Kuka Interbus 1.1 User manual

Controller Option
Interbus 1.1
For KUKA System Software 8.2
For VW System Software 8.2
KUKA Roboter GmbH
Issued: 29.11.2012
Version: KR C4 Interbus 1.1 V2 en (PDF)

Interbus 1.1
2 / 65 Issued: 29.11.2012 Version: KR C4 Interbus 1.1 V2 en (PDF)
© Copyright 2012
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 KUKA Roboter GmbH.
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
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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub KR C4 Interbus 1.1 (PDF) en
Bookstructure: KR C4 Interbus 1.1 V2.1
Version: KR C4 Interbus 1.1 V2 en (PDF)

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Contents
1 Introduction .................................................................................................. 5
1.1 Target group .............................................................................................................. 5
1.2 Industrial robot documentation ................................................................................... 5
1.3 Representation of warnings and notes ...................................................................... 5
1.4 Trademarks ................................................................................................................ 6
1.5 Terms used ................................................................................................................ 6
2 Product description ..................................................................................... 9
2.1 Overview ....................................................................................................................9
2.2 IBS PCI SC controller board ...................................................................................... 10
2.3 PCP functionality ........................................................................................................ 10
3 Safety ............................................................................................................ 11
4 Installation ................................................................................................... 13
4.1 System requirements ................................................................................................. 13
4.1.1 PCI slot assignment .............................................................................................. 13
4.2 Installing or updating INTERBUS (KSS) .................................................................... 13
4.3 Installing INTERBUS (VSS) ....................................................................................... 14
4.4 Uninstalling INTERBUS (KSS) ................................................................................... 14
5 Start-up and recommissioning ................................................................... 15
5.1 IBS PCI SC/RI-LK ...................................................................................................... 15
5.2 Connecting fiber-optic cables ..................................................................................... 16
5.3 CMD interface ............................................................................................................ 16
5.4 IBS PCI SC/RI/I-T ...................................................................................................... 18
5.5 External power supply to slave .................................................................................. 18
6 Configuration ............................................................................................... 21
6.1 Overview ....................................................................................................................21
6.2 DIP switches on the master module .......................................................................... 21
6.3 DIP switches on the slave module ............................................................................. 22
6.4 Configuring the file IBSPCI.XML ................................................................................ 24
6.5 Configuring the bus with WorkVisual ......................................................................... 28
6.5.1 Inserting segments in the DTM Catalog (Catalog Scan) ...................................... 28
6.5.2 Configuring the INTERBUS master ...................................................................... 29
6.5.3 Configuring the INTERBUS slave ......................................................................... 30
6.5.4 Configuring the INTERBUS master and slave ...................................................... 32
6.5.5 Setting an offset .................................................................................................... 33
6.5.6 Entering the IP address of the line interface ......................................................... 34
7Operation...................................................................................................... 35
7.1 Coupling/decoupling segments .................................................................................. 35
7.1.1 Coupling/decoupling segments via HMI ............................................................... 35
7.1.2 Coupling/decoupling segments via KRL ............................................................... 35
7.2 Activating/deactivating the Interbus driver ................................................................. 36
8 Diagnosis ..................................................................................................... 37
8.1 Displaying diagnostic data ......................................................................................... 37
Contents

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Interbus 1.1
8.2 Status information of the driver .................................................................................. 38
8.3 LEDs on the master module ...................................................................................... 39
8.4 LEDs on the slave module ......................................................................................... 40
8.5 IOCTL commands ..................................................................................................... 41
8.5.1 Generating a dump file ......................................................................................... 42
8.5.2 Restart .................................................................................................................. 42
8.5.3 Switching segments on and off ............................................................................. 43
8.5.4 Extended state polling of slave ............................................................................. 43
8.5.5 Polling the state of a module ................................................................................ 43
8.6 PCP functionality of the slave .................................................................................... 44
8.6.1 PCP hardware settings ......................................................................................... 44
8.6.2 Establishing the connection .................................................................................. 44
8.6.3 Reading data ........................................................................................................ 44
8.6.4 Writing data .......................................................................................................... 47
8.6.5 Terminating the connection .................................................................................. 48
8.6.6 PCP connection settings ...................................................................................... 48
8.6.7 PCP server response to a fault in the master ring ................................................ 48
9 Messages ...................................................................................................... 49
9.1 KUKA.HMI error messages ....................................................................................... 49
10 KUKA Service ............................................................................................... 55
10.1 Requesting support ................................................................................................... 55
10.2 KUKA Customer Support ........................................................................................... 55
Index ............................................................................................................. 63

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1 Introduction
1Introduction
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 bus systems
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
Documentation for the manipulator
Documentation for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
This warning draws attention to procedures which serve to prevent or remedy
emergencies or malfunctions:
Notes These hints serve to make your work easier or contain references to further
information.
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 program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.
These warnings mean that it is certain or highly probable
that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may
occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if
no precautions are taken.
These warnings mean that damage to property may oc-
cur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.
Procedures marked with this warning must be followed
exactly.

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Interbus 1.1
1.4 Trademarks
Windows is a trademark of Microsoft Corporation.
1.5 Terms used
Tip to make your work easier or reference to further information.
Term Description
CMD Configuration, Monitoring, Diagnostic: software
for configuration, monitoring and troubleshooting
in Interbus interfaces.
CR Communication reference.
DTM Device Type Manager
Device description file
I/O Inputs/outputs, e.g. at terminals and on
machines.
Remote bus Designation for the main ring of an Interbus sys-
tem
FSMA Field-installable SubMiniature Assembly: Fiber-
optic connector with screw lock, outwardly simi-
lar to the electrical SMA connector.
FW Firmware: normally unchangeable operating
software of a device which is automatically
loaded when the device is activated.
HCS fiber HCS fiber (Hard Cladded Silica): a FOC variant
consisting of a glass fiber core with a plastic
cladding.
HW Hardware: physical, electronic components and
modules.
IBS Interbus
Interbus A field bus introduced by Phoenix Contact. It is
defined as a ring system in which every device
regenerates and forwards the incoming signal.
The Interbus offers high data throughput at a low
cycle rate and is particularly immune to interfer-
ence. It is defined for normal copper cables and
also for fiber-optic cables. Up to 512 slaves can
be connected to an Interbus (master-slave struc-
ture) and up to 4096 I/Os can be served. The
main ring (remote bus) can contain up to 256
devices; local buses or loop segments can be
coupled, e.g. in a machine, by means of bus
couplers.
ISA Industry Standard Architecture: commonly-used
PC bus before PCI.

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1 Introduction
KCP The KCP (KUKA Control Panel) teach pendant
has all the operator control and display functions
required for operating and programming the
industrial robot.
The KCP variant for the KR C4 is called KUKA
smartPAD. The general term “KCP”, however, is
generally used in this documentation.
Configuration file Text files with specifications for parameters and
settings.
KR C KUKA Robot Controller.
KRL KUKA Robot Language: KUKA robot program-
ming language.
KUKA.HMI The KUKA user interface on the screen of the
robot controller.
Local bus Designation for the sub-rings of an Interbus sys-
tem.
FOC Fiber-optic cables: made of glass or plastic
fibers. Greater immunity to interference than
copper cables; electrical potential differences
have no effect.
MAU Medium Attachment Unit: connection unit for a
bus device.
MAU warning Warning of decreasing transmission quality/
weakening reception level on the optic transmis-
sion link, in order to be able to isolate and elimi-
nate the cause (maladjustment, dirt, etc.) before
it leads to a malfunction.
MPM Multi-Port Memory: Interbus component that
communicates between the bus and the proces-
sors.
PCI Peripheral Component Interconnect: PC bus for
coupling plug-in cards to the processor.
PCP Peripherals Communication Protocol: protocol
for sending info telegrams (e.g. message texts to
be displayed) via an Interbus. It is not actively
used by robot controllers, but forwarded.
PDU Protocol Data Units: data packets on the Inter-
bus
Polymer fiber cable Plastic cable. Cheaper than glass fiber or HCS
fiber, but with a shorter range.
PLC Programmable Logic Controller: is used in sys-
tems as a higher-level master module in the bus
system.
SW Software
Telnet Simple terminal communications protocol. It is
used, for example, to configure individual hard-
ware units.
Term Description

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2 Product description
2 Product description
2.1 Overview
The Interbus PCI interface is a combined master/slave controller board. Mas-
ter and slave are housed on two separate PCI plug-in cards and equipped with
their own processors.
The factory-installed firmware can be updated via the serial diagnostic inter-
face. The parameterization can be saved in a non-volatile memory on the
module. Process data channels and parameter channels (PCP) are support-
ed.
Configuration, mapping and diagnosis can be carried out using the Config+
tool from Phoenix Contact or WorkVisual from KUKA Roboter GmbH.
The Interbus enables communication between the robot controller and the var-
ious I/O units.
The Interbus PCI controller board is available in two versions: one for connec-
tion via copper cables and one for fiber-optic cables.
Interbus is a field bus system that works with a ring structure and active cou-
pling between the devices. The bus access procedure is a master/slave sys-
tem. The data are passed from the master to the slaves as if through a shift
register.
Properties Data transmission via ring system
Master/slave system
Connected devices are automatically loaded by means of an identification
cycle
Supports PCP functionality
Configurable and parameterizable across the network
No terminating resistors
No device address settings have to be made on-site
Can be expanded simply
Flexible adaptation to system topology
Diagnostic options
Transmission speed of 500 or 2000* kBaud (baud rate). Transmission at
2000 kBaud must be supported by all devices.
I/O units can be switched on/off
Branches are easy to implement using remote bus branch terminals
Branches can be cascaded freely
Maximum of 512 devices, of which max. 254 remote bus devices
Maximum of 62 PCP devices
Maximum cable length between the slave devices: 400 m
Maximum cable length with copper cables: 13 km
Maximum cable length with polymer fibers: 70 m
Maximum cable length with HCS (hard-clad silica): 400 m
Maximum cable length with fiberglass cable: 3500 m
Optional operation of master and slave at 500 kBaud or 2 MBaud
The range of functions of the G4 firmware (= 4th generation) is re-
stricted by the driver as follows: the driver does not support the distri-
bution of process data from the slave to multiple address blocks. The
slave process data range must thus be located in a single block starting at a
freely selected address in the MPM.

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Interbus 1.1
Up to 4096 I/Os (FW version 4.49)
Up to 64 PCP devices (FW version 4.49)
The slave part is supplied independently via an external 24 V power supply
Compatibility KR C4 Interbus 1.1 is compatible with the following field buses:
KR C4 PROFINET 2.0, 2.1 and 2.2
KR C4 EtherCAT
2.2 IBS PCI SC controller board
The IBS PCI SC controller board, the Interbus PCI interface for the KR C4 ro-
bot controller, is available in two versions:
IBS PCI SC/RI-LK for connection of fiber-optic cables
IBS PCI SC/RI/I-T for connection of copper cables
(>>> 4.1.1 "PCI slot assignment" Page 13)
The controller board consists either of both master and slave cards or just a
master card. The master card can also be installed and operated without a
slave part. The slave card, however, can only be installed and operated in
combination with a master card.
The master card is installed in PCI slot 1 and the slave card is installed in PCI
slot 2.
2.3 PCP functionality
The slave part of the Interbus PCI interface supports the Peripherals Commu-
nication Protocol. PCP makes it possible to access the lower-level Interbus
from a higher-level Interbus via the MPM (I/O range). By reading from or writ-
ing to the MPM from the higher-level Interbus, it is possible to read inputs and
outputs in the lower-level Interbus and to set outputs there.
No PCP data are sent to the robot controller. The PCP functionality is restrict-
ed to the Interbus driver and to reading and writing I/O data in the MPM from
the higher-level controller. When making the parameter channel and process
data channel settings for the PCP functionality, the DIP switch settings on the
slave module (>>> 6.3 "DIP switches on the slave module" Page 22) must be
observed.

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3 Safety
3 Safety
This documentation contains safety instructions which refer specifically to the
product described here. The fundamental safety information for the industrial
robot can be found in the “Safety” chapter of the operating or assembly instruc-
tions for the robot controller.
The “Safety” chapter in the operating instructions or as-
sembly instructions of the robot controller must be ob-
served. Death to persons, severe injuries or considerable damage to
property may otherwise result.

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4 Installation
4 Installation
4.1 System requirements
Robot controller Hardware:
KR C4
Software:
KUKA System Software 8.2
Or VW System Software 8.2
Laptop/PC The system requirements for installation of WorkVisual are contained in
the WorkVisual documentation.
4.1.1 PCI slot assignment
Description The IBS PCI SC controller board, the Interbus PCI interface for the KR C4 ro-
bot controller, is installed as follows:
The controller board consists either of both master and slave cards or just a
master card. The master card can also be installed and operated without a
slave part. The slave card, however, can only be installed and operated in
combination with a master card.
4.2 Installing or updating INTERBUS (KSS)
Description There is an option CD for INTERBUS:
KR C4 Interbus 1.0
Fig. 4-1: Installing the master and slave cards
Slot Designation Plug-in card
1 PCI1 Interbus master card
2 PCI2 Interbus slave card
3 to 7 - Field bus, slots 3 to 7
The KR C4 cannot be operated with multiple master or slave cards.

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Interbus 1.1
If a version of INTERBUS is already installed, its configuration is carried over
automatically. If this is not desired, the existing version must first be unin-
stalled.
Precondition Software on KUKA.USBData stick
No program is selected.
T1 or T2 operating mode
“Expert” user group
Procedure 1. Plug in USB stick.
2. Select Start-up > Install additional software in the main menu.
3. Press New software. If a software package that is on the USB stick is not
displayed, press Refresh.
4. Select the entry KRC4 Interbus and press Install. Reply to the request for
confirmation with Yes. The files are copied onto the hard drive.
5. Repeat step 4 if another software package is to be installed from this stick.
6. Remove USB stick.
7. It may be necessary to reboot the controller, depending on the additional
software. In this case, a corresponding prompt is displayed. Confirm with
OK and reboot the robot controller. Installation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
4.3 Installing INTERBUS (VSS)
The KR C4 Interbus 1.0 option CD is included in VSS 8.2. KR C4 Interbus 1.0
is automatically installed together with VSS 8.2.
4.4 Uninstalling INTERBUS (KSS)
Precondition “Expert” user group
Procedure 1. In the main menu, select Start-up > Additional software. All additional
programs installed are displayed.
2. Select the entry KRC4 Interbus and press Uninstall. Reply to the request
for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
It is advisable to archive all relevant data before updating a software
package.
Only the KUKA.USB data stick may be used. Data may
be lost or modified if any other USB stick is used.
It is advisable to archive all relevant data before uninstalling a soft-
ware package.

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5 Start-up and recommissioning
5 Start-up and recommissioning
5.1 IBS PCI SC/RI-LK
Fig. 5-1: Configuration of the IBS PCI SC/RI-LK controller board
1 Reset button (slave)
2 Master interface (Remote Out, outgoing remote bus)
3 External 24 V supply voltage (slave)
4 Slave interface (Remote Out, outgoing remote bus)
5 Slave interface (Remote In, incoming remote bus)
6 Indicator elements (LEDs)
7 DIP switches for the slave configuration
8 DIP switches for the master configuration

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5.2 Connecting fiber-optic cables
The IBS PCI SC/RI-LK can work with HCS and polymer fiber cables with
FSMA connectors. The connectors must be secured with union nuts.
5.3 CMD interface
The CMD configuration and diagnostic software or Config+ from Phoenix Con-
tact can access the IBS PCI SC controller board via the RS232 serial interface.
Using CMD, the user can configure, parameterize and diagnose the Interbus.
The parameterization and configuration can be stored in a non-volatile mem-
ory on the controller board using CMD. It is also possible to update the firm-
ware of the IBS PCI SC controller board via the RS232 interface.
Fig. 5-2: Connecting the fiber-optic cables
1 Remote IN, incoming remote bus
2Slave
3 Remote OUT, outgoing remote bus of the slave card
4Master
5 Remote OUT, outgoing remote bus of the master card

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5 Start-up and recommissioning
The CMD interface is designed as a 6-contact mini-DIN socket (PS/2) on the
front plate.
It is connected to the diagnostic PC via a special RS232 cable that is available
from Phoenix Contact.
Fig. 5-3: CMD interface: 6-pin mini-DIN socket (PS/2)
Fig. 5-4: RS232 cable for connection to diagnostic PC

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Interbus 1.1
5.4 IBS PCI SC/RI/I-T
5.5 External power supply to slave
An external 24 V DC power supply is required for operation of the slave mod-
ule. This is connected via a 2-pin MINI-COMBICON connector.
Fig. 5-5: Configuration of the IBS PCI SC/RI/I-T controller board
1 RS232 interface (CMD connection)
2 Master interface (Remote Out, outgoing remote bus)
3 External 24 V supply voltage (slave)
4 Slave interface (Remote Out, outgoing remote bus)
5 Slave interface (Remote In, incoming remote bus)
6 Indicator elements (LEDs)
7 DIP switches for the slave configuration
8 DIP switches for the master configuration

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5 Start-up and recommissioning
Fig. 5-6: Connection of the external 24 V power supply to the slave mod-
ule

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