KUKA+PLC problem with PROFIBUS

[ktys]

Hi,

First sorry for my english.
Two i study and this is my first time with profibus and kuka so...I create the pdf with my problem.

I beg you help me i must end this soon.

[SkyeFire]

Assuming the configuration of the slave devices on the bus is correct, your setup is nearly complete.

You will need to activate the S7 option to "Export .LDB file," and then compile the Profibus setup.  The .LDB file generated during the compile process will need to be copied into the INI directory on the robot.  You will need to adjust the PFBMS.INI file in the INI directory to use that .LDB file as the scanlist. 

The Profibus manual was recently uploaded to the Manuals sub-forum.

[ktys]

I thought if KUKA is only Slave, i don't need to create LDB file.

'The empty database Slave.ldb is located in the directory KRC\INIT.
This can be used if the master is not going to be started.'

[MASTER]
MASTER_USED=0
DATABASE_PATH=init/Slave.ldb<--- here  ?
FIRMWARE_PATH_A1=drivers/FW_5613.bin
FIRMWARE_PATH_A2=drivers/FW5613A2.bin
WATCHDOG_TIME=3
MAPPING_USED=0
MAPPING_PATH=init/
;DEACTIVATED_SLAVES=

[SLAVE]
MODUL_USED=1
MODUL_ADDRESS=3
DATABASE_PATH=init/Slave.ldb <--- or here  ?
START_TIME=60
ERROR_ACTION=1
STANDBY=0
SLAVE_TIMEOUT=0
CHECK_CONFIGURATION_DATA=0
ACCEPTABLE_INPUT_LENGTH=244
ACCEPTABLE_OUTPUT_LENGTH=244
IO_DATA_BASE=0
CONSISTENCE=0  

------------------------------------------------------------

Whether these error  8022 and 1033 can suggest  that the problem is in the configuration of the PLC?

'Bus error in the slave circuit:
If a bus error occurs in the higher--level circuit, in which the slave module is integrated, the
slave module cannot be accessed either to read or write.
The master can access its slaves with authorization to read, but not to write.'

 

[SkyeFire]

 

Apologies.  I saw the NCM software and assumed you were using the KRC as a Master.  You are correct:  no .LDB file is necessary if the KRC is only acting as a Slave.

Leave the MASTER section untouched, except to ensure that the MASTER_USED setting is 0.

Don't add any lines to the SLAVE section.  Your settings appear to be valid.  The address of 3 matches your NCM screen capture.  So, what problem are you having?  What error messages?

Have you uncommented the PFBMS driver in the top of IOSYS.INI?

[ktys]

KUKA error messages(Polish)

8022 Profibus błąd w obwodzie Slave(Profibus error in Slave circuit(?))

1033 Błąd przy odczytywaniu sterownik CP561DRV%2 (Error on reading driver CP561DRV%2)
 
2858 Potwierdzenie STOP z powodu błędu magistrali(Confirmation STOP the error bus (?))or (Ack Stop for error fieldbus)

iosys.ini:

[DRIVERS]
;CNKE2=21,cnke2CPInit,cnke2drv.o
;DNSC6=20,dnsc6Init,dnsc6drv.o
;DNSC5=19,dnsc5Init,dnsc5drv.o
;DNSC4=18,dnsc4Init,dnsc4drv.o
;DNSC3=17,dnsc3Init,dnsc3drv.o
;CNKE1=16,cnke1CPInit,cnke1drv.o
;INTERBUSPCI=15,ibsCPPciInit,ibpcidrv.o
;DSEIO=14,dseIoInit,dseiodrv.o
;DNSC2=13,dnsc2Init,dnsc2drv.o
;DNSC1=12,dnsc1Init,dnsc1drv.o
PBMASL=11,pbmsInit,pfbmsdrv.o
;DEVNET=2,dnInit,dn2drv.o
;INTERBUS=1,ibusInit,ibusdrv.o
;MFC=0,mfcEntry,mfcdrv.o

 [PBMASL]

INB1=127,0,x1 ;$IN[9-16]
OUTB1=127,0,x1 ; $OUT[9-16]

Pfbms.log

FILE_PTR_POS=001154
26/01/09 11:38:42 : Logfile for Profibus CP5613/14 (V2.01.0.8)                 
26/01/09 11:38:42 : use default DATABASE_PATH=init/slave.ldb                   
26/01/09 11:38:42 : Downloading Firmware and Database.........                 
26/01/09 11:38:43 : CP5613/14 started!                                         
26/01/09 11:38:43 : Slave Application registered at the CP!                     
26/01/09 11:38:43 : Slave started!                                             
26/01/09 11:38:43 : Accessed pointer to DPR from CP!                           
26/01/09 11:38:43 : SLAVE_MODUL: State = WAIT_FOR_PARAMETER                     
26/01/09 11:38:45 : Slavemodul is not in mode data_exchange within 6000 millisec
>onds!                                                                         
26/01/09 11:38:45 : Slave is stopped!                                           
26/01/09 11:38:45 : DP_Pointer released!                                       
26/01/09 11:38:46 : Slave Application cancelled at the CP!                     
26/01/09 11:38:46 : CP is resetted!                                             
=====  LAST_ENTRY  =====

All what i did is in pdf file.

[SkyeFire]

Hm.  This pattern suggests that the PLC is never taking ownership of the KRC.  Under Profibus, the Master auto-negotiates bus speed with the slaves during startup, and then sends configuration data to each slave before starting the bus.  From the log file, I would say that for whatever reason, the PLC is never performing this process.  I don't think that the logfile would look the same if the problem were a parameter mismatch.
The simplest explanation would be a bad cable, or bad terminations.  Or possibly the PLC is not performing the bus startup for some reason. 

[ktys]

This error messages appears when i plug and unplug(STANDBY=1)  cable so...

Hmm maybe i will try to configure PLC one more time, maybe i miss something, or I change cable

One more thing:

-is it normal when both LED lit when MASTER_USED=0?

-Have i must enter something here( screen )?

-if i have wrong program(PLC) connection  doesn't work(KUKA error messages)?

Sorry for this may be stupid questions, but i must be sure about this thinks.


THX SkyeFire for helping me.

[SkyeFire]

On my robot that has only MASTER=1, I only have 1 LED.  On the robot that has SLAVE=1 and MASTER=0, I have two LEDs (one green, one yellow).

I've never seen anyone need to change the hex parameters in order to get a KUKA profibus link working before.  It shouldn't be necessary.

The error message is consistent with the PLC never engaging the KRC as a slave device.

Hm... looking back at your first image, I can't tell which exact version of the CP56xx card you have selected.  I seem to recall that there are some non-obvious selections that have to be made here.  You might even need to select a particular Version of the 5613 rather than the 5614, even though the physical card is a 5614.  You could try the different versions of the 56xx cards and see if one of them works.
My manuals say to use the 5613, SW V6.0 SP4.  I would try that one first.

Now that my memory has been jogged, I think I recall how this happened.  Originally, KUKA only supported the 5613 card, which only operated as a Slave.  The 5614 card adds a Master port, but at the driver level, the Slave port still looks like a 5613, and your PLC's NCM setup has to use that config.  I suspect this is b/c the driver firmware KUKA provides to use the card from VxWorks is still the original 5613 version.

[ktys]

Ahh i deleted some lines in pbfm.ini but i did earlier copy this file. i pasted and configured one more time...

Pfbms.log

FILE_PTR_POS=001154
26/01/09 11:38:42 : Logfile for Profibus CP5613/14 (V2.01.0.8)                 
26/01/09 11:38:42 : use default DATABASE_PATH=init/slave.ldb                   
26/01/09 11:38:42 : Downloading Firmware and Database.........                 
26/01/09 11:38:43 : CP5613/14 started!                                         
26/01/09 11:38:43 : Slave Application registered at the CP!                     
26/01/09 11:38:43 : Slave started!                                             
26/01/09 11:38:43 : Accessed pointer to DPR from CP!                           
26/01/09 11:38:43 : Slave Baudrate 1,5 MB                     
26/01/09 11:38:45 : SLAVE_MODULE:State=WAIT_FOR_CONFIGURATION
26/01/09 11:38:45 : SLAVE_MODULE:State=DATA_EXCHANGE                                                                                   
=====  LAST_ENTRY  =====                 
                                       
KUKA error messages(Polish)

8022 Profibus błąd w obwodzie Slave(Profibus error in Slave circuit(?))

1033 Błąd przy odczytywaniu sterownik CP561DRV%2 (Error on reading driver CP561DRV%2)
 
1034 Error on writing driver CP561DRV%2

2858 Potwierdzenie STOP z powodu błędu magistrali(Confirmation STOP the error bus (?))or (Ack Stop for error fieldbus)

The configuration is the same!

Hm... looking back at your first image, I can't tell which exact version of the CP56xx card you have selected.  I seem to recall that there are some non-obvious selections that have to be made here.  You might even need to select a particular Version of the 5613 rather than the 5614, even though the physical card is a 5614.  You could try the different versions of the 56xx cards and see if one of them works.
My manuals say to use the 5613, SW V6.0 SP4.  I would try that one first.

Now that my memory has been jogged, I think I recall how this happened.  Originally, KUKA only supported the 5613 card, which only operated as a Slave.  The 5614 card adds a Master port, but at the driver level, the Slave port still looks like a 5613, and your PLC's NCM setup has to use that config.  I suspect this is b/c the driver firmware KUKA provides to use the card from VxWorks is still the original 5613 version.

I don't understand.
The gds file is only one. Physically this is 5614 but i don't have 5613 card too try.

[SkyeFire]

The new PFBMS.LOG file is good -- the messages indicate that the PLC is in fact finding the 5614 card on the Profibus and assigned a baud rate, and the 5614 went into Data Exchange mode.  This is good.  I'm not sure why you would have error messages at this point, unless you have a mapping error in IOSYS.INI, or possibly a size mismatch between your NCM file and the ACCEPTABLE_x_LENGTH parameter in PFMBS.INI.

Whatever number of bytes you describe the 5614 card as having in your NCM file, the ACCEPTABLE_x_LENGTH parameter in PFMBS.INI needs to be larger.

Hm... your IOSYS settings appear reasonable.  But try commenting out the INB and OUTB lines in the PBMASL section of IOSYS and see if that does anything to change the error messages.

Given this new data, you should probably disregard my earlier comments regarding the 5614/5613 setting.  It would appear that this only applies when one is using NCM to set up the Master port of the 5614 card.

[ktys]

I don't know what happened but it work. Maybe someone helping me when i don't look 
I commented INB OUTB and it work, but when i back to previous  version it also works.

I remember  between this two error 1033 1034 ther was something like...:

configure or unconfigure ..... A1
configure or unconfigure ..... A2
configure or unconfigure ..... A3...

maybe someone configured it 

At any rate, i do this exactly as in pdf file...and it work. I don't get it.

Thanks again for your help  SkyFire

[fluke]

in the Step 7 side please declare your input output type "Universal".

[basbasan]

conversely ktys ı havent make a profibus connections and ı want to use delta plc with kuka but ı dont know where ı must start. ı will be pleasure if u can help me too.

[SkyeFire]

1.  Will the robot be master or slave?
2.  Do you have the correct tools for setting up the Profibus on the Delta PLC?

[basbasan]

ı can use sıemens too robot will be master. and ı want to now also can ı use the siemens i/o modules without plc?