Epson EM07ZS1647F User manual

Rev.6 EM07ZS1647F
EPSON RC+ Option
Fieldbus I/O

E
PSON RC+ Option Fieldbus I/O Rev.6

EPSON RC+ Option
Fieldbus I/O
Rev.6
Copyright © 2005-2007 SEIKO EPSON CORPORATION. All rights reserved.
Fieldbus I/O Rev.6 i

FOREWORD
This manual contains important information necessary to use the EPSON RC+ option
Fieldbus I/O properly and safely. This manual is intended for personnel who perform any
operations that use the pendant, such as teaching robot points.
Please thoroughly read this and other related manuals before and while using the
equipment.
WARRANTY
The robot and its optional parts are shipped to our customers only after being subjected to
the strictest quality controls, tests, and inspections to certify its compliance with our high
performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1. Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2. Malfunctions caused by customers’ unauthorized disassembly.
3. Damage due to improper adjustments or unauthorized repair attempts.
4. Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1. If the robot or associated equipment is used outside of the usage conditions and
product specifications described in the manuals, this warranty is void.
2. If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3. We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.
ii Fieldbus I/O Rev.6

TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
TRADEMARK NOTATION IN THIS MANUAL
Microsoft® Windows® 2000 Operating system
Microsoft® Windows® XP Operating system
Throughout this manual, Windows 2000, and Windows XP refer to above respective
operating systems. In some cases, Windows refers generically to Windows 2000, and
Windows XP.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
INQUIRIES
Contact the following service center for robot repairs, inspections or adjustments.
If service center information is not indicated below, please contact the supplier office for
your region.
Please prepare the following items before you contact us.
- Your controller model and its serial number
- Your manipulator model and its serial number
- Software and its version in your robot system
- A description of the problem
SERVICE CENTER
Fieldbus I/O Rev.6 iii

MANUFACTURER & SUPPLIER
Japan & Others SEIKO EPSON CORPORATION
Suwa Minami Plant
Factory Automation Systems Dept.
1010 Fujimi, Fujimi-machi,
Suwa-gun, Nagano, 399-0295
JAPAN
TEL : [phone]
FAX : [phone]
SUPPLIERS
North & South America EPSON AMERICA, INC.
Factory Automation/Robotics
18300 Central Avenue
Carson, CA 90746
USA
TEL : [phone]
FAX : [phone]
E-MAIL : [email protected]
Europe EPSON DEUTSCHLAND GmbH
Factory Automation Division
Otto-Hahn-Str.4
D-40670 Meerbusch
Germany
TEL : [phone]
FAX : [phone]
E-MAIL : [email protected]
iv Fieldbus I/O Rev.6

Before Reading This Manual
This section describes what you should know before reading this manual.
Safety Precautions
Installation and transportation of robots and robotic equipment shall be performed by
qualified personnel and should conform to all national and local codes.
Please carefully read this manual and other related manuals before installing the robot
system or before connecting cables.
Keep this manual handy for easy access at all times. Please read the Safety chapter in
User’s Guide to understand safety requirements before installing the robot system.
Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
This sign indicates that a danger of serious injury or death will
exist if those instructions are not followed.
WARNING
This sign indicates that a danger of possible harm to people
caused by electric shock will exist if those instructions are not
followed.
CAUTION
This sign indicates that ignoring these instruction may cause
harm to people or physical damage to equipment and facilities.
Fieldbus I/O Rev.6 v

vi Fieldbus I/O Rev.6

Table of Contents
1. Introduction ...................................................................... 1
1.1 Overview of Fieldbus I/O............................................................ 1
1.2 DeviceNet .................................................................................. 2
Overview of DeviceNet ............................................................................ 2
Features of DeviceNet............................................................................. 2
General Specifications............................................................................. 4
1.3 PROFIBUS DP .......................................................................... 5
Overview of PROFIBUS DP .................................................................... 5
Features of PROFIBUS DP ..................................................................... 5
General Specifications............................................................................. 7
1.4 EtherNet/IP ................................................................................ 8
Overview of EtherNet/IP .......................................................................... 8
Features of EtherNet/IP .......................................................................... 8
General Specifications........................................................................... 10
2. Installation...................................................................... 11
2.1 How to Setup a DeviceNet Network......................................... 11
2.2 DeviceNet Network Construction ............................................. 12
2.3 How to Setup a PROFIBUS DP Network ................................. 19
2.4 PROFIBUS DP Network Construction ..................................... 20
2.5 How to Setup a EtherNet/IP Network....................................... 24
2.6 EtherNet/IP Network Construction ........................................... 25
2.7 DeviceNet Board Installation.................................................... 26
2.7.1 Board Appearance........................................................................ 26
2.7.2 Specifications................................................................................ 27
2.7.3 Software Installation ..................................................................... 27
2.7.4 Board Installation.......................................................................... 29
2.7.5 Master Mode................................................................................. 31
2.7.6 Slave Mode................................................................................... 37
2.8 PROFIBUS DP Board Installation ............................................ 41
2.8.1 Board Appearance........................................................................ 41
2.8.2 Specifications................................................................................ 42
2.8.3 Software Installation ..................................................................... 42
2.8.4 Board Installation.......................................................................... 44
2.8.5 Master Mode................................................................................. 46
2.8.6 Slave Mode................................................................................... 51
2.8.7 GSD File ....................................................................................... 53
Fieldbus I/O Rev.6 vii

Table of Contents
2.9 DeviceNet Board Installation ................................................... 54
2.9.1 Board Appearance ........................................................................ 54
2.9.2 Specifications ................................................................................ 54
2.9.3 Software Installation...................................................................... 55
2.9.4 Board Installation ..........................................................................57
2.9.5 Master Mode ................................................................................. 60
2.9.6 Slave Mode ................................................................................... 64
2.10 EPSON RC+ Fieldbus I/O Installation ................................... 67
Fieldbus I/O Software Configuration ...................................................... 67
3. Operation....................................................................... 69
3.1 Fieldbus I/O Addressing in SPEL+ .......................................... 69
3.2 SPEL+ Fieldbus I/O Commands.............................................. 69
3.3 Outputs Off by Emergency Stop and Reset Instruction ........... 70
3.4 Waiting for Input or Output Status............................................ 70
3.5 Using FbusIO_SendMsg ......................................................... 71
3.6 Using Slave Mode ................................................................... 72
3.7 Remote Control Slave ............................................................. 72
3.8 Devices available for Fieldbus I/O Option................................ 73
3.9 Fieldbus I/O Response Performance....................................... 73
DeviceNet .............................................................................................. 73
PROFIBUS DP....................................................................................... 75
4. Troubleshooting ............................................................. 77
4.1 DeviceNet Troubleshooting ..................................................... 77
Exclusion................................................................................................ 77
Tools ...................................................................................................... 77
4.1.1 Examining a Problem .................................................................... 78
4.1.2 Problems and Countermeasures................................................... 80
4.1.3 Procedures for Examining Possible Causes ................................. 98
4.2 PROFIBUS DP Troubleshooting.............................................111
Exclusion...............................................................................................111
Tools .....................................................................................................111
4.2.1 Examining a Problem .................................................................. 112
4.2.2 Problems and Countermeasures................................................. 114
4.2.3 Procedures for Examining Possible Causes ............................... 130
4.3 EtherNet/IP Troubleshooting.................................................. 140
Exclusion.............................................................................................. 140
4.3.1 Examining a Problem .................................................................. 141
4.3.2 Problems and Countermeasures................................................. 143
4.3.3 Procedures for Examining Possible Causes ............................... 144
viii Fieldbus I/O Rev.6

Table of Contents
5. Maintenance Parts List ................................................ 151
Appendix A applicomIO Upgrade.................................... 153
Fieldbus I/O Rev.6 ix

Table of Contents
x Fieldbus I/O Rev.6

1. Introduction
1. Introduction
1.1 Overview of Fieldbus I/O
The Fieldbus I/O option is an integrated I/O system that supports DeviceNet, PROFIBUS DP,
and EtherNet/IP fieldbuses.
A fieldbus is a standard of signal communications between field devices operating in a
factory (sensor, actuator, robot controller, etc.) and controller (PLC or robot controller) using
serial communications. Compared to signal communications using analog signals, a fieldbus
has the following features:
• Access to signals from multiple devices and multiple data from each device using
one cable.
• Precise signal transmission since there is no need for A/D conversion and D/A
conversion.
• Less wiring costs, including signal relay board costs and installation area due to
several dozen (or a hundred) devices connected on one fieldbus.
• More flexible modification and expansion of a system because multiple devices are
simply added to one fieldbus without additional wiring.
• Slave devices can transmit self-diagnostics information.
Controller
RS-232c RS-232c Fieldbus
Controller
Sample Parallel Connection Sample Fieldbus Connection
For each fieldbus on the RCxxx controller, there is at least one board installed. You can use
more that one fieldbus type on the same controller. You can also use multiple boards for the
same fieldbus type. The EPSON RC+ software key Fieldbus I/O Option must be enabled to
use this option.
Response times for Fieldbus I/O can vary and depend on several factors, including baud rate,
scan rate, number and types of devices, number of SPEL+ tasks, etc. When the fastest and
most consistent response times are required, please use EPSON standard digital I/O, which
incorporates interrupt driven inputs and outputs.
)
NOTE
Fieldbus I/O Rev.6 1

1. Introduction
1.2 DeviceNet
Overview of DeviceNet
DeviceNet is a fieldbus network that provides easy interconnection between control devices
(PLC, PC, sensor, actuator, etc.).
DeviceNet was developed by Allen-Bradley as an open communication standard to connect
various field devices (sensor, actuator, robot controller, etc.). Because of the open
communication standard, DeviceNet users can easily construct a multi-vendor system with
various devices developed around the world.
Controller
Motor Driver
from Company A
Motor Driver
from Company B
Intelligent I/O
from Company C
Intelligent I/O
from Company D
Photo Sensor
from Company E
Analog Device
from Company G
HMI Device
from Company F
DeviceNet Network
Features of DeviceNet
Reduced Wiring
Compared with parallel wiring, DeviceNet employs a dedicated 5-wire cable (signal wires
and power wires) which substantially reduces the number of necessary wires, wiring time and
cost.
Detachable communication connectors provide you with simple wiring between nodes and
easy network separation or reconstruction.
Specified environment-resistance cables allow you to construct an environment-resistant
system at low cost.
Open Standard (Multi-vendor)
Due to an open communication standard, various devices from many manufacturers are
available. Standardized communication connectors provide you with easy network
construction.
The maintenance spare parts stored on site (factory, etc.) can be reduced because different
manufacturers’ devices are used in case of a breakdown. Similar products are available
around the world due to a global standard DeviceNet.
Large Numbers of Inputs/Outputs
For EPSON RC+ standard I/O and expansion I/O, the number of inputs/outputs is limited to
512 inputs and 512 outputs. When configuring a device to be a master of fieldbus I/O, you
can control more than 16,000 total inputs and outputs.
For a slave device, 2,040 inputs (255 bytes) and 2,040 outputs (255 bytes) are available.
2 Fieldbus I/O Rev.6

1. Introduction
Different Connection Types
There are two messaging connections: I/O messaging connection and explicit messaging
connection. The I/O messaging connection includes polling, strobe, cyclic, and change of
state. I/O messaging connections are explained below:
Polling: First, a master device sends output data to a slave device and then the slave device
responds. Data is normally exchanged in every communication cycle. The
communication frequency can be changed by setting. This connection type is the
most often used.
Strobe: First, a master device requests slave devices to send data with multicast messages,
and then, each slave device responds separately.
Data from many sensors on the system can be effectively gathered. When the master
does not receive responses from all requested slave devices, a timeout error occurs.
Change Of State:
A device sends data whenever it changes. Signals for device diagnosis are sent
regularly in the background. This connection type is useful for remedying DeviceNet
communication traffic.
Cyclic: A slave device transfers data regularly according to its internal timer. This
connection type is typically used for communicating with a temperature controller.
The data transfer frequency is defined by master configuration.
For Change of State and Cyclic, you can disable the ACK that is for verifying that
communication is completed. Never disable ACK, since communication errors cannot be
detected.
)
NOTE
Functions of Master
The Master device gathers and controls all nodes on one network.
A DeviceNet master can control up to 64 nodes (max. 2 kbytes) on one network.
A PLC is typically configured as a master and controls all nodes in factory automation system,
but EPSON RC+ is also capable of being a master.
DeviceNet network configuration is specified by configuration management software. This
software is normally provided by a master device manufacturer. The configuration
management software determines parameters for each slave device via an Electronic Data
Sheet (EDS).
Available connection types are Polling, Strove, Cyclic, Change Of State, and explicit
messaging.
Available baud rates are 125 kbps, 250 kbps, and 500 kbps.
Functions of Slave
A slave can exchange data with a master device.
The configuration management software identifies parameters of each slave device via
Electronic Data Sheet (EDS) where the parameters are registered.
Available connection types are Polling, Strobe, Cyclic, and Change of State.
Available baud rates are 125 kbps, 250 kbps, and 500 kbps.
Fieldbus I/O Rev.6 3

1. Introduction
General Specifications
Electrical Specifications
Item Specification
Supply Voltage 5 V DC (supplied from a controller)
Power Consumption 7 W
Ambient Temperature 5-40 deg C
Relative Humidity 20-80%
DeviceNet Communication Specifications
Item Specification
Supported Connection - I/O messaging connection
(Polling, Strove, Cyclic, Change of State)
- Explicit messaging connection
All connections are conformed to DeviceNet communication
protocol.
Baud Rates 125 kbps, 250 kbps, 500 kbps
Baud Rates Max. Network
Length Drop Length Total Drop
Line Length
Transfer Distance
500 kbps
250 kbps
125 kbps
100 m
250 m *
500 m *
6 m or under
6 m or under
6 m or under
39 m or under
78 m or under
156 m or under
Maximum Nodes 64 (including master unit)
Data Length / Frame 8 byte (The data can be divided and transferred.)
Bus Access CSMA/NBA
Error Detection CRC error / Duplicate node address check
Cable 5-wire cable dedicated to DeviceNet (2 wires for signal,
2 wires for power supply, 1 shield wire)
Communications
Power Supply Voltage
24 V DC (supplied from a connector)
* When thin cable is used for trunk line, the maximum network length is 100 m.
4 Fieldbus I/O Rev.6

1. Introduction
1.3 PROFIBUS DP
Overview of PROFIBUS DP
PROFIBUS DP is one of fieldbus networks that provide easy interconnection between control
devices (PLC, PC, sensor, actuator, etc.).
PROFIBUS DP was co-developed by Siemens, Bosch, and ABB as an open communication
standard to connect various field devices (sensor, actuator, robot controller, etc.). Because of
the open communication standard, PROFIBUS DP can easily construct multi-vendor system
with various devices developed around the world.
Controller
Intelligent I/O
from Company C
Photo Sensor
from Company E
A
nalog Device
from Company G
HMI Device
from Company F
Motor Driver
from Company A
PROFIBUS DP Network
Motor Driver
from Company B
Intelligent I/O
from Company D
Features of PROFIBUS DP
Reduced Wiring
Compared with a parallel wiring, PROFIBUS DP employing dedicated 2-wire cable
substantially reduces the number of necessary wires, wiring time and cost.
Detachable communication connector provides you a simple wiring between devices
(stations) and an easy network separation or reconstruction.
Fast Communication
PROFIBUS DP communication speed can be set up to 12Mbps. This is faster than
DeviceNet, another communication standard supported by the fieldbus I/O.
Open Standard (Multi-vendor)
Due to an open communication standard, various devices from many manufacturers are
available. Standardized communication connectors allow you to reconstruct your network
easily.
The sort of maintenance parts stored on site (factory, etc.) can be reduced because different
manufacturers’ devices are used in case of a breakdown. Similar products are available
around the world due to a global standard PROFIBUS DP.
Large Numbers of Inputs/Outputs
For the standard I/O and expansion I/O, the number of inputs/outputs is limited to up to 512
inputs and 512 outputs. When configuring a device to be a master of fieldbus I/O, you can
control more than 16,000 total inputs and outputs.
For a slave device, 1,952 inputs (244 bytes) and 1,952 outputs (244 bytes) are available.
Fieldbus I/O Rev.6 5

1. Introduction
Functions of Master
There are two types of PROFIBUS DP master: DPM1 and DPM2. DPM1 (DP Master Class
1) gathers and controls all stations on one PROFIBUS DP network. DPM2 (DP master Class
2) operates network configurations, network maintenance, and diagnosis.
PROFIBUS DP master can control up to 126 stations (max. 2 kbytes) on one network.
A PLC is typically configured as a master and controls all devices in factory automation
system, but EPSON RC+ is also capable of being a master.
PROFIBUS DP network configuration is specified by configuration management software.
This software is normally provided by a master device manufacturer. The configuration
management software determines parameters for each slave device via an Electronic Data
Sheet (GSD).
The connection type is token passing procedure and master-slave communication. The token
passing procedure is applied to the PROFIBUS DP network with more than two master
devices to transfer network control between masters. The master-slave communication is
applied to the communication between the master device with network control and its slave
devices.
Available baud rates are 9.6 kbps, 19.2 kbps, 93.75 kbps, 187.5 kbps, 500 kbps, 1500 kbps, 3
Mbps, 6 Mbps, and 12 Mbps.
Functions of Slave
A slave can exchange data with a master device.
The configuration management software identifies parameters of each slave device via an
electronic data sheet (GSD) file where the parameters are registered.
The communication type is a cyclic master-slave communication.
The input/output data of each station is up to 244 bytes.
Available baud rates are 9.6 kbps, 19.2 kbps, 93.75 kbps, 187.5 kbps, 500 kbps, 1500 kbps, 3
Mbps, 6 Mbps, and 12 Mbps.
6 Fieldbus I/O Rev.6

1. Introduction
General Specifications
Electrical Specifications
Item Specification
Supply Voltage 5 V DC (supplied from a controller)
Power Consumption 5.5 W
Ambient Temperature during Operation 5-40 deg C
Relative Humidity during Operation 20-80%
PROFIBUS DP Communication Specifications
Item Specification
Connection Method Hybrid
(token passing procedure and master-slave communication)
Baud Rates 9.6 kbps, 19.2 kbps, 93.75 kbps, 187.5 kbps, 500 kbps,
1500 kbps, 3 Mbps, 6 Mbps, and 12 Mbps.
Baud Rates Cable LengthTransfer Distance
12 Mbps
6 Mbps
3 Mbps
1500 kbps
500 kbps
187.5 kbps
93.75 kbps
19.2 kbps
9.6 kbps
100 m
100 m
100 m
200 m
400 m
1000 m
1200 m
1200 m
1200 m
Maximum Stations 126 (including master unit and repeater)
Data Length / Frame 244 bytes
Cable 2-wire cable dedicated to PROFIBUS (2 wires for signal)
Fieldbus I/O Rev.6 7

1. Introduction
1.4 EtherNet/IP
Overview of EtherNet/IP
EtherNet/IP is a fieldbus network that provides easy interconnection between control devices
(PLC, PC, sensor, actuator, etc.).
EtherNet/IP was developed by Allen-Bradley as an open communication standard to connect
various field devices (sensor, actuator, robot controller, etc.). Because of the open
communication standard, EtherNet/IP users can easily construct a multi-vendor system with
various devices developed around the world.
Controller
Motor Driver
from Company A
Motor Driver
from Company B
Intelligent I/O
from Company C
Intelligent I/O
from Company D
Photo Sensor
from Company E
Analog Device
from Company G
HMI Device
from Company F
Ethernet/IP Network
Features of EtherNet/IP
Reduced Wiring
Compared with parallel wiring, EtherNet/IP employs a standard Ethernet cable which
substantially reduces the number of necessary wires, wiring time and cost.
Detachable communication connectors provide you with simple wiring between nodes and
easy network separation or reconstruction.
Specified environment-resistance cables allow you to construct an environment-resistant
system at low cost.
You can use the generic Ethernet hub or Ethernet switch for the EtherNet/IP. However, be
sure to a use product complying with the industrial standards or noise resistant Ethernet
cable (STP cable). If you use an office use product or UTP cable, it may causes
communication errors and may not offer the proper performance.
)
NOTE
Open Standard (Multi-vendor)
Due to an open communication standard, various devices from many manufacturers are
available. Standardized communication connectors provide you with easy network
construction.
The maintenance spare parts stored on site (factory, etc.) can be reduced because different
manufacturers’ devices are used in case of a breakdown. Similar products are available
around the world due to a global standard EtherNet/IP.
8 Fieldbus I/O Rev.6