KR C2 Interbus PCI en PDF

KUKA Roboter GmbH
Controller Option
Interbus PCI
For KR C2
Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en
Issued: 24.07.20
Interbus PCI
© Copyright 2008
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 the KUKA ROBOT GROUP.
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 de-
scribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guaran-
tee total conformity. The information in this documentation is checked on a regular basis, however, and
necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Publication: Pub KR C2 Interbus PCI en

Book structure: KR C2 Interbus PCI V0.6
Label: BA KR C2 Interbus PCI V1
V0.4
2 / 63
22.03.200
6 pub de Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en
Contents
Contents
1 Introduction ...................................................................................................... 5
1.1 Target group ................................................................................................................... 5
1.2 Terms used ..................................................................................................................... 5
2 Product description ......................................................................................... 7

2.1 Overview ......................................................................................................................... 7
2.2 IBS PCI SC system coupler ............................................................................................ 8
2.3 PCP functionality ............................................................................................................ 8
3 Safety ................................................................................................................ 9
3.1 Representation of warnings and notes ........................................................................... 9
3.2 Operation of the robot system ........................................................................................ 9
4 Installation ....................................................................................................... 11
4.1 Software installation ........................................................................................................ 11
4.2 Version compatibility ....................................................................................................... 11
5 Start-up ............................................................................................................. 13
5.1 IBS PCI SC/RI-LK ........................................................................................................... 13
5.2 Connecting fiber-optic cables ......................................................................................... 14
5.3 IBS PCI SC/RI/I-T ........................................................................................................... 15
5.4 CMD interface ................................................................................................................. 15
5.5 External power supply to slave ....................................................................................... 16
6 Configuration ................................................................................................... 19
6.1 IBSPCI1.INI file ............................................................................................................... 19
6.2 IOSYS.INI file .................................................................................................................. 24
6.3 Assigning digital inputs and outputs ............................................................................... 25
6.4 Assigning analog inputs and outputs .............................................................................. 26
6.5 Offset-Table .................................................................................................................... 28
6.6 DIP switches on the master module ............................................................................... 30
6.7 DIP switches on the slave module .................................................................................. 31
7 Example ............................................................................................................ 35
7.1 I/O configuration ............................................................................................................. 35
8 Diagnosis .......................................................................................................... 39
8.1 LEDs on the master module ........................................................................................... 39
8.2 LEDs on the slave module .............................................................................................. 40
8.3 KUKA.HMI error messages ............................................................................................ 41
8.4 IOCTL commands ........................................................................................................... 45
8.4.1 Generating a dump file .............................................................................................. 46
8.4.2 Restart ....................................................................................................................... 46
8.4.3 Switching segments on and off .................................................................................. 47
8.4.4 Warm start ................................................................................................................. 47
8.4.5 State polling ............................................................................................................... 47
8.4.6 Extended state polling of master ............................................................................... 48
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Interbus PCI
8.4.7 Extended state polling of slave .................................................................................. 49

8.4.8 Polling the state of a module ..................................................................................... 49
8.4.9 Stopping the Interbus ................................................................................................ 50
8.5 PCP functionality of the slave ......................................................................................... 50
8.5.1 PCP hardware settings .............................................................................................. 50
8.5.2 Establishing the connection ....................................................................................... 50
8.5.3 Reading data ............................................................................................................. 51
8.5.4 Writing data ................................................................................................................ 53
8.5.5 Terminating the connection ....................................................................................... 54
8.5.6 PCP connection settings ............................................................................................ 54
8.5.7 PCP server response to a fault in the master ring ..................................................... 54
9 KUKA Service ................................................................................................... 55

9.1 Requesting support ......................................................................................................... 55
9.2 KUKA Customer Support ................................................................................................ 55
Index .................................................................................................................. 61
4 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

1. Introduction
1 Introduction
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
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 pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.
1.2 Terms used
Term Description
CMD Configuration, Monitoring, Diagnostic: software
for configuration, monitoring and troubleshooting
in Interbus interfaces.
CR Communication reference.
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.
IOSYS.INI Configuration file of the I/O system. This is
where the bus drivers are activated and the
inputs and outputs of the individual bus devices
are assigned.

Interbus PCI
Term Description
ISA Industry Standard Architecture: commonly-used
PC bus before PCI.
KCP KUKA Control Panel: the KCP teach pendant
has all the functions required for operating and
programming the robot system.
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 fib-
ers. Greater immunity to interference than cop-
per cables; electrical potential differences have
no effect.
MACID Address in the bus system. It may only be
assigned once. MACIDs must be specified in
ascending order, but gaps are permissible.
Permissible values: 0 … 63
Default setting: 5
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.

2. Product description
2 Product description
2.1 Overview
The Interbus PCI interface is a combined master/slave system coupler. Master

and slave are housed on two separate PCI plug-in cards and equipped with
their own processors. Standalone operation of the master or slave module is
thus also possible. For combined master/slave operation, both cards must be
connected using the enclosed ribbon cable jumper.
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.
The Phoenix Contact software configuration tool CMD is available for config-
uration, setup and diagnosis.
The basic functions of the Interbus PCI interface are supported by CMD ver-
sion 4.50 or higher. The full range of functions is only available following an
additional update (host adaptation) with the corresponding software (different
versions for fiber-optic and copper cards). The software is stored on the KRC
CD under the installation path “ibs_cmd”.
The range of functions of the G4 firmware (= 4th generation) is restricted by

the driver as follows: the driver does not support the distribution 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.
The Interbus enables communication between the robot controller and the var-
ious I/O units.
The Interbus PCI system coupler is available in two versions: one for connec-
tion via copper cables and one for fiber-optic cables.
Field bus systems can be divided into:
physical buses for transmission
bus protocols
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.

Interbus PCI
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
Optional operation of master and slave at 500 kBaud or 2 MBaud
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
2.2 IBS PCI SC system coupler
The IBS PCI SC system coupler, the Interbus PCI interface for the KR C2 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
The performance of the card is similar to that of the older ISA system coupler
IBS ISA SC/RI/RT-LK. The main difference is the separation of the Interbus
master and slave parts onto two different cards.
The master card contains the system coupler’s PCI connection, which the card
uses for communicating with the robot controller. The slave card, on the other
hand, only has the PCI terminal strip for mechanical reasons; it has no electri-
cal function here. It is also possible, however, to break off the terminal strip
and screw the two cards together, thereby saving one PC slot.
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 (>>> 6.7 "DIP switches on the slave module" page 31) must be
observed.

3. Safety
3 Safety
3.1 Representation of warnings and notes
Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.
Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.
Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.
Tips to make your work easier or references to further information.
3.2 Operation of the robot system
The robot system with Interbus PCI must be operated in accordance with the
applicable national laws, regulations and standards.

Interbus PCI

4. Installation
4 Installation
4.1 Software installation
The following files are required for operating the Interbus PCI interface.
Drivers\Ibpcidrv.o
Init\Ibspci1.ini
Once they have been installed, they are located in the KRC directory of the ro-
bot installation.
4.2 Version compatibility
The following table shows which driver, firmware (Phoenix) and CMD config-
uration tool (Phoenix) versions are compatible with one another.
PCI driver Firmware CMD tool

1.01 4.49 4.51
1.02 4.49 4.51
1.03 4.49 4.51
1.04 4.49, 4.53 4.51
1.05 4.49, 4.53, 4.63 4.51, 4.61

Interbus PCI

5. Start-up
5 Start-up
5.1 IBS PCI SC/RI-LK
Fig. 5-1: Structure of the IBS PCI SC/RI-LK system coupler
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

Interbus PCI
5.2 Connecting fiber-optic cables
Fig. 5-2: Connecting the fiber-optic cables
“Remote In”, slave: incoming remote bus

“Remote Out”, slave: outgoing remote bus of the slave card
“Remote Out”, master: outgoing remote bus of the master card
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. Start-up
5.3 IBS PCI SC/RI/I-T
Fig. 5-3: Structure of the IBS PCI SC/RI-I/T system coupler
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
5.4 CMD interface
The CMD configuration and diagnostic software from Phoenix Contact can ac-
cess the IBS PCI SC system coupler 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 memory on
the system coupler using CMD. It is also possible to update the firmware of the
IBS PCI SC system coupler via the RS232 interface.

Interbus PCI
Fig. 5-4: CMD interface: 6-pin mini-DIN socket (PS/2)
The CMD interface is designed as a 6-contact mini-DIN socket (PS/2) on the

front plate.
Fig. 5-5: RS232 cable for connection to diagnostic PC
It is connected to the diagnostic PC via a special RS232 cable that is available

from Phoenix Contact.
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.

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

Interbus PCI

6. Configuration
6 Configuration
6.1 IBSPCI1.INI file
Description The file IBSPCI1.INI contains all the settings which affect the Interbus connec-
tion.
Precondition All communications cables have been installed.

User group “Expert”
Procedure 1. Open the file IBSPCI1.INI.

2. Check the settings stored in the individual segments and adapt them if re-
quired.
3. Save changes.
The robot controller adopts the modified data.
Always save the changes via the menu sequence Configure > I/O Driver >
Reconfigure I/O Driver.
The menu item Reset restarts the bus. Changes are not saved.
IBSPCI1.INI is divided into the following sections:
[INTERBUS]
Entry Value Function

Board number 1 ... 8 Assigns a unique identifier to the system coupler for the
data channel; this must match the number selected by
Default: 1
means of the DIP switches on the master module.
(>>> 6.6 "DIP switches on the master module" page 30)
[CMD_CONFIGURAT
ION]

CMD_FILE Default: - Name of the SVC file and the path relative to the KRC
directory.
MSGDELAY 50 ... 1000 Length of time in seconds that the system waits for a
confirmation message after transmitting messages. If
Default:
this time elapses, the message is considered not to
100
have been confirmed.
USEBLOCKID 0, 1 This flag can be used to deactivate the use of the Block
ID and the Block Offset. It should normally be left
Default: 1
unchanged.
0: Block ID and Block Offset are not evaluated.
1: Block ID and Block Offset are evaluated.
BRK_IB_ERR 0, 1 If this flag is set, the loading of the SVC configuration file
is aborted in the absence of a confirmation.
Default: 1
0: Loading of the SVC configuration file is not aborted in
the absence of a confirmation.
1: Loading of the SVC configuration file is aborted in the
absence of a confirmation.

Interbus PCI

TIMEOUT 50 ... 65000 Maximum length of time in seconds used for various
tasks, e.g. transmitting and receiving messages, during
Default:
loading of the SVC configuration file.
60000
BAUDRATE Default: Baud rate of the CMD serial interface
9600
EXTERN_START 0, 1 0: Interbus is configured and started by the driver.
Default: 0 1: Interbus is configured and started by an external tool,
such as CMD, or a boot project. CMD_FILE entry is
ignored.
[CONFIGURATION]

LOGFILE Default: - Specification of a file name activates logging. The name
can be specified along with its path relative to the KRC
directory.
SWAP_MASTER_BYTES 0, 1 This entry can be used to specify that the bytes of the
modules in the master are to be swapped automatically
Default: 0
by the driver. The driver only carries out this swapping,
however, in the case of digital modules; analog modules
are not swapped.
0: The bytes are not swapped.
1: The bytes are swapped.
RESET 0 ... n (s) In order to set the system coupler to a defined state
when the driver is run up, a reset can be carried out
Default: 1
before it is initialized.
(15 s)
0: No reset is carried out when the driver is run up.
1: A reset is carried out when the driver is run up; the
system waits for a maximum of 15 s for the system cou-
pler to become operational once again. If it is not possi-
ble to address the system coupler within these 15 s, the
loading of the driver is aborted.
2 ... n: A reset is carried out when the driver is run up;
the system waits for the specified number of seconds, at
most, for the system coupler to become operational
once again. If it is not possible to address the system
coupler within n seconds, the loading of the driver is
aborted.

6. Configuration

WATCHDOG 0 ... 7 The watchdog on the card is triggered every time data is
read. If the watchdog is not triggered within the time
Default: 0
specified, the system coupler stops and displays a cor-
responding error message on the KUKA.HMI. The spec-
ified value sets the watchdog monitoring times
according to the following list:
7: 16.4 ms
6: 32.8 ms
5: 65.5 ms
4: 131.1 ms
3: 262.1 ms
2: 524.3 ms
1: 1048.6 ms
0: Watchdog deactivated
The watchdog is only activated if inputs have also been
configured in IOSYS.INI, because it is only triggered in
the read function and the read function is only called if
inputs have also been configured.
CHECKLEVEL 0, 1 0: The configuration is not checked.
Default: 0 1: The number of configured I/O bits of the master is
compared with the actual modules present. In the case
of a discrepancy, the loading of the driver is aborted.
INACCURACY is taken into consideration.
INACCURACY Default: 0 Inaccuracy of the configuration check: determines how
many more bits can be configured in IOSYS.INI than are
connected to the system coupler.
TEST_OUTPUT 0, 1 0: Debug outputs deactivated.
Default: 0 1: Debug outputs are displayed on the TelNet shell.
DUMPFILE Default: - Specification of a file name activates the ibsPciDump
function. The name can be specified along with its path
relative to the KRC directory.
PASSIVE_UPDATE 0, 1 0: In the case of an error, the read function is disabled
and the inputs are no longer read.
Default: 0
1: Even in the case of an error, the read function contin-
ues to be executed and the inputs are updated.
In both cases, a read error message is displayed on the
KUKA.HMI.
CONTINUE_WITH 0, 1 0: In the case of a periphery fault, the read and write
_WARNING functions are disabled, as in the case of a bus error. A
Default: 1
read/write error message is displayed on the
KUKA.HMI. The disabling of the read and write function
is automatically withdrawn again as soon as the fault
has been eliminated.
1: The read and write function is not disabled in the
event of a periphery fault; the inputs and outputs con-
tinue to be read/written.

Interbus PCI

MASTERRING 0, 1 0: The master of the system coupler is not initialized.
Only the slave is initialized and started.
Default: 1
1: Master and slave of the system coupler are initialized
and started.
ON_ERR_CLEAR_MPM_ 0, 1 This can prevent the outputs in the MPM from being set
OUT to 0 as soon as a bus error occurs in the master ring.
Default: 1
0: Bus errors do not affect MPM outputs.
1: Outputs in the MPM are set to 0 in the event of bus
errors.
[DIAGNOSTIC_REGI This section is not evaluated when the system coupler is started via the SVC
STERS] file or externally.

STATUS Word I/O address for status register
PARAMETER1 Word I/O address for 1st parameter register
PARAMETER2 Word I/O address for 2nd parameter register
SLAVE_STATUS Word I/O address for slave status register
STATUS Word I/O address for slave parameter register
[TASK]

AUTORESTART 0 ... n 0: Bus is not automatically restarted.
Default: 0 8 ... 20: An attempt is made, at the specified repeat rate
in s, to restart the Interbus.
n < 8 or n > 20: An attempt is made every 8 s to restart
the Interbus.
IBSTASK_CYCLE_TIME Default This entry can be used to set the cycle time of the tasks.
time 1 sec-
Specification in 1/100 seconds.
ond
[SLAVE]

6. Configuration

ID Default: The slave ID consists of two parts: the length of the
0x0403 slave process data in the High byte and the actual slave
ID in the Low byte. Slave ID 3 thus designates a digital
input and output module.
If no slave ID has been specified, the slave is initialized
with the ID 0x0403. This entry is not evaluated when the
system coupler is started via the SVC file or externally.
If the slave ID has been changed, the slave module
must be disconnected briefly from the external 24 V
supply in order for the new data to be accepted.
SWAP_SLAVE_BYTES 0, 1 This entry can be used to specify that the bytes of the
modules in the slave are to be swapped automatically
Default: 0
by the driver. The driver only carries out this swapping in
the case of digital modules; analog modules are not
swapped.
0: The bytes are not swapped.
1: The bytes are swapped.
SLAVERING 0, 1 0: Slave is not initialized and no error messages are
generated.
Default: 1
1: Slave is initialized and error messages are gener-
ated.
CONTINUE_BY_ERR 0, 1 0: In the case of a fault in the slave ring, the read and
write functions are disabled, as in the case of a bus
Default: 1
error. A read/write error message is displayed on the
KUKA.HMI. The disabling of the read and write function
is automatically withdrawn again as soon as the fault
has been eliminated.
1: The read and write function is not disabled in the
event of a fault in the slave ring; the inputs and outputs
continue to be read/written.
MASTER_TO_SLAVE 0 ... n This signals, in the higher-level ring, that the Interbus
_OK driver on the robot controller is still in the RUNNING
state. This bit is not visible from the subordinate ring.
This bit is reset as soon as the driver is in the RUNNING
state. It is withdrawn if it is in a fault state or has not
been started, and is not set, following a restart or a
warm start, until the output data have been written. This
bit cannot be be set or deleted manually from the robot
controller.
0: Bit is not set.
1 ... n: Bit position in the I/O output memory after the
start address of the slave.
[NAMES]

Interbus PCI
Entry Function
N%d=S.T:Name Assigns names to the individual modules.
%d: Digit(s) for numbering the entries in increasing order
S: Segment number
T: Position in segment
A character string with a maximum length of 18 characters can be used
in place of the name. Additional characters will be ignored.
Example:
N1=1.0: Segment 1.0
N2=1.1: Segment 1.1
A maximum of 60 entries are evaluated. The name of the segment is
then always displayed on the KUKA.HMI together with an error mes-
sage, e.g. from the periphery.
6.2 IOSYS.INI file
Description The file IOSYS.INI is the configuration file of the I/O system.

Procedure 1. Open the IOSYS.INI file.

2. Activate the Interbus driver.
3. Configure the inputs and outputs.
4. Save changes.
Always save the changes via the menu sequence Configure > I/O Driver >
Reconfigure I/O Driver.
The menu item Reset restarts the bus. Changes are not saved.
Activating the An entry of the following type is required in the [DRIVERS] section:
Interbus driver INTERBUSPCI =15,ibsCPPciInit,ibpcidrv.o
The individual entries have the following meaning:
Entry Function
INTERBUSPCI Section name. This must agree with the name in the
title line of the section containing the I/O assign-
ments for the Interbus connection.
15 Driver ID. Number between 0 and 20. Used by the I/
O system. It must be unambiguous and may be
used only once.
ibsCPPcilnit Name of the start function of the Interbus driver.
Must be entered exactly as shown – including the
distinction between upper and lower case.
ibpcidrv.o File of the Interbus driver. The file must exist in the
\drivers directory.

6. Configuration
6.3 Assigning digital inputs and outputs
Procedure 1. Open the file IOSYS.INI.

2. Assign inputs and outputs in [INTERBUS].
3. Save changes.
Description
Fig. 6-1: Overview: assignment of digital I/Os
The specifications of the I/O positions in the robot controller (1) are made up
of three parts arranged consecutively without gaps.

Processing direc- IN, OUT IN: robot controller input
tion
OUT: robot controller output
Data width B, W, B: byte = 8 bits
DW
W: word = 16 bits = 2 bytes
DW: double word = 32 bits = 4 bytes
This specification determines the number
of bytes reserved after the byte offset
address.
Byte offset 0 ... 127 The byte offset values range from 0 to
127 for both the digital inputs and the dig-
ital outputs. Multiple assignment is not
possible for any memory position in the I/
O system.
The specifications on the Interbus side (2) refer to the position of the process
data in the MPM and are separated by commas.

tion

Interbus PCI

DW
address.
O system.
Example Device 1:
16 digital inputs, 16 digital inputs, 16 digital outputs
The first inputs of device 1 should have a data width of 2 bytes (1 word) and
be assigned to input address 0 of the robot controller. Address range 0 is de-
fined and the range width remains unchanged (x1):
INW0=3,0,x1
The next inputs should have a data width of 8 bits (1 byte) and be assigned to
input address 2 of the robot controller. Address range 2 is defined and the
range width is doubled (x2):
INB2=3,2,x2
The outputs should have a data width of 2 bytes (1 word) and be assigned to
output address 0 of the robot controller. Address range 0 is defined and the
range width remains unchanged (x1):
OUTW0=3,0,x1
Entry for device 1 in IOSYS.INI:

[INTERBUS]
INW0=3,0,x1 ; $IN[1-16]
INB2=3,2,x2 ; $IN[17-32]
OUTW0=3,0,x1 ; $OUT[1-16]
For further examples, see (>>> 7.1 "I/O configuration" page 35).
6.4 Assigning analog inputs and outputs
Procedure 1. Open the file IOSYS.INI.

2. Assign inputs and outputs in [INTERBUS].
3. Save changes.

6. Configuration
Description
Fig. 6-2: Overview: assignment of analog I/Os
The specifications of the I/O positions in the robot controller (1) are made up
of two parts arranged consecutively without gaps.

Processing direc- ANIN, ANIN: robot controller input
tion ANOUT
ANOUT: robot controller output
Index Inputs: With analog I/Os, each index can only be
1 ... 8 used once. The index is positioned
immediately after ANIN or ANOUT with-
Out-
out a space.
puts: 1
... 16
The specifications on the Interbus side (2) refer to the position of the process
data in the MPM and are separated by commas.

Byte offset 0 ... Specifies the position of an analog value
1023 in the input or output map of the Interbus
PCI system coupler. The same rules
apply for the start of the slave range as
for digital I/Os.
Exponent 2 8, 16 Specifies the number of bits used to rep-
resent the numeric value of an analog
datum.
Type 0 ... 3 Specifies how the bits are arranged and
whether or not the leading bit should be
interpreted as a plus/minus sign before
the numeric value.
0: right-justified without sign
1: right-justified with sign
2: left-justified without sign
3: left-justified with sign
Example Device 2: I/O module

2 analog inputs, 2 analog outputs
Input 1 of device 2 is to be assigned to input address 1 of the robot controller.
The defined address range (position of the I/Os in the MPM of the Interbus de-
vice) is 1 and the defined representation width of the individual bits is 16. The
arrangement is specified as 3 (left-justified with sign):
ANIN1=1,16,3
Input 2 of device 2 is to be assigned to input address 2 of the robot controller.

Address range 3 is defined. Representation width and arrangement remain
unchanged:

Interbus PCI
ANIN2=3,16,3
Output 1 of device 2 is to be assigned to output address 1 of the robot control-

ler. Address range 0 is defined. Representation width and arrangement re-
main unchanged:
ANOUT1=0,16,3
Output 2 of device 2 is to be assigned to output address 2 of the robot control-

ler. Address range 2 is defined. Representation width and arrangement re-
main unchanged:
ANOUT2=2,16,3
Entry for device 2 in IOSYS.INI:

[INTERBUS]
ANIN1=1,16,3 ; $ANIN[1]
ANIN2=3,16,3 ; $ANIN[2]
ANOUT1=0,16,3 ; $ANOUT[1]
ANOUT2=2,16,3 ; $ANOUT[2]
For further examples, see (>>> 7.1 "I/O configuration" page 35).
6.5 Offset-Table
The offset byte and the related input and output addreses are specified in this
table.
Formula for start address: Offset x 8 + 1
Address Address Address Address

Byte Byte
from to from to
0 1 8 64 513 520
1 9 16 65 521 528
2 17 24 66 529 536
3 25 32 67 537 544
4 33 40 68 545 552
5 41 48 69 553 560
6 49 56 70 561 568
7 57 64 71 569 576
8 65 72 72 577 584
9 73 80 73 585 592
10 81 88 74 593 600
11 89 96 75 601 608
12 97 104 76 609 616
13 105 112 77 617 624
14 113 120 78 625 632
15 121 128 79 633 640
16 129 136 80 641 648
17 137 144 81 649 656
18 145 152 82 657 664

6. Configuration

Byte Byte
from to from to
19 153 160 83 665 672
20 161 168 84 673 680
21 169 176 85 681 688
22 177 184 86 689 696
23 185 192 87 697 704
24 193 200 88 705 712
25 201 208 89 713 720
26 209 216 90 721 728
27 217 224 91 729 736
28 225 232 92 737 744
29 233 240 93 745 752
30 241 248 94 753 760
31 249 256 95 761 768
32 257 264 96 769 776
33 265 272 97 777 784
34 273 280 98 785 792
35 281 288 99 793 800
36 289 296 100 801 808
37 297 304 101 809 816
38 305 312 102 817 824
39 313 320 103 825 832
40 321 328 104 833 840
41 329 336 105 841 848
42 337 344 106 849 856
43 345 352 107 857 864
44 353 360 108 865 872
45 361 368 109 873 880
46 369 376 110 881 888
47 377 384 111 889 896
48 385 392 112 897 904
49 393 400 113 905 912
50 401 408 114 913 920
51 409 416 115 921 928
52 417 424 116 929 936
53 425 432 117 937 944
54 433 440 118 945 952
55 441 448 119 953 960
56 449 456 120 961 968
57 457 464 121 969 976
58 465 472 122 977 984
59 473 480 123 985 992
60 481 488 124 993 1000

Interbus PCI

Byte Byte
from to from to
61 489 496 125 1001 1008
62 497 504 126 1009 1016
63 505 512 127 1017 1024
6.6 DIP switches on the master module
The DIP switches are on the top left-hand side of the master module.
KUKA default: DIP switches 1 to 8 OFF
Fig. 6-3: DIP switches on the master module
1 ... 3: Numbers If multiple IBS PCI SC system couplers are used in a PC, different numbers
must be set for them so that the system can distinguish between them. DIP
switches 1 to 3 are used to set these numbers from 1 to 8 as binary coded val-
ues.
The default setting (factory setting) is 1. If only one IBS PCI SC system coupler
per PC is used, as is customary in robot controllers, the number is not to be
changed.
Number DIP 1 DIP 2 DIP 3

1 OFF OFF OFF
2 ON OFF OFF
3 OFF ON OFF
4 ON ON OFF
5 OFF OFF ON
6 ON OFF ON
7 OFF ON ON
8 ON ON ON
4 ... 6: Reserved DIP switches 4, 5 and 6 are reserved for expansions and must not be
changed.

6. Configuration
7: Baud rate DIP switch 7 determines the baud rate of the lower-level Interbus system:
OFF: 500 kbaud
ON: 2 MBaud
The baud rate setting saved in an existing boot project has a higher priority
than the DIP switch setting.
There are two alternative ways of changing the baud rate setting:
Delete the existing boot project – the switch setting will then be applied
during the subsequent I/O reconfiguration.
Create a new boot project using CMD and adapt the baud rate under Con-
troller board > Settings > I/O coupling.
In the case of the IBS PCI SC/RI/I-T system coupler for wired networks, the
baud rate is determined automatically; DIP switch 7 has no function in this
case.
8: Test mode DIP switch 8 activates a Test mode; in normal operation, it should always be
set to OFF.
6.7 DIP switches on the slave module
The DIP switches are on the top left-hand side of the slave module.
KUKA default: DIP 1 … 4 OFF, DIP 5 ON, DIP 6 … 9 OFF, DIP 10 ON
Fig. 6-4: DIP switches on the slave module
1, 2: Parameter DIP switches 1 and 2 are used for setting the parameter channel (PCP). This
channel setting also defines the ID code of the remote interface. The parameter chan-
nel and the process data channel can have a maximum width of 16 words.
DIP 1 DIP 2 Parameter channel ID code (decimal)

OFF OFF 0 words 3
ON OFF 1 word 235

Interbus PCI
DIP 1 DIP 2 Parameter channel ID code (decimal)

OFF ON 2 word 232
ON ON 4 words 233
3 ... 6: Process data DIP switches 3 to 6 are used for setting the process data length. The length of
length the process data also defines the length code.
Length code
DIP 3 DIP 4 DIP 5 DIP 6 Process data
(decimal)
OFF OFF OFF OFF 0 words 0
ON OFF OFF OFF 1 word 1
OFF ON OFF OFF 2 words 2
ON ON OFF OFF 3 words 3
OFF OFF ON OFF 4 words 4
ON OFF ON OFF 5 words 5
OFF ON ON OFF 6 words 6
ON ON ON OFF 7 words 7
OFF OFF OFF ON 8 words 8
ON OFF OFF ON 9 words 9
OFF ON OFF ON 10 words 10
ON ON OFF ON 11 words 11
OFF OFF ON ON 12 words 12
ON OFF ON ON 13 words 13
OFF ON ON ON 14 words 14
ON ON ON ON 16 words 16
The module can be adapted to special requirements by setting the width of the
parameter channel and the process data length. The following combinations
are possible:
Parameter
Process data length (in words)
channel
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16
0 words X X X X X X X X X X X X X
1 word X X X X X X X X X X X X
2 words X X X X X X X X X X X
4 words X X X X X X X X X X
7: Reset response DIP switch 7 determines whether a reset of the lower-level master system trig-
gers a periphery fault in the higher-level system so that it can respond:
OFF: no fault signaled in the higher-level system
ON: fault signaled in the higher-level system
8: Reconfigure DIP switch 8 determines whether a Reconfigure request can be triggered via
request the OPC bus terminal:
OFF: no Reconfigure request possible via the OPC bus terminal
ON: Reconfigure request possible via the OPC bus terminal
9: Baud rate DIP switch 9 determines the baud rate of the slave part of the system coupler:
OFF: 500 kbaud
ON: 2 MBaud

6. Configuration
10: Configuration DIP switch 10 determines whether DIP switches 1 to 9 are activated:
selection OFF: DIP switches 1 to 9 ineffective; parameterization from stored resi-
dent configuration or from configuration received by lower-level master
ON: DIP switches 1 to 9 determine parameterization

Interbus PCI

7. Example
7 Example
7.1 I/O configuration
In the following example, the robot controller participates as a slave in the

higher-level Interbus ring with 16 digital inputs and 16 digital outputs.
As master, the robot controller checks the devices in the lower-level ring.
Spread over three bus terminals, a total of 56 digital inputs, 24 digital outputs,
2 analog inputs and 2 analog outputs are connected to the robot.
Fig. 7-1: Example of a bus structure
Slave ring 16 DI, 16 DO

Master ring, bus terminal 1 16 DI, 16 DI, 16 DO
Master ring, bus terminal 2 2 AI, 2 AO, 8 DI
Master ring, bus terminal 3 16 DI, 8 DO

Interbus PCI
[INTERBUS]
;Master Inputs
INW0=0 ;$IN[1-16]
INB2=2,x2 ;$IN[17-32]
ANIN1=4,12,3 ;$ANIN[1]
ANIN2=6,12,3 ;$ANIN[2]
INB4=8 ;$IN[33-40]
INW5=9 ;$IN[41-56]
;Master Outputs
OUTW0=0 ;$OUT[1-16]
ANOUT1=2,12,3;$ANOUT[1]
ANOUT2=4,12,3;$ANOUT[2]
OUTB2=6 ;$OUT[17-24]
;Slave Inputs
INW12=896 ;$IN[97-112]
;Slave Outputs
OUTW12=896 ;$OUT[97-112]
Extract of the Interbus section in IOSYS.INI

The Interbus section of IOSYS.INI contains assignments between the I/O map
of the I/O system of the robot controller on the left-hand side of the equation
and that of the Interbus connection on the right-hand side. The comments after
the semicolons refer to the corresponding input and output variables which are
available in a robot program for Interbus communication. They have no effect
on the configuration and are purely displayed for information purposes.
The assignment within the sections is based on the sequence of the modules
in the bus structure and thus the physical addressing of the master ring. The
digital input and output signals are not assigned individually, but in groups of
8, 16 and 32 bits. These groups mirror the data format used by the I/O system
to operate the process data communication. The following data formats are
available:
Byte = 8 bits
Word = 16 bits = 2 bytes
Double Word = 32 bits = 4 bytes
Robot controller, The specification of the I/O position in the I/O system is made up of three parts
digital I/O arranged consecutively without gaps:

tion
DW
address.
O system.
Robot controller, The specification of the I/O position in the I/O system is made up of three parts
analog I/O arranged consecutively without gaps:

7. Example

Processing direc- ANIN, ANIN: robot controller input
tion ANOUT
ANOUT: robot controller output
Index Inputs: With analog I/Os, each index can only be
1 ... 8 used once. The index is positioned
immediately after ANIN or ANOUT with-
Out-
out a space.
puts: 1
... 16
Interbus connection, The specifications refer to the position of the process data in the I/O map of
digital I/O the Interbus card. The specifications are separated from one another by com-
mas:

Byte offset 0 ... The byte offset on the Interbus side des-
1023 ignates the position of the I/Os in the
internal MPM memory of the Interbus PCI
system coupler. The byte offsets, again
counted separately for all the inputs and
all the outputs, range from 0 to 1023. The
number of addressed bytes after the off-
set depends on the data width specified
on the robot side.
If physical addressing is used, positions
from byte offset 896 upwards on the
Interbus cards are reserved for the slave
ring. In the case of logical addressing,
this limit can be changed using the CMD
program.
Multiplier 1, 2, 3 The multiplier assigns multiple I/Os to
groups; the data width of these groups is
specified on the robot side.
Interbus side, analog The specifications refer to the position of the process data in the I/O map of
I/O the Interbus card. The specifications are separated from one another by com-
mas:

Byte offset 0 ... Specifies the position of an analog value
1023 in the input or output map of the Interbus
PCI system coupler. The same rules
apply for the start of the slave range as
for digital I/Os.
Exponent 2 8, 16 Specifies the number of bits used to rep-
resent the numeric value of an analog
datum.
Type 0 ... 3 Specifies how the bits are arranged and
whether or not the leading bit should be
interpreted as a plus/minus sign before
the numeric value.
0: right-justified without sign
1: right-justified with sign
2: left-justified without sign
3: left-justified with sign

Interbus PCI

8. Diagnosis
8 Diagnosis
8.1 LEDs on the master module
The diagnostic LEDs on the master module are all accommodated on the front
plate. The basic functions of the module are checked when it is switched on.
If no faults are detected, “SC” flashes green after approx. 5 seconds. “HF”
goes out when the drivers are activated.
Fig. 8-1: LEDs on the master module
The state of the Interbus is indicated by other LEDs:
Designation Color Meaning

FC Green Reserved
SC RDY/RUN Green Interbus Ready
The controller board has the state READY or
ACTIVE
SC RDY/RUN Flash- Interbus Running
ing
The controller board has the state RUN
HF Yellow Host Failure
System fault of the host
FAIL Red Failure
A fault has occurred in the Interbus system
PF Yellow Peripheral Failure
Periphery fault of a device
BSA Yellow Bus Segment Aborted
One or more bus segments are switched off
The CMD interface is designed as a 6-contact mini-DIN socket (PS/2) on the

front plate (>>> 5.4 "CMD interface" page 15).

Interbus PCI
The master module also has an LED FO3 (Fiber Optic 3) for diagnosis of the
outgoing fiber-optic cable.
Fig. 8-2: LED for diagnosis of the outgoing fiber-optic cable interface

FO3 Yellow Fiber Optic 3
Lights up when the initialization of the outgo-
ing interface is not OK, or a MAU warning is
present due to poor transmission quality on
the path. This applies to the outgoing data
path/transmitter to the following module; the
state of the return data path/receiver is diag-
nosed by the following module.
8.2 LEDs on the slave module
The diagnostic LEDs of the slave module indicate its state and that of the high-
er-level Interbus system:

UL Green U Logic
Operating voltage present
RC Green Remote bus Check
The connection to the higher-level controller
board has been established
BA Flash- Bus Active
ing
Bus is in the ACTIVE state
BA Green Bus Running
Bus is in the RUN state
RD Red Remote bus Disabled
The outgoing remote bus interface is deacti-
vated

8. Diagnosis
Fig. 8-3: LEDs on the slave module
The slave module also has two other LEDs for diagnosis of the fiber-optic ca-
ble:

FO1, FO2 Yellow Fiber Optic 1, Fiber Optic 2
Light up when the initialization of the outgoing
interface is not OK, or a MAU warning is
present due to poor transmission quality on
the path. This applies to the outgoing data
path/transmitter to the following module; the
state of the return data path/receiver is diag-
nosed by the following module.
8.3 KUKA.HMI error messages
Bus error and periphery fault messages are implemented as “status messag-
es” in the KUKA.HMI. In this way, messages are withdrawn by the driver when
the faults have been eliminated or a different error message is present. Error
codes and additional information generated with the messages come from the
firmware. The meaning of these codes is explained in chapter 5.2 of the Phoe-
nix Contact documentation “Interbus User Manual – Firmware Services and
Error Messages – IBS SYS FW G4 UM”.

Interbus PCI
In the event of a fault, the Interbus driver returns a negative value for the read
and write functions according to the settings in the INI file. This negative val-
ue causes the I/O system to display error messages on the KUKA.HMI for
read/write errors. These messages cause, for example, the execution of KRL
programs to be interrupted.
Since the write function is only called by the I/O system if an output is set, the
error message for a write error is also only displayed if an output is to be set.
This must be taken into consideration, particularly if no inputs have been con-
figured. In this case, for example, if a bus error occurs, execution of a KRL
program is not interrupted until an output is to be set and the write error is
subsequently displayed.
%1, %2 and %3 are individual variables of the error messages.
Interbus, general IBS %1:

Message text
Current configuration is diffrent from active
The BSA_BIT in the diagnostic register has been set;
Causes the current configuration does not match the active
configuration.
Effect The current configuration cannot be loaded.
Adapt current configuration or delete active configura-
Remedy
tion and then start the current one.
IBS %1:
Message text
diagnostic register shows faulty data cycle bit
The “faulty data cycles” bit in the diagnostic status reg-
Causes ister has been set. This is only used in synchronous
mode.
See description of the diagnostic status register of the
Effect
controller board.
See description of the diagnostic status register of the
Remedy
controller board.
IBS %1:
Message text
Too many input bytes in IOSYS.INI projected
The configured input bytes checked do not match the
Causes
inputs of the connected modules.
No input and outputs data are exchanged with the sys-
Effect
tem coupler.
Compare the configured input bytes with the inputs of
Remedy the connected modules. Check the CHECKLEVEL and
INACCURACY specifications in the INI file of the driver.
IBS %1:
Message text
Too many output bytes in IOSYS.INI projected
The configured output bytes checked do not match the
Causes
outputs of the connected modules.
Effect
tem coupler.
Compare the configured output bytes with the outputs
of the connected modules. Check the CHECKLEVEL
Remedy
and INACCURACY specifications in the INI file of the
driver.

8. Diagnosis
IBS %1:
Message text
Error while loading svc-file
An error occurred during execution of the command in
Causes
the SVC file.
Effect Bus system cannot be started.
Remedy Check the SVC file.
IBS %1:
Message text
Restart is already in process
Causes A restart is being carried out (possibly automatically).
Effect The restart command is ignored.

If the automatic restart has been activated in the INI file
Remedy
of the driver, it can be deactivated again.
IBS %1:
Message text
Restart is not processed because no error is present
The restart is not executed, as the Interbus is running
Causes
or has not yet ben started.
Effect Restart is not carried out.
If the driver is to be restarted, carry out an I/O reconfig-
Remedy
uration.
IBS %1:
Message text
Error Statusregister %2, Parameterregister %3
Indicates an error about which the driver has no further
information. A description of the status and parameter
Causes
registers can be found, for example, in the CMD help
files.
Effect The effect depends on the specific error.
Remedy See description of the registers.
IBS %1:
Message text
Synchronisation error
A synchronization error has occurred in “bus synchro-
Causes
nous” mode.
Effect
tem coupler.
Check your system or set the PD cycle time to a higher
Remedy
value using the “Set Value” service (0750hex).
IBS %1:
Message text
transfer frequency quality bit is set
The “specified error density exceeded” bit in the diag-
Causes
nostic status register has been set.
Effect Not all data cycles are correctly executed.
Remedy Check bus structure.
IBS %1:
Message text
Waiting for extern start
“External start” has been selected in the INI file and the
Causes driver is now waiting for the bus to be started, e.g. by
CMD.

Interbus PCI

Effect
tem coupler.
Remedy Start the Interbus using an external tool.
Interbus master IBS %1 Master:

Message text
User error %2 Add Info %3
Operator error by the user, e.g. incorrect parameter
when calling a firmware service. The error code is
Causes
saved by the firmware. A description of the error codes
can be found, for example, in the CMD help files.
The effect depends on the specific error. See descrip-
Effect
tion of the error code.
Remedy See description of the error code.
IBS %1 Master:
Message text
Bus Error %2 AddInfo %3
A bus error has occurred. The error code and addi-
tional information are saved by the firmware. A descrip-
Causes
tion of the error codes can be found, for example, in the
CMD help files.
Effect
tem coupler.
Remedy Eliminate bus error and reset the driver.
IBS %1 Master:
Message text
Bus error %2 segment %3
Bus error with specification of the device in which the
Causes
error was localized.
Effect
tem coupler.
Remedy Eliminate bus error and reset the driver.
IBS %1 Master:
Message text
Bus error. Error detection in process
The firmware has discovered a bus error and is now
Causes
searching for the cause.
Effect
tem coupler.
Remedy Wait until the firmware has found the cause of the error.
IBS %1 Master:
Message text
The watchdog is expired
The SYS_FAIL bit in the diagnostic status register has
Causes
been set.
Effect
tem coupler.
Carry out I/O reconfiguration, reboot controller,
Remedy
exchange system coupler.
IBS %1 Master:
Message text
Error %2 switching on/switching off segment %3
An error occurred when switching a segment on/off.
Causes The error code from Phoenix Contact describes the
error.

8. Diagnosis
The effect depends on the specific error. See descrip-

Effect
tion of the error codes.
Remedy See description of the error codes.
IBS %1 Master:
Message text
Error open file %2
Causes An error occurred when opening the specified file.
Effect The driver cannot be started.

Check whether the file is present in the correct direc-
Remedy
tory and with the correct format.
IBS %1 Master:
Message text
Periphery failure segment %2
Causes A periphery fault has occurred in the device.
If CONTINUE_WITH_WARNING has been set to 0 in
Effect IBSPCI1.INI, the exchange of input and output data is
stopped.
Remedy Eliminate the periphery fault.
IBS %1 Master:
Message text
System Error %2 AddInfo %3
System error, probably in the hardware. The error code
Causes is saved by the firmware. A description of the error
codes can be found, for example, in the CMD help files.
Effect
tem coupler.
See description of the error code. It may be necessary
Remedy
to exchange the system coupler.
Interbus slave IBS %1 Slave:

Message text
Bus error in slave circle
There is a bus error in the slave ring or the slave ring
Causes
has not yet been started.
No data are exchanged with the slave ring. If
CONTINUE_BY_ERR has been set to 0 in
Effect
IBSPCI1.INI, no more input and output data are
exchanged with the master ring.
Remedy Eliminate bus error in slave ring or start slave ring.
IBS %1 Slave:
Message text
Error %2 AddInfo %3
There is an error in the slave part of the controller
Causes board. The error code and additional information come
from the firmware and describe the error.
No files are exchanged with the slave ring. If
CONTINUE_BY_ERR has been set to 0 in
Effect
IBSPCI1.INI, no more input and output data are
exchanged with the master ring.
Remedy Eliminate bus error in slave ring or start slave ring.
8.4 IOCTL commands
Description The IOCTL commands are used for advanced troubleshooting.

Interbus PCI

Procedure IOCTL commands can be entered via TELNET or KRL.

TelNet shell:
RETURN VALUE = iosysIoctl (DRIVER ID, REQUEST, Parameter)
KRL interface:
RETURN VALUE = IOCTL (DRIVER ID, REQUEST, Parameter)
Parameter
Return value Depends on the function (REQUEST number)
called.
Driver ID Can be found in the [DRIVERS] section of the
IOSYS.INI file (>>> 6.2 "IOSYS.INI file" page 24).
For the Interbus PCI driver: 15
Overview of The specification of the I/O position in the I/O system on the left-hand side is
functions made up of three parts arranged consecutively without gaps:
Entry Request Parameter Function

CP_IB_DUMP 1012 Creation of a dump file (MPM log file)
CP_IB_RESTART 12 Restart
CP_IB_SEGM_ON 1006 Segment Activation of alternative groups
CP_IB_SEGM_OFF 1007 Segment Deactivation of alternative groups
CP_IO_FREEZE 20 Freeze
CP_IO_CONTINUE 21 Continue
CP_IO_STATE 3 1: Driver running
0: Driver not running
CP_IB_GET_MASTER 1010 Current state of master module
_STATE
CP_IB_GET_SLAVE 1011 Current state of slave module
_STATE
CP_IB_GET_MODULE 1013 Segment, Current state of a module
_STATE Position
CP_IB_POWERFAIL 1004 Deactivate driver (stop system coupler,
set MPM outputs to 0)
8.4.1 Generating a dump file
CP_IB_DUMP
The name of the dump file can be specified in the entry DUMPFILE in the
[CONFIGURATION] section of IBSPCI1.INI (>>> 6.1 "IBSPCI1.INI file"
page 19). In this case, all write access operations are recorded on the MPM.
The ibsPciDump function can be called either from the Telnet shell or using
the IOCTL command CP_IB_DUMP.
8.4.2 Restart
CP_IO_RESTART
An attempt is made to restart the system coupler by means of the firmware
command Start_Data_Transfer_Request. If the system coupler is still
active (including in the case of a periphery fault), no restart is carried out, an

8. Diagnosis
error message to this effect is sent to the KUKA.HMI and the function is aban-
doned with an error code (ERROR). This informs the user that the system cou-
pler is active, but that there is still a periphery fault.
If an error occurs during the restart, the corresponding error treatment is car-
ried out. The restart is triggered on the KUKA.HMI by means of “Reset”.
8.4.3 Switching segments on and off
CP_IB_SEGM_ON, CP_IB_SEGM_OFF
These IOCTL commands can be used to activate and deactivate alternative
groups (segments). In the event of a warm start, the Interbus driver saves the
last active segment during the shut-down procedure and automatically acti-
vates it again on rebooting. In the case of a cold start, the segment to be acti-
vated (if any) must be communicated to the Interbus by means of an IOCTL
command from the kernel system. In the event of an error, the IOCTL com-
mand returns the following values:
Message Value Meaning

ERROR -1 Unable to send message
IBS_PCI_SWITCH_WRONG_MODULE -2 Invalid segment number
IBS_PCI_TRY_SWITCH_ON_SECOND_SEGM -3 Attempt to switch on a second alterna-
tive segment
IBS_PCI_TRY_SWITCH_OFF_FIRST_SEGM -4 Attempt to switch off the first device
IBS_PCI_NO_EXCLUSIVE_RIGHTS -5 No exclusive rights for the service
IBS_PCI_SWITCH_GROUP_ERR -6 Group conflict when devices switched
on or off
IBS_PCI_SWITCH_MODULE_ERR -7 Device conflict when devices switched
on or off
IBS_PCI_UNKNOWN_ERR -100 Unknown error
If the segment was switched correctly, the command returns the number of the
switched segment.
8.4.4 Warm start
CP_IO_FREEZE, CP_IO_CONTINUE
CP_IO_FREEZE sets the Interbus driver in the freeze state. This renders the
driver inactive and the resources can be prepared so that the Interbus can be
set back to the previous state by means of the command CP_IO_CONTINUE.
CP_IO_CONTINUE sets the Interbus driver from the freeze state back to the
previous state (the state prior to CP_IO_FREEZE). This includes activating the
previously active segment. It is thus assumed that the same bus structure is
present. The INI file is no longer read when the Interbus is activated.
8.4.5 State polling
CP_IO_STATE
This service can be used to inquire whether the Interbus driver of an entity is
still active (RUNNING) or inactive (NOT_RUNNING).

NOT_RUNNING 0x0000 No data cycles can be carried out.
RUNNING 0x0001 Data cycles are possible.

Interbus PCI
8.4.6 Extended state polling of master
CP_IB_GET_MASTER_STATE
This service can be used to poll the current state of the master of an entity of
the Interbus driver. As the slave can be operated independently of the master,
the slave also has its own states (see “Extended state polling of the slave”).
The master can have the following states:

FREE 0x0001 Initial state: no instance has yet been created using the
Create function.
RUNNING 0x0002 This state is achieved once the Create function has
been completed successfully: the Interbus is activated
and running. From this state onwards it is possible to
send messages to the Interbus. The error treatment task
is started and checks the Interbus.
STOP_USER 0x0003 This state occurs if the Interbus has been stopped by
means of the IOCTL command CP_IB_POWERFAIL.
The Interbus is stopped and no more process data are
exchanged with the Interbus.
STOP_ERR 0x0004 This state occurs if there is an error on the Interbus (e.g.
bus error) and the firmware has determined the cause of
the error. In this state, no process data can be
exchanged with the Interbus.
STOP_ERR_UPDATE 0x0005 This state occurs if there is an error on the Interbus (e.g.
bus error). In this state, the Interbus continues to read
the input process data. This means, for example, that
the diagnostic registers continue to be updated (insofar
as they have been configured in the I/O map) so that
they always match the MPM map. For this state to
occur, the PASSIVE_UPDATE entry in IBSPCI1.INI
must be set to 1.
WAITING_FOR_EXTERN 0x0006 This state occurs if the EXTERN_START flag has been
_START set in IBSPCI1.INI, the driver has been initialized, but
the Interbus has not yet been started externally.
STOP_WARN 0x0007 This state occurs following a periphery fault on the Inter-
bus. The Interbus continues to run, but the driver pre-
vents the exchange of process data with the Interbus.
For this state to occur, CONTINUE_WITH_WARNING in
IBSPCI1.INI must be set to 0.
STOP_WARN_UPDATE 0x0008 This state occurs following a periphery fault on the Inter-
bus. The Interbus continues to run, but the driver pre-
vents the writing of process data. Only the input process
data continue to be read.
For this state to occur, PASSIVE_UPDATE must be set
to 1 and CONTINUE_WITH_WARNING must be set to
0 in IBSPCI1.INI.
STOP_RUN_FREEZE 0x0009 This state occurs if the IOCTL command FREEZE has
been sent to the Interbus driver. The Interbus is
stopped, no more process data can be exchanged and
all resources are prepared for the CONTINUE com-
mand.

8. Diagnosis

STOP_FREEZE 0x000A This state occurs once FREEZE has been executed
successfully. The Interbus is stopped and no more proc-
ess data are exchanged. This state is abandoned if the
IOCTL command CONTINUE is sent to the Interbus
driver.
The command can only be executed if FREEZE has
been carried out first. In this state, the previously frozen
resources are activated once again and the Interbus is
restarted.
STOP_RESET 0x000B In this state, a reset is executed and no process data
can be exchanged with the Interbus.
STOP_ERR_OPEN 0x000C This state occurs if it is detected during opening that the
data length of the I/O system is too great.
STOP_WATCHDOG 0x000D This state occurs once the watchdog on the card has
expired. The read and write function is disabled and the
firmware resets all outputs.
STOP_HW_ERR 0x000E This state occurs if the BASP/SYS_FAIL bit in the diag-
nostic register has been set. Otherwise, the driver
behaves in the same way as in the case of a bus error.
STOP_SLAVE_ERR 0x0100 This state occurs if the controller board slave has
entered a fault state. This also stops operation of the
master, i.e. in the event of this fault the read and write
function of the driver is disabled.
STOP_SLAVE_ERR 0x0200 This state is the same as STOP_SLAVE_ERR, with the
_UPDATE difference that in this case the PASSIVE_UPDATE flag
is set and thus only the write function is disabled.
8.4.7 Extended state polling of slave
CP_IB_GET_SLAVE_STATE
As the slave can be operated independently of the master, the slave also has
its own states. The read and write functions are the same for the master and
slave.
The slave can have the following states:
Slave Data Transfer (bit 1)
Fail (bit 2)
Slave Initialized (bit 3)
Power On (bit 4)
Ready (bit 5)
8.4.8 Polling the state of a module
CP_IB_GET_MODULE_STATE
This IOCTL command can be used to poll the state of a module. The return
value given by this command is the state of the module. This command must
be sent to the driver along with the number of the module in the form of the
segment and position number.
A device (module) can have the following states:
Alarm Output (bit 0)
Error Output (bit 1)

Interbus PCI
MAU detection of the incoming remote bus interface (towards data ring)
(bit 9)
MAU detection of the incoming remote bus interface (away from data ring)
(bit 10)
Periphery Fail (bit 11)
All other bits in the word are reserved.
A detailed description of the state information can be found in the Interbus doc-
umentation from Phoenix Contact under the firmware command
Read_Device_State_Request.
8.4.9 Stopping the Interbus
CP_IB_POWERFAIL
This command can be used to stop the Interbus and set the Interbus driver to
the inactive state. All outputs in the MPM are set to 0.
8.5 PCP functionality of the slave
Unambiguous remote addresses are determined for each PCP device in the
higher-level ring for the purpose of managing the services PCP (parameter
data channel) and PNM7 (remote management utility). Unlike the local com-
munication reference (CR) of the lower-level ring (master ring), the remote ad-
dress issued is unambiguous in the network. Each PCP-capable device is
referenced in the higher-level ring by means of the position of the data in the
summation frame protocol. The CRs in the master ring are issued in ascending
order, as a continuous series starting with 2. 2 CRs can be issued for an Inter-
bus system coupler: one each for PCP and PNM7.
Name Abbreviation Function

REQUEST REQ Request for a 0xxxhex
service
INDICATION IND Receipt of the 4xxxhex
service request
RESPONSE RES Response to the Cxxxhex
service request
CONFIRMA- CON Confirmation of 8xxxhex
TION the service
PCP messages that are evaluated by the driver have the identifier 40xxhex.
Before further processing, the received CR is compared with the preset CR in
the driver to check that they match.
8.5.1 PCP hardware settings
See (>>> 6.7 "DIP switches on the slave module" page 31).
8.5.2 Establishing the connection
PCP_INITIATE_IND_CODE
If the driver receives a message with the command
PCP_INITIATE_IND_CODE, a positive response message is returned. The
parameters Access_Group and Password are ignored and set to 0 in the re-
sponse message.

8. Diagnosis
8.5.3 Reading data
PCP_READ_IND_CODE
If a message is received with the command PCP_READ_IND_CODE, a check
is made to see if the PCP object 0x5FFF is involved. If the message contains
a different PCP object, a negative response message is returned with the error
code 0x0607 (Index not supported). If the message contains a PCP object with
the index 0x5FFF, the subindex is evaluated according to the two following ta-
bles.
If the subindex is between 1 and 32, then 128-byte data are read from the
input range of the MPM and these data are returned in a positive re-
sponse.
If the subindex is between 34 and 66, then 128-byte data are read from the
output range of the MPM and these data are returned in a positive re-
sponse.
If the subindex is 0, data are read from the input range of the MPM, using
the write service with subindex 1 according to the settings that have been
made, and these data are returned with a positive response.
Subindex 33 functions in the same way as subindex 0, except that in this
case the data are read from the output range of the MPM.
Subi
Index MPM range Length Access
ndex
0x5FFF 0 Can be set Variable, max. Read-only
using object 240 bytes
5FFE
subindex 1
0x5FFF 1 0 ... 127 128 bytes Read-only

Interbus PCI
Subi
ndex
MPM input data range from address 1000hex
Subi
ndex
0x5FFF 33 Can be set Variable, max. Read-only
using object 240 bytes
5FFE
subindex 1
MPM output data range from address 0000hex

8. Diagnosis
8.5.4 Writing data
PCP_WRITE_IND_CODE
If a message is received with the command PCP_WRITE_IND_CODE, a check
is made to see if the PCP object 0x5FFE is involved. If the message contains
a different PCP object, a negative response message is returned with the error
code 0x0607 (Index not supported). If the message contains a PCP object with
the index 0x5FFE, the subindex is evaluated according to the above tables. If
the subindex is 1 or 2, a check is made to see if the specified range is valid.
In the MPM, 4096 bytes are saved for the input data and 4096 bytes for the
output data. The start address can thus be selected between 0 and 4096. Here
also, a check is made to see if the start address plus the length of the data to
be read is less than 4096. If the check of the start address and length fails, a
negative response is returned with the error code 0x0605 (Application error).
If the specified data are correct, they are accepted and a positive response is
returned.
Subin Lengt Defau Acces

Index Meaning of user data
dex h lt s
0x5FF 1 Byte 0: MPM In start 3 0 Read/
F address (high) bytes Write
0
Byte 1: MPM In start
240
address (low)
Byte 2: Length of the
MPM range
0x5FF 2 Byte 0: MPM Out start 3 0 Read/
F address (high) bytes Write
0
Byte 1: MPM Out start
240
address (low)
Byte 2: Length of the
MPM range
Configuration objects for variable access

If the subindex of the PCP message is 10, user data are to be written to the
MPM output range. Before the data are written to the MPM, the specified ad-
dress range is checked. If the address of the data to be written exceeds the
limit of 4095 bytes, the data are not accepted and a negative response is re-
turned with the error code 0x0605 (Application error). If the address range is
OK, the data are written to the MPM accordingly and a positive response is re-
turned.
Subind
Index Meaning of user data Length Access
ex
0x5FFF 10 Byte 0: MPM Out start Varia- Read/
address (high) ble, Write
max.
Byte 1: MPM Out start
240
address (low)
bytes
Byte 2: User data 1
...
Byte n: User data n-1
Writing objects for user data

Interbus PCI
8.5.5 Terminating the connection
The PCP messages PCP_ABORT_IND_CODE and

PCP_REJECT_IND_CODE are received, but the driver does not react to
these messages.
8.5.6 PCP connection settings
When the Interbus is started, the driver checks whether the controller board
slave supports PCP. If so, the PDU size of PCP objects 0x5FFF and 0x5FFE
is changed to 246 bytes.
8.5.7 PCP server response to a fault in the master ring
If the Interbus driver is switched to the inactive state as the result of a fault on
the Interbus, all incoming PCP messages receive a negative response. The
Error_Class and Error_Code word are set to 0x0902.

9. KUKA Service
9 KUKA Service
9.1 Requesting support
Introduction The KUKA Robot Group documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Faults leading to production downtime should be reported to the local KUKA

subsidiary within one hour of their occurrence.
Information The following information is required for processing a support request:

Model and serial number of the robot
Model and serial number of the controller
Model and serial number of the linear unit (if applicable)
Version of the KUKA System Software
Optional software or modifications
Archive of the software
Application used
Any external axes used
Description of the problem, duration and frequency of the fault
9.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au

Interbus PCI
Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn
Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de

9. KUKA Service
France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
www.kuka.in
Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it
Japan KUKA Robotics Japan K.K.

Ogikubo TM Building 7F
5-26-13 Ogikubo, Suginami-ku
Tokio
167-0051
Japan
Tel. +81 353 47-9831
Fax +81 353 47-9835
kuka.co.jp
Korea KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com

Interbus PCI
Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt

9. KUKA Service
Russia OOO KUKA Robotics Rus

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru
Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland KUKA Roboter Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch
Spain KUKA Sistemas de Automatización S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com
South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Interbus PCI
Taiwan KUKA Robot Automation Taiwan Co. Ltd.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com
UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk

Index
Index
A M
Analog inputs and outputs, assigning 26 MACID 6
MAU 6
C MAU warning 6
CMD 5 MPM 6
CMD interface 15
Configuration 19 O
Configuration files 6 Offset-Table 28
Connecting fiber-optic cables 14 Operation of the robot system 9
CR 5 Overview 7
D P
Diagnosis 39 PCI 6
Digital inputs and outputs, assigning 25 PCP 6
DIP switches, master module 30 PCP functionality 8
DIP switches, slave module 31 PCP functionality of the slave 50
PDU 6
E PLC 6
Error messages 41 Polymer fiber cable 6
Example 35 Product description 7
External power supply to slave 16 Properties 7
F R
FOC 6 Remote bus 5
FSMA 5
FW 5 S
Safety 9
H Safety instructions 9
HCS fiber 5 Service, KUKA Roboter 55
HW 5 Software installation 11
Start-up 13
I Support request 55
I/O 5 SW 6
IBS 5
IBS PCI SC system coupler 8 T
IBS PCI SC/RI-LK 13 Target group 5
IBS PCI SC/RI/I-T 15 Telnet 6
IBSPCI1.INI, configuration 19 Training program 5
Installation 11
Interbus 5 V
Introduction 5 Version compatibility 11
IOCTL commands 45
IOSYS.INI 5 W
IOSYS.INI, configuring 24 Warnings 9
ISA 6
K
KCP 6
KR C 6
KRL 6
KUKA Customer Support 55
KUKA.HMI 6
L
LEDs, master module 39
LEDs, slave module 40
Local bus 6

Interbus PCI


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KUKA Roboter GmbH

Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

Publication: Pub KR C2 Interbus PCI en

2 Product description ......................................................................................... 7

Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en 3 / 63

8.4.7 Extended state polling of slave .................................................................................. 49

9 KUKA Service ................................................................................................... 55

4 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

1.1 Target group

1.2 Terms used

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6 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

The Interbus PCI interface is a combined master/slave system coupler. Master

The range of functions of the G4 firmware (= 4th generation) is restricted by

Properties  Data transmission via ring system

Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en 7 / 63

 I/O units can be switched on/off

2.2 IBS PCI SC system coupler

2.3 PCP functionality

8 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

3.1 Representation of warnings and notes

Tips to make your work easier or references to further information.

3.2 Operation of the robot system

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10 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

4.1 Software installation

4.2 Version compatibility

PCI driver Firmware CMD tool

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12 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

5.1 IBS PCI SC/RI-LK

Fig. 5-1: Structure of the IBS PCI SC/RI-LK system coupler

1 Reset button (slave)

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5.2 Connecting fiber-optic cables

Fig. 5-2: Connecting the fiber-optic cables

 “Remote In”, slave: incoming remote bus

14 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

5.3 IBS PCI SC/RI/I-T

Fig. 5-3: Structure of the IBS PCI SC/RI-I/T system coupler

1 RS232 interface (CMD connection)

5.4 CMD interface

Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en 15 / 63

Fig. 5-4: CMD interface: 6-pin mini-DIN socket (PS/2)

The CMD interface is designed as a 6-contact mini-DIN socket (PS/2) on the

Fig. 5-5: RS232 cable for connection to diagnostic PC

It is connected to the diagnostic PC via a special RS232 cable that is available

5.5 External power supply to slave

An external 24 V DC power supply is required for operation of the slave mod-

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18 / 63 Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en

6.1 IBSPCI1.INI file

Precondition  All communications cables have been installed.

Procedure 1. Open the file IBSPCI1.INI.

IBSPCI1.INI is divided into the following sections:

Entry Value Function

Entry Value Function

Issued: 24.07.2008 Version: BA KR C2 Interbus PCI V1 en 19 / 63

Entry Value Function

Entry Value Function

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Entry Value Function

Properties Data transmission via ring system

I/O units can be switched on/off

“Remote In”, slave: incoming remote bus

Precondition All communications cables have been installed.

Precondition All communications cables have been installed.

Example Device 2: I/O module