IAI RCM-GW-PR User manual

PROFIBUS Gateway
Operation Manual, First Edition
PROFIBUS
Gateway Unit
RCM-GW-PR

PROFIBUS 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 of Gateway Unit ........................................................................................................... 4
1.5 Description of Model Name......................................................................................................... 6
2. Specifications and Name of Each Part.......................................................................7
2.1 General Specifications................................................................................................................ 7
2.2 External Dimensions ................................................................................................................... 8
2.3 Name and Function of Each Part................................................................................................ 9
3. Installation and Noise Elimination Measures............................................................15
3.1 Installation Environment............................................................................................................ 15
3.2 Supply Voltage.......................................................................................................................... 15
3.3 Noise Elimination Measures and Grounding............................................................................. 15
3.4 Installation................................................................................................................................. 17
4. Wiring.......................................................................................................................18
4.1 Overall Configuration ................................................................................................................ 18
4.2 I/O Signals of Gateway Unit...................................................................................................... 20
4.3 Design of SIO Communication Network (SIO Communication)................................................ 23
5. Slave Function .........................................................................................................32
5.1 Address Configuration in Each Operation Mode....................................................................... 33
5.1.1 Gateway Control Signals.............................................................................................. 33
5.1.2 Simple Direct/Position-number Specification Mode..................................................... 36
5.1.3 Numerical Specification Mode...................................................................................... 53
5.1.4 Position-number Specification Mode............................................................................ 59
5.2 Communication Signal Details.................................................................................................. 63
5.2.1 Overview of Communication Signal Timings................................................................ 63
5.2.2 Communication Signals and Operation Timings.......................................................... 64
5.2.3 Command Transmission .............................................................................................. 76
5.3 System Design.......................................................................................................................... 77
5.3.1 Settings for Controller Communication......................................................................... 77
5.3.2 Settings for Profibus-DP Communication..................................................................... 78
5.3.3 Creation of Network Configuration............................................................................... 81
5.3.4 Example of Actual Assignments................................................................................... 86

PROFIBUS Gateway
5.4 Supported S7 Function Blocks/Functions................................................................................. 87
5.4.1 GW_CTL_11................................................................................................................. 88
5.4.2 RC_NVC_11................................................................................................................. 89
5.4.3 RC_ESYNC_00............................................................................................................ 90
5.4.4 RC_BCMOVP_00......................................................................................................... 91
5.4.5 RC_READ_00 .............................................................................................................. 92
5.4.6 RC_WRITE_00............................................................................................................. 93
5.4.7 RC_PROM_00.............................................................................................................. 94
5.4.8 RC_PMSL_00............................................................................................................... 94
Appendix 1. Sample Programs for S7-300...................................................................95
Appendix 2. Supply Format and Use Procedure of FB/FCt..........................................98

1
PROFIBUS 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-SE, ACON-SE, SCON and ERC2-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.

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PROFIBUS 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.
(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.
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

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PROFIBUS 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)

4
PROFIBUS Gateway
1.4 Features of Gateway Unit
With the Gateway Unit, a desired operation mode can be selected from five patterns of the numerical
specification mode, one pattern of the position-number specification mode, and three patterns of the
simple direct/position-number specification mode.
(1) Numerical specification mode
In positioning operation in the numerical specification mode, the actuator is operated by directly
specifying the position data, speed, acceleration/deceleration, and in-position band, in numerical
values.
In push-motion operation in the numerical specification mode, the actuator is operated by directly
specifying the position data, speed, acceleration/deceleration, push band, and current-limiting value
for setting push force, in numerical values.
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] Numerical specification mode, maximum 4 axes
[2] Numerical specification mode, maximum 6 axes
[3] Numerical specification mode, maximum 8 axes
[4] Numerical specification mode, maximum 10 axes
[5] Numerical specification mode, maximum 16 axes
(2) Position-number specification mode
The actuator is operated by specifying position numbers. The position data, speed,
acceleration/deceleration, etc., must be entered beforehand in the position data table for each axis.
Various status signals can be input/output and current position data can be read.
Up to 16 axes can be connected in the position-number specification mode
(3) Simple direct/position-number specification mode
In this mode, the actuator can be moved via combination of position number specification and direct
specification (position data is specified in numerical values, while other movement parameters are
specified by position numbers).
Axis numbers must be assigned from position-number specification axes first, followed by simple
direct specification axes. Depending on the size of the assigned area, this mode is available in the
large pattern (160 bytes for input and output, respectively), middle pattern (128 bytes for input and
output, respectively), and small pattern (64 bytes for input and output, respectively). Up to 16 axes
can be connected as a total of both types of axes.
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.

5
PROFIBUS Gateway
Operation Modes and Key Functions
Key function Numerical
specification mode Position-number specification mode
Simple direct/
position-number
specification mode
Operation by position data
specification {X {
Direct specification of speed
and acceleration/deceleration {X X
Push-motion operation {{{
Reading of current position {X {
Operation by position number
specification X {{
Reading of completed position
number X {{
Number of connectable axes 16 16 16
Settable axis numbers (*1) 0 to 15 0 to 15 0 to 15
Maximum specifiable position
data 9999.99 mm Set in the position table.
Caution
*1 A range of effective axis numbers that can be set for axes connected for SIO communication. Axes
exceeding the maximum limit will be ignored. No alarm will generate.

6
PROFIBUS Gateway
1.5 Description of Model Name
Base model Profibus specification
Gateway Unit

7
PROFIBUS 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 server
Communication standard
Insulated node of network powered operation type
Bit strobe
Polling
Communication specification Master-slave connection
Cyclic
Baud rate 500 k / 250 k / 125 kbps (Changed by DIP switches)
Baud rate Maximum
network length Maximum branch length Total branch length
500 kbps 100 m 39 m
250 kbps 250 m 78 m
125 kbps 500 m 6 m 156 m
Communication cable length (*1)
Note) When a large cable is used.
Profibus specifications
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.
Connected units 16 axes max.
SIO communication
specifications
Communication cable Double shielded twisted-pair cable
(Recommended cable:
HK-SB/20276 X L, 2P X AWG22 by Taiyo Electric Wire & Cable)
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
PROFIBUS Gateway
2.2 External Dimensions
(Installed dimension)

9
PROFIBUS 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: Modbus error
[2] Controller 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 equipment connector
[12] Power-supply input

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PROFIBUS 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 A communication error occurred between the Profibus Gateway and the
controller.
(No response, overrun, framing 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)

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PROFIBUS Gateway
[3] Mode setting switch
This switch is used to set the operation mode of the Profibus Gateway.
Operate the switch after turning off the Profibus Gateway power.
{: ON X: OFF
SW1 I/O bytes
No. 4 3 2 1 Description Output Input
1 X X X X Numerical specification mode, maximum 4 axes 52 28
2 X {X X Numerical specification mode, maximum 6 axes 76 40
3 {X X X Numerical specification mode, maximum 8 axes 100 52
4 {{X {Numerical specification mode, maximum 10 axes 124 64
5 {{X X Numerical specification mode, maximum 16 axes 196 100
6 X X {X Position-number specification mode,
maximum 16 axes 48 48
7 X X X {Simple direct/position-number specification mode,
Large 160 160
8 X {X {Simple direct/position-number specification mode,
Middle 128 128
9 {X X {Simple direct/position-number 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.
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.
Refer to 4.2, “I/O Signals of Gateway Unit” for details.
[6] Profibus communication connector
This connector is used to connect the Profibus communication lines.
Connector assignments (D-sub, 9-pin)
Pin Signal
Housing Shield
1 NC
2 NC
3 B-Line
4 RTS*
5 GND BUS**
6 +5V BUS**
7 NC
8 A-Line
9 NC

12
PROFIBUS Gateway
[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.

13
PROFIBUS 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 OfflineLINE-OFF Red Unlit Not offline
Blinking at 1-Hz
frequency Configuration error Example: The I/O length determined by the mode
setting switch [3] is different from the I/O
length set by the configuration tool.
Blinking at 4-Hz
frequency Communication ASIC initialization error
ERR Red
Unlit No error

14
PROFIBUS Gateway
[10] Port switch
This switch is used to enable the teaching pendant/PC connector (TP) (PORT ON = Start
communication).
Set this switch to the OFF position when connecting/removing the communication cable
connector for teaching pendant or PC software. To use the teaching pendant or PC software,
plug in the connector first, and then set the switch to the ON position.
(Also check the signal status of the port switching input [4].)
Port switch ON: Power (24 VDC) is supplied to the teaching pendant. The emergency stop circuit of
the teaching pendant is enabled.
Port switch OFF: Power (24 VDC) to the teaching pendant is cut off. The emergency stop circuit of
the teaching pendant is disabled.
[11] Teaching pendant/PC connector
This connector is used to connect the communication cable connector for teaching pendant or PC
software.
[12] Power-supply input
This connector is used to connect the Profibus Gateway power (24 VDC). Refer to “I/O Signals of
Gateway Unit” in Chapter 4.

15
PROFIBUS Gateway
3. Installation and Noise Elimination Measures
Exercise due caution regarding the installation environment.
3.1 Installation Environment.
a. The Gateway Unit is not dustproof or waterproof (oilproof). Accordingly, avoid using the
Gateway Unit in a dusty place or place where the unit may come in contact with oil mist or
splashed cutting fluid.
b. Prevent the Gateway Unit from receiving direct sunlight or irradiated heat from large heat
sources such as heat treatment ovens.
c. Use the Gateway Unit in an environment of 0 to 40°C in ambient temperature and 85% or
below in humidity (non-condensing) and free from corrosive or flammable gases.
d. Use the Gateway Unit in an environment where the unit will not receive external vibration or
shock.
e. Prevent electrical noise from entering the Gateway Unit or its cables.
3.2 Supply Voltage
24 VDC ±10% / Current consumption: 300 mA max.
3.3 Noise Elimination Measures and Grounding
a. Installing the Gateway Unit
Connect the Gateway Unit by directly securing it onto a metal enclosure using screws.
Use as thick a cable as
possible and connect it
over the shortest
possible distance.
Metal
enclosure
* Provide class D (3) grounding for the enclosure.

16
PROFIBUS Gateway
b. Notes on wiring method
Separate the communication lines of the Gateway Unit and Profibus module from lines carrying
large current such as power circuits. (Do not bundle them together or place them in the same
cable duct.)
c. Noise sources and elimination of noise
There are many noise sources, but the ones you should pay most attention to when building
your system are solenoid valves, magnet switches and relays. Noise from these sources can
be eliminated using the following measures.
[1] AC solenoid valves, magnet switches, relays
Measure --- Install a surge killer in parallel with the coil.
[2] DC solenoid valves, magnet switches, relays
Measure --- Install a diode in parallel with the coil. Determine an appropriate diode capacity
in accordance with the load capacity.
←
Point
Install the surge killer in a location as close as
possible to each coil.
If the surge killer is installed on a terminal block
or away from the coil, its noise elimination
effect will decrease.
In a DC system, connecting the diode in reverse polarities may
damage the diode, internal controller parts, and DC power supply.
Exercise due caution.
Anode Cathode