Bus
4.2.1 Path to Bus Configuration File
Parent
Path to Bus Configuration File belongs to the type Bus, in the topic I/O.
Cfg name
CfgPath
Description
Path to Bus Configuration File specifies the path to a Step 7 configuration file of
type .XDB that is located on the IRC5 system.
Usage
The Path to Bus Configuration File system parameter is used to download a Step
7 configuration to DSQC 678 without using Step 7. If the configuration file is placed
in the HOME directory of the system, it will also be included in backups. For more
information see, Step 7 Configuration files on page 32.
Prerequisites
PROFINET IO Master/Slave option must be installed.
Default value
The default value is an empty string.
Allowed values
A-Z, a-z, _, .

4 System parameters
4.2.2 Automatic Firmware Upgrade
4.2.2 Automatic Firmware Upgrade
Parent
Automatic Firmware Upgrade belongs to the type Bus, in the topic I/O.
Cfg name
PN_AutoFirmwareUpgrade
Description
Automatic Firmware Upgrade activates the firmware upgrade function of DSQC
678.
Usage
The Automatic Firmware Upgrade parameter specifies if the system should perform
a firmware upgrade of DSQC 678 to the firmware version specified in the ‘System
Info/Hardware devices/Controller/Computer system/PCI bus/Profinet board’ menu.
For more information, see Automatic firmware upgrade on page 39.
Prerequisites
Limitations
Not possible to upgrade to firmware version other than that included in RobotWare.
Default value
Deactivated.
Allowed values
Activated or Deactivated.

4 System parameters
4.2.3 Connector ID
4.2.3 Connector ID
Parent
Connector ID belongs to the type Bus, in the topic I/O.
Cfg name
ConnectorID
Description
The parameter Connector ID specifies the hardware interface (connection port)
that the PROFINET IO Master/Slave option shall use.
Usage
The Connector ID parameter is used to select one of the available connection ports
to use.
Prerequisites
Allowed values
First Channel
LAN Port
Ethernet Port 1
Ethernet Port 2
Ethernet Port 3
Ethernet Port 1 on Board 2
Fieldbus Adapter

4 System parameters
4.3.1 PROFINET Address
4.3 Unit
4.3.1 PROFINET Address
Cfg name
PN_Address
Description
The parameter PROFINET Address corresponds to the device number in the
external PROFINET configuration tool.
Usage
PROFINET Address specifies the address that the I/O unit uses on the network.
Prerequisites
Default values
The default value is 0.
Allowed values
An integer value between 0 and 65535.
The value must be zero (0) when configuring the internal slave.

4 System parameters
4.3.2 Fast Unit Startup
4.3.2 Fast Unit Startup
Parent
Fast Unit Startup belongs to the type Unit, in the topic I/O.
Cfg name
PN_FastUnitStartup
Description
The parameter Fast Unit Startup specifies if the I/O unit should use a faster
connection attempt algorithm or not.
Usage
The parameter Fast Unit Startup is used mainly to speed up tool change
applications. The normal PROFINET connection attempt takes a few seconds to
complete, but with Fast Unit Startup enabled devices, this time is shorted to about
1 second. For more information, see Using Fast Unit Startup on page 40.
Prerequisites
The option PROFINET Master/Slave must be installed.
Limitations
The Ethernet switches between the IRC5 controller and the I/O unit that uses the
Fast Unit Startup functionality must be configured to disable the auto cross over
and automatic speed detection functions on used connectors, the speed rate must
be set to 100 Mbit (full duplex).
Default value
The default value is Deactivated
Allowed values
• Deactivated
• Activated

4 System parameters
4.4.1 Input Size
4.4 Unit Type
4.4.1 Input Size
Parent
Input Size belongs to the type Unit Type, in the topic I/O.
Cfg name
PN_InputSize
Description
Input Size is used to configure the input slot configuration of the IRC5 internal
PROFINET slave.
Input Size sets the size of the digital inputs for PN_INTERNAL_SLAVE.
Prerequisites
Limitations
Input Size is only available for the unit type PN_INTERNAL_SLAVE.
Allowed values
Allowed values are the integers 0-128.
Additional information
The values other than 4, 8, 16, 20, 32, 64, and 128 results in digital input size
rounded up to the closest of these values.
If DSQC 678 firmware version 2.2 is used:
The Input Size set to 8 results in two slots with 4 bytes each. The Input Size set to
32 results in two slots with 16 bytes each. For other values there will be one slot
with 4, 16, 20, or 64 bytes.
Input Size Slot size
1-4 4 bytes
5-8 2 slots with 4 bytes each
9-16 16 bytes
17-20 20 bytes
33-64 64 bytes

1-4 4 bytes
5-8 8 bytes

4 System parameters
4.4.1 Input Size
Continued

9-16 16 bytes
17-20 20 bytes
21-32 32 bytes
33-64 64 bytes
65-128 128 bytes

4 System parameters
4.4.2 Output Size
4.4.2 Output Size
Parent
Output Size belongs to the type Unit Type, in the topic I/O.
Cfg name
PN_OutputSize
Description
Output Size is used to configure the output slot configuration of the IRC5 internal
PROFINET slave.
Output Size sets the size of the digital outputs for PN_INTERNAL_SLAVE.
Prerequisites
Limitations
Output Size is only available for the unit type PN_INTERNAL_SLAVE.
Allowed values
Allowed values are the integers 0-128.
Additional information
Any other values than 4, 8, 16, 20, 32, 64, and 128 results in digital output size
rounded up to the closest of these values.
The Output Size set to 8 results in two slots with 4 bytes each. The Output Size
set to 32 results in two slots with 16 bytes each. For other values there will be one
slot with 4, 16, 20, or 64 bytes.
Output Size Slot size
1-4 4 bytes
9-16 16 bytes
17-20 20 bytes
33-64 64 bytes

1-4 4 bytes
5-8 8 bytes
9-16 16 bytes

4 System parameters
4.4.2 Output Size
Continued

17-20 20 bytes
21-32 32 bytes
33-64 64 bytes
65-128 128 bytes

5 Trouble shooting
5.1 Scenarios
5 Trouble shooting
5.1 Scenarios
How to reset a DSQC 678 (CP1616)

If the DSQC 678 doesn’t accept changed device name or IP address parameter
via Step7 in the PLC – Edit Ethernet Node window, follow these steps to reset or
set the values:
1 On the ABB menu, tap X-Start to restart the controller.
This is to ensure that the controller will not attempt to connect to the DSQC
678 for any reasons.
2 Unplug all the cables from the DSQC 678’s internal switch.
This is to prevent communication to any connected device, if a project is
loaded in the board and running.
3 Connect the programming unit (PC with Step7) via a cable directly to any of
the DSQC 678’s internal ports.
4 Start the Simatic Manager at the programming unit.
5 From the PLC menu select the Edit Ethernet Node entry.

5 Trouble shooting
5.1 Scenarios
Continued
6 Click Browse in the Ethernet node field.
en1200001205
7 Select DSQC 678 (CP1616) device and click OK.

5 Trouble shooting
5.1 Scenarios
Continued
To ensure if the selected device is the correct DSQC 678 device, click Flash.
The selected device will then flash periodical with its LED’s.
en1200001206
8 Now try to change the device name and/or IP address. Click Assign to confirm
for each of the two settings.

5 Trouble shooting
5.1 Scenarios
Continued
Alternatively, the DSQC 678 can be reset to its factory settings using the
Reset button in the Reset to factory settings field.
en1200001207
9 When all the settings have been successfully done, Click Close.
10 Restart the controller using the power switch.
The controller will start without a system. Select the system you wish to use
and warm restart the controller using the Flex Pendant.
11 Finally reconnect all the cables and unplug the programming pc if it is not
needed anymore.
How can I download configuration to DSQC 678 using Step 7

See the preceding scenario, How to reset a DSQC 678 (CP1616) on page 77.

5 Trouble shooting
5.1 Scenarios
Continued
The Ethernet switch on the DSQC 678 can be operated using an external power supply unit. Why is
it not working?
The DSQC 678 board must first be initialized by the PROFINET IO Master/Slave
option software driver before the Ethernet switch can be used. When this is done,
the external power supply unit can be connected to the DSQC 678 board.
In Step 7 the DSQC 678 board can be "Reset to factory settings". After that the IRC5 controller cannot
detect that the PCI-board is inserted.
When this command is issued from Step 7, the DSQC 678 board will perform
additional operations next time it reboots. This will increase the startup time of the
board so much that the IRC5 controller will fail to detect it. The solution is to restart
the IRC5 controller again.
My digital group/analogue signal seem to be data inconsistent.

With the DSQC 678 board data consistency is only guaranteed on a submodule
basis.
For example, an I/O unit with the following configuration:
Slot 1 8 bits (1 byte)
Slot 2 8 bits (1 byte)
will not have data consistency on a 16 bit digital I/O group signal in the IRC5
controller that stretches over both slot 1 and 2.
PROFINET-IO Routing is not working

Make sure that the Enable PROFINET IO device operation check box is selected
in the configuration that is downloaded to the DSQC 678 used as an IRC5 internal
PROFINET slave. See Configuring IRC5 internal PROFINET slave on page 57.
How do I upgrade/downgrade the firmware on DSQC 678?

For information about upgrading/downgrading the firmware on DSQC 678, refer
the sections Upgrade or downgrade firmware using Step7 on page 33 and Automatic
firmware upgrade on page 39.
What should I do when the communication between my PLC and the DSQC 678 Slave is slow?
When configuring the communication against the DSQC 678 in your PLC project,
ensure that the I/O Cycle parameter of the DSQC 678 is set correctly. In some
versions of Step 7, by default, this parameter is set to 128 ms. Set this parameter
to automatic or fixed update time with a more useful value.
Poor performance using fast startup

In general the startup time for one unit using fast startup is about 700-900 ms,
together with the robot controller. This is highly dependent upon the unit itself. A
unit might support fast startup but does not have the performance to boot faster
than a second. Check with the device vendor for detailed description about units
that support fast startup with corresponding performance figures.
• Make sure that the port/ports used for fast startup is selected in the IO
configuration.
5 Trouble shooting
5.1 Scenarios
Continued
• Check with the unit vendor for optimal settings when using the unit with fast
startup. Sometimes unit behavior is configurable with a vendor specific tool
or through the network configuration tool. According to the GSDML file.
• Check that the switch settings are correct according to below:
- 100 Mbit speed rate with full duplex.
- Auto negotiation shall be switched off.
- Disable "switch intelligent features" such as flow control and MDIX
(medium dependent interface crossover) that might cause delays during
startup.

Index
Index Prioritized Startup, 40

PROFINET, 13
cables, 21
A configuration, 47
automatic firmware upgrade, 39
configuration tool, 16, 27, 45
B hardware, 14
bus error, 21 master, 28, 42, 44
network, 15, 21
C option 701-1, 22
collective error, 21 option 888-1, 22
Connector ID, 70 predefined I/O bus, 28
controller software, 27 predefined I/O unit type, 28–29
slave, 29, 43–44, 57
D standardization, 13
DSQC 639, 14 versions, 13
DSQC 678, 14, 22, 53 PROFINET-IO routing, 16, 24–25, 44
installation, 19 configuration, 45, 63
PROFINET-IO routing, 24 trouble shooting, 81
PROFINET master, 16, 28
E configuration, 42, 44
ethernet PROFINET network, 15, 48
RJ-45 connector, 21 PROFINET slave, 16
external PROFINET configuration tool, 15, 27, 45 configuration, 44
PROFINET versions, 13
F compatibility, 14
fail safe state, 43 PROFIdrive, 13
Fast Start Up, 40 PROFIenergy, 13
Fast Unit Startup, 9, 40, 72 PROFINET-CBA, 13
FSU, 40 PROFINET-IO, 13–14
PROFIsafe, 13
G
GSDML file, 29 R
GSDML ID, 16 RJ-45 connector, 20–21
I S
I/O units, 14, 17 safety, 12
configuration, 47 signal mapping, 56
ET200S, 47, 50 Step 7, 15, 27, 47
industrial ethernet, 13, 23, 48 module mapping, 56
internal PROFINET slave, 29, 43, 57 Step 7 configuration file, 32
configuration, 43 system parameters, 67
Input Size, 29, 73
L Output Size, 29, 75
LED Profinet Address, 54, 71
activity LED, 20
bus error, 21 T
collective error, 21 topic I/O type
link LED, 20 Bus, 67
Unit, 71
M Unit Type, 67
module mapping, 56 trouble shooting, 77
P U
prioritized startup, 51 unit mapping, 56

Contact us
3HAC031975-001, Rev K, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.

5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

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3 PROFINET Master/Slave configuration 27

Application manual - PROFINET Master/Slave 5

Who should read this manual?

Continues on next page

Continues on next page

Application manual - PROFINET Master/Slave 9

Product documentation, M2004

Technical reference manuals

Continues on next page

Application manual - PROFINET Master/Slave 11

12 Application manual - PROFINET Master/Slave

Application manual - PROFINET Master/Slave 13

1.2 PROFINET, IRC5

PROFINET version compatibility

Continues on next page

A Line PLC, PROFINET-master

Continues on next page

Specification overview, Master

Specification overview, Slave

16 Application manual - PROFINET Master/Slave

1.3 Definition of I/O units

Application manual - PROFINET Master/Slave 17

Installation of DSQC 678

A,B,C, and D Possible slot for DSQC 678

Continues on next page

A LED, SF (collective error), red

Continues on next page

LED Meaning State Remarks

Article number and firmware version

Article number Firmware version Description

Connections, RJ-45 connectors

Cables and connectors

Application manual - PROFINET Master/Slave 21

2.2 LAN connection

Ethernet cable between DSQC 678 and LAN port

PROFINET in combination with option 707-1

22 Application manual - PROFINET Master/Slave

2.3 Connections, general

Application manual - PROFINET Master/Slave 23

2.4 PROFINET-IO Routing

In the IRC5 I/O configuration it is possible to configure digital output signals on

Continues on next page

With the PROFINET-IO Routing functionality it is possible to configure:

Application manual - PROFINET Master/Slave 25

3 PROFINET Master/Slave configuration

3.1.1 Software overview

The PROFINET IO Master/Slave option must be installed on the IRC5 controller.

Application manual - PROFINET Master/Slave 27

3.2 Configuration overview

3.2.1 PROFINET master

Predefined Unit Type

28 Application manual - PROFINET Master/Slave

3.2.2 IRC5 internal PROFINET slave

Predefined Unit Type

Input and output size