Profibus Release 4.x, 5.x

SOFTWARE KR C2 Seminar workbook of ………………… Field Bus Technology - Profibus Release 4.x, 5.x Issued: April 2004

© Copyright KUKA Roboter GmbH This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim 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 described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent editions. Subject to technical alterations without an effect on the function.

of 163 Workbook FBT PRB KR C2 04.04.01

Workbook FBT PRB KR C2 04.04.01 of 163

Contents

1. Introduction field bus technology.......................................................5

1.1. Why bus systems?.....................................................................5

1.2. Bus topologies, bus access methods.........................................9

2. Profibus basics................................................................................21

2.1. Functional principle..................................................................21

2.2. Profibus topology .....................................................................27

2.3. Transmission media.................................................................35

2.4. Bus terminator .........................................................................41

2.5. Key data for Profibus ...............................................................47

2.6. Interface to the KRC ................................................................51

3. Profibus configuration software.......................................................57

3.1. SIMATIC-NCM-PC-MANAGER ...............................................57

3.2. Installation SIMATIC-NCM-PC-MANAGER .............................61

3.3. Operating SIMATIC-NCM-PC-MANAGER...............................65

3.4. Installing a new GSD file..........................................................83

3.5. Consistency .............................................................................85

3.6. COMPROFIBUS V3.x for KSS V4.x ........................................89

4. Configuration KRC ..........................................................................93

4.1. Configuration ...........................................................................93

4.2. PFBMS.INI...............................................................................97

4.3. IOSYS.INI ..............................................................................109

4.4. Offset table ............................................................................127


5. Transfer program ..........................................................................129

6. Coupling segments .......................................................................137

7. Diagnosis ......................................................................................145

8. Exercises ......................................................................................157


1. Introduction field bus technology

1.1. Why bus systems?


I 03.09.2003 I College IPRh I 1KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College

Communications pyramid

Data volumeCycle time

Mbytemin

kBytes

Byte0.1s

Bitms

Cell level

Field level

Managementlevel Office bus

Factory bus

Process /cell bus

S/A bus

Field bus

Corporatelevel

Productionmanagement level

Process coordination /control (system) level

(Basic)control level

"Decentralized periphery"

Sensor/Actuator level

Communications pyramid Field buses are characterized by the very fast transmission of small quantities of data. Transmission times are in the millisecond range. The data transmission time is constant. This is in contrast to the office bus (office network), where several Mbytes of data may be involved. Compared to the field bus, the transmission time is slow and variable.



In the past:

With bus system:

PLC KRC

PLC KRC

Bus voltage

Why field buses?

Why bus systems?

• Bus systems require less wiring. As a result, wiring costs are 70% less compared to conventional wiring.

• Bus systems make it easier to expand or convert existing systems. • Bus systems make quick diagnosis possible.



In the past:

With bus system:

Why field buses?


1.2. Bus topologies, bus access methods


I 03.09.2003 I College I PRhI 1KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College

Bus topologies

Line Tree

Ring (active) Ring (physical)



Line structure (Profibus or DeviceNet)

Device Device

Device Device Device

Line structure In the line structure, all devices are connected in parallel. Line structure is used in Profibus and DeviceNet.



Tree structure

Device Device

Device CouplerCoupler Device

DeviceDevice

Tree structure With the tree structure, the bus can be expanded at any point. The expansion can be cascaded. This structure is used by the ASI bus.



Ring structure, active

Device

Device Device

Device

Ring structure, active In the ring structure, the last device must be connected to the first device. This ring structure is used by the ESC circuit on the robot.



Ring structure, physical (Interbus)

Device

DeviceDevice Device

DeviceDevice Device

Ring structure, physical In a physical ring, the outgoing and incoming lines are in a single cable. Interbus is an example of this structure.



Bus access procedures

Master/slave (Profibus)Token passing & master/slave(Profibus)

Priority (DeviceNet) Summation frame (Interbus)

Slave Slave Slave SlaveSlave Slave Slave Slave

MasterMaster Master Master

Master Slave Slave Slave

Master Master Slave

Slave Slave Slave Slave

Master

Token

Bus access procedures There are various procedures for transferring data via a bus system.



Master/slave (Profibus or DeviceNet)

Master


Master/slave In the master/slave bus access procedure, the bus traffic is controlled by the master. The slaves answer only in response to a prompting telegram from the master. Otherwise the slaves remain passive.



Multimaster token passing (Profibus)

Master Master Master


Token

Token passing In token passing, a token is passed from one master module to the next master module. The master module holding the token has complete bus access to all of the slaves. The token is passed on after a defined time interval. No communication takes place between the individual master modules. The master modules access the slaves in accordance with the master/slave principle.



Summation frame (Interbus)


Master

Summation frame All of the slaves together form a shift register. Writing and reading of data take place in a shift cycle (telegram). No addresses have to be set for the devices.



Bus interfaces in the KR C1/2

MFC card20 outputs16 inputs(With KR C1 on MFCcard,with KR C2 external card)

Serial interface(BOSCH_IO,PERCEPTRON)

EthernetDeviceNet

=> Assignment configured in the IOSYS.INI

Option:FIP_IO card

Option: VISION SBIP card

Option: SENSOR LIBO card

Option: DeviceNetLPDN Scanner card

Option:Interbus card

Option:Profibus card


2. Profibus basics

2.1. Functional principle



Profibus


Profibus variants (1)

Profibus

Profibus FMSFMS - Fieldbus

MessageSpecification

Generalautomation

Profibus PAPA - ProcessAutomation

Process automation

Profibus DPDP -

Decentralized Periphery

Production automation



Profibus variants (2)

System coupler

Physical layer (1)DIN19245Part 1

Data link layer (2)

Layers 3 to 6 are notdistinguished

DP profilesDP basic functions

DIN19245Part 3


Data link layer (2)


Application layer (7)with FMS

DIN19245Part 2


Data link layer (2)


PA profilesPA basic functions

DIN19245Part 4

Profibus DP Profibus FMS Profibus PA


Master-slave principle (workbook)

SlaveADR3

SlaveADR4

SlaveADR5

SlaveADR6

MasterADR1

RequestInputs send+ outputs

Inputs



Token passing principle (workbook)

SlaveADR3

SlaveADR4

SlaveADR5

SlaveADR6

MasterADR2

MasterADR1

Token

Token


Communications structure

Start Length Length Start DA SA FC DATA FCS End

0 -1968 bitsEach character 11 bits

Telegram structure:

Note:

Telegram for data exchange (no SAPs)



Modular slaves, configurable slaves

•Profibus modules are available in a number of different variants.

•Profibus modules are often of modular design.

•Slave modules are not as "intelligent" and therefore cost less than a master module.

•A slave module can generally not be configured as a master module.(Exception: PLCs)


Modular slaves, configurable slaves

•The slave modules have only RAM.

•The configuration files are stored in the master module.

•The slave modules receive their configuration data from the Profibus mastervia a configuration telegram.



Configuration by the master (1)

MasterMaster sends configuration telegrams

MasterSlaves answer when they are configured



Master

Data exchange between master and slave modules


2.2. Profibus topology



Line topology

SlaveADR3

SlaveADR4

SlaveADR5

SlaveADR6

MasterADR1

Line topology is used with Profibus


Profibus segment

SlaveADR3

SlaveADR4

SlaveADR5

SlaveADR6

MasterADR1

Maximum of 32 devices per segment

The master module is also a device



Profibus segment bus terminator

•There must be a bus terminator fitted at the start and end of each segment.•The terminator is often located in the Profibus connector.

SlaveADR3

SlaveADR4

SlaveADR5

SlaveADR6

MasterADR1


Repeater (1)

•Additional 31 devices can be connected if a repeater is used. (Repeater is also a device)•The maximum number of slaves is 125 (with 4 repeaters).


Master


Repeater

Segment 1 Segment 2



Repeater (2)

•The repeater electrically isolates the segments.•There must be a bus terminator fitted at the start and endof each segment.•The repeater does not use any Profibus address.•The repeater amplifies the Profibus signals.


Master


Repeater

Segment 1 Segment 2


Repeater (3)


Master


Repeater

Repeater from Siemens

The bus terminator can be activated by means of a DIPswitch



Repeater (4)


Master


Repeater


Segment 1 Segment 2


Two-wire cable (1)

Master



Two-wire cable (2)

Master

All Profibus devices are connected to the bus in parallel

Profibus requires two strands (wires).•Green = Signal A•Red = Signal B


Cable routing (1)

•The Profibus cable is routed from one device to the next.•Each of the many slave modules has only a single Profibus connection. Theseemploy connectors which can be connected to the Profibus cable.

Profibus cable

Master

Profibus connector



Cable routing (2), stubs

•A stub may not be more than 6m long!•A device on a stub does not require a bus terminator.•Recommendation: do not use stubs.

Profibus cable Profibusconnector

Branch

Stub6m max.

Master


2.3. Transmission media



Standard

•The cables most often used are two-strand, twisted, shielded cables.•Special configuration tools are available for these cables.•The Profibus cable is connected to theProfibus device by means of a 9-poleSub-D connector.


Fiber-optic

•Fiber-optic cables are still rarely seenin conjunction with Profibus



Hybrid cable with optical fibers

•Hybrid cable: data lines and power supply in the same cable.•Two optical fibers are used for data transfer.


Hybrid cable, Multibus cable

•Multibus cable: a cable which is suitable for more than one bus system.Developed by/for KUKA Roboter. Is often used in the automotive industry.•Multibus cable: data lines and power supply in the same cable. Max. 50 m spur length. Two voltage potentials:

Potential 1: max. permissible load 4APotential 2: max. permissible load 7.5A

•There are slave modules which can be connected directly to the Multibus:Siemens ET200R and Turck FLDPxxx

Master



Hybrid cable, Multibus cable connector assignments

Profibus

Voltage potential 2

Voltage potential 1

Female connector

Maleconnector


Hybrid cable, Multibus cable Interconnectron connectors



Hybrid cable, Multibus cable slave modules

Turck FLDP xxx Siemens ET200R

These modules can be connected directly to the Multibus cable.


2.4. Bus terminator


I 03.09.2003 I College I PRhI 1Hery-Park 3000, D-86368 Gersthofen +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College

Profibus segment bus terminator

•There must be a bus terminator fitted at the start and end of each segment.•The terminator is often located in the Profibus connector.

SlaveADR3

SlaveADR4

SlaveADR5

SlaveADR6

MasterADR1


Terminators on the connector

Bus terminator



External bus terminator

There are terminators which have to be connected as an additional component.

Bus terminator


Active bus terminator (1)

•For the bus terminator tofunction, it has to be supplied with power.

•This power is supplied by theProfibus device.

•The Profibus standard specifies that each device has to supply the power for a bus terminator.

•The bus terminator requires5VDC.

PIN 6 (5V+)PIN 5 (5VGND)

PIN 3 (Signal A)PIN 8 (Signal B)

A1

B1

A2

B2Bus terminator



Terminators on the connector

Bus terminator

+5VDC

GND

Data B

Data AR=390ohm

R=220ohm

R=390ohm


1

Profibus pin assignment

Repeater control signal9

Received Data/Transmitted Data Minus8

24V potential7

Supply voltage of the terminators(5VDC)

6

Supply voltage of the ground terminators (GND)

5

Repeater control signal4

Received Data/Transmitted Data Plus3

Ground of the 24V potential2

Shield/functional ground1

MeaningPinno.

CNTR-N

RxD/TxD

P24

VP

DGND

CNTR-P

RxD/TxD

M24

Shield

Signal




If the last device in the Profibus segment is deenergized:•Then the bus terminator is no longer functional.•Communication is no longer possible.

Power supply off(e.g. Emergency Stop)

Note: Connect bus devices to two voltage potentials.•Potential1: bus coupler•Potential2: power, e.g. outputs and proximity switch supply.The second potential can be switched off via the E-Stop function.

Master



If the last device in a Profibus segment is switched off (deenergized), then the entire Profibus segment is faulty.Communication is no longer possible.

Master

Main switch off(service work)

PLC is master Robots are slaves

Note: use an I/O module as the last device, or a bus terminator module.



Bus terminator module

•A bus terminator module can be used to terminate the bus.•The bus terminator module requires 24VDC, and supplies the necessary voltage for terminating the bus.


Bus connector for transmission rates >1.5Mbit/s

•For transfer rates greater than 1.5Mbit/s, connectors with built-in interference suppression coils must be used.•If a connector is suitable for more than 1.5Mbit/s, then "12MBd" will be printed on the connector.•For all other connectors, the maximum transfer rate is 1.5Mbit/s

A1

B1

A2

B2Bus terminator

Coils with 110nH each


2.5. Key data for Profibus



Key data for Profibus

•A maximum of 125 slaves can be connected to a single Profibus master.

•32 devices per segment.

•Transfer rate selectable in steps between 9.6 Kbit/s and 12Mbits/s.

•Maximum data of a Profibus slave module:244 bytes of inputs and244 bytes of outputs

•The devices may be arranged as desired.


Transfer rate and segment length

•The segment length is dependent on the transfer rate.Low transfer rate – long segmentHigh transfer rate – short segment

•Standard value is 1.5 Mbit/s

0.0096

1200

0.0192

1200

0.0937

1200

0.1875

1000

0.5

400

1.5

200

3.0

100

6.0

100

12

100

Mbit/sm

•When using the Multibus cable, the transfer rate must notexceed 1.5Mbit/s!

•The cable length of a Profibus network can be increased if arepeater is used.



Bus cycle time

•The robot reads the inputs every 12 ms.•The robot writes the outputs immediately.

2

4

6

8

10 (160 I/Os) 20 (320 I/Os) 30 (480 I/Os)Number of slaves

Bus cycle time/ms

Each slave has 2 bytes of input data and 2 bytes of output data

10

12

14

12 Mbit/s

1.5 Mbit/s

500 kbit/s


2.6. Interface to the KRC



Master

Interface options on the robot, robot is master

Robot is Profibus master


Interface options on the robot, robot is slave

Master

Robot is Profibus slave



Interface options on the robot, robot is master and slave

Master

Robot is:•Profibus master and•Profibus slaveat the same time

Robot is slave

Robot is master


Profibus interface module CP5613/14 (1)

Profibus master connection

Profibus slave connection

The Profibus master part is electrically isolated from the Profibus slave part

CP5613 = masterCP5614 = slaveCP5613/14 = master and slave on a single card



Green LED:flickers: DP master:

•Token passing.off: DP master:

•Incorrect bus parameters•Defective bus•CP not in operation

flashes once per second: DP master:•Database contains errors

Yellow LED:flickers: DP slave:

•Polling by higher-level master (normal operation).off: DP slave:

•Connection is not being addressed

Green and yellow LEDs blink alternately:•Module is being addressed by diagnostic module

Profibus interface module CP5613/14 (2)


Profibus interface module CP5613/14 in the KRC (1)

CP5613/14

KUKA robot with optional PSA interface

X12A Profibus slave INX12B Profibus slave OUTX14 Profibus master



Profibus interface module CP5613/14 in the KRC (2)

KUKA robot with optionalInterbus Cu and Profibus M/S(e.g. DaimlerChrysler)

X12A Profibus slave INX12B Profibus slave OUTX15 Profibus master


Profibus interface module CP5613/14 in the KR C2 (3)

CP5613/14 can be installed inslot 5 or 6.

Profibus master connection X850

Profibus slave connection X851

KR C2


3. Profibus configuration software

3.1. SIMATIC-NCM-PC-MANAGER




Master sends configuration telegrams

•In order for the Profibus master to configure the slaves, the master needs a database.•The database must be created using the SIMATIC NCM PC Manager.

Database (NAME.LDB)

Master


Functional principle of the SIMATIC NCM PC Manager (1)

MasterMaster configures the slaves

Database (NAME.LDB)

*.GSD*.GSE*.GSG

SIMATIC NCM PC Manager




•For each Profibus slave type there is a device master data file (GSD).•GSD files have the following file name extensions:

•GSD (international)•GSE (English)•GSG (German)

•The GSD file contains information about how the Profibus slave can be configured.•If the required GSD file is not contained in the SIMATIC NCM PC Manager, or if the existing GSD file is too old, it can be updated.•The GSD files for most Siemens devices are already present in the SIMATIC NCM PC Manager. For all other devices, the GSD files have to be loaded as anupdate.


Examples of GSD files

GSD file for CP5614 S0100008.GSD (KUKArobot as slave)

;===============================================; GSD-File for CP5614 Sample SIEMENS AG; MLFB : 6GK1 561-4AA00; Auto_Baud_supp, 12MBaud;; Date : 15.03.99 mm; File : SIE_0008.GSD;===============================================#Profibus_DP; Unit-Definition-List:GSD_Revision=1Vendor_Name="KUKA Roboter GmbH"Model_Name="KUKA CP5614 Slave"Revision="V1.0"Ident_Number=0x0008

;==============================================; GSD-File for ET 200S Siemens AG ; MLFB : 6ES7 151-1AA02-0AB0; 6ES7 151-1AA01-0AB0; 6ES7 151-1AA00-0AB0;; Date : 23.10.00 V1.7 GW ;; File : SIEM806A.GSG==============================================#Profibus_DP

; <Prm-Text-Def-List>

PrmText = 1Text(0) = "disable"Text(1) = "enable"

GSD file for ET200SSIEM806A.GSG




•Configuring a Profibus network by means of the SIMATIC NCM PC Manager produces the following files:

•Project data directory. The files in this directory can be used to edit or supplement an existing project.

•Database. The database is a file with the extension .ldb. The name of the file can be selected freely (max. of 8 characters).

•In order to function, the CP5613/14 in the robot only requires the database (*.ldb)LDB=Local Data Base

•The database must be saved in the directory C:\KRC\Roboter\INIT.


3.2. Installation SIMATIC-NCM-PC-MANAGER



Installing the SIMATIC NCM PC Manager (1)

•The SIMATIC NCM PC Manager can be installed on a Windows PC (notebook), or on the KRC.



•If the Step7 software from Siemens is on the notebook, then the SIMATIC NCM PC Manager cannot be installed.

•The SIMATIC NCM PC Manager is a part of the Step7 software.

•If Step7 is installed, then the SIMATIC NCM PC Manager is not needed.

•Configuration with Step7 is exactly the same as with the SIMATIC NCM PC Manager.




•The SIMATIC NCM PC Manager can be installed on a Windows PC (notebook), or on the KRC.•Software requirements:WinNT, Win2k, WinXP•Hardware requirements:RAM >=64MbyteFree hard disk space >=120Mbyte

Installation on the KRC:•Run up computer without HMI (hold down the CTRL key while booting).•Deactivate virus scanner.



The setup files are located on the KUKA CD starting with V 5.2.3.Path:D:\INTERNAT\BUS\PROFIBUS\NCM_PC_MANAGER\DISK1\SETUP.EXE


3.3. Operating SIMATIC-NCM-PC-MANAGER



Working with the SIMATIC NCM PC Manager

There are several ways of working with the SIMATIC NCM PC Manager. One of those ways is described here.

If you are an inexperienced user and problems arise, it is advisable tocreate a new project and repeat all of the steps from the beginning.

In order to work effectively with the SIMATIC NCM PC Manager, you should use a mouse.


Working with the SIMATIC NCM PC Manager



Creating a new project

Project name

Project path


Inserting a Simatic PC Station

Popup menu Insert New Object /Simatic PC StationSimatic PC Station

Right-click withthe mouse (popup menu)MPI can be

deleted



Opening hardware configuration

Double-click on SIMATIC PC Station

Double-click on Configuration(hardware configuration is started)


Hardware configuration

Virtual PC rack. The slots do nothave to correspond to reality.

Hardware configuration is an extra program which is started from the SIMATIC NCM PC Manager.



Inserting CP5613

1. Hide/show hardware catalog

2. Select slot 1

3. Select CP5613, SW V6.0 SP4 (double-click)


Properties of CP5613

Master addressRecommendation:Address 2 or 1

•Connect CP5613 with Profibus.

•This requires creation of anew Profibus network.

•To do this, select New.

•The properties window ofthe new Profibus network then opens.



Properties of Profibus, general

No settings are requiredon the General tab.

The Network Settings tab is used to set the parameters for theProfibus network.


Properties of Profibus, network settings

The transfer rate can be set here.Recommendation: 1.5Mbit/s(default)

Select bus profile DP (default)

Confirm the entry by pressing OK.

Also confirm entries forCP5613 properties by pressing OK.



Working with the SIMATIC NCM PC Manager (1)

The CP5613 is now on logical slot 1.

Detail view of PC rack.


Inserting a user application

1. Show hardware catalog

2. Select slot 2

3. Select a user application (double-click)



Selecting CP5613 object properties

Select CP5613 object properties

Popup menu: CP5613/Object Properties


CP5613 object properties, General tab

No changes are required here



CP5613 object properties, Mode tab (1)

Select DP master

Select Generate LDBfile

Specify path and nameof the LDB file

If the NCM Manager is located on the KRC, then the directoryC:\Roboter\KRC\INIT can simply be selected here.


CP5613 object properties, Mode tab (2)

If Autoclear is activ and one module has an error, all outputs of all I/O-Moduls are set to a safe state (mostly state False)

Autoclear is used e.g. for arc-welding.



Profibus master system (1)

Select Profibus.

The Profibus symbol is dark.


Working with the SIMATIC NCM PC Manager (1)

Select the desired module from theProfibus DP hardware catalog.(double-click)

Some modules are listed more than once. If in doubt, check the ordernumber.



Slave address

The slave address can be set here.The lowest slave address which should be used is 3.

If you wish to change the slave address again later, you can return tothis window by selecting the slave, right-clicking, and then Properties.


Configuring slave modules (1)

1. Select slave.

2. Select slot 1.

3. Under the Profibusmodule are additionalmodules which can be operated with this one.

4. Select the appropriate modules.




The selected module is now on slot 1.



Select the appropriate modules.



Configuring slave modules (4), packing the ET200S

The address values have no meaning for the KRC.The distribution to the bytes can be seen here. Each 2 DI module occupies one byte.


Configuring slave modules (5), packing the ET200S

1. Select module.

The inputs can be grouped together. This applies only to theET200S. It is similar for the other modules. Please follow the instructions in the module documentation.

2. Pack addresses.



Configuring slave modules (6), parameterization

Select Object Properties.

Some modules can be parameterized, e.g. analog inputs, analogoutputs, fast counters, encoders, etc.



Under Parameters are the parameters for the corresponding module.




Module-specific parameters are located here.



Selection window for module parameters, e.g. voltage range.The appropriate settings can be made here.



General parameters, slave module (1)

Right-click on a slave module – Object Properties.



Module-specific parameters are located here.




Selection window for module parameters.


Save configuration, generate *.ldb

Save project and compile

•When saving, the configuration is saved and an *.LDB file is generated.•The *.LDB can then be copied from the selected directory (the directory is specified under Properties of CP5613) and inserted in the directory C:\Roboter\KRC\INIT.


3.4. Installing a new GSD file




•For each Profibus slave type there is a device master data file (GSD).•GSD files have the following file name extensions:

•GSD (international)•GSE (English)•GSG (German)

•The GSD file contains information about how the Profibus slave can be configured.•If the required GSD file is not contained in the SIMATIC NCM PC Manager, or if the existing GSD file is too old, it can be updated.•The GSD files for most Siemens devices are already present in the SIMATIC NCM PC Manager. For all other devices, the GSD files have to be loaded as an update.


Installing a new GSD file

Install new GSD file.

Specify source path andname of the GSD file.

If the required GSD file is not contained in the SIMATIC NCM PC Manager,or if the existing GSD file is too old, it can be updated.


3.5. Consistency



Consistency

•Profibus operates in a byte-oriented manner.

•Large quantities of data are sometimes transferred using more than one telegram.

•Consistent data transfer can be used for safe transfer of values>=2bytes.


Consistency (2)

Bit no.Byte 1 Byte 0

256

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Value 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0The integer value now changes to 255.


255

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Value 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 Byte 0 is transferred first.


511

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Value 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1


255

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Value 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

The integer value is 256.

If the controller reads the integervalue now, the value will be incorrect!

Byte 1 is transferred now. The value is now correct again.



Consistency (3)

Remedy:Transferring data consistently.

•Profibus can transfer a number of blocks consistently.

•A consistent data block can contain up to 16 words.

•"Consistent transfer" can be set in the configuration tool (SIMATIC NCM PC Manager).

•If consistent data transfer is required, $OPTION.DAT must be edited appropriately.


SIMATIC NCM PC Manager, configuring consistency (1)

Object properties



SIMATIC NCM PC Manager, configuring consistency (2)

If this entry is activated, in this example a 5-byte block will be transferred consistently over its total length.


$OPTION.DAT

..BOOL $DATA_INTEGRITY=TRUE ;SIGNAL DATA CONSISTENCY ON/OFF..

$OPTION.DAT

This functionality is available fromV4.1.7 SP1 B307 onwards

Path:C:\KRC\Roboter\ KRC\STEU\MADA\$OPTION.DAT


3.6. COMPROFIBUS V3.x for KSS V4.x



Installing COMPROFIBUS

•Run the COMPROFIBUS setup program. Path: KUKA CD:\INTERNAT\PROFIBUS\COMPROFIBUS\GER3.3\INSTALL\SETUP.EXE

•For the Profibus master the corresponding type file SI8075AX.2MH must be copied from the KUKA CD to the subdirectory C:\COMPB33\MASTERS. The type file is located here: Path: KUKA CD:\INTERNAT\PROFIBUS\COMPROFIBUS

•For slave modules which are not integrated into COMPROFIBUS, the associated GSD file must be copied into the subdirectory C:\COMPB33\GSD.


"File - New" takes you to the dialog box "New Master System". Here select the master type "CP 5613/CP 5614".

New master system



Here you can use Drag and Drop to assign the desired slaves to the master stored in the system.

In the event of ambiguities, the order number must be taken into account.

Configuring slaves


An *.LDB file can be generated under File - Export - NCM File. This file must then be copied into the ...\INIT directory on the robot.

Generating an *.LDB file


4. Configuration KRC

4.1. Configuration



General information on operator control

• User privileges: Expert Modee.g. in order to edit files other than robot programs

• Selection of files and editing

• Alternatively: switch to Windows by means of a keyboard shortcut


Directories of the C:\ partition

Home directory of the robot controller:C:\Program Files\KRC\

or C:\KRC\Roboter\

• Directory of the configuration files:C:\...\INIT

• Directory for log files:C:\...\LOG

• Directory of the driver programs:C:\...\DRIVERS

The names of the directories should be viewed only as examples, since there are different variants of the KRC withdifferent directory structures.



Configuration and driver files

CP5613/14

• C:\...\INIT\IOSYS.INI: Configuration file of the I/O system

• C:\...\INIT\PFBMS.INI: Parameterization file of the Profibusdriver

• C:\...\DRIVERS\PFBMSDRV.O: Driver program for Profibus CP5613/14

• C:\...\DRIVERS\FW_5613.BIN: Firmware file for Profibus CP5613/14


4.2. PFBMS.INI



Sections of PFBMS.INI for the CP5613/14

PFBMS.INI [CP_5613/14] ; General settings[MASTER]; Master parameters

[SLAVE]; Slave parameters

[SWAP]; Exchange high byte with low byte



PFBMS.INI: General settings

[CP_5613/14]DEBUG=1LOGFILE_PATH=log/pfms.logERROR_TEXT=GermanFORCE_RESET=0OLD_ERROR_DB=0

PFBMS.INI

This entry is optional

[CP_5613/14] General settings. DEBUG Default setting: DEBUG=1 This parameter can be used to switch Telnet outputs on and off. LOGFILE_PATH Default setting: LOGFILE_PATH=log/pfbms.log Specify path and file name (within the directory C:\KRC\Roboter). Messages from the boot sequence and relevant messages from ongoing operation are logged in the log file. If this entry is missing, no log file is created. ERROR_TEXT Default value: ERROR_TEXT=German The language version of the log file can be selected here. The languages German and English are available. FORCE_RESET Default value: FORCE_RESET=0 If this value is 0 or the entry is missing, the CP5613/14 master or slave module is only restarted in the event of a reset command from the HMI if a bus error is genuinely present.


If this value is 1, the master and the slave module are always restarted in the event of a reset command from the GUI. OLD_ERROR_DB This entry is normally not present. If a Profibus driver of version 4.1.7 or higher is used in a system with version 4.1.6 or lower, then this entry must be OLD_ERROR_DB=1. In all other cases, this entry is not necessary.



PFBMS.INI: Master settings

[MASTER]MASTER_USED=1DATABASE_PATH=init/FIRMWARE_PATH=drivers/FW_5613.binWATCHDOG_TIME=3MAPPING_USED=0MAPPING_PATH=init/;DEACTIVATED_SLAVES=

PFBMS.INI

[MASTER] Settings for the master. MASTER_USED=1 Default setting: MASTER_USED=1 The master can be activated (1) and deactivated (0) here. DATABASE_PATH Default setting: DATABASE_PATH=init/name.ldb This entry must correspond to the directory (within the C:\KRC\Roboter directory) and the name of the database. If the driver does not find a database at the specified location, the bus cannot be put into operation. Special case: If the entry MASTER_USED has the value 0 and no database is specified, then the file SLAVE.LDB from the INIT directory is loaded by default. FIRMWARE_PATH Default value: FIRMWARE_PATH=drivers/FW_5613.bin This entry must correspond to the directory (within the C:\KRC\Roboter directory) and the name of the firmware. WATCHDOG_TIME Default value: WATCHDOG_TIME=3 This entry is used to set the watchdog which monitors the robot controller. The setting is made in increments of 10 ms. If the watchdog is not retriggered in the time


set, the master goes to the operational state Clear and the slaves are set to a defined state. If this entry is 0, the watchdog is deactivated. MAPPING_USED Default value: MAPPING_USED=0 If this value is 0, the mapping function is deactivated and the entry MAPPING_PATH is ignored. If this entry is 1, the mapping table specified in the following entry is read and the mapping function is executed according to this table. This entry must correspond to the directory (within the C:\KRC\Roboter directory) and the name of the mapping table. If the driver does not find a mapping table at the specified location, the bus cannot be put into operation. MAPPING_PATH Default value: MAPPING_PATH=init/ If the entry is MAPPING_USED=0, the entry MAPPING_PATH is ignored. If MAPPING_USED=1, this entry must correspond to the directory (within the C:\KRC\Roboter directory) and the name of the mapping table. If the driver does not find a mapping table at the specified location, the bus cannot be put into operation. DEACTIVATED_SLAVES Default value: ;DEACTIVATED_SLAVES= Slaves which are not connected to the bus when the driver is booted, but which have been configured.



PFBMS.INI: Slave settings

[SLAVE]MODUL_USED=0MODUL_ADDRESS=;START_TIME=20ERROR_ACTION=1STANDBY=0SLAVE_TIMEOUT=0CHECK_CONFIGURATION_DATA=0ACCEPTABLE_INPUT_LENGTH=244ACCEPTABLE_OUTPUT_LENGTH=244IO_DATA_BASE=0CONSISTENCE=0

PFBMS.INI

[SLAVE] Settings for the slave. MODUL_USED Default setting: MASTER_USED=0 If this value is 0, the slave module is not started and is thus not available to a higher-level DP network. If this value is 1, the slave module is started. After booting, the module waits for the parameterization and configuration data of the corresponding master. Once these are received, the module goes into data exchange mode. MODUL_ADDRESS Default setting: MODUL_ADDRESS= The address, selected during configuration, of the slave module in the higher-level Profibus system must be entered here. START_TIME Default setting: ;START_TIME=20 In order to be able to compare, during the loading process, the configuration of the slave module with the data range in the file IOSYS.INI, the module must be in DATA_EXCHANGE mode. This is assured by means of this time factor (min. 20 as default value). ERROR_ACTION Default value: ERROR_ACTION=1


If this value is 0 and the master of the slave module goes to the state CLEAR (e.g. STOP in the Siemens S7), the KRC is not stopped and no error message is generated. If this value is 1 and the master of the slave module goes to the state CLEAR, the KRC is stopped and a corresponding error message is generated. STANDBY Default setting: STANDBY=0 This function is only supported from Profibus driver version 1.18 onwards. If the value is 0, then in order to start, the slave module must be subordinated to a master, otherwise the driver is deactivated. An I/O reconfiguration must be carried out before it can be started again. If the value is 1, then error messages of the slave module are ignored. As long as the slave module is not initialized by a master, read and write errors will appear. If the slave is initialized by a master, the read and write errors are automatically cleared and the exchange of data can begin. Checking of data lengths is carried out cyclically with each read and write access, and not during initialization as is the case with Standby=0. Errors in the configuration of the slave module (IOSYS.INI) thus appear only after successful initialization by a master. SLAVE_TIMEOUT Default value: SLAVE_TIMEOUT=0 This function is only supported from driver version 1.24 onwards. If this value is 0, the cyclical change in status of the slave is not monitored. If the value is >0, then a max. counter value is set and a timer-controlled counter is activated. The counter evaluates the status WAIT_FOR_CONFIGURATION of the slave module. If this status is left and then reached again within 5 seconds, an internal counter is incremented. If the value SLAVE_TIMEOUT is exceeded by the counter, the driver is unloaded, since a reset cannot correct the error. The following error message is transmitted to the HMI: "Configuration error I/O driver CP561DRV : Slave configuration" If no status change takes place, the counter is reset after 15 seconds. CHECK_CONFIGURATION_DATA Default setting: CHECK_CONFIGURATION_DATA=0 If this value is 0, the configuration data that the slave module receives from the master in the higher-level Profibus system are accepted without being checked. If this value is 1, the configuration data received by the slave module are checked. The criteria for this check are defined in the following entries. ACCEPTABLE_INPUT_LENGTH ACCEPTABLE_INPUT_LENGTH=244 If CHECK_CONFIGURATION_DATA=1, the maximum configured input data length may not exceed this specified value. If the slave module receives a configuration


telegram exceeding this value, it is rejected and the slave module does not go into data exchange mode. If the slave module is divided into several individual modules, the value refers to each of the modules in the slave module. Thus the value which is entered must correspond to the module with the largest data width. ACCEPTABLE_OUTPUT_LENGTH ACCEPTABLE_OUTPUT_LENGTH=244 If CHECK_CONFIGURATION_DATA=1, the maximum configured output data length may not exceed this specified value. If the slave module receives a configuration telegram exceeding this value, it is rejected and the slave module does not go into data exchange mode. If the slave module is divided into several individual modules, the value refers to each of the modules in the slave module. Thus the value which is entered must correspond to the module with the largest data width. IO_DATA_BASE IO_DATA_BASE=0 0 means byte as database, 1 means word. If CHECK_CONFIGURATION_DATA=1, the database which was used to configure the slave module must correspond with this entry. If the slave module receives a configuration telegram which does not agree with this value, it is rejected and the slave module does not go into data exchange mode. CONSISTENCE CONSISTENCE=0 0 signifies no guarantee of consistency over the whole slave module. If this entry is 1, data consistency is guaranteed over the entire length of the module. If CHECK_CONFIGURATION_DATA=1, the consistency condition which was used to configure the slave module must correspond with this entry. If the slave module receives a configuration telegram which does not agree with this value, it is rejected and the slave module does not go into data exchange mode.



PFBMS.INI: Swap settings

[SWAP]INWORD_SLAVE_3=2,4OUTWORD_SLAVE_3=2

INWORD_SLAVE_4=0,2OUTWORD_SLAVE_4=0,2

PFBMS.INI

[SWAP] Settings for swapping (exchanging bytes) Syntax: INWORD_SLAVE_X=Y "INWORD_SLAVE" means: data are read by the KRC. X stands for the DP address of the slave, within which a word is to be swapped. Y stands for the offset of the word in the slave. If several words have to be swapped within a slave, this can be specified in the following way: INWORD_SLAVE_X=Y,A,B where "Y, A, B" stand for the different offsets of the words in the slave. NOTE: A "SWAP entry" is only effective if the corresponding data object has a data width of 2 bytes (or 1 word). This is the case for all analog inputs and outputs or if the object has been created accordingly in IOSYS.INI (e.g. INB10=4,0,x2 or INW12=6,2,x1). Syntax: OUTWORD_SLAVE_X=Y "OUTWORD_SLAVE" means: data are written by the KRC. X stands for the DP address of the slave, within which a word is to be swapped. Y stands for the offset of the word in the slave. If several words have to be swapped within a slave, this can be specified in the following way: OUTWORD_SLAVE_X=Y,A,B where "Y, A, B" stand for the different offsets of the words in the slave.


NOTE: A "SWAP entry" is only effective if the corresponding data object has a data width of 2 bytes (or 1 word). This is the case for all analog inputs and outputs or if the object has been created accordingly in IOSYS.INI (e.g. OUTB10=4,0,x2 or OUTW12=6,2,x1).


4.3. IOSYS.INI



I/O system

CALL-P

MFC DeviceNetProfibus

Periphery management

Soft PLCRobot system

Interbus


Structure of IOSYS.INI

[CONFIG]VERSION=2.00

[DRIVERS];MFC=0,mfcEntry,mfcdrv.o;INTERBUS=1,ibusInit,ibusdrv.o;DEVNET=2,dnInit,dndrv.o......PBMASL=11,pbmsInit,pfbmsdrv.o

[MFC]INW0=0 ;$IN[1-16]OUTW0=0 ;$OUT[1-16]OUTW2=2 ;$OUT[17-32]

IOSYS.INI

Profibusmaster/slave, CP5613/14

Caution!Observe

upper/lower-case!



Activating the Profibus driver

Profibusmaster/slave,CP5613/14

Activation

IOSYS.INI [CONFIG]VERSION=2.00

[DRIVERS]MFC=0,mfcEntry,mfcdrv.oINTERBUS=1,ibusInit,ibusdrv.oDEVNET=2,dnInit,dndrv.o......PBMASL=11,pbmsInit,pfbmsdrv.o

[PBMASL];PROFIBUS I/O assignments


+24V=TRUE, 0V=FALSE

OUTPUTS$OUT[1]$OUT[2]$OUT[3]$OUT[4]$OUT[5]...$OUT[1024]

INPUTS$IN[1]$IN[2]$IN[3]$IN[4]$IN[5]...$IN[1024]$IN[1025]=TRUE$IN[1026]=FALSE

From the periphery

To the periphery

Inputs and outputs of the KRC controller (1)



Inputs and outputs of the KRC controller (2)

The KRC controller is shipped as standard with 1024 inputs and outputs available.

The inputs and outputs can be increased to 4096 by modifying the$OPTION.DAT file.

The KRC controller is shipped as standard with 1024 inputs and outputs available. The inputs and outputs can be increased to 4096 by modifying the $OPTION.DAT file.



I/O assignment, digital I/Os (1)

Example: INB2=3,2,x2

OUTW6=3,0,x1

Profibus address

, Byte offset=

Profibus side

INOUT

BWDW

Byte offset

Robot side

, xMultiplier

Configuration of digital inputs and outputs Robot side The specification of the I/O position in the I/O system on the left-hand side is made up of three parts arranged consecutively without gaps: Processing direction IN : robot controller input OUT : robot controller output Data width B : byte = 8 bits (signals) W : word = 2 bytes = 16 bits (signals) DW : double word = 2 words = 4 bytes = 32 bits (signals) This specification determines the number of bytes reserved after the byte offset address. Byte offset Byte offset = { 0, 1, 2, ... , 127 } The byte offset values range from 0 to 127 for both the digital inputs and the digital outputs. Please note that multiple assignment is not possible for any memory position in the I/O system.


Profibus side The specifications on the right-hand side refer to the position of the process data in the I/O map of the Profibus card. The specifications are separated from one another by commas: Profibus DP address Profibus DP address = { 0,1,2, ... , 127 } The Profibus DP address is set on each Profibus module. If data are needed from the slave part of the card, the DP address 127 is used. Byte offset Byte offset = { 0,1,2, ... , 243 } The byte offset on the Profibus side designates the position of the I/Os in the memory of the Profibus device. The byte offsets, again counted separately for all the inputs and all the outputs. Multiplier Multiplier = { 1, 2, 3, ... } Using the multiplier, you can assign multiple I/Os (according to the value of the multiplier) to groups; the data width of these groups depends on the data width specified on the robot side.



DI

DO

DI

DO

Configuration of digital I/Os (3)

If data is to be accessed from the slave interface,then the address 127 must be used on the Profibusside.

Example:INB20=127,0,x8 OUTB20=127,0,x8

-An output on the PLC is aninput on the robot.-An input on the PLC is anoutput on the robot.


Sl: 16 DISl: 16 DO

KRC

Master

DP 3

16DI

16DI

16DO

DP 4

8DI

8DO

8DO

DP5

16DI

8DO

0-1 0

0-1 2-3 0-1

0 0 1

Example of a bus configuration

• Slave ring: 16 DI, 16 DO

• Master ring:

Slave DP address 3: 16 DI, 16 DI, 16 DO

Slave DP address 4: 8 DI, 8 DO, 8 DO

Slave DP address 5: 16 DI, 8 DO



Configuration of the inputs and outputs (1)

[PBMASL]; Profibus DP slave 3INW0=3,0,x1 ; $IN[1-16]INB2=3,2,x2 ; $IN[17-32]OUTW0=3,0,x1 ; $OUT[1-16]; Profibus DP slave 4INB4=4,0,x1 ; $IN[33-40]OUTB2=4,0,x1 ; $OUT[17-24]OUTB3=4,1,x1 ; $OUT[25-32]; Profibus DP slave 5INB5=5,0,x1 ; $IN[41-48]INB6=5,1,x1 ; $IN[49-56]OUTB4=5,0,x1 ; $OUT[33-40]

IOSYS.INI

Sl: 16 DISl: 16 DO

KRC

Master

DP3

16DI

16DI

16DO

DP4

8DI

8DO

8DO

DP5

16DI

8DO

0-1 0

0-1 2-3 0-1

0 0 1


[PBMASL]; Profibus DP slave 3INW0=3,0,x1 ; $IN[1-16]INB2=3,2,x2 ; $IN[17-32]OUTW0=3,0,x1 ; $OUT[1-16]; Profibus DP slave 4INB4=4,0,x1 ; $IN[33-40]OUTB2=4,0,x1 ; $OUT[17-24]OUTB3=4,1,x1 ; $OUT[25-32]; Profibus DP slave 5INB5=5,0,x1 ; $IN[41-48]INB6=5,1,x1 ; $IN[49-56]OUTB4=5,0,x1 ; $OUT[33-40]; Data from and to the slave part (PLC)INB20=127,0,x2 ; $IN[161-176]OUTB20=127,0,x2 ; $OUT[161-176]


IOSYS.INI

Sl: 16 DISl: 16 DO

KRC

Master

DP3

16DI

16DI

16DO

DP4

8DI

8DO

8DO

DP5

16DI

8DO

0-1 0

0-1 2-3 0-1

0 0 1



ANALOG OUTPUTS$ANOUT[1]...$ANOUT[32]

ANALOG INPUTS$ANIN[1]...$ANIN[32]

From the periphery

To the periphery

Analog inputs and outputs of the KRC controller



Configuration of analog I/Os (1)

Profibusaddress

Exponent2

Type

Profibus side

=ANINANOUT

Index

Robot side

Cal factor

CAL factor: limitation of the value range

This entry is optional.For the analog module, the specified value in digits corresponds to the nominal value (e.g. 10V).

Type: justification, sign

2 : left, without sign3 : left, with sign

0 : right, without sign1 : right, with sign

Byte offset

, , , ,

Analog inputs and outputs Robot side Processing direction ANIN : analog controller input ANOUT : analog controller output Index: Index = { 1, ..., 32 } for inputs Index = { 1, ..., 32 } for outputs With analog I/Os, each index can only be used once. The index is positioned immediately after ANIN or ANOUT without a space. Profibus side Profibus DP address Profibus DP address = { 0,1,2, ... , 127 } The Profibus DP address is set on each Profibus module. If data are needed from the slave part of the card, the DP address 127 is used. Byte offset


Byte offset = { 0,1,2, ... , 243 } The byte offset on the Profibus side designates the position of the I/Os in the memory of the Profibus device. The byte offsets, again counted separately for all the inputs and all the outputs. Exponent 2 Exponent2 = { 8, ..., 16 } The parameter Exponent 2 specifies the number of bits used to represent the numeric value of an analog value. Type Type = { 0, 1, 2, 3 } The parameter Type specifies how the Exponent 2 bits are arranged in the word and whether or not the leading bit of the Exponent 2 should be interpreted as a plus/minus sign before the numeric value. The possible parameter values have the following meanings: 0 : right-justified without sign 1 : right-justified with sign 2 : left-justified without sign 3 : left-justified with sign Cal factor The Cal factor specifies the value in digits at which an analog output outputs its nominal value (e.g. 10V). For an analog input, the value of the Cal factor corresponds to the nominal input value.




ANIN1=3,4,16,3,CAL30000

Example: Phönix IB IL AI 2/SF:

IOSYS.INI:

From the manual:



ANOUT1=3,4,16,2 or

ANOUT1=3,4,16,2,CAL65535

Example: Phönix IB IL AO 1/SF: IOSYS.INI:

From the manual:

FFFFHex = 65535Dec




ANIN1=3,4,13,3 or

ANIN1=3,4,13,3,CAL4095

Example: Phönix ST modules:

IOSYS.INI:

From the manual:

Note: 7FF8Hex = 1111 1111 1111 1000Bin 111 1111 1111 1Bin = 8191Dec (13bits)

With positive and negative range – 4096 to + 4095



ANIN1=3,4,16,3,CAL27648

Example: Siemens analogmodules (ET200S, ET200M):

IOSYS.INI:

From the manual:



Particular characteristics (1), Intel/Motorola format (1)

Intel format

Byte 1 Byte 0

1 word

Bit 8 value 256 (2exp8)

In the Motorola format, the bytes within a word are interchanged.


Motorola format

Byte 0 Byte 1

1 word





PC-based controllers use the Intel format. (KUKA KRC)

Depending on the module, it may be necessary to swap the bytes within a word!

Phoenix and Siemens use the Motorola format.

Example:

INB0=3,1,x1 ;Word 0

INB1=3,0,x1 ;Word 0

INB2=3,3,x1 ;Word 2

INB3=3,2,x1 ;Word 2

IOSYS.INI:




.

.

.

.[SWAP]INWORD_SLAVE_4=1,3OUTWORD_SLAVE_4=0,2

OUTWORD_SLAVE_5=2,4

PFBMS.INI


Particular characteristics (2), control signals

•There are some modules, e.g. analog inputs, which can be configured by means of control signals (outputs on the robot).•These control signals should be configured when necessary.•Control signals can be used to specify the analog format, for example.

•There are modules with 8 inputs, for example. These modules still occupy 1word in the Profibus memory (Profibus offset), however. The unused byte has no function.



KRC

master

DP 3

16DI

16DI

16DO

DP 4

8DI

2AI

2AO

DP5

16DO

2AO

0-1 2-3 0-1

0-1 2-3,4-5

0 1-2,3-4

0-1,2-3

Example of a bus configuration

Master ring:

Slave DP address 3: 16 DI, 16 DI, 16 DO

Slave DP address 4: 8 DI, 2 AI, 2 AO

Slave DP address 5: 16 DO, 2 AO

All modules are from Siemens.


KRC

master

DP 3

16DI

16DI

16DO

DP 4

8DO

2AO

2AO

DP5

16DO

2AO

0-1 2-3,4-5

0-1 2-3 0-1

0 1-2,3-4

0-1,2-3


[PBMASL]; Profibus DP slave 3INW0=3,0,x1 ; $IN[1-16]INB2=3,2,x2 ; $IN[17-32]OUTW0=3,0,x1 ; $OUT[1-16]; Profibus DP slave 4INB4=4,0,x1 ; $IN[33-40]ANIN1=4,1,16,3,CAL27648 ;ANIN[1]ANIN2=4,3,16,3,CAL27648 ;ANIN[2]ANOUT1=4,0,16,3,CAL27648 ;ANOUT[1]ANOUT2=4,2,16,3,CAL27648 ;ANOUT[2]; Profibus DP slave 5OUTB2=5,0,x1 ; $OUT[17-24]OUTB2=5,1,x1 ; $OUT[25-32]ANOUT3=5,2,16,3,CAL27648 ;ANOUT[3]ANOUT4=5,4,16,3,CAL27648 ;ANOUT[4]

IOSYS.INI



KRC

master

DP 3

16DI

16DI

16DO

DP 4

8DI

2AI

2AO

DP5

16DO

2AO

0-1 2-3 0-1

0-1 2-3,4-5

0 1-2,3-4

0-1,2-3


.

.

.

.[SWAP]INWORD_SLAVE_4=1,3OUTWORD_SLAVE_4=0,2

OUTWORD_SLAVE_5=2,4

PFBMS.INI


4.4. Offset table



Table: offset byte and input/output (1)

Offset byte Start End0 1 .. 81 9 .. 162 17 .. 243 25 .. 324 33 .. 405 41 .. 486 49 .. 567 57 .. 648 65 .. 729 73 .. 80

10 81 .. 8811 89 .. 9612 97 .. 10413 105 .. 11214 113 .. 12015 121 .. 12816 129 .. 13617 137 .. 14418 145 .. 15219 153 .. 16020 161 .. 16821 169 .. 17622 177 .. 18423 185 .. 19224 193 .. 200

Offset byte Start End25 201 .. 20826 209 .. 21627 217 .. 22428 225 .. 23229 233 .. 24030 241 .. 24831 249 .. 25632 257 .. 26433 265 .. 27234 273 .. 28035 281 .. 28836 289 .. 29637 297 .. 30438 305 .. 31239 313 .. 32040 321 .. 32841 329 .. 33642 337 .. 34443 345 .. 35244 353 .. 36045 361 .. 36846 369 .. 37647 377 .. 38448 385 .. 39249 393 .. 400


Formula for start address: Offset x 8 +1


Table: offset byte and input/output (2)



Offset byte Start End125 1001 .. 1008126 1009 .. 1016127 1017 .. 1024


5. Transfer program



Transfer configuration program

Master Robot is slave

Robot is master

TR Config

•Data can be transferred from the master component to the slave part of theProfibus card and vice versa.•The transfer takes place in real time.•The transfer function is executed directlyon the Profibus card, independently ofthe KRC.


Installing the transfer configuration program

•The transfer configuration program is located on theKUKA CDPath:Drive:\Internat\Bus\Profibus\PCI_Card\German\TR_Config.exe

•This program can be started directly, or copied to the harddisk and started there.



Working with the transfer configuration program (1)



Address=byte offset

Remote master = Slave part of the CP5613/14

The higher-level master sees the robot as an I/O module.The "connections" of this module come from the robot masterpart.

Address=byte offset




In this example, the inputs from slave 3 of the robot master ring are transferredto the higher-level master. The first byte (offset 0) of the inputs is transferred.The higher-level master sees these data as inputs at its location.



Important:In order for the data to be transferred to the higher-level master, the data must be output on the slave part of the card as outputs. The first output byte of the slave part contains these data. This byte may no longer be used for any other data, i.e.:IOSYS.INI:OUTB20=127,0,x1; This entry has no function. The output byte 0

is occupied by the transfer configuration program

Profibus

CP5613/14Master part Slave partAddress 2 Address 10Input OutputSlave 3, byte 0 Byte 0

Byte 1TR Config Byte 2

Byte 3

Higher-level master (PLC)

Data from slave 10InputByte 0 Data from robot slave 3Byte 1 Other dataByte 2 Other dataByte 3 Other data




IOSYS.INI:INB0=3,0,x1; The inputs of slave 3, byte 0 can be used by the KRC

Profibus

CP5613/14Master part Slave partAddress 2 Address 10Input OutputSlave 3, byte 0 Byte 0


Byte 3


Data from slave 10InputByte 0 Data from robot slave 3Byte 1 Other dataByte 2 Other dataByte 3 Other data



Transfer list.

The transfer entry must be insertedinto the transfer list.




In this example, the outputs from slave 3 of the robot master ring are controlled by the higher-level master. The first byte (offset 0) of the outputs is controlled.The higher-level master sees these data as outputs at its location.



In order for the output data to be transferred to the higher-level master, the data must be read in on the slave part of the CP5613/14 card as input data. The first input byte of the slave part contains these data. These data can also be made accessible to the KRC, i.e.:IOSYS.INI:INB20=127,0,x1; Here you can read in the status of the outputs on slave 3,

byte 0.

Profibus

CP5613/14Master part Slave partAddress 2 Address 10Output InputSlave 3, byte 0 Byte 0


Byte 3


Data from slave 10OutputByte 0 Data to robot slave 3Byte 1 Other dataByte 2 Other dataByte 3 Other data




Caution:Outputs can only be controlled from a single location. The following entry in theIOSYS.INI has no effect.IOSYS.INI:OUTB0=3,0,x1; This entry has no function. These outputs are controlled

by the higher-level master.

Such entries are invalid and must be avoided!

Profibus

CP5613/14Master part Slave partAddress 2 Address 10Output InputSlave 3, byte 0 Byte 0


Byte 3


Data from slave 10OutputByte 0 Data to robot slave 3Byte 1 Other dataByte 2 Other dataByte 3 Other data



Transfer list.

The transfer entry must be insertedinto the transfer list.




The transfer list must now be given a name. The file extension is *.tra. Save the transfer list in the directory C:\KRC\Roboter\Init.


PFBMS.INI

[MASTER]MASTER_USED=1DATABASE_PATH=init/Rob1.ldbFIRMWARE_PATH=drivers/FW_5613.binWATCHDOG_TIME=3MAPPING_USED=1MAPPING_PATH=init/Rob1.tra;DEACTIVATED_SLAVES=

PFBMS.INI

Activate mapping with the transfer configuration program (1).

Enter the name of the transfer list.


6. Coupling segments



Coupling and decoupling slave modules

I/O modules are often located onthe tool. If an automatic tool change is necessary, the I/O module on the first tool must be decoupled and theI/O module on the second tool must be coupled.

I/O module


Tool changer

I/O module

Tool changer on weld gun

Tool changer on robot wrist



Hardware requirements (1)

If the last device is decoupled, then the bus terminator is no longer present.The entire bus system enters the fault state.

Remedy:Install a repeater upstream of the device that is to be decoupled.The repeater creates electrical isolation between the two bus segments.

Repeater


Hardware requirements (2)

If the last device is decoupled, then the bus terminator is no longer present.The entire bus system enters the fault state.

Remedy:•Install modules with an intelligent bus terminator(Turk FLDP).•Install modules with an integrated repeater(Siemens ET200R).



Software requirements (1) SIMATIC NCM PC Manager

SIMATIC NCM PC Manager:Configure the bus structure as if all slave modules are connected at the sametime.

Tool 4

Tool 3Tool 2

Tool 1

Each tool is given its own Profibus DP address.


Software requirements (2) IOSYS.INI

IOSYS.INI:Configure the bus structure as if all slave modules are connected at the sametime.

[PBMASL];Tool 1 large weld gun slave 3INB0=3,0,x1 ; $IN[1-8]INB1=3,1,x1 ; $IN[9-16]OUTB0=3,0,x1 ; $OUT[1-8]OUTB1=3,1,x1 ; $OUT[9-16];Tool 2 medium weld gun slave 4INB2=4,0,x1 ; $IN[17-24]INB3=4,1,x1 ; $IN[25-32]OUTB2=4,0,x1 ; $OUT[17-24];Tool 3 small weld gun slave 5INB4=5,0,x1 ; $IN[32-40]OUTB3=5,0,x1 ; $OUT[24-32]..

IOSYS.INI



Software requirements (3) PFBMS.INI

PFBMS.INI:So that the Profibus driver knows which modules are connected to the bus, allmodules which are not connected have to be deactivated.

.

.

.[MASTER]MASTER_USED=1DATABASE_PATH=init/Rob1.ldbFIRMWARE_PATH=drivers/FW_5613.binWATCHDOG_TIME=3MAPPING_USED=0MAPPING_PATH=init/DEACTIVATED_SLAVES=3,4,5,6...

PFBMS.INI


Software requirements (3) PFBMS.INI

After I/O reconfiguration or after switch-on, the modules which have been deactivated in PFBMS.INI are no longer addressed by the Profibus driver.

.

.

.[MASTER]MASTER_USED=1DATABASE_PATH=init/Rob1.ldbFIRMWARE_PATH=drivers/FW_5613.binWATCHDOG_TIME=3MAPPING_USED=0MAPPING_PATH=init/DEACTIVATED_SLAVES=3,4,5,6...

PFBMS.INI



Activating/deactivating modules by means of KRL

•If a deactivated module is to be activated, this information must be given to theProfibus master. Otherwise, no data can be exchanged with the module.

•If an activated module is to be deactivated, this information must likewise be given to the Profibus master. If this is not done, a program stop will occur andan error message will appear.

•Deactivation and activation can be carried out via the KRL program.The IOCTL system function is available for this purpose.



Syntax: Result = IOCTL ( 11 , 1002 , 3 )

KRL command

Driver identification number for Profibus (master/slave)

Code number for "Deactivate slave" command(1001 = activate,1002 = deactivate)

Slave no. 3

Integer variable(0 = command executed)




Deactivate

Activate

Example:


Activating/deactivating modules by means of the KCP

For test purposes, modules can alsobe activated and deactivated by meansof "manual input" on the KCP.At Version <5.x the “=“-Sign is not necessary.


7. Diagnosis



Diagnostic options (1) Hardware tester

•For checking the bus cable and wiring.•Wiring errors are displayed.•Tests accessibility of the slaves.

Siemens BT200


Diagnostic options (2) HMI message window (GUI)

In the event of a bus fault, error messages appear on the HMI

Messages on theHMI



Diagnostic options (3) Log file

Log file is written when the driver is started.Progress of the startup procedure is logged.

PFBMS.LOGFILE_PTR_POS=001559

04/03/04 08:35:58 : Logfile for Profibus CP5613/14 (V1.25.7.0)

04/03/04 08:35:58 : Downloading Firmware and Database.........

04/03/04 08:36:00 : CP5613/14 started!

04/03/04 08:36:00 : Master Application registered at the CP!

04/03/04 08:36:00 : Accessed pointer to DPR from CP!

04/03/04 08:36:00 : Hardware version: 3.08

04/03/04 08:36:00 : Firmware version: 2.01

04/03/04 08:36:00 : Master baudrate : 1,5 MB

04/03/04 08:36:01 : next CP state: DP_STOP

04/03/04 08:36:01 : DP_Master has changed mode to: DP_STOP

04/03/04 08:36:01 : next CP state: DP_CLEAR

04/03/04 08:36:01 : DP_Master has changed mode to: DP_CLEAR

04/03/04 08:36:01 : next CP state: DP_OPERATE

04/03/04 08:36:01 : DP_Master has changed mode to: DP_OPERATE

04/03/04 08:36:01 : Slave Application registered at the CP!

04/03/04 08:36:01 : Slave started!

04/03/04 08:36:01 : Slave baudrate : 1,5 MB

04/03/04 08:36:01 : SLAVE_MODUL: State = WAIT_FOR_CONFIGURATION

04/03/04 08:36:01 : SLAVE_MODUL: State = DATA_EXCHANGE

===== LAST_ENTRY =====


Case example: Everything is OK, only the master part is active




16/03/04 12:27:39 : CP5613/14 started!













Master is active



Case example: Everything is OK, master and slave parts are active




16/03/04 12:53:53 : CP5613/14 started!













16/03/04 12:53:54 : Slave started!





Master is active

Slave is active



HMI: Slave 3 is not present, only the master part is active

HMI

•Communication error•Error in the master ring•Driver error


Log file: Slave 3 is not present, only the master part is active




16/03/04 12:27:39 : CP5613/14 started!













Master is active

It cannot be determined from the log file whether the connected slaves are active.The log file shows the state of the master.



HMI: Connection to the higher-level master is not available

HMI

•Error in slave ring


Log file: Connection to the higher-level master is not available

PFBMS.LOG.

.

.












16/03/04 13:29:14 : Slave started!




16/03/04 13:29:27 : SLAVE_MODUL: State = WAIT_FOR_PARAMETER


The slave part waits for aconfiguration telegram from the higher-level master.



Log file: Connection to the higher-level master is OK again

PFBMS.LOG.

.












16/03/04 13:29:14 : Slave started!







Slave part is active again.



HMI: Connection to the higher-level master is not available

HMI

Driver configuration error

PFBMS.INI contains the entry STANDBY=0. After I/O reconfiguration a driver configuration error appears.


Log file: Connection to the higher-level master is not available

PFBMS.LOG.


.



16/03/04 14:59:30 : Slave started!


16/03/04 14:59:32 : Slavemodul is not in mode data_exchange within 2000millisec

>onds! 4 14:59:32 : Slavemodul is not in mode data_exchange within 2000millisec

16/03/04 14:59:32 : Slave is stopped!

16/03/04 14:59:33 : Slave Application cancelled at the CP!


.

16/03/04 14:59:33 : DP_Master has changed mode to: DP_OFFLINE

16/03/04 14:59:33 : DP_Pointer released!

16/03/04 14:59:33 : Master Application cancelled at the CP!

16/03/04 14:59:33 : CP is resetted!


The slave part does not receive any configuration telegram from the higher-level master. The entire driver is therefore deleted.

PFBMS.INI contains the entrySTANDBY=0. After I/Oreconfiguration a driver configuration error appears.



HMI: Connection to the higher-level master has no bus terminator

HMI

Fault in the slave line

A faulty bus terminator causes reflections in the bus. After a very short time, avery large number of messages are active. Then the only output on the HMI is"Overflow Message Interface".


Log file: Connection to the higher-level master has no bus terminator


17/03/04 12:16:19 : DP-Error: 8034 0.

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

17/03/04 12:16:19 : DP-Error: 8034 0

.

The slave part receives aconfiguration telegram from the higher-level master.Shortly after that, the slave once again waits for aconfiguration telegram from the master.



HMI: Configuration error, incorrect slave address in IOSYS.INI

HMI

In IOSYS.INI, the slave address is incorrect in one or more entries. A general"configuration error message" appears on the HMI.

•Communiction error•Configuration error


Log file: Configuration error, incorrect slave address in IOSYS.INI




17/03/04 12:29:00 : CP5613/14 started!












17/03/04 12:29:02 : read channel: configured slave with address 4 not in database!

17/03/04 12:29:02 : read channel: configured slave with address 4 not in database!


In IOSYS.INI there are two entries referring to the slave withaddress 4. The slave with the address 4 is not present in thissystem.



HMI: Configuration error, incorrect offset in IOSYS.INI

HMI

In IOSYS.INI, the offset of the slave is incorrect in one or more entries. Ageneral "configuration error message" appears on the HMI.

Configuration error


Log file: Configuration error, incorrect offset in IOSYS.INI (1)




17/03/04 12:42:19 : CP5613/14 started!












17/03/04 12:42:21 : read data ERROR: data(1)+offset(10) > slavedata(0), [3]!



In IOSYS.INI there are two entries for which the slave offset is too high.



Log file: Configuration error, incorrect offset in IOSYS.INI (2)

PFBMS.LOG.

.




data(1) = data object with a size of 1 byte.

offset(10) = slave module offset10.

slavedata(0) = the data object size is0 (not present).

[3] = slave address.For this slave, the offset byte 10 and 11is not present.


8. Exercises



Overview: Profibus exercises

1. Exercise: Installing the SIMATIC NCM PC Manager2. Exercise: Creating an LDB file with the SIMATIC NCM PC Manager3. Exercise: Robot is Profibus master (digital I/Os)4. Exercise: Robot is Profibus master (analog I/Os)5. Exercise: Robot is Profibus slave6. Exercise: Robot is Profibus master and Profibus slave7. Exercise: Mapping with TR Config8. Exercise: Coupling/decoupling slave modules9. Exercise: Diagnosis10. V4.x exercise: Installing ComProfibusV3.311. V4.x exercise: Creating an LDB file with COMPROFIBUS V3.3


1st exercise: Installing the SIMATIC NCM PC Manager

•Switch the robot controller on and hold the CTRL key down; this ensures that only Windows is started, and not the HMI.

•Deactivate the virus scanner.•Install the SIMATIC NCM PC Manager from the KUKA CD. Path:D:\KRC1_CD\Internat\Bus\Profibus\Disk1\SETUP.EXE

•Confirm or modify the information in the setup dialog.•When you have finished the setup procedure, reboot the PC.



2nd exercise: Creating an LDB file with the SIMATIC NCM PC Manager

•Start the SIMATIC NCM PC Manager. Create a new project.•Create a project as described in the chapter on operator control of theSIMATIC NCM PC Manager.

•Check that the LDB file is located in the INIT directory of the robot.


3rd exercise: Robot is Profibus master (digital I/Os)

•Edit the PFBMS.INI file. Activate the master and specify the name ofthe *.LDB file.

•Edit the IOSYS.INI file. Activate the Profibus master/slave driver,deactivate all other drivers.

•Carry out an I/O reconfiguration.•Check that all of the Profibus modules on the bus are active (greenLED).

•Configure the robot inputs and outputs in IOSYS.INI. Configure only one module. Configure only the digital inputs and outputs.

•Carry out an I/O reconfiguration.•Check the inputs and outputs.•Configure the other modules in the same manner.



4th exercise: Robot is Profibus master (analog I/Os)

•Add the entries for the analog inputs and outputs to the IOSYS.INI file.•Carry out an I/O reconfiguration.•Check the analog inputs and outputs.Note: the analog inputs cannot be tested everywhere. A measuring instrument is available for the analog outputs.


5th exercise: Robot is Profibus master and Profibus slave

•Edit the PFBMS.INI file on the lower-level robot. Activate the slave partand specify the slave number (robot 1 = address 3, robot 2 = address4, etc.). Set the parameter STANDBY to 1.

•Edit the IOSYS.INI file on the lower-level robot. Here the data from the higher-level master should be present from input 161 onwards andfrom output 161 onwards.

•Carry out an I/O reconfiguration on the higher-level master. Then dothe same on the lower-level robot.

•Create a Profibus configuration on the higher-level master. Each robotshould have 4 input bytes and 4 output bytes.

•Edit the files PFBMS.INI and IOSYS.INI on the higher-level master.•Check the inputs and outputs.



6th exercise: Robot is Profibus slave

•Edit the PFBMS.INI file on the lower-level robot. Deactivate the masterpart. Specify Slave.ldb as the database. Activate the slave part andspecify the slave number.

•Edit the IOSYS.INI file on the lower-level robot. Deactivate the entries for the master ring. The data from the higher-level master should be present on the robot from input 161 onwards and from output 161onwards.

•Create a Profibus configuration on the higher-level master. Each robotshould have 4 input bytes and 4 output bytes.

•Edit the files PFBMS.INI and IOSYS.INI on the higher-level master.•Carry out an I/O reconfiguration on the higher-level master. Then dothe same on the lower-level robot.

•Check the inputs and outputs.


7th exercise: Mapping with TR Config

•Re-establish the configuration "robot is master and slave". Configure 3bytes of the higher-level master in the IOSYS.INI file of the lower-levelrobot (OUTB20=127,0,x1, OUTB21=127,1,x1, OUTB22=127,2,x1,).

•Copy the program TR_CONFIG from the KUKA CD into the directoryC:\. Start the program.

•Select as the source Slave no. 3, Input, Byte, Address 0, Quantity 1.•Select as the destination Remote Master, Input, Byte, Address 3.•In the Edit menu, select Insert Entry.•Save the file in the ...\INIT directory. The file has the extension .TRA•Edit the PFBMS.INI file. Activate MAPPING and underMAPPING_PATH specify the name of the file created by means of TR_CONFIG.

•Carry out an I/O reconfiguration on the higher-level master. Then dothe same on the lower-level robot.

•Check the inputs and outputs. The inputs are now visible on the higher-level master.



8th exercise: Decoupling and coupling a Profibus slave

•Re-establish the configuration "robot is master".•Once the controller has run up, slave no. 4 has to be deactivated(decoupled). To do this, make the following entry in the PFBMS.INI file:DEACTIVATED_Slaves=4

•I/O reconfiguration. Slave no. 4 should now be deactivated. Unplug theProfibus connector on slave no. 4. No error message should appear onthe HMI. Plug the Profibus connector back in again.

•Couple slave no. 4. To do this, go to the menu Monitor - Variable -Single. Enter the following there: "IOCTL(11,1001,4)". Check slave no. 4.

•Decouple slave no. 4. To do this, go to the menu Monitor - Variable -Single. Enter the following there: "IOCTL(11,1002,4)".

•Couple slave no. 4 again.•Optional: write the corresponding KRL program and test it. Note: it is not necessary to program any motion.


9th exercise: Diagnosis

•Re-establish the configuration "robot is master".•Unplug the connector on slave no. 4. Observe the response on theGUI.

•Plug the connector back in again. Observe the response on the GUI.Acknowledge all messages.

•Unplug the connector on slave no. 4 once again.•Carry out an I/O reconfiguration. Look at the Profibus.log file.•Re-establish the configuration "robot is master".•Change the configuration in IOSYS.INI; instead of slave no. 4,configure slave no. 44. Carry out an I/O reconfiguration. Observe the response on the GUI. Look at the Profibus.log file.

•Re-establish the configuration "robot is master".•Change the configuration in the IOSYS.INI file; instead of INB0=3,0,x1,configure INB0=3,0,x10. Carry out an I/O reconfiguration. Observe the response on the GUI. Look at the Profibus.log file.



10th exercise: Installing COMPROFIBUS

•Switch the robot controller on.•Carry out installation from the KUKA CD.•Copy the master type file Si8075ax.2mh into the directoryC:\Compb33\Masters

•Copy the device master data files for the required slaves into the directory C:\COMPB33\GSD. For example, the file SIEM806A.GSG for the ET200S module.


11th exercise: LDB file with COMPROFIBUS

•Start COMPB33.•Open a new project and select CP5613/14 as the master.•Select the slave modules and configure them. The slave modules should have the addresses 3 (ET200S), 4 (ET200S) and 5 (ET200M).

•Check the configured baud rate. This is under Configure - Bus Parameters

•Save the file.•Create an *.LDB file under File - Export - NCM File. Save the file in the...\INIT directory.

Profibus Release 4.x, 5.x

Documents

Transcript of Profibus Release 4.x, 5.x