error 6502 - error during reading INI file

    Hi everyone. I hope that someone can give me a pointer on this error and hints on how to correct.

    I am commissioning a used Kuka robot into a new installation. The system is a KRC2 controller running WPe and KSS 5.2.12. The robot controller has a multi power tap A30 module. The devicenet output from the mfc card is connected to the MPT and from there 2 devicenet nodes are connected - one to a PLC (node 30) and one to a Renishaw RMP60 measuring unit (node 5)

    On power up of the controller, we go to the windows desktop, which has KRC on it. Then upon starting KRC, it starts up and goes into the normal screen however we get an extensive list of errors, the first of which is "error #6502 Error during reading INI file init/iosys.ini 1" There are multiple other "error 6502", referring to ; init/motiondrv.ini 1 ; HW_INF.INI ; PROGRESS.INI ; and MEMCONFIG.INI
    There are other errors listed but I think these first items are creating the subsequent faults.

    Checking the iosys.ini file it appears OK and the correct devicenet driver is installed and enabled.

    First question - does anyone have the documentation on configuring the A30 Multi Power Tap?? I cannot see in the iosys.ini file how the devicenet nodes on the multipower tap are configured and enabled - there are no active DNSCx drivers - does the Multipower tap need this defined?

    Symptoms that exist along with the error listing are: devicenet is not working as the PLC on node 30 is not seeing any of the KRC outputs (eg robot in T1 mode even though this bit is set). Also the RJ-45 X804 connection on the mfc appears not be working, and if I connect a ethernet switch to the RJ-45 X804 socket I get a "RTWLoadVxD(LPVXWRT).(#0x1) device driver could not be initated (not found or wrong path). In a number of ways this is similar to the thread started by Martin H in Aug 2007 on the robot-forum.de site, with very similar hardware - though he didn't make mention to the error 6502. The original Kuka wiring diagram for the controller refers to the X804 as either a DSEIBS3AUX or DSEIBSC33. The system also had an X33 plug added to the robot at some time in the past - which today I discovered has been disconnected - I suspect when the unit was upgrade to run XP and the radio measuring probe added (but this is supposition).

    Any and all suggestions are greatfully received.

    I would get the controller with no errors then start to check the devicenet.
    You sound like you understand how to do this :smiling_face:

    The multi tap doesn't need any drivers or configuration, it's just a way of connecting several devicenet plugs, it's got a 24v power connection and if you look all the of the CAN lines are joined. One of the leads should go up to the MFC.

    Best to post your IOSYS.INI file so we can look :smiling_face:

    Sent with Tapatalk.

    Hi Eusty. Copy of iosys.ini attached (bottom text removed)

    ;==========================================================
    ; IOSYS.INI - Configuration file for the IO-System
    ;==========================================================
    ; For configuration help go to the end of this file.
    ;----------------------------------------------------------

    ; ATTENTION !!!! Since V5.0 Build13 we have removed the DeviceNet
    ; driver "dndrv.o". Now you have to use the driver
    ; "dn2drv.o" and the appropriate syntax (form 2)

    [CONFIG]
    VERSION=2.00


    [DRIVERS]
    DEVNET=2,dnInit,dn2drv.o
    ;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
    ;INTERBUS=1,ibusInit,ibusdrv.o
    ;MFC=0,mfcEntry,mfcdrv.o

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


    [INTERBUS]
    INW50=896 ;$IN[401-416]
    INW52=898 ;$IN[417-432]
    INW54=900 ;$IN[433-448]
    INW56=902 ;$IN[449-464]
    OUTW50=896 ;$OUT[401-416]
    OUTW52=898 ;$OUT[417-432]
    OUTW54=900 ;$OUT[433-448]
    OUTW56=902 ;$OUT[449-464]


    [DEVNET]
    ;plc
    INW0=30,0,x15
    OUTW0=30,0,x15

    ;probe io
    INB30=5,0,x1
    OUTB30=5,0,x1


    [PBMASL]


    [DNSC1]


    [DNSC2]


    [DNSC3]


    [DNSC4]


    [DNSC5]


    [DNSC6]


    [DSEIO]
    INDW0=0 ;$IN[1-32]
    OUTDW0=0 ;$OUT[1-32]


    [INTERBUSPCI]
    INW50=896 ;$IN[401-416]
    INW52=898 ;$IN[417-432]
    INW54=900 ;$IN[433-448]
    INW56=902 ;$IN[449-464]
    OUTW50=896 ;$OUT[401-416]
    OUTW52=898 ;$OUT[417-432]
    OUTW54=900 ;$OUT[433-448]
    OUTW56=902 ;$OUT[449-464]


    [CNKE1]
    ; =ConNo, additional offset,xSize

    [CNKE2]
    ; =ConNo, additional offset,xSize

    [IOLINKING]

    It looks OK, but I'm not 100% sure there maybe an overlap at input/output 240, I'd try moving your measuring device to say INB32/OUTB32 just to make sure?

    The trouble with the DeviceNet on the MFC is that it's a 'cut down' version so it either works or falls over! Also you need to check that the PLC/measuring device are set OK as these will cause it to fall over too! Although that won't cause the error in the IOSYS.INI

    X33 is the fast measurement input isn't it? I've no info here at home so I'm going on my shaky memory!!

    I'm more concerned about the other .INI files. Even with a bad MFC DevNet config, I've never seen errors like this occur -- worst case, I got DevNet-specific errors. Those other .INI files should be entirely unaffected, no matter how messed up IOSYS is. Quickest way to check would be to comment out the DEVNET=2 line in IOSYS -- that'll turn off the Devnet entirely and render all other DevNet settings ignored. If you still have file-read errors at that point, I suspect a more serious problem.

    Honestly, my first thought is to re-install KSS and see if that helps. My second thought is to wonder if there's a hardware issue on the MFC card that could cause these various errors.

    I agree with SkyeFire, comment out DeviceNet driver until everything else is under control.
    If this used to work (with all software packages ), you may have to reinstall KSS and the software options.
    If this was never working before with all tech packages installed, check compatibility - things like SafeRobot may require newer KSS.

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    Thanks for the replies everyone. I have tried commenting out the devnet driver, and this morning tried a replacement mfc card. Still no solution with the same and multiple .....ini file errors on boot up - so have put the original card back in. I am searching for a next thing to try.

    The system has OPC, and KRDIRLOADER on it, and was connected to a larger system. Could that be impacting the boot up from the .ini files?

    On another lead, when looking at the DSE-RDW diagnostic tool, I get the MFC recognized (- MFC2(V4)Port:0x260. But is get "unknown DSE", the state is "down", the DPRAM test is "succeeded", and RDW is "not detected" Does this seed any other thoughts?

    Bent pins in the DSE-RDW cable is one of the things most likely to happen when a robot is relocated.

    Did this robot have additional axes at one time? A KRC which has more than 8 axes has to have an additional RDC card, and a "daughterboard" mounted to the DSE which connects to the secondary RDC. I once had a robot whose extra axes were removed but whose DSE was not restored to 8-axis configuration. Still, that robot did not show any .INI file issues, only the DSE-RDC errors.

    Firstly - a big thank you to all of you that have provided suggestions for this problem.

    In reply to the suggestions:
    1. Yes the devnet.ini file is configured as shown by "the leg"
    2. I have rechecked all of the x21-x31 connectors, both at the controller, on the gantry (an extension cable) and on the robot - all pins a straight, and only the pins that are not connected though the system (pins 1,16,17 by memory) are missing from all plugs. Plugs are tight
    3.have swapped in a spare mfc2 card - same faults
    4. Today reloaded KSS - D drive only had a version of 5.2.7 on it (not the original 5.2.12). Reloaded OK, had 2 errors at the end of the reload, but all booted up OK. Unfortunately still had exactly the same errors 6502 on init/iosys.ini init.motiondrv.ini WH_INF.INI PROGRESS.INI MEMCONFIG.INI LTC initialization failed KCP connection timeout error then DSE1 program boot up failure followed by a string of compilation failures.

    A frustrating problem that has me pulling my hair out - and I don't have much to start with!

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