IAI RCM-GW-PR User manual

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

CAUTION
Note on Connecting a PC or Teaching Pendant to the Gateway
Unit Grounded via the Positive Terminal of Its 24-V Power Supply
If the positive terminal of the gateway unit’s 24-V power supply is grounded, use a SIO converter as
shown below to connect a teaching pendant or PC to the gateway unit. In this case, do not connect the FG
of the SIO converter.
Teaching pendant PC, etc.
PC software
RS232 connection type
<Model number: RCM-101-MW>
USB connection type
<Model number: RCM-101-USB>
* The cables are supplied with the
PC software.
SIO converter (optional)
(with built-in terminal resistor)
Model number: RCB-TU-SIO-A (B) Gateway unit
Do not
connect
the FG.
* One e-CON connector, one junction
and one terminal resistor are supplied
with each controller link cable.
e-CON connector (3-1473562-4 by AMP)
Junction (5-1473574-4 by AMP)
Terminal resistor
R = 220Ω
Controller link cable
Model number: CB-RCB-CTL002
24-V power
supply

CAUTION
If the positive terminal of the gateway unit’s 24-V power supply is grounded, the gateway unit cannot be
connected directly to a teaching pendant or PC.
If a teaching pendant or PC is connected directly to the gateway unit grounded in this condition, the
power-supply circuit may be shorted and the PC/teaching pendant may be damaged.
Cannot be connected directly.
This teaching
pendant cannot be
used this way.
Gateway unit
24-V power
supply

PfofiBus Gateway
Table of Contents
1. Overview................................................................................................................... 1
1.1 ProfiBus Gateway Unit ................................................................................................................ 1
1.2 What Is ProfiBus?........................................................................................................................ 2
1.3 Application Example of Gateway Unit......................................................................................... 3
1.4 Features and Key Functions........................................................................................................ 4
1.4.1 Features ......................................................................................................................... 4
1.4.2 Key Functions ...................................................................................................................... 4
1.5 Description of Model Name......................................................................................................... 7
1.6 Accessories ................................................................................................................................. 7
2. Specifications and Name of Each Part...................................................................... 8
2.1 General Specifications................................................................................................................. 8
2.2 External Dimensions.................................................................................................................... 9
2.3 Name and Function of Each Part.............................................................................................. 10
3. Installation and Noise Elimination Measures........................................................... 16
3.1 Installation Environment............................................................................................................ 16
3.2 Supply Voltage .......................................................................................................................... 16
3.3 Noise Elimination Measures and Grounding............................................................................. 16
3.4 Installation.................................................................................................................................. 18
4. Wiring...................................................................................................................... 19
4.1 Overall Configuration................................................................................................................. 19
4.2 I/O Signals of Gateway Unit ...................................................................................................... 22
4.3 Design of SIO Communication Network (SIO Communication)................................................ 25
4.3.1 Wiring ........................................................................................................................... 25
4.3.2 Axis Number Setting..................................................................................................... 33
4.4 How to Connect the Teaching Tool When the Positive Terminal of the 24-V Power Supply Is
Grounded................................................................................................................................... 34
5. Address Configuration of Gateway Unit .................................................................. 35
5.1 Position Number Specification Mode ........................................................................................ 35
5.1.1 Overall address configuration....................................................................................... 36
5.1.2 Gateway Control/Status Signals................................................................................... 37
5.1.3 Assignment for Each Axis ............................................................................................ 40
5.2 Direct Numerical Specification Mode ........................................................................................ 43
5.2.1 Overall Address Configuration ..................................................................................... 44
5.2.2 Gateway Control/Status Signals................................................................................... 46
5.2.3 Assignment for each axis............................................................................................. 49
5.3 Command Specification Mode................................................................................................... 53
5.3.1 Overall Address Configuration ..................................................................................... 55
5.3.2 Gateway Control/Status Signals................................................................................... 57
5.3.3 Assignment for Each Axis ............................................................................................ 60
5.3.4 Command Area ............................................................................................................ 65
6Communication Signal Details ................................................................................ 75
6.1 Overview of Communication Signal Timings............................................................................. 75
6.2 Communication Signals and Operation Timings....................................................................... 77
6.3 Basic Operation Timings ........................................................................................................... 85

PfofiBus Gateway
6.4 Command Transmission............................................................................................................ 95
7. Building Your Network System................................................................................ 96
7.1 Procedure.................................................................................................................................. 96
7.2 Setting the Controller................................................................................................................. 97
7.3 Setting the Gateway Unit and PLC Master................................................................................ 99
7.4 PLC Address Assignment........................................................................................................ 100
8. Supported S7 Function Blocks/Functions.............................................................. 106
8.1 GW_CTL_11............................................................................................................................ 107
8.2 RC_NVC_11............................................................................................................................ 108
8.3 RC_ESYNC_00....................................................................................................................... 109
8.4 RC_BCMOVP_00.................................................................................................................... 110
8.5 RC_READ_00 ......................................................................................................................... 111
8.6 RC_WRITE_00........................................................................................................................ 112
8.7 RC_PROM_00......................................................................................................................... 113
8.8 RC_PMSL_00.......................................................................................................................... 113
Appendix 1. Sample Programs for S7-300 .............................................................. 114
Appendix 2. Supply Format and Use Procedure of FB/FCt ..................................... 117

PfofiBus Gateway
1. Overview
1.1 ProfiBus Gateway Unit
The ProfiBus Gateway Unit (hereinafter referred to as “ProfiBus Gateway” or “Gateway Unit”) is used to
connect a ProfiBus communication protocol network on which a host programmable controller (hereinafter
“PLC”) operates, to a SIO communication sub-network (Modbus communication protocol) linking ROBO
Cylinder controllers.
The physical standard to which the SIO communication network conforms is RS-485, and the slave
addresses on this network are 1 through 16.
All data exchanged between the ProfiBus communication network and the Modbus SIO communication
network are tentatively saved in the internal memory of the Gateway Unit, and then transferred cyclically.
The PLC recognizes the Gateway Unit as a remote I/O device.
The Gateway Unit supports PCON-C/CG/SE, ACON-C/CG/SE, SCON-C and ERC2-NP/PN/SE
controllers.
* “Gateway” is a term used in communication networks, referring to a device that converts data to/from
different media and protocols to enable communication between networks.
* ProfiBus protocols include ProfiBus-DP for factory automation (FA) and ProfiBus-PA for process
automation (PA). Of these two protocols, this manual covers ProfiBus-DP. Accordingly, “ProfiBus”
refers to ProfiBus-DP throughout this manual.
Caution
This manual only describes the controls feasible using the Gateway Unit. In the event of any conflict
between this manual and the operation manual for the controller, the content of this manual will
prevail. Refer to the operation manual for each controller for any function, parameter setting, alarm
detail or any other information not described in this manual.
1

PfofiBus Gateway
1.2 What Is ProfiBus?
(1) FA communication system
In FA communication, each communication specification varies depending on the communicating
equipment, type of information, and purpose of communication, among others. In general, however,
the FA communication system is divided into the information level, controller level and field level, as
shown below.
Information
level
Controller levelField level
FA computer
Robot Remote
I/O
Motor
driver
Installed
instrument Solenoid valve Limit switch
Sensor level
Device level
Key open network
(2) Information level
Also called “PLC upper network.” The main purpose of this network level is to transmit production
information, etc., to information terminals. Ethernet is the most commonly used communication
method for the information level.
(3) Controller level
Also called “Inter-PLC network.” This network level often handles real-time information of production lines.
(4) Field level
Also called “PLC lower network.” This network level is mainly used to save wirings for systems
controlled by a single controller. In this sense, this network is regarded as a means for “wire-saving
communication.” The field level is largely divided into the device level and the sensor level.
2

PfofiBus Gateway
(5) ProfiBus
ProfiBus is an open field network most commonly used in the world today. It was first established
under DIN 19245 (German standard) in Germany in 1989, and standardized under EN 50170
(European standard) in July 1996. In January 2000, ProfiBus became an international standard under
IEC 61158. There are two ProfiBus protocols designed for different purposes: ProfiBus-DP for factory
automation (FA), and ProfiBus-PA for process automation.
This manual covers ProfiBus-DP.
The key features of ProfiBus-DP are as follows:
[1] A field network realizing complete multi-vendor connectivity
[2] Able to send large amounts of data at high speed.
•Up to 244 bytes of data per device
•Maximum baud rate of 12 Mbps
[3] Up to 125 nodes can be connected.
* For details on ProfiBus, refer to the operation manuals for your master unit and PLC.
Along with this manual, also read the operation manual for each controller connected.
This ProfiBus Gateway cannot be used in any way not described as feasible in this manual.
To prevent malfunction, the customer is also advised not to use settings, wirings and other uses other
than those described as feasible in this manual.
1.3 Application Example of Gateway Unit
The network illustrated below gives an application example of the Gateway Unit.
CPU
unit
ProfiBus
unit
(master
station)
Remote I/O
station ProfiBus Gateway
(Remote I/O station)
Remote I/O
station Remote I/O station
SIO communication network (Modbus)
3

4
PfofiBus Gateway
1.4 Features and Key Functions
1.4.1 Features
The ProfiBus gateway unit lets you select a desired operation mode from three modes including the
position number specification mode, direct numerical specification mode and command specification
mode.
(1) Position number specification mode
In this mode, a desired position number is specified to operate the actuator. Up to 16 axes can be
connected. The position data, speed, acceleration/deceleration, etc., must be input to the position
table beforehand.
Although the input/output of various status signals and completed position number can be read, the
current position cannot be monitored in this mode.
(2) Direct numerical specification mode
In the direct numerical specification mode, the position data, speed, acceleration/deceleration,
positioning band and push-current limiting value are specified directly as numerical values to operate
the actuator.
Various status signals can be input/output and current position data can be read.
There are five patterns in the numerical specification mode, each accommodating a different number
of connected axes.
[1] Direct numerical specification mode/Up to 4 axes can be connected
[2] Direct numerical specification mode/Up to 6 axes can be connected
[3] Direct numerical specification mode/Up to 8 axes can be connected
[4] Direct numerical specification mode/Up to 10 axes can be connected
[5] Direct numerical specification mode/Up to 16 axes can be connected
(3) Command specification mode
In this mode, the actuator can be operated in one of two operation patterns: “positioner operation” in
which a desired position number is specified to operate the actuator, and “simple direct operation”
where only the position data is specified directly as a numerical value and all other items such as the
speed, acceleration/deceleration, positioning band and push-current limiting value are specified via a
position number. As for the axis configurations, these two operation patterns can be used separately
or in combination. If the two patterns are combined, the axis numbers must be assigned sequentially
from the axes used in positioner operation, followed by the axes used in simple direct operation. You
can select the Large mode (160 input bytes, 160 output bytes), Middle mode (128 input bytes, 128
output bytes) or Small mode (64 input bytes, 64 output bytes) depending on the size of the assigned
areas, and up to 16 axes can be connected.
1.4.2 Key Functions
A comparison table of key functions provided by the gateway unit in the respective modes is given on the
following page.
Use this table as a reference in conjunction with the explanation of each operation mode in Chapter 5.

Command specification mode
Key function Position number
specification mode Direct numerical specification mode Positioner operation Simple direct operation
Operation by position data specification X (P table specification) {{(P table rewriting) {
Direct specification of speed and
acceleration/deceleration X (P table specification) {{(P table rewriting) X (P table specification)
Direct specification of positioning band X (P table specification) {{(P table rewriting) X (P table specification)
Push-motion operation {(P table specification) {{(P table specification) {(P table specification)
Operation by position number specification {X {X
Position table enabling {X {{
Maximum number of storable position
numbers 64 - 512 512
Reading of completed position number {X {X
Selection of controller PIO pattern X X {*2 X
Zone (parameter) {(2) X {*3 X
Position zone (P table) X X {*4 X
Reading of various status signals {{{{
Speed change during movement {{{{
Operation at different acceleration and
deceleration {{{{(P table specification)
Monitoring of current position *5 X {X {
Sending/receiving of
commands/responses X X {{
Reading/writing of P table data X X {X
Reading of current position *6 X X {{
Reading of alarm code X X {{
Command
Broadcasting X X
{X
Number of connectable axes 16 4 6 8 10 16 16 16
Maximum specifiable value of position data P table specification 9999.99 mm 9999.99 mm 9999.99 mm
Large mode Middle mode Small mode
Mode setting SW1 2 0 4 8 13 12 1 5 9
Input 48 28 40 52 64 100 160 128 64
Gateway I/O bytes Output 48 52 76 100 124 196 160 128 64
*1 P table: Position table
PROFIBUS Gateway
*2 PIO patterns 0 to 4 can be selected.
*3 PIO patterns 1 to 3 are not supported.
*4 PIO pattern 3 is not supported.
*5 In the current position monitoring function, the current position data is assigned to a gateway output signal.
Accordingly, the current position can be read directly from the PLC.
*6 Reading the current position means reading the current position data indirectly with the PLC issuing a read command to the gateway.

PfofiBus Gateway
Next, the relationship of the number of positions supported by each controller under each PIO pattern, and
the maximum number of positions that can be stored in the gateway unit, is explained. Take note that the
number of positions may become subject to restrictions.
PIO pattern (Parameter No. 25)
0 1 2 3 4 SE
Operation type
Standard Solenoid
type
Zone
signal
type
Position
zone type - Dedicated
SIO
operation
Number of positioning
points 8 3 16 16 - 64
Home return signal {X X X - {
Zone signal {X {X - {
P zone signal X X X {- {
Maximum
number of
gateway
positions
Position number
specification mode 8
*1 X 16 *1 16 *1 - 64 64
Positioner
operation *1 *3
8 (0) X *1 *3 16 (2) *1 *3 16 (3) - *3 64 (0) 512
ERC2
Gateway control
Command
specification
Simple direct
operation - X - - - - 512
Operation type
Positioning
mode Teaching mode 256-point mode 512-point mode Solenoid mode 1
Dedicated
SIO
operation
Number of positioning
points 64 64 256 512 7 64
Home return signal {{{{{{
Zone signal {X X X
{{
P zone signal {{{X {{
Maximum
number of
gateway
positions
Position number
specification mode 64 64
256
↓
64 *2
512
↓
64 *2 7 64 64
Positioner
operation *3
64 (0) *3 64 (1) *3 256 (2) *3 512 (3) *3 7 (4) *3 64 (0) 512
PCON
ACON
SCON
Gateway control
Command
Command
specification
ifi ti
Simple direct
operation - - - - - - 512
*1 In the operation mode based on position number specification, the number of positions is limited
according to the selected PIO pattern (parameter No. 25). (The gateway can handle more positions.)
*2 Since the gateway can handle 64 positions, the number of controller positions is limited.
*3 In the case of a positioner operation axes operating in the command specification mode, the PIO
pattern selection parameter of the controller must correspond to the I/O pattern set by gateway
control signals PPS0 to PPS2. The numbers of positions shown in parentheses ( ) indicate values set
by PPS0 to PPS2.
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PfofiBus Gateway
1.5 Description of Model Name
Base model ProfiBus specification
Gateway Unit
1.6 Accessories
[1] Power-supply input connector plug 1 pc
MC1•5/4-ST-3•5 (Phoenix Contact)
[2] SIO communication connector plug 1 pc
MC1•5/6-ST-3•81 (Phoenix Contact)
7

PfofiBus Gateway
2. Specifications and Name of Each Part
2.1 General Specifications
Item Specification
Power supply 24 VDC ±10%
Current consumption 300 mA max.
Group 2 only serverCommunication standard Insulated node of network powered operation type
Bit strobe
Polling
Communication specification Master-slave connection
Cyclic
Baud rate 9.6 kbps to 12 Mbps (Set automatically)
9.6 kbps 1500 m
500 kbps 400 m
1.5 Mbps 200 m
3 Mbps 200 m
ProfiBus specifications
Communication cable length (*1)
12 Mbps 100 m
Transmission path configuration IAI’s original multi-drop differential communication
Communication method Half-duplex
Synchronization method Asynchronous
Transmission path type EIA RS485, 2-wire type
Baud rate 230.4 kbps
Error control method No parity bit, CRC (*2)
Communication cable length Total cable length: 100 m max.
Communication cable Double shielded twisted-pair cable
(Recommended cable:
HK-SB/20276 X L, 2P X AWG22 by Taiyo Electric Wire & Cable)
SIO communication
specifications
Connected units 16 axes max.
Ambient operating temperature 0 to 40°C
Ambient operating humidity 85% RH or below (non-condensing)
Operating ambience Free from corrosive or flammable gases, oil mist or powder dust
Storage temperature -10 to 65°C
Storage humidity 90% RH or below (non-condensing)
Environment
Vibration durability 4.9 m/s2(0.5 G)
Protection class IP20
Weight 480 g or below
*1 Refer to the operation manuals for your master unit and PLC in the case of T-branch communication.
*2 CRC: Cyclic Redundancy Check
A data error detection method commonly used in synchronous transmission.
8

PfofiBus Gateway
2.2 External DimensionsDimensions
(Installed dimension)
9

PfofiBus Gateway
2.3 Name and Function of Each Part
[1] Gateway Status LEDs
RUN: Normal
G.ER: Error
C.ER: ProfiBus controller error
T.ER: SIO link error
[2] SIO communication status
LEDs
TxD: Sending data
RxD: Receiving data
[3] Mode setting switch
[4] Port switching input
PORT IN: Port switching input
PORT N: N
[5] Controller communication lines
SDA: Communication line
SDB: Communication line
GND: Ground
FG: Frame ground
[10] Port switch
ON: Port ON
OFF: Port OFF
[6] ProfiBus communication connector
[7] Termination switch
[8] Address setting switches
X10 and X1 (decimal, 2 digits)
[9] ProfiBus communication Status LEDs
ON: Online
OFF: Offline
ERR: Error
[11] Teaching pendant/PC connector
[12] Power-supply input connector
10

PfofiBus Gateway
[1] Gateway status LEDs
Indicated status Description
Steady green The Gateway CPU is operating.RUN Unlit CPU operation is stopped. If this LED does not come on after turning on
the power, the Gateway is experiencing a CPU error.
Steady red The Gateway is experiencing a CPU error or major shutdown failure.G.ER Unlit Normal state.
Steady red The ProfiBus module is experiencing an error or the Gateway CPU
cannot recognize the ProfiBus connection. (Check the ProfiBus
communication status in [9].)
Even if this LED is lit, the teaching pendant or PC software can still be
connected as long as the RUN LED is lit.
Blinking red While the port is ON, this LED blinks at 1-second intervals.
C.ER
Unlit Normal state.
Steady red All axes generated a communication error based on SIO communication
between the ProfiBus gateway and controller.
Blinking red At least one axis generated a communication error based on SIO
communication between the ProfiBus gateway and controller. (No
response, overrun, flaming error or CRC(*) error)
T.ER
Unlit Normal state.
* CRC: Cyclic Redundancy Check
A data error detection method commonly used in synchronous transmission.
[2] SIO communication status LEDs
These LEDs are used to check the communication status between the ProfiBus Gateway and the
controller.
Each LED blinks when the host PLC and controller are not communicating via the ProfiBus Gateway,
or when the controller is communicating with the teaching pendant or PC software connected via the
ProfiBus Gateway.
Indicated status Description
Blinking green Sending data (ProfiBus Gateway →Controller) TxD Unlit Not sending data (ProfiBus Gateway →Controller)
Blinking green Receiving data (Controller →ProfiBus Gateway) RxD Unlit Not receiving data (Controller →ProfiBus Gateway)
11

PfofiBus Gateway
[3] Mode setting switch
This switch is used to set the operation mode of the ProfiBus gateway.
Before operating this switch, turn off the ProfiBus gateway power.
If any position between No. 1 and No. 5 is selected, the position table settings of the controller will
become invalid.
SW1 turns ON when tilted
to the right.
{: ON X: OFF
SW1 I/O bytes
No. 4 3 2 1 Description Output Input
1 X X X X
Direct numerical specification mode/Up to 4
axes can be connected 52 28
2 X {X X
Direct numerical specification mode/Up to 6
axes can be connected 76 40
3 {X X X
Direct numerical specification mode/Up to 8
axes can be connected 100 52
4 {{X {Direct numerical specification mode/Up to 10
axes can be connected 124 64
5 {{X X
Direct numerical specification mode/Up to 16
axes can be connected 196 100
6 X X {X Position-number specification mode,
maximum 16 axes 48 48
7 X X X {Command specification mode Large 160 160
8 X {X {Command specification mode Middle 128 128
9 {X X {Command specification mode Small 64 64
[4] External port switching input
The ON/OFF status of the teaching pendant/PC connector port can be switched using external
signals (no-voltage contact type).
The connector port is enabled when the port switch [10] on the ProfiBus Gateway is OFF. When the
input signal is ON, the port is also ON. (Refer to [10], “Port switch.”)
PORT IN: Port control input
PORT N: Port control input, N side
Use an input current of 7 mA and external signals of no-voltage contact type
[5] Controller communication lines
This terminal is used to connect the communication lines to the SIO communication connector.
12

PfofiBus Gateway
[6] ProfiBus communication connector
This connector is used to connect the ProfiBus communication lines.
D-sub, 9-pin connector (female)
ProfiBus communication connector
Pin No. Signal name Description
1 NC Not connected
2 NC Not connected
3 B-Line Communication line B (RS485)
4 RTS Request to send
5 GND Signal ground (insulated)
6 +5V +5-V output (insulated)
7 NC Not connected
8 A-Line Communication line A (RS485)
9 NC Not connected
Housing Shield
Cable shield
Connected to the frame.
The mating connector (cable end) is not supplied.
[7] Termination switch
A terminal resistor must be provided at the end of the ProfiBus trunk line to prevent bus reflection.
Set the termination switch to the ON position when the ProfiBus Gateway is the terminal module.
However, the switch should be set to the OFF position if an external termination connector is used.
Set the switch to the OFF position if the Gateway is not the terminal module.
[8] Address setting switches
The two rotary switches are used to set a decimal node address in a range of 1 to 99.
X10: Set the 10’s digit of the two-digit decimal address.
X1: Set the 1’s digit of the two-digit decimal address.
This switch is normally set to 2 for the master unit, and 3 or greater for the slave.
13

PfofiBus Gateway
[9] ProfiBus status LEDs
The three LEDs of (LINE-) ON, LINE-OFF and ERR on the front face of the board indicate the node
status and network status. (The remaining LED is not used.)
These LEDs illuminate in one of two colors (red or green), and each LED indicates a different
monitored status, as shown in the table below.
LED name Color Indicated status Description (meaning of indication)
Lit Online
(LINE-) ON
Green
Unlit Not online
Lit Offline
LINE-OFF
Red
Unlit Not offline
Blinking at 1-Hz
frequency
Configuration error
Example: The I/O size determined by
the mode setting switch [3]
does not match the I/O size
set by the configuration tool.
Blinking at 4-Hz
frequency Communication ASIC initialization error
ERR
Red
Unlit No error
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