Posts by kvlada5


    I've managed to get the Profinet link working.

    Here's my post-mortem report of things to do.

    1. IPC inside KR C2 edition 2005:

    • Before doing anything, turn off power, wait for IPC to shutdown, and create full exact disk image (sector-by-sector) of hard drive inside KRC. If you accidentally delete something during install, you will have a backup. I've tested Aomei Backupper to work correctly for making or restoring disk images, and it's freeware.
    • KCP screen and keyboard are hard to use for Windows maintenance. It is much easier to connect PS/2 keyboard and mouse to IPC. Mouse with a USB port will work well in Windows, but USB keyboard might not be detected by BIOS, so you won't be able to enter BIOS Setup by pressing F2. VGA external monitor can also be used.
    • To minimize risk of damage, all IPC peripherals except USB must be (dis)connected while IPC is turned off.
    • Disable LAN adapter on IPC mainboard if not needed. It can interfere with Kuka software. Disable it in BIOS, so that Windows no longer sees it, and it doesn't appear in Windows' Device Manager.
    • Ideally, there must be no devices with error in Device Manager.
    • When Windows and KRC software have finished booting, exit KRC software and go back to Windows:
      • Login as Administrator (soft button Configure -> User -> Administrator -> default password is "kuka")
      • Now you have Windows access.
      • Press Ctrl+Esc on keyboard to show Windows taskbar.
      • In system tray, right-click the semaphore icon, and choose "Kill Application" in the menu
      • In a few moments, KRC software will shutdown, and you will have classic Windows interface.
    • Uninstall any Kuka related software in Windows ("Add/remove programs" in Control Panel). Some apps cannot be uninstalled because Windows won't allow it.
    • Now, reinstall Kuka app from D:\KRC1_CD\Setup.exe. If you don't have the original installation, then you're out of luck, and will have to try find it elsewhere.
      • KRC Setup mostly works automatically. Antivirus software supplied with KRC Setup is certainly outdated and usually not needed.
      • During Setup, choose to install only communication bus protocols which are actually needed. Installed protocols with missing hardware will generate messages like: Error on writing: DRIVER_NAME in the message log.
      • Wait for install to be over, and wait for Windows to reboot.
    • KRC software should now work.
    • Activity lights should blink on CP16xx card inside Kuka.
    • Check if Profinet driver is loaded and operating correctly: in KRC software choose Configuration -> I/O Driver -> I/O driver reset, and on the right side of the screen you'll see a list of installed and running drivers. Profinet is called "PNET" and it should have a red circle light. If the light is gray, it means the driver doesn't work or has crashed.

    2. Mitsubishi R-series PLC:

    • Preferrably, use newest version of GX Works3.
    • Make sure Profinet module on PLC is configured to use a different IP address than Kuka's Profinet card.
    • Using PN-Configurator, this GSDML file worked for me: GSDML-V2.0-Siemens-CP16xx-20070524.xml (link: GSDML-V2.0-Siemens-CP16xx-20070524.txt) (Rename it to XML to work.)
    • This is a generic GSDML file for Siemens CP16xx Profinet PCI card. You might try out other files, for other firmwares and hardware versions. Siemens software versions are a bit tedious.
    • In PN-Configurator, the device which worked for me was "V1.0 DAP 1". Your mileage may vary. Make sure the device name is set to be same as in robot. If different it might now work.
    • Configure slots like this:
      • PLC-to-robot bytes and words are DI (inputs),
      • Robot-to-PLC bytes and words are DO (outputs).
    • Screenshots of GSD configuration:
    • fgATS2U.jpg

    • nyExJa4.jpg
    • JT504cw.jpg

    • Now save the configuration, compile and download to PLC.
    • It might be necessary to reset the PLC afterwards.

    3. After you've finished:

    • Shutdown IPC in KRC, and create another disk image.
    • This will help you restore things if anything breaks.

    Hope this helps someone!

    there is a DN card for iQ series PLCs, which can be used as slave so this is clearly doable

    Thankks, already checked. It costs 1400€ and 2 months delivery time. That would be my last resort. I'll probably go with a DeviceNet I/O gateway and a few slice modules with 24V inputs and outputs. That way I'll get discrete I/O, so I'm no longer PLC or BUS dependent.

    Bump. Still nothing works.

    I'm thinking of moving to another protocol, like DeviceNet (on MPC3) or Modbus TCP. I've asked Kuka already, but it might take them a long time to answer.

    What do you think about Modbus TCP on KR C2 ed2005? Impossible, very hard, hard, easy?

    I had lots of trouble in the past because these numbers didn't match the subslots configured on PLC side (so in Your case it would be at Mitsubishi project, not in STEP7/CP1616 project).

    In the PLC project I have this configuration (structured language):

    Profinet slave's (robot) slots 1 and 2 are inputs, and 3 and 4 are outputs.

    SLV001 = slave 1

    SLOT00x = profinet slot number

    Okay, looks like I'm stuck again.

    I was getting these errors: "Error on writing driver: PNIODRV" and there's still no communication.

    Kuka software is version V5.6.1.2.

    Dummy driver for CP1616 seems to be installed correctly.

    This is the state of the installed hard drive.

    Some random diagnostic I've found.

    I've managed to reinstall KRC software (found the installation dir at D:\KRC1_CD\) but it was the same version as the one already installed).

    I've tried reinstalling CP1616 driver at D:\KUKA_OPT\PROFINETIO\ it installs correctly but still doesn't work.

    Configuration files:

    INB5=1,1,x1 ;IN41-48 (plc -> robot)
    INB6=1,2,x1  ;IN49-56 (plc -> robot)
    OUTB5=1,3,x1  ;OUT41-48 (robot -> plc)
    OUTB6=1,4,x1  ;OUT49-56 (robot -> plc)
    Code: C:\KRC\ROBOTER\INIT\pnioDrv.ini

    On the PLC side, in Mitsubishi's profibus configuration software, the CP1616 is reported like this. I think the 0x21 are the inputs, and 0x22 are outputs.

    Finally, here is the output from web server of CP1616: [1]   [2]   [3]   [4]

    if i was dealing with this system, my top priority would be to make image backup or HDD.

    Yeah, I know. Should've known better. My first priority was to avoid dismantling the PC at all costs, but then I remembered I could boot some ancient 32-bit Live linux and create a disk image to an USB flash...

    I'm going to try some things tomorrow. First I need to make the KRC2 operational, and make sure Profinet is working from robot side. I got some "cannot write to pnio" messages. Maybe something messed up after CHKDSK.

    I've found multiple IO.SYS files on KRC2 hard-drive, some on C partition, some on D partition. Which one is the right one?

    Then I'm going to search for some Profinet diagnostic software.

    Luckily I found a working Siemens Step7 V5.7 installation in a VM. Found some CP1616 GSD files, maybe they'll help someone.

    example of changing area size for transfer.

    btw this was done using first version of the board (6GK1 161-GAA00, firmware 2.6) and the address space is grayed out. also there is no "customization" option.

    btw. This was done with an old VM that happened to still have an expired Step7 V14 trial. :winking_face:

    There should be no issues getting it from KUKA. You might need to provide them the exact model of your Profi card, and maybe the model data for the KPC. But KUKA has always been able and willing to provide that. The card and robot were made by KUKA, the original integrator is irrelevant.

    Well, this is the response I got from KUKA:

    As far as I know the GSDs are PLC independent. So basically the one you download from the siemens homepage, should fit.

    In former times, the CP1616 was also imported in Omron PLCs, or even Allen Bradley PLCs (I mean PLCs from 10-15 years ago).

    We do not store these GSDs, or GSDMLs from Siemens, we delivered them together with the controller, or Profinet Cards via an external CD. Card and CD were 1 package/box, we never had them separate.

    >Note: Despite the fact that this Profi card appears to be a "standard" Siemens product, the firmware is probably customized for use in KRC2s. So Siemens probably cannot provide a working GSDML, although they may have one for a model number that looks identical.

    That's what I was afraid of...

    If I can't make the Profinet work, then my only other option is to use direct I/O (24VDC), that is, if they're available on the unit.

    KRC4s avoid most of this, since almost(?) every add-on is connected to the internal network, not added to the KPC motherboard as a "direct" hardware resource.

    Haven't had the luck to work with KRC4s yet, but this is definitely a better approach! Instead of having to mess with low-level OS stuff, you simply define hardware through network setup, via standardized comm interfaces.

    It's like how older PLCs had a physical hardware backplane for their modules, while newer PLCs (CoDeSys, etc.) are just an independent "command box" basically a realtime computer which interacts with the rest of the world through EtherCAT, CANopen, or similar realtime interface.

    correct way is to get one from manufacturer

    AFAIK, the robot has been bought second-hand from some Turkish supplier, and the machine's manufacturer (who integrated robot with the palletizer) doesn't want to share it, or they lost it. Either way, it's unavailable...

    I'll post some screenshots later.

    Bump. I had the same error today, and the reason was I fed cp16xx.sys to Windows "find new hardware" dialog, for the CP-1616 card and placed it in the Device manager.

    Once I "uninstalled" the card from device manager and removed the drivers from System32/Drivers folder, the error disspeared.

    The Windows drivers seemed to have somehow interfered with KRC (and VxWorks VM).

    Hi all,

    I'm trying to make KR C2 and a Mitsubishi PLC talk over Profinet. These two were happily married, but then the PLC software had to be changed. The owner did not have source code, and the previous company who did maintenance lost all the files, so I had to work with what I could read from the PLC.

    Problem is, after downloading new PLC program, the Profinet communication stopped. It had worked previously, I am sure of that. I've checked Inputs and Outputs on KCP and they transferred correctly back and forth with PLC.

    I think maybe the problem is because GSD file was not stored in the PLC, so when I uploaded project fro PLC, the PN configuration was blank. When I downloaded a new program, it got a blank config, and thus the comms stopped.

    I've read manuals from here, that didn't help much because it was for configuring a Siemens PLC, not Mitsubishi.

    I've tried using GSD files from here. When I import them, Mitsubishi Profinet Configuration tool takes the files, but when I configure the PLC PN module and go online, there is no communication.

    I can ping both the PLC and CP1616 card. Activity lights on the LAN switch are blinking furiously. CP1616 is already configured, so I think the problem must be in the PLC.

    Using GxWorks3.

    PLC CPU is R04EN, Profinet comms module is RJ71PN92. Kuka controller is KR C2 + CP1616 PN card. PLC and Kuka were exchanging 16 inputs and 16 outputs, all binary, no analog.

    Where to go from here? Are the generic GSDML files for CP1616 not suitable here, or I'm configuring them wrong?

    Is there a possibility that there is a GSDML file stored somewhere on the KR C2 hard drive?

    Thank you all very much!

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