Omron C200HW-PRM21 Installation manual

C200HW-PRM21
PROFIBUS-DP Master Unit
OPERATION MANUAL
Cat. No. W349-E2-2

C200HW-PRM21
PROFIBUS-DP Master Unit
Operation Manual
Produced May 2000

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Notice:
OMRON products are manufactured for use according to proper procedures by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injury to people or dam-
age to the product.
Indicates information that, if not heeded, is likely to result in loss of life or serious injury.
Indicates information that, if not heeded, could possibly result in loss of life or serious injury.
Indicates information that, if not heeded, could result in relatively serious or minor injury,
damage to the product, or faulty operation.
OMRON Product References
All OMRON products are capitalised in this manual. The word “Unit” is also capitalised when it refers to
an OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PLC” means Programmable Logic Controller and is not used as an abbreviation for
anything else.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of
information. Note Indicates information of particular interest for efficient and convenient operation
of the product.
1, 2, 3…Indicates lists of one sort or another, such as procedures, checklists, etc.
OMRON, 2000
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written
permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is
constantly striving to improve its high-quality products, the information contained in this manual is subject to change
without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the
information contained in this publication.
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Caution
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DANGER!
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WARNING

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TABLE OF CONTENTS
PRECAUTIONS .........................................................................................xi
1 Intended Audience........................................................................................................................................................xii
2 General Precautions......................................................................................................................................................xii
3 Safety Precautions ........................................................................................................................................................xii
4 Operating Environment Precautions.............................................................................................................................xii
5 Application Precautions...............................................................................................................................................xiii
6 EC Directives ..............................................................................................................................................................xiv
1 PROFIBUS-DP...................................................................................... 1
1-1 Introduction..............................................................................................................................................................2
1-2 Protocol architecture ................................................................................................................................................2
1-3 Device types.............................................................................................................................................................4
1-4 PROFIBUS-DP characteristics.................................................................................................................................4
1-5 Device Data Base files .............................................................................................................................................8
1-6 Profiles.....................................................................................................................................................................8
2 INSTALLATION.................................................................................. 9
2-1 Physical layout of the unit......................................................................................................................................10
2-2 Mounting the C200HW-PRM21 ............................................................................................................................13
2-3 Setting up a network...............................................................................................................................................14
3 SPECIFICATIONS AND PERFORMANCE..................................17
3-1 Overall Specifications............................................................................................................................................18
3-2 Performance ...........................................................................................................................................................20
4 CONFIGURATOR.............................................................................29
4-1 General...................................................................................................................................................................30
4-2 Setup ......................................................................................................................................................................31
4-3 Operation................................................................................................................................................................32
4-4 Debug mode...........................................................................................................................................................46
5 PLC INTERFACE..............................................................................51
5-1 Unit Settings...........................................................................................................................................................52
5-2 Input / Output Mailbox...........................................................................................................................................59
5-3 Control and status area...........................................................................................................................................60
5-4 LEDs ......................................................................................................................................................................70
6 MESSAGE COMMUNICATION, IOWR / IORD .........................73
6-1 Message communication........................................................................................................................................74
6-2 IOWR.....................................................................................................................................................................74
6-3 IORD......................................................................................................................................................................76
6-4 Messages................................................................................................................................................................77
7 TROUBLESHOOTING AND MAINTENANCE ...........................83
7-1 Error Indicators......................................................................................................................................................84
7-2 Troubleshooting .....................................................................................................................................................84
7-3 Maintenance...........................................................................................................................................................90

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Appendices ..................................................................................................93
Appendix A Tips and sample programs....................................................................................................93
Appendix B GSD file for C200HW-PRM21 ..........................................................................................101
Appendix C CS1 PLC series compatibility.............................................................................................103
Index ..........................................................................................................105
Revision History .......................................................................................107

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About this Manual:
This manual describes the installation and operation of the PROFIBUS-DP Master Unit and includes the
sections described below.
Please read this manual carefully and be sure you understand the information provided before attempt-
ing to install and operate the PROFIBUS-DP Master Unit. Be sure to read the precautions provided
in the following section.
Section 1 gives a brief description of PROFIBUS-DP.
Section 2 describes the installation of the C200HW-PRM21.
Section 3 describes the overall specifications and the communication performance of the Unit.
Section 4 describes the software for configuring the PROFIBUS-DP network.
Section 5 describes the interface with the user.
Section 6 describes the message communication.
Section 7 describes the troubleshooting procedures and maintenance operations.
Failure to read and understand the information provided in this manual may result in
personal injury or death, damage to the product, or product failure. Please read
each section in its entirety and be sure you understand the information provided in
the section and related sections before attempting any of the procedures or
operations given.
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WARNING

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PRECAUTIONS
This section provides general precautions for using the PROFIBUS-DP Master Units, Programmable Controllers, and
related devices.
The information contained in this section is important for the safe and reliable application of the PROFIBUS-DP
Master Units. You must read this section and understand the information contained before attempting to set up or
operate a PROFIBUS-DP Master Unit and PLC system.
1 Intended Audience........................................................................................................................................................xii
2 General Precautions......................................................................................................................................................xii
3 Safety Precautions ........................................................................................................................................................xii
4 Operating Environment Precautions.............................................................................................................................xii
5 Application Precautions...............................................................................................................................................xiii
6 EC Directives ..............................................................................................................................................................xiv

Operating Environment Precautions
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1 Intended Audience
This manual is intended for the following personnel, who must also have
knowledge of electrical systems (an electrical engineer or the equivalent).
•Personnel in charge of installing FA systems.
•Personnel in charge of designing FA systems.
•Personnel in charge of managing FA systems and facilities.
2 General Precautions
The user must operate the product according to the performance
specifications described in the operation manuals.
Before using the product under conditions which are not described in the
manual or applying the product to nuclear control systems, railroad systems,
aviation systems, vehicles, combustion systems, medical equipment,
amusement machines, safety equipment, and other systems, machines, and
equipment that may have a serious influence on lives and property if used
improperly, consult your OMRON representative.
Make sure that the ratings and performance characteristics of the product are
sufficient for the systems, machines, and equipment, and be sure to provide
the systems, machines, and equipment with double safety mechanisms.
This manual provides information for installing and operating OMRON
PROFIBUS-DP Master Units. Be sure to read this manual before operation
and keep this manual close at hand for reference during operation.
It is extremely important that a PLC and all PLC Units be used for the
specified purpose and under the specified conditions, especially in
applications that can directly or indirectly affect human life. You must consult
with your OMRON representative before applying a PLC system to the above
mentioned applications.
3 Safety Precautions
Never attempt to disassemble any Units while power is being supplied. Doing
so may result in serious electrical shock or electrocution.
Never touch any of the terminals while power is being supplied. Doing so may
result in serious electrical shock or electrocution.
4 Operating Environment Precautions
Do not operate the control system in the following places.
•Where the PLC is exposed to direct sunlight.
•Where the ambient temperature is below 0°C or over 55°C.
•Where the PLC may be affected by condensation due to radical
temperature changes.
•Where the ambient humidity is below 10% or over 90%.
•Where there is any corrosive or inflammable gas.
•Where there is excessive dust, saline air, or metal powder.
•Where the PLC is affected by vibration or shock.
•Where any water, oil, or chemical may splash on the PLC.
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WARNING
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Application Precautions
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The operating environment of the PLC System can have a large effect on the
longevity and reliability of the system. Improper operating environments can
lead to malfunction, failure, and other unforeseeable problems with the PLC
System. Be sure that the operating environment is within the specified
conditions at installation and remains within the specified conditions during
the life of the system.
5 Application Precautions
Observe the following precautions when using the PROFIBUS-DP Master
Units or the PLC.
Failure to abide by the following precautions could lead to serious or possibly
fatal injury. Always heed these precautions.
•Always ground the system to 100 Ωor less when installing the system to
protect against electrical shock.
•Always turn OFF the power supply to the PLC before attempting any of the
following. Performing any of the following with the power supply turned ON
may lead to electrical shock:
•Mounting or removing any Units (e.g., I/O Units, CPU Unit, etc.) or
memory cassettes.
•Assembling any devices or racks.
•Connecting or disconnecting any cables or wiring.
Failure to abide by the following precautions could lead to faulty operation of
the PLC or the system or could damage the PLC or PLC Units. Always heed
these precautions.
•Use the Units only with the power supplies and voltages specified in the
operation manuals. Other power supplies and voltages may damage the
Units.
•Take measures to stabilise the power supply to conform to the rated supply
if it is not stable.
•Provide circuit breakers and other safety measures to provide protection
against shorts in external wiring.
•Do not apply voltages exceeding the rated input voltage to Input Units. The
Input Units may be destroyed.
•Do not apply voltages exceeding the maximum switching capacity to Output
Units. The Output Units may be destroyed.
•Always disconnect the LG terminal when performing withstand voltage
tests.
•Install all Units according to instructions in the operation manuals. Improper
installation may cause faulty operation.
•Provide proper shielding when installing in the following locations:
•Locations subject to static electricity or other sources of noise.
•Locations subject to strong electromagnetic fields.
•Locations subject to possible exposure to radiation.
•Locations near power supply lines.
•Be sure to tighten Backplane screws, terminal screws, and cable connector
screws securely.
•Do not attempt to take any Units apart, to repair any Units, or to modify any
Units in any way.
The following precautions are necessary to ensure the general safety of the
system. Always heed these precautions.
•Provide double safety mechanisms to handle incorrect signals that can be
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Caution
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generated by broken signal lines or momentary power interruptions.
•Provide external interlock circuits, limit circuits, and other safety circuits in
addition to any provided within the PLC to ensure safety.
6 EC Directives
PROFIBUS-DP Master Units that meet EC directives also meet the common
emission standard (EN50081-2). When PROFIBUS-DP Master Units are built
into equipment, however, the measures necessary to ensure that the
standard is met will vary with the overall configuration, the other devices
connected, and other conditions. You must therefore confirm that EC
directives are met for the overall machine or device.
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1PROFIBUS-DP
This section gives a brief description of PROFIBUS-DP.
1-1 Introduction................................................................................................................................................................2
1-2 Protocol architecture..................................................................................................................................................2
1-3 Device types...............................................................................................................................................................4
1-4 PROFIBUS-DP characteristics ..................................................................................................................................4
1-4-1 Bus Access Protocol.........................................................................................................................................4
1-4-2 Data throughput...............................................................................................................................................5
1-4-3 Diagnostics functions .......................................................................................................................................6
1-4-4 Protection mechanisms.....................................................................................................................................6
1-4-5 Network states ..................................................................................................................................................7
1-5 Device Data Base files...............................................................................................................................................8
1-6 Profiles.......................................................................................................................................................................8

Introduction Section 1-1
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1-1 Introduction
Multi-vendor
Standard
EN 50170
High speed
Process Automation
Higher level
Uniform bus access protocol
PROFIBUS is a vendor-independent, open fieldbus standard for a wide range
of applications in manufacturing, process and building automation. Vendor
independence and openness are guaranteed by the PROFIBUS standard
EN 50170. With PROFIBUS, devices of different manufacturers can
communicate without special interface adjustments.
The PROFIBUS family consists of three compatible versions:
PROFIBUS-DP
DP stands for Decentralised Periphery. It is optimised for high speed and low-
cost interfacing, especially designed for communication between automation
control systems and distributed I/O at the device level.
PROFIBUS-PA
PA stands for Process Automation. It permits sensors and actuators to be
connected on one common bus line even in intrinsically-safe areas. It permits
data communication and power supply over the bus using 2-wire technology
according the international standard IEC 1158-2.
PROFIBUS-FMS
FMS stands for Fieldbus Message Specification. This version is the general-
purpose solution for communication tasks at a higher level. Powerful services
open up a wide range of applications and provide great flexibility. It can also
be used for extensive and complex communications tasks.
PROFIBUS-DP and PROFIBUS-FMS use the same transmission technology
and a uniform bus access protocol. Thus, both versions can be operated
simultaneously on the same cable. However, FMS field devices cannot be
controlled by DP masters or vice versa.
It is not possible to exchange one of these family members by another family
member. This will cause faulty operation.
The rest of this section only describes PROFIBUS-DP.
1-2 Protocol architecture
OSI The PROFIBUS protocol architecture is oriented on the OSI (Open System
Interconnection) reference model in accordance with the international
standard ISO 7498. Layer 1 (physical layer) of this model defines the physical
transmission characteristics. Layer 2 (data link layer) defines the bus access
protocol. Layer 7 (application layer) defines the application functions.
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Protocol architecture Section 1-2
3
Layer 1, 2 and user interface
Transmission medium
High-speed, inexpensive
Easy installation
Cable length
PROFIBUS-DP uses layers 1 and 2, and the user interface. Layers 3 to 7 are
not defined. This streamlined architecture ensures fast and efficient data
transmission. The application functions which are available to the user, as
well as the system and device behaviour of the various PROFIBUS-DP device
types, are specified in the user interface. RS-485 transmission technology or
fibre optics are available for transmission. RS-485 transmission is the most
frequently used transmission technology. Its application area includes all
areas in which high transmission speed and simple inexpensive installation
are required. Twisted pair shielded copper cable with one conductor pair is
used.
The RS-485 transmission technology is very easy to handle. Installation of the
twisted pair cable does not require expert knowledge. The bus structure
permits addition and removal of stations or step-by-step commissioning of the
system without influencing the other stations. Later expansions have no effect
on stations which are already in operation.
Transmission speeds between 9.6 kbit/s and 12 Mbit/s can be selected. One
unique transmission speed is selected for all devices on the bus when the
system is commissioned.
The maximum cable length depends on the transmission speed (see table
below). The specified cable lengths are based on type-A cable (see
section 2-3-1). The length can be increased by the use of repeaters. The use
of more than 3 repeaters in series is not recommended.
DP-Profiles
DP-Extensions
User Interface Layer DP Basic Functions
(7) Application Layer
(6) Presentation Layer
(5) Session Layer NOT DEFINED
(4) Transport Layer
(3) Network Layer
(2) Data Link Layer Fieldbus Data Link (FDL)
(1) Physical Layer RS-485 / Fibre Optics
Baud rate (kbit/s) Distance/segment (m)
9.6 1200
19.2 1200
93.75 1200
187.5 1000
500 400
1500 200
3000 100
6000 100
12000 100

Device types Section 1-3
4
1-3 Device types
Master devices
Active stations
DPM1, DPM2
Slave devices
Passive stations
PROFIBUS distinguishes between master devices and slave devices.
Master devices determine the data communication on the bus. A master can
send messages without an external request when it holds the bus access
rights (the token). Masters are also called active stations in the PROFIBUS
protocol.
There are two types of master devices: DP master class 1 (DPM1) and DP
master class 2 (DPM2). A DPM1 is a central controller which exchanges
information with the decentralised stations (i.e. DP slaves) within a specified
message cycle. DPM2 devices are programmers, configuration devices or
operator panels. They are used during commissioning for configuration of the
DP system or for operation and monitoring purposes.
Slave devices are peripheral devices. Typical slave devices include
input/output devices, valves, drives and measuring transmitters. They do not
have bus access rights and they can only acknowledge received messages or
send messages to the master when requested to do so. Slaves are also
called passive stations.
The C200HW-PRM21 is a DPM1 device.
1-4 PROFIBUS-DP characteristics
1-4-1 Bus Access Protocol
Layer 2
Medium Access Control
Token passing
Polling procedure
The bus access protocol is implemented by layer 2. This protocol also
includes data security and the handling of the transmission protocols and
telegrams.
The Medium Access Control (MAC) specifies the procedure when a station is
permitted to transmit data. The token passing procedure is used to handle the
bus access between master devices and the polling procedure is used to
handle the communication between a master device and its assigned slave
device(s).
The token passing procedure guarantees that the bus access right (the token)
is assigned to each master within a precisely defined time frame. The token
message, a special telegram for passing access rights from one master to the
next master must be passed around the logical token ring - once to each
master - within a specified target rotation time.
The polling or master-slave procedure permits the master, which currently
owns the token, to access the assigned slaves. The picture below shows a
possible configuration.