KUKA Ethernet/IP 2.0: Controller Option

Controller Option KUKA Roboter GmbH
KUKA Ethernet/IP 2.0
For KR C2 edition2005
Issued: 03.04.2009
Version: BA EtherNet/IP 2.0 V1 en

© Copyright 2009
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 Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original operating instructions
KIM-PS5-DOC
Publication: Pub KUKA Ethernet/IP 2.0 en

Book structure: KUKA.Ethernet/IP 2.0 V1.5
Label: BA EtherNet/IP 2.0 V1
2 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

Contents
Contents
1 Introduction .................................................................................................. 5
1.1 Target group .............................................................................................................. 5
1.2 Robot system documentation .................................................................................... 5
1.3 Trademarks ................................................................................................................ 5
1.4 Terms used ................................................................................................................ 5
2 Product description ..................................................................................... 7

2.1 KUKA EtherNet/IP 2.0 ................................................................................................ 7
3 Safety ............................................................................................................ 9
3.1 Representation of warnings and notes ...................................................................... 9
4 Installation ................................................................................................... 11
4.1 System requirements ................................................................................................. 11
4.2 Installing the KUKA Ethernet/IP drivers ..................................................................... 11
4.3 Uninstalling the KUKA Ethernet/IP drivers ................................................................. 11
4.4 Installing the KUKA Ethernet/IP configuration software ............................................. 12
4.5 Uninstalling the KUKA Ethernet/IP configuration program ......................................... 12
5 Configuration ............................................................................................... 13
5.1 Ethernet/IP network configuration .............................................................................. 13
5.2 Notes on use of the Ethernet/IP configuration software ............................................. 13
5.3 Starting the configuration software ............................................................................ 14
5.3.1 Adapting the configuration settings ....................................................................... 16
5.4 Assigning devices ...................................................................................................... 19
5.4.1 General tab ........................................................................................................... 20
5.4.2 General tab – Network Properties ........................................................................ 21
5.4.3 Chassis tab ........................................................................................................... 22
5.4.4 Connections tab .................................................................................................... 23
5.4.5 Changing the connection type .............................................................................. 24
5.4.6 Changing the connection properties ..................................................................... 25
5.4.7 Checking the device identity ................................................................................. 26
5.4.8 Online Parameters tab .......................................................................................... 26
5.4.9 Module Informations tab ....................................................................................... 27
5.4.10 Port Configuration tab ........................................................................................... 28
5.4.11 EDS File tab .......................................................................................................... 29
5.4.12 Defining the input/output assignment ................................................................... 30
5.5 Transferring the configuration to the robot controller ................................................. 31
5.6 Configuring the robot controller .................................................................................. 32
5.6.1 IOSYS.INI configuration ........................................................................................ 32
5.6.2 IOCTL commands ................................................................................................. 35
5.6.3 Configuring the file ENIP.INI ................................................................................. 36
6 Troubleshooting .......................................................................................... 39
6.1 ApplicomIO status ...................................................................................................... 39
7 Repair ........................................................................................................... 41
7.1 Installing the KUKA Ethernet/IP board ....................................................................... 41
Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 3 / 51

7.2 Removing the KUKA Ethernet/IP board .................................................................... 41
8 KUKA Service ............................................................................................... 43

8.1 Requesting support ................................................................................................... 43
8.2 KUKA Customer Support ........................................................................................... 43
Index ............................................................................................................. 49

1. Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:
Expert system knowledge of the robot controller system
Expert knowledge of the Windows operating system
Advanced knowledge of network technology
Für den optimalen Einsatz unserer Produkte empfehlen wir unseren Kunden
eine Schulung im KUKA College. Informationen zum Schulungsprogramm
sind unter www.kuka.com oder direkt bei den Niederlassungen zu finden.
1.2 Robot system documentation
The robot system documentation consists of the following parts:

Operating instructions for the robot
Operating instructions for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Each of these sets of instructions is a separate document.
1.3 Trademarks
Windows is a trademark of Microsoft Corporation.
1.4 Terms used
Term Description
KUKA.HMI The Human-Machine Interface (HMI) is an interface which
allows a human to communicate with a machine.
TCP/IP The Transmission Control Protocol (TCP) is a protocol for
data exchange between the devices in a network.
TCP constitutes a virtual channel between 2 sockets in a
network connection. Data can be transmitted along this
channel in both directions.
The Internet Protocol (IP) has the task of transporting data
packets via a number of networks from a transmitter to a
receiver.
RPI The Requested Package Interval (RPI) is the time interval
between 2 telegrams.
Subnet Exact specification of part of the IP address space.


2. Product description
2 Product description
2.1 KUKA EtherNet/IP 2.0
Description
Fig. 2-1: KUKA Ethernet/IP board (PCU-ETHIO)
Item Description
1 Jumper for setting the board number:
Value: 1 ... 8
Default setting: 1
2 Jumper for the PCI bus identifier:
Default setting: 1
3,4 LEDs for visualizing the data transfer
5 RJ45 port
The KUKA Ethernet/IP board (PCU-ETHIO) supports the following features:

Connection type RJ45
Different speeds e.g. Automatic, 10 Mbps (in half- and full-duplex modes),
100 Mbps (in half- and full-duplex modes)
In conjunction with Siemens Scalance x208 Switch, only use “Autoconfigura-

tion” and “100 MBit Full Duplex” modes.
Static TCP/IP configuration via DHCP or BOOTP

Ethernet/IP scanner and adapter (local slave) functions
Automatic organization of the input and output memory
Up to 14 kB on inputs and outputs
Detailed data transfer
Equipment support for up to 127 devices and 256 connections
Multicast, Point to point, Real time Format, Trigger, Unique RPI


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.
Specific safety instructions

In addition to the Safety chapter, the operating instructions for the robot sys-
tem and its options contain further safety instructions. These must be ob-
served.


4. Installation
4 Installation
4.1 System requirements
Robot controller Hardware

KR C2 edition2005
KUKA Ethernet/IP board
Software
KUKA System Software 5.5
KUKA Ethernet/IP option CD
Laptop/PC Hardware
CD-ROM drive
Software
Windows XP with SP1
4.2 Installing the KUKA Ethernet/IP drivers
Precondition CD-ROM with additional software

Only required if there is no CD-ROM drive on the control cabinet:
Bootable USB CD-ROM/DVD drive
User group “Expert”
Procedure 1. Select the menu sequence Setup > Install Additional Software.
2. Press the New SW softkey. If Ethernet/IP is not yet displayed, press the
Refresh softkey.
3. Select Ethernet/IP and press the Install softkey. Answer the request for
confirmation with Yes. The files are copied onto the hard drive.
4. Reboot the robot controller. The installation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
Ethernet/IP update:
In the case of an Ethernet/IP update, the configuration settings may be de-
leted. A new configuration must be created.
(>>> 5.3 "Starting the configuration software" page 14)
4.3 Uninstalling the KUKA Ethernet/IP drivers
It is advisable to archive all relevant data before uninstalling a software pack-

age.
Precondition User group “Expert”
Procedure 1. Select the menu sequence Setup > Install Additional Software. All in-
stalled additional programs are displayed.
2. Select Ethernet/IP and press the De-install softkey. Answer the request
for confirmation with Yes.
“De-installation prepared” is displayed in the State column.
3. If required, repeat step 2 to uninstall further software.
4. Reboot the robot controller. Uninstallation is resumed and completed.

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
4.4 Installing the KUKA Ethernet/IP configuration software
If the Ethernet/IP configuration program has already been used on the same
computer and if malfunctions occur after reinstallation, then it must be
checked that only one Ethernet/IP driver is activated.
Precondition CD-ROM with configuration software

Local administrator rights
Procedure 1. Start the program on the CD-ROM.

Installation is prepared and the installation window opens.
2. Press Next to proceed.
3. In the User Name box, enter the name of the user.
In the Organisation box, enter the name of the company.
Activate the radio button Anyone who uses this computer and click on
Next.
4. Select the installation folder for Ethernet/IP. Press Next to proceed.
5. Click on Install.
The Ethernet/IP is installed.
6. Click on Finish.
4.5 Uninstalling the KUKA Ethernet/IP configuration program
Precondition Local administrator rights
It is advisable to archive all relevant data before uninstalling a software pack-

age.
Procedure 1. Start the program on the CD-ROM.

The uninstallation window opens.
2. Press Next to proceed.
3. Activate the radio button Remove and click on Next.
4. Click on Remove. Ethernet/IP is removed.
5. Click on Finish.

5. Configuration
5 Configuration
5.1 Ethernet/IP network configuration
Overview The Ethernet/IP configuration software manages the devices in a subnet.
Fig. 5-1: Configuration (example)
Item Description
1 Configuration link
2 Diagnostic link
For technical reasons, do not use a hub for the network connection.
The robot controller and the configuration PC must be located in the
same subnet.
The Ethernet/IP board and the bus devices must be located in the same
subnet.
5.2 Notes on use of the Ethernet/IP configuration software
On activating Expert mode via the menu sequence File > Preferences >
Expert Mode, additional configuration options are shown. These options
are indicated with an icon.
In the configuration windows, the button opens a selection box with the
options Properties and Edit. Both options allow changes to be made in
the configuration.
The Properties option is described in this documentation (>>> Fig. 5-2).

Additional information about the configuration parameters that are not de-
scribed in this documentation is given in the Description info boxes of the
individual configuration windows. (>>> Fig. 5-2).
5.3 Starting the configuration software
The configuration data created for Ethernet/IP are not saved on the card after
the robot controller is switched off. When the robot controller is rebooted,
these configuration data are reloaded onto the Ethernet/IP card.
Procedure 1. Start the Console icon on the desktop. Alternatively, select the menu se-
quence Programs > KUKA > Ethernet_IP > 2.3 >Console.
The program applicomIO console opens. If configurations have already
been created using this program, the last used configuration is loaded.
If the program is started for the first time, the following window is displayed:
Fig. 5-2: TCP/IP tab

5. Configuration
Item Description
1 Configuration list box:
Static: Manual setting
Default setting for the IP address: 192.168.0.1
DHCP
Settings are automatically obtained from the memory of the
DHCP server.
BOOTP
Settings are automatically obtained from the memory of the
BOOTP server.
2 Properties button
3 Work area
4 Description info box
2. Select ApplicomIO channel IP Address.
3. Click on the button and assign an IP address for the Ethernet/IP board.
The Ethernet/IP board must be located in the same subnet as the bus devic-
es which are to be added later.
4. In the Configuration list box, select the required mode.
5. On the Advanced tab, select the parameters. Click on the button to

check or modify the settings.
Fig. 5-3: TCP/IP Advanced tab

Parameter Description
Number of Number of times that the ApplicomIO® board
retries attempts to send an unacknowledged data packet.
1 ... 12
Default setting: 2
Interval Time interval between attempts at transmitting a
between retries data packet. The time interval is increased after
every attempt by the factor “Number of retries”.
1 ... 5 s
Default setting: 1
Connection Activates the TCP/IP function Keep Alive in order to
servicing perform a cyclical check of the TCP connection to
the device.
DHCP, DNS Time interval between DHCP polls.
Time-Out (>>> 5.6.3 "Configuring the file ENIP.INI" page 36)
Maximum number of polls: 5
Value: 1 ... 30 s
Default setting: 3
6. Confirm with OK.
5.3.1 Adapting the configuration settings
Procedure 1. Select the menu sequence File > Configuration Manager.
Fig. 5-4: Configuration Manager window
2. In the Configuration Manager, select an existing configuration or click on

the button New.
If a new configuration is created using the button New, the configura-
tion program is restarted and the TCP/IP tab opens. Steps 2 and 3 of
the IP address assignment must be carried out again.
(>>> 5.3 "Starting the configuration software" page 14)
If an existing configuration is selected, the Properties window opens.
Make the relevant settings.

5. Configuration
Fig. 5-5: Properties window
Item Description
1 Name of the configuration.
2 Description of the configuration.
3 Checkbox activated:
The configuration can be downloaded to the robot controller.
4 IP address of the robot controller.
5 FTP user name of the robot controller.
Default setting: target
6 Password for the robot controller.
Default setting: vxworks

Item Description
7 Checkbox activated:
Direct access to the Ethernet/IP board in the robot controller is
possible, including the following functions:
Diagnostics
Online access to Ethernet/IP devices, e.g. for configuration
Network detection
8 Select EtherNet/IP Board button for direct access.
The connection to Ethernet/IP can be updated in the status
box of the Configured boards state.
(>>> 5.4 "Assigning devices" page 19)
3. Click on the Select EtherNet/IP Board button to open the Network

Adapter Properties window.
Fig. 5-6: Network Adapter Properties window
Item Description
1 Local Network Adapters group: Selection of a local network
adapter which can be used to establish a connection to the
Ethernet/IP board.
Board Name: Name of the network adapter
2 Automatic/Manual tabs:
Automatic: Automatic detection of the available network
adapter(s) by clicking on the Detect button
Manual: Manual selection an available network adapter
3 Configured Board group:
Serial Number: Input box for the serial number of the net-
work adapter
Connection Test button: Start the connection test
4. After establishing a direct connection to the Ethernet/IP network, confirm

with OK.
5. The Properties window of the Configuration Manager is opened.
(>>> Fig. 5-5)

5. Configuration
6. Confirm the settings with OK.
5.4 Assigning devices
Precondition The IP address has been assigned to the Ethernet/IP board

(>>> 5.3 "Starting the configuration software" page 14).
The physical bus architecture is known.
Caution!
Substantial damage to property may occur. The bus architecture modeled in
the configuration program must correspond to the physical bus architecture.
Procedure 1. Drag the relevant devices from the Equipment Library into the work area
using Drag&Drop.
Fig. 5-7: applicomIO window
Item Description
1 Equipment Library
2 Configuration work area
3 Configured boards state:
The connection to the Ethernet/IP card can be updated by
right-clicking on the state of the board.
If no EDS file is available:

Ask the manufacturer for an EDS file.
Create an EDS file from the Equipment Library by inserting the element
Generic EDS into the Configuration work area.
2. The configuration window for the tabs opens.

Fig. 5-8: Configuration window with tabs
Item Description
1 Tabs
The following tabs are available:

General (>>> 5.4.1 "General tab" page 20)
Chassis (>>> 5.4.3 "Chassis tab" page 22)
Connection (>>> 5.4.4 "Connections tab" page 23)
Online Parameters (>>> 5.4.8 "Online Parameters tab" page 26)
Module Information (>>> 5.4.9 "Module Informations tab" page 27)
Port Configuration (>>> 5.4.10 "Port Configuration tab" page 28)
EDS File (>>> 5.4.11 "EDS File tab" page 29)
5.4.1 General tab
Description On assigning a device, the General tab is displayed

5. Configuration
Fig. 5-9: General tab
Item Description
1 Name of the device
2 Number of the device
Value: 0 to 127
3 Link Parameters checkbox
Checkbox activated:
The device number is linked to the device IP address.
The device name is linked to the host name.
Check box not activated:
The device number is separated from the device IP address.
The device name is separated from the host name.
4 Set the network properties (>>> 5.4.2 "General tab – Network
Properties" page 21)
5 Blank text box for additional description
Max. 80 characters
6 Active Configuration checkbox
Checkbox activated:
Configuration of the device is activated.
Check box not activated:
Configuration of the device is not activated, but remains saved
in the applicomIO® console.
Confirm the changes made with OK.
5.4.2 General tab – Network Properties
Procedure 1. In the Network Properties selection box, select the line Address Type.

2. Click on the button.

3. Select the Address Type IP or Hostname.
4. Confirm your selection with OK.
The IP address and host name can only be changed if the Link Parameters
checkbox is deactivated. (>>> 5.4.1 "General tab" page 20)
Fig. 5-10: Network Properties
Item Description
1 Address Type
2 Address Type:
IP (default)
Host name
3 Properties
5.4.3 Chassis tab
Description Assigning modules to a chassis
Procedure 1. Select a chassis from the Equipment Library.

2. Select a module from the Available Modules for the Chassis work area
and drag it into the Configured Modules work area using Drag&Drop.
3. Confirm with OK.

5. Configuration
Fig. 5-11: Chassis tab
Item Description
1 Chassis selection in the Equipment Library
2 Available Modules work area
3 Configured Modules work area
5.4.4 Connections tab
Description Setting the connection parameters
Procedure 1. Select an element in the Configured Connection box.
2. Click on the button to check the settings and modify them if necessary.
3. Confirm with OK.

Fig. 5-12: Connections tab
Item Description
1 Name of device or module
2 Connection type
3 Connection properties
4 Device identity check
5 Configuration settings
6 Add button (disabled)
Is enabled when a setting is removed
7 Remove button (disabled)
Is enabled when a setting is selected
5.4.5 Changing the connection type
Procedure 1. Select the connection type element in the Configured Connection box.
(>>> Fig. 5-12)
2. Remove the connection type using the Remove button.
3. Add a connection type using the Add button.
4. Select the connection type from the list box. (>>> Fig. 5-13)
5. Confirm with OK.
Fig. 5-13: Example of the list box for connection type

5. Configuration
The connection type Rack Optimization can only be used with digital devic-
es.
All offset values of the modules are listed in the 1st module. Errors in subor-
dinate modules cannot be detected by the firmware.
5.4.6 Changing the connection properties
Procedure 1. Select the element General in the Configured Connection box and dis-
play the assigned values.
2. Select the required assignment.
3. Click on the button to check or modify the settings.

4. Confirm with OK.
Fig. 5-14: Connections Parameters box
Request Packet Default setting for the refresh rate: 10 ms
Interval (RPI)
Input Size EDS standard setting
Input Mode Input Mode defines the type of data transmission:
Point to Point: Transmission from adapter to scan-
ner
Multicast: Transmission from adapter to a multicast
IP address
Null: No transmission
Input Type The setting Fixed is predefined and cannot be
changed.
Priority Connection priority
Trigger Type In connection with the RPI, the following trigger types
can be set for data transmission:
Cyclic: Cyclic data transmission depending on the
RPI
Change of State: Data transmission on status
change
Application: Data polling by adapter
Output Size EDS standard setting
Output Mode Output Mode defines the type of data transmission:
Point to Point: Transmission from scanner to
adapter
Multicast: Transmission from scanner to a multi-
cast IP address
Null: No transmission

Output Type The setting Fixed is predefined and cannot be
changed.
Priority Connection priority
The data output of the ApplicomIO® Scanner is cyclically triggered.
5.4.7 Checking the device identity
Procedure 1. Select the Check Module Identity element in the Configured Connec-
tion box.
2. The assigned value is displayed in the Connections Parameters box.
Default setting: Disable
3. Mark the element.
4. Click on the Properties button to check the settings and modify them if
necessary.
5. Confirm with OK.
Fig. 5-15: Check Identity list box
Must Match Exactly Exact identity check
Disable No identity check (default setting)
Must Be Compatible The device adapts its identity parameters to the
EDS.
Custom User-defined identity
None No identity check
5.4.8 Online Parameters tab
Description Checking and changing the parameters of the available devices.
Precondition The Ethernet/IP board is initialized.
Procedure 1. Select a parameter from the work area.

2. The following options are available:

5. Configuration
Synchronize button: Check and change the values.

Get Values from EDS button: Load the default values from the EDS
file.
3. Confirm with OK.
Fig. 5-16: Online Parameters tab
Item Description
1 Work area
2 Synchronize button
3 Get Values from EDS button
5.4.9 Module Informations tab
Description Detailed identification and status of the modules.
Procedure 1. Select an item from the Object group.

2. Select a parameter from the work area.
Get Informations button: Check the values.
Reset Equipment button: Restore the default values.
4. Click on the button to check the settings and modify them if necessary.
5. Confirm with OK.

Fig. 5-17: Module Informations tab
Item Description
1 Work area
2 Get Informations button
3 Object group
4 Reset Equipment button
5.4.10 Port Configuration tab
Description Checking and setting connections
Procedure 1. Select an item from the Set Part of Values group.

2. Select the parameter from the work area.
Get Values from Equipment button: The setting is transferred from
the IP board.
Set Values to Equipment button: The values of the selected element
are transferred to the IP board.
Set All Values to Equipment button: All values in the work area are
transferred to the IP board.
4. Click on the Properties button to check and modify the settings.
5. Confirm with OK.

5. Configuration
Fig. 5-18: Port Configuration tab
Item Description
1 Work area
2 Get Values from Equipment button
3 Set Part of Values group
4 Set Values to Equipment button
5 Set All Values to Equipment button
5.4.11 EDS File tab
Description With the View or Print EDS File button, information about the EDS file and
the bus devices can be displayed in an editor.

Fig. 5-19: EDS file
Item Description
1 View or Print EDS File button
5.4.12 Defining the input/output assignment
Description The offset values in the input/output display are required for the configuration
of IOSYS.INI.
Precondition The devices are assigned and configured.
Procedure 1. In the Configuration work area (>>> Fig. 5-7), select the device and open
the tree structure.

5. Configuration
Fig. 5-20: Configuration work area
2. Click on the module and open the input/output display.
Fig. 5-21: Input/output display
3. In the input/output display, read the offset values from the “Offset/equip.”
column and transfer them manually to IOSYS.INI on the robot controller.
(>>> 5.6.1 "IOSYS.INI configuration" page 32)
The function of the input/output display depends on the module type. If there
is no entry, read the offset values from the Online Parameters tab, or con-
tact the manufacturer.
With the setting Rack Optimization, all offset values are listed in the 1st
module.
Take care not to mix up the offset values in the input/output display, and en-
sure that the values are correctly transferred.
5.5 Transferring the configuration to the robot controller
Precondition The configuration has been saved

Any firewalls on the configuration PC and the robot controller must allow
the FTP protocol (port 21).

Procedure Configuration PC:

Select the menu sequence File > Download Configuration.
The configuration is transferred to the robot controller.
Robot controller:
Select the menu sequence Configure > I/O Driver > Reconfigure I/
O Driver on the KUKA.HMI.
The configuration is transferred.
5.6 Configuring the robot controller
5.6.1 IOSYS.INI configuration
Description The file IOSYS.INI is located in the directory C:\KRC\ROBOTER\INIT.

Activating the bus drivers and configuring the inputs/outputs.

The Ethernet/IP configuration has been transferred to the robot controller.
Procedure 1. Select the menu sequence Configure > I/O Driver > Edit I/O Config..
The file IOSYS.INI is opened.
2. Check or modify the settings.
3. Save changes.
4. Select the menu sequence Configure > I/O Driver > Reconfigure I/O
Driver to apply the changes.
Example of 1 [CONFIG]
IOSYS.INI 2 VERSION=2.00
3 [DRIVERS]
4 EthernetIP=23,eipInit,eipdrv.0
5 [EthernetIP]
6 INB0=3,4,x8
7 OUTB0=3,10,x8
8 ANIN1=6,24,14,1,CAL16384
9 ANOUT1=6,17,14,1
Line Description
1 [CONFIG] section
2 Indication of the version number
3 [DRIVERS] section
4 Activation of the Ethernet/IP bus driver
5 [EthernetIP] section
6 Configuration of a digital input:
Input 0 is assigned to device 3 with offset 4.
Multiplier 8.
7 Configuration of a digital output:
Output 0 is assigned to device 3 with offset 10.
Multiplier 8.

5. Configuration
Line Description
8 Configuration of an analog input:
Input 1 is assigned to device 6 with offset 24.
Data width 14 bits; type 1; calibration value 16384.
9 Configuration of an analog output:
Output 1 is assigned to device 6 with offset 17.
Data width 14 bits; type 1.
The name of the section EthernetIP must be identical to the name of the bus
driver.
IN INGranularityNumber=Device ,Offset,Multiplier
Element Description
Granularity Data type: CHAR
Byte, word, double word
B, W, DW
Number Data type: INT
Number of the digital input
0 ... 1023
Device Data type: INT
Address of the device
0 ... 127
Offset Data type: INT
Offset on the device address
(>>> 5.4.12 "Defining the input/output assignment"
page 30)
Multiplier x: Multiplier for byte length of the data object
(x4 = 1 data object with byte length 4)
xx: multiplier for data object with byte length 1
(xx4 = 4 data objects with byte length 1)
OUT OUTGranularityNumber=Device ,Offset,Multiplier
Element Description
Granularity Data type: CHAR
Byte, word, double word
B, W, DW
Number of the digital output
0 ... 1023
0 ... 127

Element Description
page 30)
Multiplier x: Multiplier for byte length of the data object
(x4 = 1 data object with byte length 4)
xx: multiplier for data object with byte length 1
(xx4 = 4 data objects with byte length 1)
ANIN ANINNumber=Input,Device ,Offset,Data width,Type,CALCalibration value
Element Description
Number of the analog input
0 ... 1023
0 ... 127
page 30)
Data width Data type: INT
1 ... 32 bits
Type Data type: INT
0...3
Specifies the alignment and sign of the data set
0: Right-justified without sign
1: Right-justified with sign
2: Left-justified without sign
3: Left-justified with sign
Calibration value Data type: INT
0 ... 65536
With analog inputs/outputs, the value is specified as a
decimal number without prefix.
0 or no specified value sets the calibration to the maxi-
mum value
ANOUT ANOUTNumber=Output,Device,Offset,Data width,Type

5. Configuration
Element Description
Analog output number
0 ... 1023
0 ... 127
page 30)
Data width Data type: INT
1 ... 32 bits
Type Data type: INT
0...3
Specifies the alignment and sign of the data set
0: Right-justified without sign
1: Right-justified with sign
2: Left-justified without sign
3: Left-justified with sign
Calibration value Data type: INT
0 ... 65536
With analog inputs/outputs, the value is specified as a
decimal number without prefix.
0 or no specified value sets the calibration to the maxi-
mum value
5.6.2 IOCTL commands
Description IOCTL commands can be used to call certain driver services.

IOCTL commands can be entered via TELNET or KRL.
TelNet shell:
RETURN VALUE = iosysIoctl (DRIVER ID, REQUEST, Parameter)
KRL program:
RETURN VALUE = IOCTL (DRIVER ID, REQUEST, Parameter)
Return value Depends on the function (REQUEST number) called.
Driver ID Can be found in the [DRIVERS] section of the IOSYS.INI
file.

IOCTL
Function Description
code
CP_EIP_UPDATE_CONFIG 1030 Loads the configuration from the current
directory of the file system into the mem-
ory of the Ethernet/IP board. The scanner
is rebooted. Any configuration already
loaded before the download is stopped.
CP_EIP_UPDATE_FIRMWARE 1031 Loads the firmware and configuration
from the current directory of the file sys-
tem into the memory of the Ethernet/IP
board. The scanner is rebooted. Any con-
figuration already loaded before the
download is stopped.
CP_EIP_RESET 1032 Resets the memory. The firmware and
configuration files are deleted from the
memory.
CP_EIP_DUMP 1033 The file name and version are read from
the memory of the Ethernet/IP board and
output to the Telnet shell.
Precondition: The TELNETOUTPUT
value in the INI file must be set to 1.
CP_EIP_DUMP_FILE 1034 The file name and version are read from
the memory of the Ethernet/IP board and
output to the file WSE_DumpFlashfile.txt.
CP_EIP_REBOOT_SLOW 1035 Reboots the firmware and configuration
from the flash memory. The scanner is
rebooted.
CP_EIP_REBOOT_QUICK 1036 Resets the firmware without rebooting.
This function is intended for servicing pur-
poses only.
CP_EIP_CHECK_CONFIGURATION 1037 Comparison of the configuration version
in the flash memory and the configuration
in the current directory of the file system.
Return value 0: Versions are identical.
Return value 1: Versions are not iden-
tical.
Return value < 0: Error when reading
the versions.
CP_EIP_DUMP_DPM_FILE 1038 Output the DPM in the file
WSE_DumpDpmFile.txt.
5.6.3 Configuring the file ENIP.INI
Description The file ENIP.INI is the configuration file of the CALL-P driver enip.o.
Procedure 1. Open the file ENIP.INI.

2. Check or modify the settings.
3. Save changes via the menu sequence Configure > I/O Driver > Edit I/O
Config..
4. Select the menu sequence Configure > I/O Driver > Reconfigure I/O
Driver to apply the changes.

5. Configuration
The menu item Reset restarts the bus. Changes are not applied.
Example of 1 [General]
ENIP.INI 2 DEBUG=0x0001
3 TELNETOUTPUT=0
4 LOGFILESIZE=500000
5 DHCPTIMEOUT=15
6 DEVICEWAITTIME=0
Line Description
1 Default setting
2 DEBUG option (bit-coded) for the log file
0x0001 = Standard logging
0x0002 = Debug outputs
0x0004 = Logging of device errors by status poll
0x0008 = Logging of errors on read/write functions
3 TELNETOUTPUT
0 = no Telnet output
1 = Telnet output
4 LOGFILESIZE
Definition of the log file size
500 KB ... 10 MB
5 DHCPTIMEOUT
Time waited by the driver until the Ethernet/IP board is
assigned an IP address by the DHCP server.
3 ... 180 s
(>>> Fig. 5-3)Parameters: DHCP, DNS Time-Out
6 DEVICEWAITTIME
Time waited by the driver until all devices are active. This
avoids unnecessary error messages during booting.
0 ... 30 s


6. Troubleshooting
6 Troubleshooting
6.1 ApplicomIO status
Description The status values are displayed via driver messages on the user interface.
Status Description Remedy

0 Function correctly executed -
1 Unknown function -
2 Error due to polled address. Device -
was selected with an incorrect
address:
PLC address range exceeded
No DNS server address as-
signed
3 Faulty data contents -
4 No data access: -
Physical address does not exist
Device does not exist
Data access-protected
32 The parameters sent to the func-
tions are faulty.
33 Feedback for timeout error. The With physical prob-
device is configured, but has no lems, check the con-
connection to the network: necting cables
Physical problems with the con- With a device error,
nection. CPU does not perform check the status
transmission With an IP address er-
Device error ror, check the device
configuration
IP address error
36 Device not configured Configure device with
applicomIO® Con-
sole
Initialize with the
Pclnitl0 application
applicomIO® interface
45 Communication program does not Initialize the Appli-
exist comIO® interface be-
fore the Pclnitl0
application uses the
interface
46 Board number not configured -
Applicom® master/client is us-
ing a channel configured as
slave/server, or vice versa
47 ApplicomIO® target board is -
invalid
ApplicomIO® target board in-
correctly initialized by IO_INIT

Status Description Remedy

49 Timeout error: Increase the “Time-
out for request in proc-
Request could not be transmit-
ess” value
ted due to missing communica-
tion channels. In such a case, Increase the value for
the “Time-Out for request in simultaneous re-
process” value is 4 quests on the set de-
vice
51 System driver problem -
53 The local slave was set to idle -
mode by the scanner
54 Device currently establishing a con- -
nection
55 Data loss due to timeout violation: Check device status
Timeout has exceeded the Check connection sta-
“Time-Out for requests in tus
progress” value
No response to confirmation re-
quest
58 Request to DHCP/BOOTP server in -
progress
59 No encryption on ApplicomIO® Use of ApplicomIO® func-
interface tions without first calling
the IO_Init function
63 Transmission error -
65 Device refuses to connect Check connection set-
tings
66 Insufficient ApplicomIO® inter- -
face memory
Insufficient capacity for addition-
al connection
70 Connection terminated by device: Check device status
Problems with the circuitry
CPU stopped
CPU does not perform the con-
nection
Not supported by the set device
77 Device not active: -
The device was not started by
the Ethernet/IP scanner
93 No driver access Reboot the robot control-
ler.
99 ApplicomIP® already started -
131 Device name accepted on the DNS -
server
132 Device name acceptance on the Check DNS server status
DNS server failed
255 Local input buffer not refreshed -
before the application
IO_RefreshInput:
Slave device is in idle mode

7. Repair
7 Repair
7.1 Installing the KUKA Ethernet/IP board
Precondition KUKA Ethernet/IP Setup.exe is installed.

Observe the ESD guidelines.
The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.
Slot 1 of the control PC is free.
Procedure 1. Select the menu sequence Configure > On/Off Options > Start Types.
The option window Start Types is opened.
2. In the group Start Types in the option window, activate the checkbox Cold
Boot.
3. Press the OK softkey.
4. Switch the robot controller off.
5. Open the control PC.
6. Remove the cover from PCI slot 1.
7. Plug the KUKA Ethernet/IP board into PCI slot 1.
Caution!
Substantial damage to property may occur:
The Ethernet/IP board must only be plugged into PCI slot 1.
The Ethernet/IP board must be firmly and uniformly engaged with the
socket of the slot.
8. Screw down the KUKA Ethernet/IP board on the control PC.

9. Close the control PC.
10. Switch on the robot controller.
7.2 Removing the KUKA Ethernet/IP board
Precondition The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.
Observe the ESD guidelines.
Procedure 1. Open the control PC.

2. Unplug the KUKA Ethernet/IP board from PCI slot 1.
3. Fasten a slot cover.
4. Close the control PC.
5. Switch on the robot controller.


8. KUKA Service
8 KUKA Service
8.1 Requesting support
Introduction The KUKA Roboter GmbH 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
8.2 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

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

8. 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

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

8. 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

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 Module Informations tab 27
ANIN 34
ANOUT 34 N
ApplicomIO status 39 Network configuration 13
Notes 13
C
Chassis tab 22 O
Configuration 13 Online Parameters 27
Configuration settings, adaptation 16 Online Parameters tab 26, 27
Configuration software, starting 14 OUT 33
Configuration work area 31
Configuration, IOSYS.INI 32 P
Configuration, robot controller 32 Port Configuration tab 28
Configuration, transferring to robot controller 31 Product description 7
Connection properties, changing 25 Properties, network adapters 18
Connection type, changing 24
Connections tab 23 S
Safety 9
D Safety instructions 9
Device identity, checking 26 Schulungen 5
Devices, assigning 19 Service, KUKA Roboter 43
Documentation, robot system 5 Support request 43
System requirements 11
E
EDS File tab 29 T
ENIP.INI, configuration 36 Target group 5
Ethernet/IP board, installation 41 Terms used 5
Ethernet/IP board, removal 41 Trademarks 5
Ethernet/IP configuration program, uninstallation Troubleshooting 39
12
Ethernet/IP configuration software, installation U
12 Uninstallation, Ethernet/IP configuration pro-
Ethernet/IP drivers, installation 11 gram 12
Ethernet/IP drivers, uninstallation 11 Uninstallation, Ethernet/IP drivers 11
Ethernet/IP network configuration 13
W
G Warnings 9
General tab 20
General tab – Network Properties 21
I
IN 33
Input/output assignment 30
Input/output display 31
Installation 11
Installation, Ethernet/IP configuration software
12
Installation, Ethernet/IP drivers 11
Introduction 5
IOCTL commands 35
K
KUKA Customer Support 43
KUKA EtherNet/IP 2.0 7
KUKA Ethernet/IP board (PCU-ETHIO) 7
M
Module Informations 27



KUKA Ethernet/IP 2.0: Controller Option

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Controller Option KUKA Roboter GmbH

KUKA Ethernet/IP 2.0

Version: BA EtherNet/IP 2.0 V1 en

Publication: Pub KUKA Ethernet/IP 2.0 en

2 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

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

Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 3 / 51

7.2 Removing the KUKA Ethernet/IP board .................................................................... 41

8 KUKA Service ............................................................................................... 43

4 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

1.1 Target group

1.2 Robot system documentation

The robot system documentation consists of the following parts:

Windows is a trademark of Microsoft Corporation.

1.4 Terms used

Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 5 / 51

6 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

2.1 KUKA EtherNet/IP 2.0

Fig. 2-1: KUKA Ethernet/IP board (PCU-ETHIO)

The KUKA Ethernet/IP board (PCU-ETHIO) supports the following features:

In conjunction with Siemens Scalance x208 Switch, only use “Autoconfigura-

 Static TCP/IP configuration via DHCP or BOOTP

Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 7 / 51

8 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

3.1 Representation of warnings and notes

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

Specific safety instructions

Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 9 / 51

10 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

4.1 System requirements

Robot controller  Hardware

4.2 Installing the KUKA Ethernet/IP drivers

Precondition  CD-ROM with additional software

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

4.3 Uninstalling the KUKA Ethernet/IP drivers

It is advisable to archive all relevant data before uninstalling a software pack-

Precondition  User group “Expert”

Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 11 / 51

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

4.4 Installing the KUKA Ethernet/IP configuration software

Precondition  CD-ROM with configuration software

Procedure 1. Start the program on the CD-ROM.

4.5 Uninstalling the KUKA Ethernet/IP configuration program

Precondition  Local administrator rights

It is advisable to archive all relevant data before uninstalling a software pack-

Procedure 1. Start the program on the CD-ROM.

12 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

5.1 Ethernet/IP network configuration

Overview The Ethernet/IP configuration software manages the devices in a subnet.

Fig. 5-1: Configuration (example)

5.2 Notes on use of the Ethernet/IP configuration software

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5.3 Starting the configuration software

Fig. 5-2: TCP/IP tab

14 / 51 Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en

2. Select ApplicomIO channel IP Address.

4. In the Configuration list box, select the required mode.

5. On the Advanced tab, select the parameters. Click on the button to

Fig. 5-3: TCP/IP Advanced tab

Issued: 03.04.2009 Version: BA EtherNet/IP 2.0 V1 en 15 / 51

6. Confirm with OK.

5.3.1 Adapting the configuration settings

Procedure 1. Select the menu sequence File > Configuration Manager.

Static TCP/IP configuration via DHCP or BOOTP

Robot controller Hardware

Precondition CD-ROM with additional software

Precondition User group “Expert”

Precondition CD-ROM with configuration software

Precondition Local administrator rights

Precondition The IP address has been assigned to the Ethernet/IP board

Description On assigning a device, the General tab is displayed

Synchronize button: Check and change the values.

Precondition The devices are assigned and configured.