Kuka Profinet CP 1616: Kuka Robot Group Controller Option

KUKA Robot Group
Controller Option
KUKA ProfiNet CP 1616

For KR C2 edition05
Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en
Issued: 04.02.20
© Copyright 2008
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of the KUKA ROBOT GROUP.
Other functions not described in this documentation may be operable in the controller. The user has no
claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software de-
scribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guaran-
tee total conformity. The information in this documentation is checked on a regular basis, however, and
necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Publication: Pub Profinet CP 1616 en

Book structure: Profinet CP 1616 V0.6
Label: OP Profinet CP1616 V1
V0.4
2 / 55
22.03.200
6 pub de Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en
Contents
Contents
1 Introduction ...................................................................................................... 5
1.1 Target group ................................................................................................................... 5
1.2 Robot system documentation ......................................................................................... 5
1.3 Representation of warnings and notes ........................................................................... 5
1.4 Trade mark ..................................................................................................................... 5
1.5 Terms used ..................................................................................................................... 6
2 Product description ......................................................................................... 7

2.1 KUKA ProfiNet CP 1616 ................................................................................................. 7
2.2 Fundamentals ProfiNet IO .............................................................................................. 8
2.3 PCI-Slot allocation .......................................................................................................... 9
3 Installation ....................................................................................................... 11
3.1 System requirements ...................................................................................................... 11
3.2 Routing the data cables .................................................................................................. 11
3.3 Installing ProfiNet IO ....................................................................................................... 11
3.4 Updating ProfiNet IO ....................................................................................................... 12
3.5 Uninstalling ProfiNet IO .................................................................................................. 12
4 Configuration ................................................................................................... 13
4.1 Overview ......................................................................................................................... 13
4.2 Configure Profinet CP 1616 as Controller ...................................................................... 13
4.3 Configure KUKA Profinet CP 1616 as Device ................................................................ 15
4.4 Configure KUKA Profinet CP 1616 as Controller and as Device .................................... 16
4.5 Set IO-Routing/Transfer bit ............................................................................................. 17
4.5.1 Configuring a higher-level PC station ........................................................................ 17
4.5.2 Configuring PC station 2 ............................................................................................ 19
4.5.3 Configuring the transfer byte ..................................................................................... 20
4.5.4 Loading a configuration into the module .................................................................... 21
4.6 Configuring the pnioDrv.ini file ........................................................................................ 22
4.6.1 Example of analog input configuration in PNIODRV.INI ............................................ 23
4.7 Configuring the IOSYS.INI file ........................................................................................ 23
4.7.1 Example of analog input configuration in IOSYS.INI ................................................. 24
4.8 Install GSDML-file ........................................................................................................... 24
4.9 Configure I/O of the Controller ........................................................................................ 24
4.10 Configure I/O of the Device ............................................................................................ 26
4.11 Configuration of the external modules ............................................................................ 27
4.11.1 Description of the file io2krlDataDrv.ini ...................................................................... 27
4.11.2 Available commands/variables .................................................................................. 28
4.11.3 Details of the KRL-command function ....................................................................... 29
4.12 Transferring the configuration to the CP 1616 card ........................................................ 29
4.13 Decoupling devices (from Version 1.3 onwards) ............................................................ 30
4.13.1 Decoupling devices via HMI (from Version 1.3 onwards) .......................................... 30
4.13.2 Decoupling devices in KRL (from Version 1.3 onwards) ........................................... 31
4.14 Coupling devices (from Version 1.3 onwards) ................................................................ 32
4.14.1 Coupling devices via HMI (from Version 1.3 onwards) .............................................. 32
Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 3 / 55

4.14.2 Coupling devices in KRL (from Version 1.3 onwards) ............................................... 33
5 Example ............................................................................................................ 35
5.1 Example device configuration ......................................................................................... 35
5.2 Example controller I/O configuration ............................................................................... 36
5.3 KRL example for writing/reading of IO-driver .................................................................. 38
5.4 KRL example for interrupt-controlled READ of IO-driver with $Data_Ext_obj1/2 ........... 39
5.5 KRL example for use of cloCtl ........................................................................................ 40
6 Diagnosis .......................................................................................................... 41
6.1 LED-display PCI-Card CP 1616 ..................................................................................... 41
6.2 Diagnosis of the construction groups .............................................................................. 41
6.3 Diagnosis CP 1616 ......................................................................................................... 42
6.4 Display data with Telnet .................................................................................................. 42
6.5 Diagnosis of the modules installed in Robot Control ...................................................... 42
7 Repair ................................................................................................................ 43
7.1 Mount KUKA Profinet CP 1616 card ............................................................................... 43
7.2 Dismount KUKA Profinet CP 1616 card ......................................................................... 43
8 Appendix ........................................................................................................... 45
8.1 Offset-Table .................................................................................................................... 45
9 KUKA Service ................................................................................................... 47

9.1 Requesting support ......................................................................................................... 47
9.2 KUKA Customer Support ................................................................................................ 47
Index .................................................................................................................. 53
4 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

1. Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:
Advanced KRL programming skills
Advanced knowledge of the robot controller system
Advanced knowledge of field buses
Knowledge of Siemens Step 7 software, Version 5.4, CP 1616 with
firmware 2.1
For optimal use of our products, we recommend that our customers take part
in a course of training at KUKA College. Information about the training pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.
1.2 Robot system documentation
The robot system documentation consists of the following parts:

Operating instructions for the robot
Operating instructions for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.
Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.
Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.
Tips to make your work easier or references to further information.
1.4 Trade mark
Windows is a trade mark of Microsoft Corporation.

Step 7 is a trademark of Siemens AG.

1.5 Terms used
Term Description
Decoupling The ProfiNet controller (CP 1616) terminates
communication with the decoupled device.
Coupling The ProfiNet controller (CP 1616) recommences
communication with the decoupled device.
ANIN Analog input
ANOUT Analog output
CP 1616 Optional ProfiNet card for KR C2 edition05 robot
controller.
Configuration file The configuration file is a text file. It contains the
values of the parameters and settings.
pnioDrv.INI Configuration file for ProfiNet driver. Setting for
controller or device operation.
IOSYS.INI The file IOSYS.INI is the configuration file of the
I/O system. This is where the bus drivers are
activated and the inputs and outputs of the indi-
vidual bus devices are assigned.
GSDML Device file for ProfiNet devices.
MAC address Hardware address of every single network
adapter for unambiguous identification of the
device in the network.
Mapping Assignment of drive letters to directories.
Telnet Telnet is the name of a network protocol.
KCP The KCP (KUKA Control Panel) teach pendant
has all the functions required for operating and
programming the robot system.
PLC Programmable logic controller
Industrial Ethernet Ethernet is a data network technology for local
area networks (LANs). It allows the exchange of
data between the connected devices in the form
of data frames.
Subnet Exact specification of part of the IP address
space.
Subnet mask Separates an IP address into a network section
and a device section.
PM Power module. Required for power supply.
DI Digital input
DO Digital output
AN IN Analog input
AN OUT Analog output
Step 7 Configuration software from Siemens.
O_File Add-on file
WORD types 2 bytes
Swapping Swapping high and low bytes.

2. Product description
2 Product description
2.1 KUKA ProfiNet CP 1616
Description The CP 1616 is a PCI card for connecting PCs to Industrial Ethernet.
Fig. 2-1: CP 1616 card
Properties The CP 1616 PCI card has the following properties:

Configurable and parameterizable across the network
Up to 256 devices
Connections rated for 10BASE-T and 100BASE-TX
Support of data transmission speeds 10 and 100 Mbit/s in Full Duplex and
Half Duplex mode
Operation of CP 1616 as controller and/or device
Configuration with NCM 5.4 or Step 7 software
Use of acyclic channels
Use of ProfiNet I/O communication
Support of shared devices
4 RJ45 ports for connection of terminals or other network components.
Integrated 4-port real-time switch.

Can be used as a network card.

Coupling/decoupling of devices with the driver running (from version 1.3
onwards)
Fig. 2-2: CP1616 connections
Connections
Item Connector Description
1 Infeed for external 6-9 V DC
power supply
2 Port 1 RJ45 port
3 Port 2 RJ45 port
4 Port 3 RJ45 port
5 Port 4 RJ45 port
LEDs The LEDs on the CP 1616 PCI card indicate the operating status and any
faults that may be present. (>>> 6.1 "LED-display PCI-Card CP 1616"
page 41)
2.2 Fundamentals ProfiNet IO
Profinet IO is an Ethernet-based communications protocol. The data ex-

change is done in a Client-Server architecture.
The following device types are used in ProfiNet IO:
Controller: is a control, which superordinate controls all components of a
system.
Device: is a field device, which is controlled by a controller. A device com-
prises of several modules and sub-modules. A device can contain several
Controllers (Masters).
Supervisor: can be a programming device or an Industrial-PC. Parallel to
the controller, it has access to all process and parameter files.
The 3 device types contain relationships for the transmission of configuration
data, process data as well as alarms.
A physical device, such as the Robot Control can be controller and/or device.
The project planning of communication devices takes place exclusively at the
controller side.
A project planning can be created with the following programs and loaded on
to the construction groups:
NCM (Siemens) till Firmware 2.0

2. Product description
Step 7 (Siemens) starting from Firmware 2.1
Basic principle of The KRL-driver connects to the IO-driver through the CP 1616 functions of the
communication IO-system. This either provides asynchronous data or accepts these.
More information is available in the documentation CREAD/CWRITE.
2.3 PCI-Slot allocation
Overview
Fig. 2-3: PCI-Slots
The PC-slots can be filled with the following plug-in cards:
Slot Plug-in card

1 PCI CP1616-Card ProfiNet
2 free
3 KVGA-Card
4 DSE-IBS-C33 AUX-Card (Option)
5 MFC3-Card
6 Network card (3COM)
7 free


3. Installation
3 Installation
3.1 System requirements
Robot controller Hardware:

KUKA ProfiNet CP 1616 card
KR C2 edition05
Software:
KUKA System Software (KSS) 5.4, 5.5
KUKA ProfiNet I/O options CD
Laptop/PC Hardware:
PC Pentium 500 MHz with 256 MB RAM
CD-ROM drive
Software: Microsoft Windows 98SE, ME, XP
3.2 Routing the data cables
The Industrial Ethernet cables are routed to the devices from the controller
or from the switch using a star or ring topology.
3.3 Installing ProfiNet IO
Precondition User group “Expert”

Windows interface (CTRL+ESC)
KUKA ProfiNet CP 1616 card is not installed
If the KUKA ProfiNet CP 1616 card is installed before setup is carried out, a
hardware configuration by Windows must be prevented. Do not execute the
Windows message New Hardware Found, Installing Driver.
Procedure 1. Insert ProfiNet IO option CD.

2. Execute setup from ProfiNet IO option CD.
The expanded pnio.Drv.ini file is loaded (only when installing for the first
time). In the case of an update, the file must be expanded manually (from
Version 1.3 onwards)
3. Switch the robot controller off.

4. Optionally: insert the CP 1616 card into slot 1 or slot 4. (>>> 7.1 "Mount
KUKA Profinet CP 1616 card" page 43)
5. Reboot the robot controller.
A dummy ProfiNet driver has been installed and is displayed in the Windows
Device Manager under “Realtime OS devices”.
What happens during installation (from Version 1.3 onwards)

First installation: the newest version of all files is installed on the robot
controller.
Update: the ProfiNet driver is exchanged. The configuration in the pnio-
Drv.ini and IOSYS.INI files is not modified/expanded.
Uninstallation: all files and drivers are deleted from the robot controller.

3.4 Updating ProfiNet IO
Precondition ProfiNet IO is installed

User group “Expert”
It is advisable to archive all relevant data before updating or uninstalling a

software package.
Procedure 1. Insert ProfiNet IO option CD.

2. Execute setup from ProfiNet IO option CD.
3. Switch the robot controller off.
4. Reboot the robot controller.
From Version 1.3 onwards, the ProfiNet driver is exchanged. The configura-
tion in the pnioDrv.ini and IOSYS.INI files is not modified/expanded.
3.5 Uninstalling ProfiNet IO
It is advisable to archive all relevant data before updating or uninstalling a

software package.
Precondition ProfiNet IO is installed

Procedure 1. Start the Uninstall.exe program in the directory ...\KRC_OPTION\PROFI-

NETIO\UNINST.
ProfiNet IO is uninstalled.
2. Delete the PROFINETIO folder in ...\KRC_OPTION.
All configurations in the pnioDrv.ini and IOSYS.INI files are deleted during
uninstallation! If the configurations are to be maintained, they must be
backed up manually.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

4. Configuration
4 Configuration
4.1 Overview
Overview Step Description

1 Configure KUKA ProfiNet CP 1616 as controller.
(>>> 4.2 "Configure Profinet CP 1616 as Controller"
page 13)
2 Configure KUKA ProfiNet CP 1616 as device.
(>>> 4.3 "Configure KUKA Profinet CP 1616 as Device"
page 15)
3 Configure KUKA ProfiNet CP 1616 as controller and
device.
(>>> 4.4 "Configure KUKA Profinet CP 1616 as Controller
and as Device" page 16)
4 Set I/O routing/transfer bit.
(>>> 4.5 "Set IO-Routing/Transfer bit" page 17)
5 Configure pnioDrv.ini file.
(>>> 4.6 "Configuring the pnioDrv.ini file" page 22)
6 Activate KUKA ProfiNet CP 1616 in IOSYS.INI.
(>>> 4.7 "Configuring the IOSYS.INI file" page 23)
7 Install GSDML file.
(>>> 4.8 "Install GSDML-file" page 24)
8 Configure I/O of controller/device (>>> 4.9 "Configure I/O
of the Controller" page 24).
(>>> 4.10 "Configure I/O of the Device" page 26)
9 Configure the external modules.
(>>> 4.11 "Configuration of the external modules"
page 27)
10 Transfer configuration to CP 1616 card.
(>>> 4.12 "Transferring the configuration to the CP 1616
card" page 29)
11 Decouple device.
(>>> 4.13 "Decoupling devices (from Version 1.3
onwards)" page 30)
12 Couple device.
(>>> 4.14 "Coupling devices (from Version 1.3 onwards)"
page 32)
4.2 Configure Profinet CP 1616 as Controller
Preconditions PC/laptop with software

Connection via crossed Ethernet cable
Step 7 software, Version 5.4, from Siemens
Service Pack 1 of the Step 7 software
HotFix 2 of the Step 7 software
Hardware Support Package of the Step 7 software


For display reasons, the Step 7 software, Version 5.4, from Siemens should
not be installed on the robot controller.
Procedure 1. Open the program Step 7.

2. Select menu sequence File > New.
Give project name. The file is saved under C:\Programme\SIEMENS\SI-
MATIC.S7proj.
3. Select menu sequence Insert > Station > PC-Station.
4.
Open PC-Station by double-clicking.
Configuration opens.
5.
Open Configuration by double-clicking.
The hardware configurator opens.
6. In the hardware catalog under SIMATIC PC-Station > select CP-Indus-
trial Ethernet > CP 1616 > V2.0 .
7.
Move CP 1616 by drag & drop from the hardware catalog to slot 1
(Index1) of the PC-Station.
Fig. 4-1: Configuration as controller
Number Name
1 Slot 1 (Index 1) of the PC-Station
2 Device number
3 IP-Address
4 Device name
5 Order number
6 Diagnostic address

4. Configuration
Number Name
7 Information field
8 Hardware catalog
8. Select menu sequence Edit > Object properties.

The dialog box Properties opens.
9. Activate the button Properties.
10. Under Parameter the following options can be set:
IP-Address
Subnet mask
Subnet
Gateway
11. Confirm with OK .
12. In the dialog box set the menu sequence Properties > PROFINET Oper-
ation mode of the CP 1616 to PROFINET IO-Controller.
Fig. 4-2: Configuring CP 1616 as controller

14. Highlight CP 1616. Select menu sequence Insert > PROFINET IO-Sys-
tem.
15. Project the devices corresponding to the requirements at PROFINET IO-
System.
16. After the projecting is completed, compile project via the menu sequence
Target system > Load and download on the Control-PC.
4.3 Configure KUKA Profinet CP 1616 as Device



2. Select menu sequence File > Open.
3. Highlight earlier project (Controller).
The project opens.
5. Open PC-Station by double-clicking.
6. Open Configuration by double-clicking.
7. In the hardware catalog under PROFINET IO > select I/O > SIMATIC PC-
CP > CP 1616.
8.
Project CP 1616by drag & drop at the network.
The CP 1616 is projected as device at the network.
9. Specify device name in the input field Device name.
The device name must be the same as the device name of the CP 1616 in
the PC-Station
10. Deactivate option Allocate IP-Address through IO-Controller.
During compiling the IP-address of the CP 1616 is allocated with the help of
the device name.
4.4 Configure KUKA Profinet CP 1616 as Controller and as Device

Procedure 1. Configure CP 1616 as Controller. (>>> 4.2 "Configure Profinet CP 1616 as

Controller" page 13) Repeat steps 1 to 14.
2. Save the project.
3. Return in the operating interface of the Step 7 PC Manager.
4. Select menu sequence Insert > Station > SIMATIC PC-Station.
5. Rename SIMATIC PC-Station project-specific.
6. Open the new SIMATIC PC-Station by double-clicking.
Configurationopens.

4. Configuration
7.
Open Configuration by double-clicking.
8. In the hardware catalog under SIMATIC PC-Station > select CP-Indus-
trial Ethernet > CP 1616
9.
Move CP 1616 by drag & drop from the hardware catalog to slot 1
(Index1) of the PC-Station.
The dialog box Properties opens.
11. Activate the button Properties.
12. Under Subnet assign to the CP 1616 a network other than the CP 1616 in
the project "Use CP 1616 as Controller".
14. In the dialog box Properties menu sequence Properties > PROFINET set
the operating mode of the CP 1616 to PROFINET IO-Controller and En-
able PROFINET IO-Device Operation
Fig. 4-3: Configuring CP 1616 as controller and device

16. Highlight CP 1616. Select menu sequence Insert > PROFINET IO-Sys-
tem.
17. In the hardware catalog under PROFINET IO > select I/O > SIMATIC PC-
CP > CP 1616 (>>> 4.3 "Configure KUKA Profinet CP 1616 as Device"
page 15) Repeat steps 8 to 10.
18. After the projecting is completed, compile project via the menu sequence
Target system > Load and download on the Control-PC.
4.5 Set IO-Routing/Transfer bit
4.5.1 Configuring a higher-level PC station




2. Select the menu sequence File > New.
Assign a project name. The file is saved under C:\Program Files\SIE-
MENS\SIMATIC.S7proj.
3. Select the menu sequence Insert > Station > PC station.
Specify a name for the higher-level PC station.
4. Select the menu sequence Insert > Station > PC station.
Specify a name for the second PC station.
5. Open the higher-level PC station. Select the PC station. Right mouse but-
ton > Open object.
Configuration is opened.
6.
Double-click to open Configuration.
The hardware configurator is opened.
7. In the hardware catalog, select SIMATIC PC Station > CP Industrial Eth-
ernet > CP 1616 > V2.1 (PN V2.0).
8.
Drag CP 1616 V2.1 (PN V2.0) from the hardware catalog to slot 1
(Index1) of the PC station by means of Drag&Drop.
9. Assign an Ethernet and an IP address to the CP 1616 V2.1.
If subsequent modification or assignment of the Ethernet and/or IP address

is required, carry out steps 10 to 13.
10.
Select CP 1616 V2.1 (PN V2.0).
11. Select the menu sequence Edit > Object properties.
The Properties dialog box is opened.
12. Press the Properties button.
13. Under Parameters, assign an Ethernet to the CP 1616 V2.1 (PN V2.0).
14. Confirm with OK.
15. In the hardware catalog, select PROFINET IO > I/O > SIMATEC PC-CP >
CP 1616 V2.1 > Migration.
16.
Configure the CP 1616 V2.1 from the ProfiNet hardware catalog by
means of Drag&Drop.
17.
Select CP 1616 V2.1. Select the menu sequence Edit > Object prop-
erties.
18. Assign device name, Ethernet and IP address. Confirm with OK.
19. Select the menu sequence Station > Save and compile.

4. Configuration
4.5.2 Configuring PC station 2

Procedure 1. Open the second PC station. Right mouse button > Open object.
Configuration is opened.
2.
Double-click to open Configuration.
The hardware configurator is opened.
3. In the hardware catalog, select SIMATIC PC Station > CP Industrial Eth-
ernet > CP 1616 > V2.1 (PN V1.0).
4.
Drag CP 1616 V2.1 (PN V1.0) from the hardware catalog to slot 1
(Index1) of the PC station by means of Drag&Drop.
5. Assign the CP 1616 V2.1 (PN V1.0) the same Ethernet, the same IP ad-
dress and the same device name as the CP 1616 configured for the high-
er-level PC station.
If subsequent modification or assignment of the Ethernet and/or IP address

is required, carry out steps 6 to 10.
6.
Select CP 1616 V2.1 (PN V1.0).
7. Select the menu sequence Edit > Object properties.
8. Press the Properties button.
9. Under Parameters, assign the CP 1616 V2.1 (PN V1.0) the same Ether-
net as the CP 1616 configured for the higher-level PC station.
10. Assign the same device name and IP address.
12. A message window is opened. Confirm the message with Yes.
13.
Select CP 1616 C2.1 (PN V1.0). Select the menu sequence Edit >
Object properties.
14. In the Properties dialog box on the ProfiNet tab, set the operating mode
of the CP 1616 V2.1 (PN 1.0) to PROFINET IO controller and set Enable
PROFINET IO device operation.
16. Assign digital input and digital output (>>> 4.9 "Configure I/O of the Con-
troller" page 24)

4.5.3 Configuring the transfer byte
Precondition The higher-level PC station and the second PC station are configured.
Procedure 1. Open configuration of the higher-level PC station.

2. In the hardware catalog, select the menu sequence PROFINET IO > I/O >
SIMATIC PC Station > CP 1616 > Migration > V2.1 > Transfer module
> DI > 1 byte.
Fig. 4-4: Hardware catalog migration
3. Drag the byte to the first slot by means of Drag&Drop.

4. Select the byte. Select the menu sequence Edit > Object properties.
The properties window of the byte is opened.
5. In the properties window, select the PROFINET IO Transfer Module tab.
The device to be accessed is defined here.
6. Open the folder 0.0.0.7.
7. Select the device that is configured in the second PC station. (>>> Fig. 4-
5)
Fig. 4-5: Selecting the device

4. Configuration
8. Select the module of the device selected under point 7 that is to be

mapped.
9. Select the digital inputs or digital outputs (depending on the configuration)
to be mapped. (>>> Fig. 4-6)
Fig. 4-6: Selecting digital inputs/outputs
10. Set the end range of the number of bytes to be mapped. (>>> Fig. 4-7)
Fig. 4-7: Setting the end range
4.5.4 Loading a configuration into the module
Procedure 1. Open the configuration of both PC stations.

2. Save and transfer the configuration.
3. In the configuration file IOSYS.INI, deactivate the driver by turning it into a
comment.
4. Select the menu sequence Configure > I/O Driver > Reconfigure I/O
Driver on the KCP.
5. Select the menu sequence Target system > Load to module in Step 7.
The configuration of the higher-level PC station and the second PC station

must be loaded into the module one after the other.

6. In the configuration file IOSYS.INI, deactivate the driver by turning it into a

comment.
Driver on the KCP.
The configuration has been loaded into the module.
4.6 Configuring the pnioDrv.ini file
Description The pnioDrv.ini file is the configuration file for operation of the CP 1616 as a
controller and/or device under Windows.
From Version 1.3 onwards, the file pnioDrv.ini has been expanded to include
the section [OPTIONS].
This expansion is only loaded when installing the software for the first time. In
the case of an update, the expansion must be added manually to the file pni-
oDrv.ini.
Precondition Setup of KUKA ProfiNet options CD

Configuration of the CP 1616 in Step 7 as controller and/or device
Procedure 1. Open the pnioDrv.ini file.

The following settings are displayed:
1 DEBUG = 1
2 ENABLECONTROLLER = 1
3 ENABLEDEVICE = 0
4 [OPTIONS]
5 DEACTIVATED_DEVICES = ...
Designation Description
DEBUG = 1 With debugging tasks on the Telnet shell
DEBUG = 0 Without debugging tasks on the Telnet
shell
ENABLE- CP 1616 is operated as a controller
CONTROLLER = 1
ENABLE-
CP 1616 is not operated as a controller
CONTROLLER = 0
ENABLEDEVICE = 1 CP 1616 is operated as a device
ENABLEDEVICE = 0 CP 1616 is not operated as a device
DEACTIVATED_DEVIC From Version 1.3 onwards. Deactivates the
ES = x, x ... devices specified after "=".
Item Description
4, 5 Expansion from Version 1.3 onwards. Devices that are
specified after the "=" with a corresponding number are
not activated when the driver is started/reconfigured.
If this expansion is missing or if there are no values after
the "=", all configured devices that are also mapped in the
file IOSYS.INI are activated.
2. Carry out and save the desired settings.

4. Configuration
4.6.1 Example of analog input configuration in PNIODRV.INI
PNIODRV.INI
[CONFIG]
DEBUG = 1
ENABLECONTROLLER = 1
ENABLEDEVICE = 1
[ANIN]
ANIN1 = 514, 4, 0, 2, TRUE
ANIN2 = 514, 4, 2, 2, TRUE
[ANOUT]
...
[SWAP]
SWAPWORD_IN = 13,15
SWAPWORD_OUT = 4, 10, 12
[OPTIONS]
DEACTIVATED_DEVICES=
Only one SWAP section is permissible. Only WORD types can be swapped.
It is not possible to access more than 2 bytes. The sequence ANIN, ANOUT,
SWAP must be observed. The additional configuration in PNIODRV.INI must
match the configuration in IOSYS.INI exactly.
ANIN1 Analog input 1
ANOUT Analog output
514 Start address. Corresponds to the ProfiNet
configuration in Step 7.
4 Total width of the module.
0 Offset within the module.
2 Access width for further processing.
TRUE SWAP command. Swapping is carried out.
4.7 Configuring the IOSYS.INI file
Description The file IOSYS.INI is the configuration file of the robot I/O system.
Precondition All communications cables have been installed.

Procedure 1. Open the IOSYS.INI file.

2. In [DRIVERS]: activate PNET=26, pnioInit, PnetDrv.o.
3. In [PNET]: assign inputs and outputs of the individual bus devices.
4. Perform I/O reconfiguration.
IOSYS.INI Description
[CONFIG] Indication of the version number
[DRIVERS] Lines for activation of the bus drivers
[PNET] Lines for assignment of the inputs and out-
puts of the selected bus devices
26 Driver ID assigned to the driver
pnoInit Start routine in the driver
pnetDrv.o File name of the driver

4.7.1 Example of analog input configuration in IOSYS.INI
IOSYS.INI:
[DRIVERS]
PNET=26, pnioInit, PnetDrv.o
[PNET]
INB10 = 10,xx1
OUTB20 = 1,6,xx1
ANIN2 = 2,514,14,3,cal8000
IOSYS.INI Description
ANIN2 Analog input 2
2 Stands for bytes that are treated separately.
This must always be 2 for ANIN and ANOUT.
514 ProfiNet address
14 Number of bits with a bit for the sign.
3 Type
calxxxx Calibration factor for 10 V+
4.8 Install GSDML-file
Description If a device is required, which is not contained in the library of Step 7, a GSDML
file is required from the manufacturer.
Prerequisites The manufacturer-specific GSDML-file is available.
Procedure 1. Open the desired project in Step 7 PC Manager and change to the hard-
ware configurator.
2. Select menu sequence Extras > Install GSD-file.
The dialog box Install GSD-files opens.
3. Press the button Search and select the GSDML-file.
4. Activate the button Install.
5. Select menu sequence Extras > Update Catalog.
The GSDML-file is installed in the Hardware catalog.
4.9 Configure I/O of the Controller
Description Assign Digital Input and Digital Output.
Prerequisites KUKA CP 1616 is configured as controller. (>>> 4.2 "Configure Profinet

CP 1616 as Controller" page 13)
The project is saved.
Step 7 Software Version 5.4 of SIEMENS, Firmware 2.1
Configurations laptop/PC with the required software
User group expert
Procedure 1. In the programStep 7 open the saved project.

2. In the hardware catalog select the menu sequence PROFINET IO > I/O >
ET200S > desired IM151....
3. Project the IM151... at the PROFINET-IO system.

4. Configuration
4. Highlight the IM151...

5. Highlight the empty slot 1.
The construction group projected in the PROFINET-IO system must have the
same order number as the installed construction group.
6. Select menu sequence Insert > Insert object.

A window opens.
Upon each further selection a new window opens.
7.
Select PROFINET IO.
8. Desired IM151... > select.
The construction group projected in the PROFINET-IO system needs a pow-

er supply. A PM (power module) must be added.
9.
Select PM.
10. Select the desired PM.
The PM is placed on the slot 1 and assigned to IM151...
11. Select and highlight the desired DI slots.
12. Repeat steps 6 to 8.
13. Select DI.
14. Select the desired DI.
The DI is placed on the selected slot.
15. Select and highlight the desired DO slot.
16. Repeat steps 6 to 8.
17. Select DO.
18. Select the desired DO.
The DO is placed on the selected slot.

Fig. 4-8: I/O configuration
Position Description
1 IM151...
2 Sub-module slots for:
PM (Power Module)
DI (Digital Input)
DO (Digital Output)
3 Input-Address
4 Output-Address
5 Projected IM151...
4.10 Configure I/O of the Device
Prerequisites The CP 1616 is projected as device at the PROFINET-IO system.

(>>> 4.3 "Configure KUKA Profinet CP 1616 as Device" page 15)
The project is saved.
Step 7 Software Version 5.4 of SIEMENS, Firmware 2.1
Laptop/PC with Software
User group expert
Procedure 1. In the programStep 7 open the saved project.

2. In the hardware catalog select the menu sequence PROFINET IO > I/O >
CP 1616 > 6GK1 161-6AA00 > V2.0.
3. Highlight CP 1616 in the PROFINET-IO system.
4. Highlight the desired slot.

4. Configuration
5. Select desired byte A under V2.0. By double-clicking this is placed on the

highlighted slot.
6. Repeat step 4.
7. Select desired byte E under V2.0. By double-clicking this is placed on the
highlighted slot.
What appears as output in the Step 7 software must be defined as input for
the robot control.
The position specifications 6 and 7 for the module result from the counting
method. Here, the top-most module is ignored, considered as 0. The count-
ing starts only with the second module = 1. (>>> 5.1 "Example device config-
uration" page 35)
4.11 Configuration of the external modules
File The external modules are declared in the file $CUSTOM.DAT.

DECL EXT_MOD_T $EXT_MOD_x={O_FILE[] " ",OPTION 0}
Parameter O_FILE[]
In square brackets the path and the file name of the O-file must be entered,
e.g. B. DRIVERS\io2krlDataDrv.o.
O-Files always lie below the folder C:\KRC:\ROBOTER. This part of the path
need not be specified.
OPTION (Bit 0)
Bit 0 of OPTION defines, what happens to an external module in case of
CCLOSE. The setting is "Force unload".
Value Description
Bit 0 = 1 "Force unload" is active. CCLOSE closes the channel to
the module, the module is unloaded.
Bit 0 = 0 "Force unload" is not active. CCLOSE closes the channel
to the module. The module remains loaded. In case of a
future COPEN the module need not be reloaded.
OPTION (Bit 1)
Bit 1 of OPTION is relevant only for external modules of the type
LD_EXT_OBJ with inactive "Force unload". The setting is "Leave data".
Value Description
Bit 1 = 1 "Leave data" is active. Upon CCLOSE all data received,
but not yet read is retained. When the channel is opened
again, this data is read by CREAD.
Bit 1 = 0 "Leave data" is not active. CCLOSE deletes all data re-
ceived, but not yet read.
4.11.1 Description of the file io2krlDataDrv.ini
Description If the driver is loaded, its INI-file is read, in order to load the desired configura-
tion.

Configuration Description
$EXT_MOD1 The driver first tries to read the INI-file with the
name "io2krlDataDrv1.ini". If this is not found,
the INI-file "iokrlDataDrv.ini" is read.
$EX_MOD2 The driver first tries to read the INI-file with the
name "io2krlDataDrv2.ini". If this is not found,
the INI-file "iokrlDataDrv.ini" is read.
This configuration serves to load multiple instances of the same driver as

$EXT_MOD1 and $EXT_MOD2. Despite identical driver, a different configu-
ration of the driver instances can be selected in the respective INI-files.
File [IODriver]
IODrvName = asyncDataDrv
[ReceiveQueue]
NrOfElements = 10
[ReceiveQueueDatBehaviour]
DeleteOn_IOreconfig = FALSE
DeleteOn_CClose = False
OverwriteOldData = FALSE
[Debug]
PrintToTlnet = FALSE
Name Description
IODrvName Internal name of the I/O-driver. with which the
KRL-data-driver is to connect
NrOfElements Number of buffered data elements in the receiv-
ing buffer, (maximum 30, minimum 1 data ele-
ment)
DeleteOn_IOReconfig TRUE:
deletes the receive buffer in case of an I/O-
reconfiguration
DeleteON_CClose TRUE:
deletes the receive buffer upon CClose.
OverwriteOldData TRUE:
If the receive buffer is completely filled and a
new data element comes from the IO-driver,
then the oldest element is deleted. The new
element is stored in the receive buffer.
FALSE:
If the receive buffer is completely filled, the
message Receive Buffer Overflow is
shown. A program reset is necessary.
PrintToTelnet TRUE:
Commands given at the Telnet shell can be doc-
umented for internal purposes.
4.11.2 Available commands/variables

4. Configuration
4.11.3 Details of the KRL-command function
4.12 Transferring the configuration to the CP 1616 card
The configuration can be transferred to a CP 1616 in one of two ways.
Precondition User group “Expert”

No program is selected
A configuration has been created
The CP 1616 card has been installed correctly
A name has been specified for the CP 1616 card
The configuration computer is in the same subnet as the CP 1616 card
and is connected to it via the network
Procedure 1 1. Select the menu sequence Configure > I/O Driver > Edit I/O Config. on
the KCP.
The file IOSYS.INI is opened.
2. Deactivate the driver PNET = ... in the file IOSYS.INI by turning it into a
comment.
3. Remove deactivated driver. Select the menu sequence Configure > I/O
Driver > Reconfigure I/O Driver.
4. Open the ProfiNet configuration on the configuration computer. Select the
menu sequence Target system > Load to module > Target module.
5. Select the corresponding CP 1616 card and start downloading the config-
uration.
6. Select the menu sequence Configure > I/O Driver > Edit I/O Config. on
the KCP.
The file IOSYS.INI is opened.
7. Reactivate the driver here by deleting the comment separator.
8. Remove activated driver. Select the menu sequence Configure > I/O
Driver > Reconfigure I/O Driver.
The driver is loaded with the current configuration.
Procedure 2 1. Open the ProfiNet configuration on the configuration computer. Select the
menu sequence Target system > Load to module > Target module.
2. Select the corresponding CP 1616 card and start downloading the config-
uration.
3. On successful completion of the configuration, message number 8069 ap-
pears: "ProfiNet configuration changed. Perform I/O reconfiguration on
KCP".
This message, which triggers a stop and disables active commands, remains
displayed until an I/O reconfiguration has been carried out. Resetting the
driver is not sufficient.
Driver on the KCP.

The driver is internally shut down during the procedure. It is restarted after
the configuration has been transferred.
When the menu is no longer displayed in the Step 7 software, it is necessary
to wait for approximately 1 minute while the configuration is completed.
The current language database version on the KRC does not yet support the
message texts that are generated. Only message numbers are displayed.
Caution!
Driver crash. If message number 8068 "Updating CP 1616 configuration,
please wait" is displayed, no operator actions may be carried out on the KCP.
4.13 Decoupling devices (from Version 1.3 onwards)
Description For certain applications, e.g. tool change, it is necessary to decouple devices.
Decoupling can be carried out via HMI (>>> 4.13.1 "Decoupling devices via
HMI (from Version 1.3 onwards)" page 30) or in KRL (>>> 4.13.2 "Decoupling
devices in KRL (from Version 1.3 onwards)" page 31).
Devices can be decoupled by means of the key DEACTIVATED_DEVICES in
pnioDrv.ini. These specified devices are then decoupled when the driver is
started. In the case of a cold start of the controller or an I/O reconfiguration,
the device list specified for DEACTIVATED_DEVICES is taken as an initiali-
zation for the devices to be deactivated when the driver is started. A warm re-
start/driver reset leaves all activated devices active (coupled) and all
deactivated devices deactivated (decoupled).
Decoupled devices cannot carry out error treatment in the case of read/write
errors. Decoupling means that the ProfiNet controller (CP 1616) terminates
communication with the ProfiNet device. All I/O operations on this device re-
main without effect.
A coupled device is disconnected from the ProfiNet or supply voltage. In this
case, a corresponding error message is generated in the HMI when this device
is configured in the file IOSYS.INI. A decoupled device, on the other hand,
does not signal an error when it is disconnected from the ProfiNet or from the
supply voltage (e.g. during tool change).
Only ProfiNet devices with I/Os mapped in the file IOSYS.INI are relevant for
the coupling and decoupling of devices. Other devices cannot be coupled/de-
coupled.
Example Devices 1 to 10 are configured in the ProfiNet configuration and loaded into
the card as a configuration. Only devices 1 to 8 are actually present in the sys-
tem, however. Devices 9 and 10 are thus irrelevant. Only devices 1 to 6 are
mapped in the file IOSYS.INI. Devices 7 and 8 are thus irrelevant. Of these de-
vices, devices 3 to 6 are always to be deactivated during every I/O reconfigu-
ration or cold start:
DEACTIVATED_DEVICES = 3,4,5,6
The CP 1616 controller thus only communicates with devices 1 and 2 when
the driver is started. Devices 3 to 6 can be coupled using the corresponding
IOCTL functions.
4.13.1 Decoupling devices via HMI (from Version 1.3 onwards)
Precondition The device is configured in the file IOSYS.INI

The device is present in the ProfiNet configuration

4. Configuration
Procedure If Profibus devices that are connected to the ProfiNet via a Profibus proxy are
decoupled, the following must be taken into consideration:
The correct device number from the configuration in the Step 7 software
must be used. Two numbers are assigned to the Profibus device here:
One number as Profibus device (module number for Profibus).
One number as ProfiNet device (device number for ProfiNet). This
number must be specified in the case of decoupling.
Example 1. Select the menu sequence Monitor > Variable > Single.
2. Enter the following in the Name selection box:
=IOCTL (26, 32774,1)
3. Confirm with ENTER.
The device is decoupled.
Designa
Description
tion
26 Driver ID assigned to the driver. This ProfiNet driver is set
in the IOSYS.INI file. This value must always be specified
when coupling/decoupling devices.
32774 Decoupling command
1 Device number from the ProfiNet configuration. Each
device must be assigned a unique device number by the
Step 7 software during configuration. This device number
must always be specified in the case of coupling/decou-
pling.
4.13.2 Decoupling devices in KRL (from Version 1.3 onwards)

If Profibus devices that are connected to the ProfiNet via a Profibus proxy are
decoupled, the following must be taken into consideration:
number must be specified in the case of decoupling.
Example Enter the following at the relevant point in the KRL code:
1 IF (NEXT_TOOL == ZANGE_1) THEN
2 RET = IOCTL (26, 32774, 2)
3 WAIT SEC 1.0
4 RET = IOCTL (26, 32773, 1)
5 ENDIF
Item Description
2 The device with the number 2 is decoupled here.

Designat
Description
ion
26 Driver ID assigned to the driver. This ProfiNet driver is set in
the IOSYS.INI file. This value must always be specified when
coupling/decoupling devices.
1, 2 Device number from the ProfiNet configuration. Each device
must be assigned a unique device number by the Step 7 soft-
ware during configuration. This device number must always
be specified in the case of coupling/decoupling.
RET IOCTL return value. RET is of type INT and can have the val-
ues 0 and -1.
0 = function successfully executed
-1 = failure
4.14 Coupling devices (from Version 1.3 onwards)
Description For certain applications, e.g. tool change, it is necessary to couple devices.
Coupling can be carried out via HMI (>>> 4.14.1 "Coupling devices via HMI
(from Version 1.3 onwards)" page 32) or in KRL (>>> 4.14.2 "Coupling devic-
es in KRL (from Version 1.3 onwards)" page 33).
The IOCTL function is executed synchronously. It only returns when the cor-
responding device is functional and can be written to once again. Writing to
and reading from deactivated devices does not provide correct results.
If a device is coupled using an IOCTL function, the CP 1616 controller restores
the connection to this device. Once the device is fully integrated into the Profi-
Net once again, an ALARM is received from the device. The ProfiNet driver
sees this as a sign that the device has been fully reactivated. Only now can I/
Os be correctly sent to the device again.
If a device is not functional, e.g. disconnected from the bus or supply voltage,
a status message indicating a timeout appears after approx. 10 seconds. It
can now normally be assumed that the device is not being correctly operated
in the ProfiNet.
4.14.1 Coupling devices via HMI (from Version 1.3 onwards)

Procedure If Profibus devices that are connected to the ProfiNet via a Profibus proxy are
coupled, the following must be taken into consideration:
number must be specified in the case of coupling.
Example 1. Select the menu sequence Monitor > Variable > Single.
2. Enter the following in the Name selection box:
=IOCTL (26, 32773.1)
3. Confirm with ENTER.

4. Configuration
4. The device is coupled.

The coupling may take several seconds. The IOCTL command is initiated
synchronously. The KRL robot/submit interpreter does not run again until the
device is coupled.
Designa
Description
tion
26 Driver ID assigned to the driver. This ProfiNet driver is set
in the IOSYS.INI file. This value must always be specified
when coupling/decoupling devices.
32773 Coupling command
1 Device number from the ProfiNet configuration. Each
device must be assigned a unique device number by the
Step 7 software during configuration. This device number
must always be specified in the case of coupling/decou-
pling.
4.14.2 Coupling devices in KRL (from Version 1.3 onwards)

If Profibus devices that are connected to the ProfiNet via a Profibus proxy are
coupled, the following must be taken into consideration:
number must be specified in the case of coupling.
Example Enter the following at the relevant point in the KRL code:
1 IF (NEXT_TOOL == ZANGE_1) THEN
2 RET = IOCTL (26, 32774, 2)
3 WAIT SEC 1.0
4 RET = IOCTL (26, 32773, 1)
5 ENDIF
Item Description
4 The device with the number 1 is coupled here.
Designat
Description
ion
26 Driver ID assigned to the driver. This ProfiNet driver is set in
the IOSYS.INI file. This value must always be specified when
coupling/decoupling devices.
1, 2 Device number from the ProfiNet configuration. Each device
must be assigned a unique device number by the Step 7 soft-
ware during configuration. This device number must always
be specified in the case of coupling/decoupling.
RET IOCTL return value. RET is of type INT and can have the val-
ues 0 and -1.
0 = function successfully executed
-1 = failure


5. Example
5 Example
5.1 Example device configuration
Components Designation Description

IN Inputs
OUT Outputs
B Granularity
1 Device number of the module
4,5... Index, start address
IOSYS.INI The IOSYS.INI file on the controller:

[PNET]
INB8=1,6,xx4 ;1=Device SubMod=6 Len=4
OUTB8=1,7,xx4 ;1=Device SubMod=7 Len=4
Position specifications 6 and 7 for the modules are based on the counting di-
rection. The uppermost module is ignored – regarded as 0 – and counting
starts from the second module = 1.

1 Module 0
2 Modules 1 to 5
3 Module 6, module 7
4 I/O modules
If a CP 1616 is configured as a device, the higher-level controller regards the

output module as being on slot 6 and the input module on slot 7. From the
point of view of the CP 1616 installed in the KRC controller, the output of the
higher-level controller is an input. The input of the higher-level controller con-
figured on slot 7 is seen as an output by the KRC.
5.2 Example controller I/O configuration
Components Designation Description

IN Inputs
OUT Outputs
B Granularity
4, 5... Index, start address
0, 1, 2, 3 Number of the bus device
INB 4, 5, 6, 7 Controller address
xx Multiplier
Example
INB10 = 20,x1 Here, a data object with a length of one byte is
mapped to address 20, starting from byte 10.
INB10 = 20,x4 Here, a data object with a length of four bytes is
mapped to address 20, starting from byte 10.
The object has to be read in its entirety (all 4
bytes at once).
INB10 = 20, xx4 Here, four data objects with a length of one byte
are mapped to address 20, starting from byte 10.
They can be read individually.
IOSYS.INI The IOSYS.INI file on the controller:

[PNET]
INB4=0,xx1 ;Controller-Daten
INB5=1,xx1
INB6=2,xx1
INB7=3,xx1
OUTB4=0,xx1
OUTB5=1,xx1
OUTB6=2,xx1
OUTB7=4,xx1

5. Example
Fig. 5-1: I/O configuration
1 IM151...
2 PM (power module)
3 DI (digital input)
4 DO (digital output)
5 Configured IM151...

5.3 KRL example for writing/reading of IO-driver
Sample file DEF asyncdata_1 ()

INT nHandle
DECL STATE_T Stat
DECL MODUS_T WMode
DECL MODUS_T RMODE
REAL TimeOut
INT Test_Int
CHAR Test_String[10]
IN Offset
COPEN (:LD_EXT_OBJ1, nHandle)

Wait for (nHandle>0)
WMode=#SYNC
RMode=#ABS
TimeOut=10
CWrite (nHandle,Stat,WMode,"Test: %i %s", 33, "...")

Wait for (Stat.Ret1==#DATA_OK)
Offset=0
Test:Int=0
Test_String[]=" "
CRead (nHandle,Stat,RMode,TimeOut,Offset,"Test: %f %i %s", Test_Real,

Test_Int, Test_String[])
Wait For ( Stat.Ret1==#DATA_END )
Wait For ( Test_Int == 33 )
Wait For ( strComp(Test_String[], "...", #CASE_SENS) )
CCLOSE (nHandle, Stat)

Wait For (Stat.Ret1==#CMD_OK)

5. Example
5.4 KRL example for interrupt-controlled READ of IO-driver with

$Data_Ext_obj1/2
Sample file DEF asyncdata_2 ()

DECL STATE_T Stat
OPEN (:LD_EXT_OBJ1, nHandle)

Wait For (nHandle>0)
If ($Data_Ext-Obj1 > 0) then
DATA_UP ()
Endif
Interrupt dec1 10 ehen $Data_Ext_Obj1>0 do Data_UP()

Interrupt on 10
wait for false
CCLOSE (nHandle, Stat)

Wait For (Stat.Ret1==#CMD_OK)
END
DEF DATA_UP ()
DECL STATE_T Stat
DECL MODUS_T RMODE
REAL TimeOut
INT Offset
BOOL tmpB
RMode=#ABS
TimeOut=0
While ($Data_Ext_Obj1 > 0)
tmpB 0= strClear ($LOOP_MSG[])
Offset=0
CRead (nHandle,Stat,RMode,TimeOut,Offset,"%r", $LOOP_MSG[])
Endwhile
END

5.5 KRL example for use of cloCtl
Sample file 1 DEF asyncdata_3 ()

2 INT nHandle
3 DECL STATE_T Stat
4 INT parRet
5 DECL MODUS_T WMode
6 INIT ()
7 COPEN (:LD:EXT_OBJ1, nHandle)

8 Wat For (nHandle>0)
9 WMode0#SYNC
10 CWrite (nHandle,Stat,WMode,"Test: %s", "<...>")
11 Wait for (Stat.Ret1==#DATA_OK)
12 parRet = 0
13 If ( cloCtl (nHandle, 1000, 0, " ", parRet) <> 0) Then halt
14 Else
15 IF ($Data_Ext_Obj1 > 0) THEN halt
16 ENDIF
17 Endif
18 CCLOSE (NHandle, Stat)

19 Wait For (Stat.Ret==#CMD_OK)
20 END
Number Description
9...11 Send three data elements to the receiving queue
via CWrite and the dummy driver
12 Delete data buffer
13 cloCtl unsuccessful
15 No more data may be present

6. Diagnosis
6 Diagnosis
6.1 LED-display PCI-Card CP 1616
Overview
Fig. 6-1: LED-display CP 1616
LED LED Meaning State Remarks

1 (red) Bus error (BF) off Communications con-
nection established.
on Link-status error
occured.
blinks I/O DeviceNet cannot
slowly be addressed or dupli-
cate IP-addresses in
the network.
2 (red) Collective error (SF) off No error occured or
loading is going on.
on Diagnostic information
is available.
1, 2 Bus error (BF) blink Blink-test for identify-
slowly ing construction
Collective error (SF)
alter- groups.
nately
blink Exception error
quickly occured. A diagnosis
via WEB or SNMP is
not possible.
3 (yellow) Activity-LED on Send and Receive.
4 (green) Link-LED on Connection exists.
6.2 Diagnosis of the construction groups
Procedure 1. Change to the user interface of the hardware configurator

2. Highlight the desired construction group.
3. Select menu sequence Target system > Construction group state.
Diagnosis is being done.

6.3 Diagnosis CP 1616
Procedure 1. Change to the user interface of the hardware configurator

2. Highlight CP 1616.
4. In the dialog box Properties select the tab Diagnosis.
5. In the tab Diagnosis select the button Execute.
The diagnosis for CP 1616 is being created.
6.4 Display data with Telnet
Information about the communication can be queried via Telnet.
Prerequisites In the file pnioDrv.ini DEBUG must be set to 1:

[TEST]
...
DEBUG=1
Procedure 1. Click on the Windows-Start button.

2. Select the menu option Execute....
3. In the field Open enter "telnet95 192.0.1.1".
4. Click on OK.
The Telnet-window opens.
Entry Description
pnioShow Query driver status
pnioMakeT- The controller configuration is written in pnet_iosys.ini

emplate
6.5 Diagnosis of the modules installed in Robot Control
If a module installed in the Robot Control is defective or damaged, it is not

shown in the Control. The message is displayed at the SPS.

7. Repair
7 Repair
7.1 Mount KUKA Profinet CP 1616 card
Prerequisites Free, PCI-slot (slot 1 or 4) with master capability

Setup of the Profinet Options-CD is executed (>>> 3.3 "Installing ProfiNet
IO" page 11)
Robot Control is switched-off and protected against unauthorized switch-
on.
Procedure 1. Open the control PC.

2. Remove the cover at the PCI-slot (slot 1 or 4)
3. Insert CP 1616 in the PCI-slot.
Caution!
The CP 1616 must be inserted properly and uniformly in the acceptance
socket of the slot.
4. Screw the CP 1616 at the Control PC.

5. Close the control PC.
6. Insert the connection cable (TP) in the corresponding socket of the front
plate of the CP 1616.
7. Switch-on Robot Control again.
7.2 Dismount KUKA Profinet CP 1616 card
Prerequisites User group expert

Robot Control is switched-off and protected against unauthorized switch-
on.
Procedure 1. Open the control PC.

2. Remove the CP 1616 from the PCI-slot (slot 1 or 4).
3. Optional: Mount Profinet CP 1616 (>>> 7.1 "Mount KUKA Profinet CP
1616 card" page 43) (>>> 3.3 "Installing ProfiNet IO" page 11)
4. Close the control PC.
5. Switch-on Robot Control again.


8. Appendix
8 Appendix
8.1 Offset-Table
The offset byte and the related input and output addreses are specified in this
table.
Formula for start address: Offset x 8 + 1
Address Address Address Address

Byte Byte
from to from to
0 1 8 64 513 520
1 9 16 65 521 528
2 17 24 66 529 536
3 25 32 67 537 544
4 33 40 68 545 552
5 41 48 69 553 560
6 49 56 70 561 568
7 57 64 71 569 576
8 65 72 72 577 584
9 73 80 73 585 592
10 81 88 74 593 600
11 89 96 75 601 608
12 97 104 76 609 616
13 105 112 77 617 624
14 113 120 78 625 632
15 121 128 79 633 640
16 129 136 80 641 648
17 137 144 81 649 656
18 145 152 82 657 664
19 153 160 83 665 672
20 161 168 84 673 680
21 169 176 85 681 688
22 177 184 86 689 696
23 185 192 87 697 704
24 193 200 88 705 712
25 201 208 89 713 720
26 209 216 90 721 728
27 217 224 91 729 736
28 225 232 92 737 744
29 233 240 93 745 752
30 241 248 94 753 760
31 249 256 95 761 768
32 257 264 96 769 776
33 265 272 97 777 784

Address Address Address Address

Byte Byte
from to from to
34 273 280 98 785 792
35 281 288 99 793 800
36 289 296 100 801 808
37 297 304 101 809 816
38 305 312 102 817 824
39 313 320 103 825 832
40 321 328 104 833 840
41 329 336 105 841 848
42 337 344 106 849 856
43 345 352 107 857 864
44 353 360 108 865 872
45 361 368 109 873 880
46 369 376 110 881 888
47 377 384 111 889 896
48 385 392 112 897 904
49 393 400 113 905 912
50 401 408 114 913 920
51 409 416 115 921 928
52 417 424 116 929 936
53 425 432 117 937 944
54 433 440 118 945 952
55 441 448 119 953 960
56 449 456 120 961 968
57 457 464 121 969 976
58 465 472 122 977 984
59 473 480 123 985 992
60 481 488 124 993 1000
61 489 496 125 1001 1008
62 497 504 126 1009 1016
63 505 512 127 1017 1024

9. KUKA Service
9 KUKA Service
9.1 Requesting support
Introduction The KUKA Robot Group documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Faults leading to production downtime should be reported to the local KUKA

subsidiary within one hour of their occurrence.
Information The following information is required for processing a support request:

Model and serial number of the application module
Description of the problem, duration and frequency of the fault
Depending on the specific components used, the following information may
also be required:
Model and serial number of the robot
Model and serial number of the controller
Version of the KUKA System Software
Optional software
Archive of the software
9.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au

Austria KUKA Roboter GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn

9. KUKA Service
France KUKA Automatisme + Robotique SAS

Techvallée
6 Avenue du Parc
91140 Villebon s/Yvette
France
Tel. +33 1 6931-6600
Fax +33 1 6931-6601
commercial@kuka.fr
www.kuka.fr
Germany KUKA Roboter GmbH

Blücherstr. 144
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
India KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
www.kuka.in
Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

Korea KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com
Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt

9. KUKA Service
Russia KUKA-VAZ Engineering

Jushnoje Chaussee, 36 VAZ, PTO
445633 Togliatti
Russia
Tel. +7 8482 391249 or 370564
Fax +7 8482 736730
Y.Klychkov@VAZ.RU
South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Spain KUKA Sistemas de Automatización S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com
Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland KUKA Roboter Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

Taiwan KUKA Robot Automation Taiwan Co. Ltd.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk
USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com

Index
Index
Symbols E
$CUSTOM.DAT 27 Example 35
$EX_MOD2 28
$EXT_MOD1 28 F
Force unload 27
A Fundamentals Profinet IO 8
AN IN 6
AN OUT 6 G
Analog input, IOSYS.INI 24 GSMD 6
Analog input, PNIODRV.INI 23
ANIN 6 I
ANOUT 6 Industrial Ethernet 6
Appendix 45 Install GSDML-file 24
Installation 11
C Installation, ProfiNet IO 11
Configuration 13 Introduction 5
Configuration files 6 io2krlDataDrv.ini 27
Configuration of the external modules, $Cus- IODrvName 28
tuom.dat 27 IOSYS.INI 6
Configure I/O of the Controller 24 IOSYS.INI, configuring, MFC 23
Configure I/O of the Device 26
Configuring a higher-level PC station 17 K
Configuring PC station 2 19 KCP 6
Configuring the pnioDrv.ini file 22 KUKA Customer Support 47
Controller 13
Controller and Device 16 L
Coupling 6 Leave data 27
Coupling devices (from Version 1.3 onwards) 32 LED-display CP 1616 41
Coupling devices in KRL (from Version 1.3 on- Loading a configuration into the module 21
wards) 33
Coupling devices via HMI (from Version 1.3 on- M
wards) 32 MAC address 6
CP 1616 6 Mapping 6
Mount CP 1616 43
D
Decoupling 6 N
Decoupling devices (from Version 1.3 onwards) 30 NrOfElements 28
Decoupling devices in KRL (from Version 1.3 on-
wards) 31 O
Decoupling devices via HMI (from Version 1.3 on- O-File 27
wards) 30 O_File 6
DeleteON_CClose 28 Offset-Table 45
DeleteOn_IOReconfig 28 Overview, configuration 13
Device 15 OverwriteOldData 28
Devices, coupling (from Version 1.3 onwards) 32
Devices, coupling via HMI (from Version 1.3 on- P
wards) 32 PCI-Slot allocation 9
Devices, decoupling (from Version 1.3 onwards) PLC 6
30 PM 6
Devices, decoupling via HMI (from Version 1.3 on- pnioDrv.INI 6
wards) 30 PrintToTelnet 28
DI 6 Procedure 1 29
Diagnosis 41 Procedure 2 29
Dismount CP 1616 43 Product description 7
DO 6 ProfiNet IO, installing 11
Documentation, robot system 5 ProfiNet IO, uninstalling 12
ProfiNet IO, updating 12

ProfNet CP 1616 7
Properties 7
S
Safety instructions 5
Service, KUKA Roboter 47
Step 7 6
Subnet 6
Subnet mask 6
Support request 47
SWAP 6, 23
Swapping 6
System requirements 11
T
Target group 5
Telnet 6, 42
Trade mark 5
Training program 5
Transferring the configuration to the CP 1616 card
29
U
Uninstallation, ProfiNet IO 12
Update, ProfiNet IO 12
W
Warnings 5
WORD types 6


Kuka Profinet CP 1616: Kuka Robot Group Controller Option

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Kuka Profinet CP 1616: Kuka Robot Group Controller Option

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KUKA Robot Group

KUKA ProfiNet CP 1616

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

Publication: Pub Profinet CP 1616 en

2 Product description ......................................................................................... 7

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 3 / 55

4.14.2 Coupling devices in KRL (from Version 1.3 onwards) ............................................... 33

9 KUKA Service ................................................................................................... 47

4 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

1.1 Target group

1.2 Robot system documentation

The robot system documentation consists of the following parts:

1.3 Representation of warnings and notes

Tips to make your work easier or references to further information.

1.4 Trade mark

Windows is a trade mark of Microsoft Corporation.

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 5 / 55

1.5 Terms used

6 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

2.1 KUKA ProfiNet CP 1616

Fig. 2-1: CP 1616 card

Properties The CP 1616 PCI card has the following properties:

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 7 / 55

 Can be used as a network card.

Fig. 2-2: CP1616 connections

2.2 Fundamentals ProfiNet IO

Profinet IO is an Ethernet-based communications protocol. The data ex-

8 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

 Step 7 (Siemens) starting from Firmware 2.1

More information is available in the documentation CREAD/CWRITE.

2.3 PCI-Slot allocation

Fig. 2-3: PCI-Slots

The PC-slots can be filled with the following plug-in cards:

Slot Plug-in card

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 9 / 55

10 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

3.1 System requirements

Robot controller  Hardware:

3.2 Routing the data cables

3.3 Installing ProfiNet IO

Precondition  User group “Expert”

Procedure 1. Insert ProfiNet IO option CD.

3. Switch the robot controller off.

What happens during installation (from Version 1.3 onwards)

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 11 / 55

3.4 Updating ProfiNet IO

Precondition  ProfiNet IO is installed

It is advisable to archive all relevant data before updating or uninstalling a

Procedure 1. Insert ProfiNet IO option CD.

3.5 Uninstalling ProfiNet IO

It is advisable to archive all relevant data before updating or uninstalling a

Precondition  ProfiNet IO is installed

Procedure 1. Start the Uninstall.exe program in the directory ...\KRC_OPTION\PROFI-

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

12 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

Overview Step Description

4.2 Configure Profinet CP 1616 as Controller

Preconditions  PC/laptop with software

Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en 13 / 55

 KUKA ProfiNet I/O options CD

Procedure 1. Open the program Step 7.

Fig. 4-1: Configuration as controller

14 / 55 Issued: 04.02.2008 Version: OP Profinet CP1616 V1 en

Can be used as a network card.

Step 7 (Siemens) starting from Firmware 2.1

Robot controller Hardware:

Precondition User group “Expert”

Precondition ProfiNet IO is installed

Precondition ProfiNet IO is installed

Preconditions PC/laptop with software

KUKA ProfiNet I/O options CD

Preconditions PC/laptop with software

Preconditions PC/laptop with software

Preconditions PC/laptop with software

Hardware Support Package of the Step 7 software

Preconditions PC/laptop with software

Precondition Setup of KUKA ProfiNet options CD

Precondition All communications cables have been installed.

Prerequisites KUKA CP 1616 is configured as controller. (>>> 4.2 "Configure Profinet

Prerequisites The CP 1616 is projected as device at the PROFINET-IO system.