Sys Tec Electronic PLCcore-5208 User manual

SYS TEC electronic GmbH - System House for distributed Automation
System Manual
PLCcore-5208
User Manual
Version 1.0
Edition September 2009
Document No.: L-1076e_1
SYS TEC electronic GmbH August-Bebel-Str. 29 D-07973 Greiz
Phone: [phone] Fax: [phone]
Web: http://www.systec-electronic.com Mail: [email protected]

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 1
Status/Changes
Status: released
Date/Version Section Changes Editor
2009/09/09
1.0
All Creation R. Sieber

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 2
This manual includes descriptions for copyrighted products that are not explicitly indicated as such.
The absence of the trademark (©) symbol does not infer that a product is not protected. Additionally,
registered patents and trademarks are similarly not expressly indicated in this manual.
The information in this document has been carefully checked and is believed to be entirely reliable.
However, SYS TEC electronic GmbH assumes no responsibility for any inaccuracies. SYS TEC
electronic GmbH neither guarantees nor accepts any liability whatsoever for consequential damages
resulting from the use of this manual or its associated product. SYS TEC electronic GmbH reserves
the right to alter the information contained herein without prior notification and does not accept
responsibility for any damages which might result.
Additionally, SYS TEC electronic GmbH neither guarantees nor assumes any liability for damages
arising from the improper usage or improper installation of the hardware or software. SYS TEC
electronic GmbH further reserves the right to alter the layout and/or design of the hardware without
prior notification and accepts no liability for doing so.
©Copyright 2009 SYS TEC electronic GmbH. All rights – including those of translation, reprint,
broadcast, photomechanical or similar reproduction and storage or processing in computer systems, in
whole or in part – are reserved. No reproduction may occur without the express written consent from
SYS TEC electronic GmbH.
Inform yourselves:
Contact Direct Your local distributor
Address: SYS TEC electronic GmbH
August-Bebel-Str. 29
D-07973 Greiz
GERMANY
Ordering
Information:
+49 (0) 36 61 / 62 79-0
[email protected]
Technical Support: +49 (0) 36 61 / 62 79-0
[e-mail]
Fax: [phone] / 6 79 99
Web Site: http://www.systec-electronic.com
Please find a list of our
distributors under:
http://www.systec-
electronic.com/distributors
1st Edition September 2009

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 3
Table of Contents
1Introduction .....................................................................................................................5
2Overview / Where to find what?.....................................................................................6
3Product Description........................................................................................................8
4Development Kit PLCcore-5208...................................................................................10
4.1 Overview.............................................................................................................................. 10
4.2 Electric commissioning of the Development Kit PLCcore-5208 .......................................... 11
4.3 Control elements of the Development Kit PLCcore-5208 ................................................... 12
4.4 Optional accessory ..............................................................................................................13
4.4.1 USB-RS232 Adapter Cable .................................................................................... 13
4.4.2 Driver Development Kit........................................................................................... 14
5Pinout of the PLCcore-5208 .........................................................................................15
6PLC Functionality of the PLCcore-5208......................................................................17
6.1 Overview.............................................................................................................................. 17
6.2 System start of the PLCcore-5208 ...................................................................................... 17
6.3 Programming the PLCcore-5208......................................................................................... 18
6.4 Process image of the PLCcore-5208 .................................................................................. 18
6.4.1 In- and Outputs of Development Kit PLCcore-5208 ............................................... 19
6.4.2 In- and outputs of user-specific baseboards........................................................... 19
6.5 Communication interfaces ................................................................................................... 20
6.5.1 Serial interfaces ...................................................................................................... 20
6.5.2 CAN interface ......................................................................................................... 20
6.5.3 Ethernet interface ................................................................................................... 20
6.6 Control and display elements .............................................................................................. 21
6.6.1 Run/Stop switch...................................................................................................... 21
6.6.2 Run-LED (green) .................................................................................................... 21
6.6.3 Error-LED (red) ....................................................................................................... 22
6.7 Local deletion of a PLC program......................................................................................... 22
6.8 Using CANopen for CAN interfaces .................................................................................... 23
6.8.1 CAN interface CAN0............................................................................................... 24
6.8.2 Additional CAN interfaces....................................................................................... 24
7Configuration and Administration of the PLCcore-5208 ...........................................25
7.1 System requirements and necessary software tools........................................................... 25
7.2 Activation/Deactivation of Linux Autostart ........................................................................... 26
7.3 Ethernet configuration of the PLCcore-5208 ....................................................................... 27
7.4 PLC configuration of the PLCcore-5208.............................................................................. 29
7.4.1 PLC configuration via WEB-Frontend..................................................................... 29
7.4.2 PLC configuration via control elements of the Development Kit PLCcore-5208.... 31
7.4.3 Setup of the configuration file "plccore-5208.cfg"................................................... 32
7.5 Boot configuration of the PLCcore-5208 ............................................................................. 34
7.6 Selecting the appropriate firmware version ......................................................................... 34
7.7 Predefined user accounts.................................................................................................... 36
7.8 Login to the PLCcore-5208.................................................................................................. 36
7.8.1 Login to the command shell.................................................................................... 36
7.8.2 Login to the FTP server .......................................................................................... 37
7.9 Adding and deleting user accounts ..................................................................................... 39
7.10 How to change the password for user accounts ................................................................. 40
7.11 Setting the system time ....................................................................................................... 41
7.12 File system of the PLCcore-5208 ........................................................................................ 42
7.13 Software update of the PLCcore-5208 ................................................................................ 43
7.13.1 Updating the PLC firmware..................................................................................... 44

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7.13.2 How to update the uClinux-Image .......................................................................... 45
8Adaption of In-/Outputs and Process Image...............................................................48
8.1 Data exchange via shared process image .......................................................................... 48
8.1.1 Overview of the shared process image .................................................................. 48
8.1.2 API of the shared process image client .................................................................. 51
8.1.3 Creating a user-specific client application .............................................................. 55
8.1.4 Example for using the shared process image ........................................................ 57
8.2 Driver Development Kit (DDK) for the PLCcore-5208......................................................... 61
8.3 Testing the hardware connections ...................................................................................... 62
Appendix A: Firmware function scope of PLCcore-5208 .................................................64
Appendix B: Reference design for the PLCcore-5208......................................................67
Appendix C: GNU GENERAL PUBLIC LICENSE................................................................69
Index......................................................................................................................................74

System Manual PLCcore-5208
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1 Introduction
Thank you that you have decided for the SYS TEC PLCcore-5208. This product provides to you an
innovative and high-capacity PLC-kernel which – due to its numerous interfaces – is well-suitable as
communication and control processor for embedded applications.
Please take some time to read through this manual carefully. It contains important information about
the commissioning, configuration and programming of the PLCcore-5208. It will assist you in getting
familiar with the functional range and usage of the PLCcore-5208. This document is complemented by
other manuals, e.g. for the OpenPCS IEC 61131 programming system and the CANopen extension for
IEC 61131-3. Table 3 in section 4.1 shows a listing of relevant manuals for the PLCcore-5208. Please
also refer to those complementary documents.
For more information, optional products, updates et cetera, we recommend you to visit our website:
http://www.systec-electronic.com. The content of this website is updated periodically and provides to
you downloads of the latest software releases and manual versions.
Declaration of Electro Magnetic Conformity for PLCcore-5208
(EMC law)
The PLCcore-5208 has been designed to be used as vendor part for the integration into devices
(further industrial processing) or as Development Board for laboratory development (hard- and
software development).
After the integration into a device or when changes/extensions are made to this product, the
conformity to EMC-law again must be assessed and certified. Only thereafter products may be
launched onto the market.
The CE-conformity is only valid for the application area described in this document and only under
compliance with the following commissioning instructions! The PLCcore-5208 is ESD-sensitive and
may only be unpacked, used and operated by trained personal at ESD-conform work stations.
The PLCcore-5208 is a module for the application in automation technology. It features IEC 61131-3
programmability, uses standard CAN-bus and Ethernet network interfaces and a standardized network
protocol. Consequently, development times are short and hardware costs are reasonable. PLC-
functionality is created on-board through a CANopen network layer. Hence, it is not necessary for the
user to create firmware.

System Manual PLCcore-5208
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2 Overview / Where to find what?
The PLCcore-5208 is based on SYS TEC ECUcore-5208 hardware and is extended by PLC-specific
functionality (I/O driver, PLC firmware). There are different hardware manuals for all hardware
components such as the ECUcore-5208 and the PLCcore-5208 (the hardware of both modules is
identical), development boards and reference circuitry. Software-sided, the PLCcore-5208 is
programmed with IEC 61131-3-conform OpenPCS programming environment. There are additional
manuals for OpenPCS that describe the handling of programming tools and SYS TEC-specific
extensions. Those are part of the software package "OpenPCS". Table 1 lists all relevant manuals for
the PLCcore-5208.
Table 1: Overview of relevant manuals for the PLCcore-5208
Information about… In which manual?
Basic information about the PLCcore-5208
(configuration, administration, process image,
connection assignment, firmware update,
reference designs et cetera)
In this manual
Development of user-specific C/C++ applications
for the ECUcore-5208 / PLCcore-5208, VMware-
Image of the Linux development system
System Manual ECUcore-5208
(Manual no.: L-1202)
Hardware description about the ECUcore-5208 /
PLCcore-5208, reference designs et cetera
Hardware Manual ECUcore-5208
(Manual no.: L-1232)
Development Board for the ECUcore-5208 /
PLCcore-5208, reference designs et cetera
Hardware Manual Development Board 5208
(Manual no.: L-1074)
Driver Development Kit (DDK) for the ECUcore-
5208
Software Manual Driver Development Kit (DDK)
for ECUcore-5208
(Manual no.: L-1231)
Basics about the OpenPCS IEC 61131
programming system
Brief instructions for the programming system
(Entry "OpenPCS Documentation" in the
OpenPCS program group of the start menu)
(Manual no.: L-1005)
Complete description of the OpenPCS IEC 61131
programming system, basics about the PLC
programming according to IEC 61131-3
Online help about the OpenPCS programming
system
Command overview and description of standard
function blocks according to IEC 61131-3
Online help about the OpenPCS programming
system
SYS TEC extension for IEC 61131-3:
- String functions
- UDP function blocks
- SIO function blocks
- FB for RTC, Counter, EEPROM, PWM/PTO
User Manual "SYS TEC-specific extensions for
OpenPCS / IEC 61131-3"
(Manual no.: L-1054)

System Manual PLCcore-5208
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CANopen extension for IEC 61131-3
(Network variables, CANopen function blocks)
User Manual "CANopen extension for
IEC 61131-3"
(Manual no.: L-1008)
Textbook about PLC programming according to
IEC 61131-3
IEC 61131-3: Programming Industrial Automation
Systems
John/Tiegelkamp
Springer-Verlag
ISBN: 3-540-67752-6
(a short version is available as PDF on the
OpenPCS installation CD)
Section 4 of this manual explains the commissioning of the PLCcore-5208 based on the
Development Kit for the PLCcore-5208.
Section 5 describes the connection assignment of the PLCcore-5208.
Section 0explains details about the application of the PLCcore-5208, e.g. the setup of the
process image, the meaning of control elements and it provides basic information
about programming the module. Moreover, information is given about the usage of
CAN interfaces in connection with CANopen.
Section 7describes details about the configuration of the PLCcore-5208, e.g. the
configuration of Ethernet and CAN interfaces, the Linux Autostart procedure as well as
choosing the firmware version. Furthermore, the administration of the PLCcore-
5208 is explained, e.g. the login to the system, the user administration and the
execution of software updates.
Section 8defines the adaptation of in- and outputs as well as the process image and it
covers the data exchange between a PLC program and a user-specific C/C++
application via shared process image.

System Manual PLCcore-5208
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3 Product Description
The PLCcore-5208 as another innovative product extends the SYS TEC electronic GmbH product
range within the field of control applications. In the form of an insert-ready core module, it provides to
the user a complete and compact PLC. Due to CAN and Ethernet interfaces, the PLCcore-5208 is best
suitable to perform decentralized control tasks.
Figure 1: Top view of the PLCcore-5208
These are some significant features of the PLCcore-5208:
•High-capacity CPU kernel (Freescale 32-Bit MCF5208 ColdFire, 166 MHz CPU clock, 159 MIPS)
•32 MByte SDRAM Memory, 4 MByte NOR-FLASH Memory, 64 MByte NAND-Flash Memory
•1x 10/100 Mbps Ethernet LAN interface (with on–board PHY)
•1x CAN 2.0B interface, usable as CANopen Manager (CiA 302-conform)
•3x asynchronous serial ports (UART)
•Flexible in-/output circuit by address /data bus leading towards the outside
•Externally usable I2C
•On-board peripherals: RTC, temperature sensor
•On-board software: uClinux, PLC firmware, CANopen Master, HTTP and FTP server
•Programmable in IEC 61131-3 and in C/C++
•Function block libraries for communication (CANopen, Ethernet and UART)
•Function block libraries for hardware components (RTC, Counter, PWM/PTO)
•Support of typical PLC control elements (e.g. Run/Stop switch, Run-LED, Error-LED)
•uClinux-based (other user programs may run in parallel)
•Easy, HTML-based configuration via WEB Browser
•Remote Login via Telnet
•Small dimension (72 x 51 mm)
There are different types of firmware available for the PLCcore-5208. They differ regarding the
protocol used for the communication between Programming PC and PLCcore-5208:
Order number: 3390014: PLCcore-5208/Z4 (CANopen)
communication with Programming PC via CANopen Protocol
(Interface CAN0)

System Manual PLCcore-5208
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Order number: 3390015: PLCcore-5208/Z5 (Ethernet)
communication with Programming PC via UDP Protocol
(Interface ETH0)
Making PLC available as an insert-ready core module with small dimensions reduces effort and costs
significantly for the development of user-specific controls. The PLCcore-5208 is also very well suitable
as intelligent network node for decentralized processing of process signals (CANopen and UDP).
Additionally, it can be used as basic component for special assemblies or as PLC in hard-to-access
areas.
The on-board firmware of the PLCcore-5208 contains the entire PLC runtime environment including
CANopen connection with CANopen master functionality. Thus, the module is able to perform control
tasks such as linking in- and outputs or converting rule algorithms. Data and occurrences can be
exchanged with other nodes (e.g. superior main controller, I/O slaves and so forth) via CANopen
network, Ethernet (UDP protocol) and serial interfaces (UART). Moreover, the number of in- and
outputs either is locally extendable or decentralized via CANopen devices. For this purpose, the
CANopen-Chip is suitable. It has also been designed as insert-ready core module for the appliance in
user-specific applications.
The address/data bus leading towards the outside provides to the user most effective degrees of
freedom for designing the in-/output circuit of the PLCcore-5208. Therewith, all in- and outputs of the
PLCcore-5208 can be flexibly adjusted to respective requirements. Saving the PLC program in the on-
board Flash-Disk of the module allows an automatic restart in case of power breakdown.
Programming the PLCcore-5208 takes place according to IEC 61131-3 using the OpenPCS
programming system of the company infoteam Software GmbH (http://www.infoteam.de). This
programming system has been extended and adjusted for the PLCcore-5208 by the company
SYS TEC electronic GmbH. Hence, it is possible to program the PLCcore-5208 graphically in
KOP/FUB, AS and CFC or textually in AWL or ST. Downloading the PLC program onto the module
takes place via Ethernet or CANopen – depending on the firmware that is used. Addressing in- and
outputs and creating a process image follows the SYS TEC scheme for compact control units. Like all
other SYS TEC controls, the PLCcore-5208 supports backward documentation of the PLC program as
well as the debug functionality including watching and setting variables, single cycles, breakpoints and
single steps.
The PLCcore-5208 is based on Embedded Linux (uClinux) as operating system. This allows for an
execution of other user-specific programs while PLC firmware is running. If necessary, those other
user-specific programs may interchange data with the PLC program via the process image. More
information about this is provided in section 8.
The Embedded Linux (uClinux) applied to the PLCcore-5208 is licensed under GNU General Public
License, version 2. Appendix C contains the license text. All sources of LinuxBSP are included in the
software package SO-1096 ("VMware-Image of the uClinux development system for the ECUcore-
5208"). If you require the LinuxBSP sources independently from the VMware-Image of the Linux
development system, please contact our support:
[e-mail]
The PLC system and the PLC- and C/C++ programs developed by the user are not subject to GNU
General Public License!