hilscher netPLC C100 User manual

User Manual
netPLC C100
Startup Guide
Hilscher Gesellschaft für Systemautomation mbH
www.hilscher.com
DOC090701UM02EN | Revision 2 | English | 2009-10 | Released | Public

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netPLC C100 | Startup Guide
DOC090701UM02EN | Revision 2 | English | 2009-10 | Released | Public © Hilscher, 2009
Table of Contents
1INTRODUCTION.........................................................................................................6
1.1 About the User Manual.............................................................................................6
1.1.1 List of Revisions ...................................................................................................6
1.1.2 Reference on Hardware, Firmware, Software and Driver....................................7
1.1.3 Conventions in this Manual ..................................................................................8
1.2 Contents of the Product DVD...................................................................................9
1.2.1 Directory Structure of the DVD.............................................................................9
1.2.2 Documentations netPLC.....................................................................................10
1.3 Legal Notes............................................................................................................11
1.3.1 Copyright ............................................................................................................11
1.3.2 Important Notes..................................................................................................11
1.3.3 Exclusion of Liability...........................................................................................12
1.3.4 Warranty.............................................................................................................12
1.3.5 Export Regulations.............................................................................................13
1.3.6 Registered Trademarks......................................................................................13
1.4 Licenses.................................................................................................................13
2SAFETY ....................................................................................................................14
2.1 Safety Instructions..................................................................................................14
2.2 Intended Use.......................................................................................................... 14
2.3 Personnel Qualification ..........................................................................................14
2.4 Commitment to read and understand the Manual................................................... 14
2.5 Labeling of Safety Instructions ...............................................................................15
2.6 Safety Instructions..................................................................................................16
2.6.1 Electrical Shock Hazard .....................................................................................16
2.7 Property Damage Messages..................................................................................16
2.7.1 Electrostatically sensitive Devices......................................................................16
2.8 Safety Instructions USA .........................................................................................17
2.8.1 Electrical Shock Hazard .....................................................................................17
2.9 Property Damage Messages USA.......................................................................... 17
2.9.1 Electrostatically sensitive Devices......................................................................17
3DESCRIPTION AND REQUIREMENTS....................................................................18
3.1 Description.............................................................................................................18
3.2 System Requirements............................................................................................19
3.2.1 System Requirements PC..................................................................................19
3.2.2 System Requirements CoDeSys........................................................................19
3.3 Requirements for Operation...................................................................................20
3.3.1 Slot PLC .............................................................................................................20
4DEVICE DRAWINGS................................................................................................21

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4.1 Device Drawing NPLC-C100-DP............................................................................21
4.1.1 Cover NPLC-C100-DP .......................................................................................22
5SYSTEM OVERVIEW ...............................................................................................23
6INSTALLING SOFTWARE........................................................................................27
6.1 Plug In SYCON.net Setup......................................................................................30
6.2 CoDeSys Programming System Setup................................................................... 35
6.3 Device Driver Setup...............................................................................................42
6.4 netPLC CoDeSys Server Setup .............................................................................45
6.5 Installing the Device Driver.....................................................................................47
6.6 Installing USB Driver..............................................................................................50
7INSTALLING HARDWARE (SLOT PLC)...................................................................54
7.1 Safety Advices .......................................................................................................54
7.1.1 Safety Advices USA ...........................................................................................54
7.2 Installing Battery.....................................................................................................55
7.3 Installing Slot PLC NPLC C100-DP........................................................................56
8FIRST PROJECT ......................................................................................................57
8.1 Overview................................................................................................................57
8.2 Preparation ............................................................................................................58
8.2.1 netPLC CoDeSys Server....................................................................................58
8.2.2 CoDeSys ............................................................................................................59
8.3 Create Control Program and Bus Configuration .....................................................61
8.3.1 Create Project.....................................................................................................61
8.3.2 Add PROFIBUS-DP Slave Device by use of a GSD File...................................66
8.3.3 Bus Configuration...............................................................................................67
8.3.4 Create PLC Program..........................................................................................73
8.3.5 Create Symbol Configuration .............................................................................77
8.3.6 Build Project .......................................................................................................81
8.4 Connect to the Slot PLC.........................................................................................82
8.4.1 Define Gateway..................................................................................................82
8.4.2 Scan Network and set Active Path.....................................................................84
8.5 Download Control Program and Bus Configuration................................................86
8.5.1 Login and Download...........................................................................................86
8.5.2 Create Boot Application......................................................................................88
8.5.3 Remove Boot Application...................................................................................88
8.5.4 Start PLC Program.............................................................................................89
8.6 Disconnect from the Slot PLC ................................................................................90
9VISUALIZATION .......................................................................................................91
9.1 OPC Configurator...................................................................................................92
9.2 OPC Client.............................................................................................................96

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10 FUNCTIONS .............................................................................................................97
10.1 Functions – CmpSysFunctions_netPLC.................................................................97
10.1.1 Battery Status – StatusOfBattery .......................................................................98
10.1.2 Status External Power Supply – StatusOfExt24VDC.........................................99
10.1.3 Status PCI Power Supply – StatusOfPCIPower...............................................100
11 HARDWARE ...........................................................................................................101
11.1 Block Diagram......................................................................................................101
11.2 Internal and External Power Supply .....................................................................102
11.3 Reset Behaviour...................................................................................................102
11.4 RUN/STOP Switch............................................................................................... 102
12 BATTERY................................................................................................................103
12.1 Changing the Battery............................................................................................104
12.2 Battery Disposal...................................................................................................106
12.3 Check the Battery Status with CoDeSys...............................................................106
13 BUS DIAGNOSTIC..................................................................................................107
13.1 Start up the Bus and Test.....................................................................................107
13.1.1 Login and Download.........................................................................................107
13.1.2 Device Assignment...........................................................................................109
13.1.3 Connect to the PROFIBUS-DP Master ............................................................112
13.1.4 Debug Bus Configuration .................................................................................114
13.1.5 Verify Input and Output Data............................................................................117
14 TROUBLESHOOTING............................................................................................119
15 LED.........................................................................................................................120
15.1 LED SYS..............................................................................................................120
15.2 LED APL..............................................................................................................121
15.3 LED PROFIBUS DP-Master.................................................................................121
16 ERROR NUMBERS ................................................................................................122
16.1 Error Numbers CmpSysFunctions_netPLC Functions.......................................... 122
17 TECHNICAL DATA .................................................................................................123
17.1 Technical Data Slot PLC...................................................................................... 123
17.1.1 NPLC C100-DP................................................................................................123
17.2 Protocols..............................................................................................................124
17.2.1 PROFIBUS DP Master.....................................................................................124
18 APPENDIX..............................................................................................................125
18.1 netPLC CoDeSys Server Program....................................................................... 125
18.1.1 Starting netPLC CoDeSys Server....................................................................125
18.1.2 netPLC CoDeSys Server Window....................................................................126

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18.1.3 Stopping netPLC CoDeSys Server ..................................................................127
18.2 Example Projects.................................................................................................128
18.2.1 netPLC PROFIBUS Simple IO .........................................................................128
18.2.2 netPLC System Functions................................................................................128
18.2.3 netPLC Open Process Control (OPC)..............................................................129
18.2.4 netPLC Real Time Clock..................................................................................130
18.3 Firmware Update..................................................................................................131
18.4 Memory Card ....................................................................................................... 135
18.5 PROFIBUS Interface............................................................................................136
18.5.1 PROFIBUS Interface Pinning...........................................................................136
18.5.2 PROFIBUS Wiring............................................................................................136
18.6 Mini-B USB Connector (5 Pin).............................................................................. 138
18.7 List of Figures ......................................................................................................139
18.8 List of Tables........................................................................................................140
18.9 Glossary............................................................................................................... 141
18.10 Contacts............................................................................................................... 142

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1 Introduction
1.1 About the User Manual
This user manual is the startup guide for the use of the PLC programming
software CoDeSys in odrer to program a slot PLC card named “NPLC
C100-DP” for a PC with an example program.
This user manual describes the product
•NPLC-C100-DP/CDS-OPC
1.1.1 List of Revisions
Index Date Chapter Revisions
2 2009-10-01 all created
Table 1: List of Revisions

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1.1.2 Reference on Hardware, Firmware, Software and Driver
Note: The listed hardware revision, firmware and driver versions or
versions of the programming software CoDeSys including the
configuration software functionally belong together.
Hardware
Hardware Revision
NPLC-C100-DP 3, 4
Table 2: Reference on Hardware
Firmware
Firmware File Fieldbus System Firmware Version
NPC1CDPM.nxf PROFIBUS-DP Master 3.3.1.20
Table 3: Reference on Firmware
Driver
Driver Driver Version
cifX Device Driver 0.945
USB Driver 5.1.2600.2180
Table 4: Reference on Driver
Server
Software Software Version
netPLC CoDeSys Server 0.9.0.3
Table 5: Reference on Server
Software
Software Software Version
CoDeSys V3.3 SP1 Patch 2
SYCONnet netX setup.exe 1.200.x.x
Table 6: Reference on Software

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1.1.3 Conventions in this Manual
Operation instructions, a result of an operation step or notes are marked as
follows:
Operation Instructions:
¾<instruction>
Or
1. <instruction>
2. <instruction>
Results:
°<result>
Notes:
Important: <important note>
Note: <note>
<note, were to find further information>

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1.2 Contents of the Product DVD
The Product DVD for the slot PLC contains:
•CoDeSys (PLC programming system) including bus configuration
software
•cifX Device Driver
•netPLC CoDeSys Server program
•Firmware with CoDeSys SP
•Documentation
•Examples
1.2.1 Directory Structure of the DVD
All manuals on this DVD are delivered in the Adobe Acrobat®Reader
format (PDF).
Directory Name Description
Adobe Flash Player Adobe Flash Player installation program
Documentation Documentation in the Acrobat®Reader Format (PDF)
Drivers PCI device driver and USB driver
Example CoDeSys example programs
Firmware Loadable Firmware (contains CoDeSys SP)
Presentation netPLC presentation in Power Point format
Software Setup for CoDeSys programming software including configuration
software
Setup netPLC CoDeSys Server
Setup Device Driver
Table 7: Directory Structure of the CD

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1.2.2 Documentations netPLC
The following documentation overview gives information about where to
find further information and refers the corresponding manual.
All manuals listed in the overview below can be found in the
Documentation directory on the CD delivered, in the Adobe Acrobat®
Reader format (PDF).
Manual Contents Document name
User Manual
Slot PLC C100 Startup Guide including installation, operation and hardware description netPLC C100 Startup Guide UM xx EN.pdf
CoDeSys Installation and first steps CoDesys Installation and Start.pdfCoDeSys OPC Server V3 OPC_V3_how_to_use_E.pdf
DTM for Hilscher NETX PROFIBUS Master
Devices PROFIBUS_Master_DTMx_en.pdf
Operating Instruction
Manual SYCON.net Generic Slave DTM for PROFIBUS DP Slave
Devices PROFIBUS_Slave_DTMx_en.pdf
Table 8: Documentations Slot PLC PROFIBUS-DP Master

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1.3 Legal Notes
1.3.1 Copyright
© 2008-2009 Hilscher Gesellschaft für Systemautomation mbH
All rights reserved.
The images, photographs and texts in the accompanying material (user
manual, accompanying texts, documentation, etc.) are protected by
German and international copyright law as well as international trade and
protection provisions. You are not authorized to duplicate these in whole or
in part using technical or mechanical methods (printing, photocopying or
other methods), to manipulate or transfer using electronic systems without
prior written consent. You are not permitted to make changes to copyright
notices, markings, trademarks or ownership declarations. The included
diagrams do not take the patent situation into account. The company
names and product descriptions included in this document may be
trademarks or brands of the respective owners and may be trademarked or
patented. Any form of further use requires the explicit consent of the
respective rights owner.
1.3.2 Important Notes
The user manual, accompanying texts and the documentation were created
for the use of the products by qualified experts, however, errors cannot be
ruled out. For this reason, no guarantee can be made and neither juristic
responsibility for erroneous information nor any liability can be assumed.
Descriptions, accompanying texts and documentation included in the user
manual do not present a guarantee nor any information about proper use
as stipulated in the contract or a warranted feature. It cannot be ruled out
that the user manual, the accompanying texts and the documentation do
not correspond exactly to the described features, standards or other data of
the delivered product. No warranty or guarantee regarding the correctness
or accuracy of the information is assumed.
We reserve the right to change our products and their specification as well
as related user manuals, accompanying texts and documentation at all
times and without advance notice, without obligation to report the change.
Changes will be included in future manuals and do not constitute any
obligations. There is no entitlement to revisions of delivered documents.
The manual delivered with the product applies.
Hilscher Gesellschaft für Systemautomation mbH is not liable under any
circumstances for direct, indirect, incidental or follow-on damage or loss of
earnings resulting from the use of the information contained in this
publication.

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1.3.3 Exclusion of Liability
The delivered product (including the technical data) is subject to export or
import laws as well as the associated regulations of different counters, in
particular those of Germany and the USA. The software may not be
exported to countries where this is prohibited by the United States Export
Administration Act and its additional provisions. You are obligated to
comply with the regulations at your personal responsibility. We wish to
inform you that you may require permission from state authorities to export,
re-export or import the product.
1.3.4 Warranty
Although the hardware and software was developed with utmost care and
tested intensively, Hilscher Gesellschaft für Systemautomation mbH does
not guarantee its suitability for any purpose not confirmed in writing. It
cannot be guaranteed that the hardware and software will meet your
requirements, that the use of the software operates without interruption and
that the software is free of errors. No guarantee is made regarding
infringements, violations of patents, rights of ownership or the freedom from
interference by third parties. No additional guarantees or assurances are
made regarding marketability, freedom of defect of title, integration or
usability for certain purposes unless they are required in accordance with
the law and cannot be limited. Warranty claims are limited to the right to
claim rectification.

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1.3.5 Export Regulations
The delivered product (including the technical data) is subject to export or
import laws as well as the associated regulations of different counters, in
particular those of Germany and the USA. The software may not be
exported to countries where this is prohibited by the United States Export
Administration Act and its additional provisions. You are obligated to
comply with the regulations at your personal responsibility. We wish to
inform you that you may require permission from state authorities to export,
re-export or import the product.
1.3.6 Registered Trademarks
Windows®XP are registered trademarks of the Microsoft Corporation.
Adobe-Acrobat®is an registered trademark of the Adobe Systems
Incorporated.
1.4 Licenses
Licenses are required for the operation of the slot PLC NPLC C100-
DP/CDS-OPC as a PROFIBUS-DP Master* as well as for CoDeSys SP.
These licenses are included in the scope of delivery.
* The master license includes operating of the slot PLC as master and the
license for the bus configuration software SYCON.net for the respective
card.

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2 Safety
2.1 Safety Instructions
The user manual, the accompanying texts and the documentation are
written for the use of the products by educated personnel. When using the
products, all safety instructions and all valid legal regulations have to be
obeyed. Technical knowledge is presumed. The user has to assure that all
legal regulations are obeyed.
2.2 Intended Use
The slot PLC described in this user manual is a PC card with PLC
functionality and fieldbus communication. Depending from the loaded
firmware, the fieldbus systems listed in the following table can be realized
using the respective slot PLC.
Slot PLC Fieldbus System
NPLC-C100-DP/CDS-OPC PROFIBUS DP Master
Table 9: Slot PLC and Fieldbus Systems realized thereby
2.3 Personnel Qualification
The slot PLC must only be installed, configured and removed by qualified
personnel.
2.4 Commitment to read and understand the Manual
Important! Read and understand all instructions in this manual before
installation or use of your device to avoid injury.

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2.5 Labeling of Safety Instructions
The safety instructions are pinpointed particularly. The instructions are
highlighted with a specific safety symbol, a warning triangle and a signal
word according to the degree of endangerment. Inside the note the danger
is exactly named. Instructions to a property damage message do not
contain a warning triangle.
Symbol Sort of Warning or Principle
Safety symbol for the warning to personal injury
Warning for Electrical Shock Hazard
Warning of danger by electrical current
Warning of damages by electrostatic discharge
Table 10: Safety Symbols and Sort of Warning or Principle
Signal Word Meaning Meaning (ANSI)
DANGER Indicates a direct hazard with high
risk, which will have as
consequence death or grievous
bodily harm if it isn't avoided.
Indicates a Hazardous Situation
Which, if not Avoided, will Result in
Death or Serious Injury.
WARNING Indicates a possible hazard with
medium risk, which will have as
consequence death or (grievous)
bodily harm if it isn't avoided.
Indicates a Hazardous Situation
Which, if not Avoided, could Result
in Death or Serious Injury.
CAUTION Indicates a minor hazard with
medium risk, which could have as
consequence simple battery if it isn't
avoided.
Indicates a Hazardous Situation
Which, if not Avoided, may Result in
Minor or Moderate Injury.
NOTICE Indicates a Property Damage
Message. Indicates a Property Damage Message.
Note Indicates an important note in the
manual. Indicates an Important Note in the Manual.
Table 11: Signal Words

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2.6 Safety Instructions
This manual contains instructions which must be observed to ensure your
own personal safety and to avoid damage to devices.
2.6.1 Electrical Shock Hazard
Electrical Shock Hazard
HAZARDOUS VOLTAGE inside of the PC or of the connecting device.
Therefore first disconnect the power plug of the PC or of the connecting
device.
Make sure, that the power supply is off at the PC or at the connecting
device.
Open the PC cabinet and install or remove the slot PLC only after
disconnecting power.
2.7 Property Damage Messages
This manual contains instructions which must must be red, understod and
observed to avoid damage to devices.
2.7.1 Electrostatically sensitive Devices
Adhere to the necessary safety precautions for components that are
vulnerable with electrostatic discharge (EN 61340-5-1 and EN 61340-5-2
as well as IEC 61340-5-1 and IEC 61340-5-2).
CAUTION!
Electrostatically sensitive Devices
This equipment is sensitive to electrostatic discharge, which cause
internal damage and affect normal operation. Follow guidelines when you
handle this equipment.
Observe the necessary safety precautions when handling components
that are vulnerable to electrostatic discharge.

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2.8 Safety Instructions USA
This manual contains instructions which must be observed to ensure your
own personal safety and to avoid damage to devices.
2.8.1 Electrical Shock Hazard
Electrical Shock Hazard
HAZARDOUS VOLTAGE inside of the PC or of the connecting device.
Therefore first disconnect the power plug of the PC or of the connecting
device.
Make sure, that the power supply is off at the PC or at the connecting
device.
Open the PC cabinet and install or remove the XXX card only after
disconnecting power.
2.9 Property Damage Messages USA
This manual contains instructions which must must be red, understod and
observed to avoid damage to devices.
2.9.1 Electrostatically sensitive Devices
Adhere to the necessary safety precautions for components that are
vulnerable with electrostatic discharge (EN 61340-5-1 and EN 61340-5-2
as well as IEC 61340-5-1 and IEC 61340-5-2).
Electrostatic Discharge
This equipment is sensitive to electrostatic discharge, which cause
internal damage and affect normal operation. Follow guidelines when you
handle this equipment.
Observe the necessary safety precautions when handling components
that are vulnerable to electrostatic discharge.

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3 Description and Requirements
3.1 Description
The slot PLC described in this user manual is a PC card with PLC
functionality and fieldbus communication. Depending from the loaded
firmware, the fieldbus systems listed in the following table can be realized
using the respective slot PLC.
Slot PLC Fieldbus System
NPLC-C100-DP/CDS-OPC PROFIBUS-DP Master
Table 12: Slot PLC
These slot PLC device is a PC card for fieldbus communication and
handles the complete data exchange between the connected fieldbus
devices and CoDeSys.
In one PC a maximum of two slot PLC can be used.

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3.2 System Requirements
3.2.1 System Requirements PC
•Windows®XP
•PC with PCI connector with 5 V for hardware revision 3 of “NPLC C100-
DP“
•PC with PCI connector with 3,3 V respectively 5 V for hardware revision
4 of “NPLC C100-DP“
•DVD ROM drive
•Graphic resolution: min. 1024 x 768 pixel or higher
•Keyboard and Mouse
3.2.2 System Requirements CoDeSys
System requirements for the programming system CoDeSys with
configuration software SYCON.net. The configuration software SYCON.net
is contained in CoDeSys as Plug In.
•Windows®XP
•Internet Explorer 5.5 or higher
•Free disk space: min. 400 MByte, recommended 1 GByte
•RAM: min. 512 MByte, recommended 1024 MByte
•Graphic resolution: min. 1024 x 768 pixel
•Keyboard and Mouse
Note: If the project file is saved and opened again or it is used on another
PC, the system requirements need to match. Particularly the DTMs need
to be installed on the used PC.

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3.3 Requirements for Operation
Note: Upgrade older versions of the cifX Device Driver necessarily on
the version V0.945.
3.3.1 Slot PLC
For the slot PLC operation as a master the following requirements must be
fulfilled:
Protocol PROFIBUS-DP Master
The device driver cifX Device Driver has to be installed (from
V0.945).
Software
Installation
The netPLC CoDeSys Server has to be installed and must run, if
communicating via PCI with the slot PLC.
Firmware The firmware NPC1CDPM.NXF has to be loaded into the slot PLC.
License Licenses are required for the operation of the slot PLC NPLC C100-
DP/CDS-OPC as a PROFIBUS-DP Master as well as for CoDeSys
SP. These licenses are included in the scope of delivery.
Configuration Die slot PLC must be configured using the configuration software.
Programming The PLC program must be created with CoDeSys and loaded into
the slot PLC.
Communication For communication slave devices for the communication system
PROFIBUS-DP are required.
Table 13: Requirements for operation of the Slot PLC