Contents

1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Installation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 BIOS settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Changing the boot sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Hard drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.3 Saving the settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Installing the operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Changing the boot sequence in the BIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 KUKA System Software (KSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 Preventing an automatic start of the “KUKA System Software” . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Installing the “KUKA System Software” manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Automatic Software Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

EinleitungBH5.2 08.03.00 en

3 of 24
Installation

EinleitungBH5.2 08.03.00 en

4 of 24
 1 Fundamentals

1 Fundamentals
1.1 Installation types
An operational version of the “KUKA System Software” (KSS) is supplied with the control
cabinet. The KSS itself runs under a specially--modified version of the Windows operating
system.

Only use the operating system supplied with the control cabinet for operating the
robot controller! Only this version ensures that the KUKA software will function
correctly.

In some circumstances, it may be necessary to install a more up--to--date version of the

operating system or the KUKA software. A number of options are available:

Procedure Action Situation

Operating system (see Chapter 2)

Configuration of the entire hard Deletion of all data on the hard Defective hard drive
disk disk;
Installation and configuration
of the operating system
KRC setup (see Chapter 3)
Installation of “KUKA System Installation and configuration Important components
Software” of the KSS alongside the oper- have changed (e.g. new
ating system that has already machine data required)
been installed
Automatic update (see Chapter 4)
Updating of “KUKA System Installation and configuration KSS update
Software” of the KSS with the operating
system running

EinleitungBH5.2 08.03.00 en

5 of 24
Installation

1.2 System requirements

A number of preconditions must be met before you can install the current KUKA Roboter
GmbH programs.
First of all, you need...
G a CD--ROM with the Windows operating system
An external keyboard is required here, for manipulating the BIOS settings and configur-
ing the operating system.
G a CD--ROM with the required release of the “KUKA System Software” (KSS)

The installation procedure is the same for the different KR C versions. The only differences
arise in the selection of the hardware used.

When upgrading from older KUKA control cabinets, the following minimum system
requirements apply:

G Cabinet version KR C2 / KR C3
G Motherboard Only KUKA--approved types
G Processor 400 MHz Celeron
G Main memory 256 MB RAM
G Hard drive 10 GB
G KUKA VGA Release 16

If your control cabinet does not meet the requirements listed, it may be possible to
exchange the control cabinet’s computer unit. More detailed information about this can be
obtained from our service department.

EinleitungBH5.2 08.03.00 en

6 of 24
 2 Operating system

2 Operating system
The hard disk in the robot control computer is reconfigured.

If there is a second hard drive installed in the system, this must either be disconnected or
deactivated in the BIOS.

Any data on the hard disk are irrevocably lost during this procedure. You should
therefore make backup copies of any relevant data. Only change settings that are
explicitly indicated.

2.1 BIOS settings

Before the software can be installed, a number of modifications must be made to the BIOS
(Basic Input Output System) settings of the robot controller.

The appearance and structure of the BIOS settings depend, among other things, on the
hardware used and may therefore differ from those illustrated in these examples.

Switch the robot controller on. During the boot sequence (just after the memory test) press
Del
the Delete key on the keyboard. This takes you to the BIOS settings main menu.

SOYO COMBO SETUP INTEGRATED PERIPHERIALS

STANDARD CMOS SETUP SUPERVISOR PASSWORD

BIOS FEATURES SETUP USER PASSWORD

CHIPSET FEATURES SETUP IDE HDD AUTO DETECTION

SAVE & EXIT SETUP

PNP/PCI CONFIGURATION EXIT WITHOUT SAVING

LOAD KUKA DEFAULTS

Esc : Quit "#z! : Select Item

F10 : Save & Exit Setup (Shift)F2 : Change Color

EinleitungBH5.2 08.03.00 en

7 of 24
Installation

The following keys are required for navigating in the BIOS settings:

Key Designation Action

Arrow keys For selecting the desired entry

Enter key Opens the window for the selected entry

Closes the current window and opens the

ESC key
previous one

PgUp PgDn
Scroll keys Selection of a parameter

Summons the BIOS settings when the

Del Del key
system is booted

2.1.1 Changing the boot sequence

The boot sequence in the BIOS determines which drive the operating system is loaded from
when the system is booted. Usually, the CD--ROM drive is deactivated in the boot sequence.
In order to install a new operating system, this setting must be changed.

SOYO COMBO SETUP

Select the option “SOYO COMBO SETUP” in the main menu and press the Enter key. In the
following screen, the entry “Boot Sequence” is of importance.

CPU Host/PCI Clock : 66/33 MHz CPU Warning Temperature : Disabled

CPU Frequency : x 6.5 = 433 MHz Current CPU1 Temperature: 57°C/136°F
SDRAM RAS-to-SAS Delay : 2 Current CPUFAN1 Speed : 0 RPM
SDRAM RAS Precharge Time : 2 Current CPUFAN2 Speed : 0 RPM
SDRAM CAS latency Time : 3 Vcore : 2.01 V +3.3 V : 3.48 V
+ 5 V : 4.97 V +12 V : 12.43 V
Boot Sequence : C,A,SCSI -12 V :-12.69 V -5 V : -5.14 V
Quick Power On Self Test : Enabled

ESC: Quit " # z !: Select Item

F1 : Help PU/PD/+/- : Modify
F5 : Old Values (SHIFT)F2 : Color
F7 : Load Setup Defaults

EinleitungBH5.2 08.03.00 en

8 of 24
 2 Operating system (continued)

Use the “PgUp” and “PgDn” keys to select the parameter “CDROM,C,A”.
Boot Sequence : CDROM,C,A

2.1.2 Hard drive parameters

If the size of the newly installed drive is different from that displayed, or if it is connected differ-
ently, this must be communicated to the system. The easiest way is the automatic detection
function.

STANDARD CMOS SETUP

Select the option “Primary Master”.

Date (mm:dd:yy) : Mon, Jun 3 2002

Time (hh:mm:ss) : 09 : 12 : 37

Hard Disks : TYPE SIZE CYLS HEAD PRECOMP LANDZ SECTOR MODE

Primary Master : None 0 0 0 0 0 0 ------

Primary Slave : None 0 0 0 0 0 0 ------
Secondary Master : None 0 0 0 0 0 0 ------
Secondary Slave : None 0 0 0 0 0 0 ------

Drive A : 1.44M, 3.5 in.

Drive B : None Base Memory : 640K
Extended Memory: 130048K
Other Memory: 384K
Video : EGA/VGA
Halt On : All,But Disk/Key Total Memory: 131072K

Esc : Quit "#z! : Select Item PU/PD+/- : Modify

F1 : Help (SHIFT)F2 : Change Color

Set both the master controllers and the slave controllers to “Auto”:
Primary Master : AUTO 0 0 0 0 0 0 AUTO
...
Secondary Slave : AUTO 0 0 0 0 0 0 AUTO

In this case, the system checks the existing drives automatically every time the system is
started. A modified configuration is thus detected automatically.

If the existing drives are not detected, this may be because they are incorrectly set. In this
case, check that the drive in question is correctly set to “Master” or “Slave”.

EinleitungBH5.2 08.03.00 en

9 of 24
Installation

2.1.3 Saving the settings

SAVE & EXIT SETUP
To save the changes, select the menu item “SAVE & EXIT SETUP” in the main menu and
press the Enter key. Confirm the safety query with “Y”. The system will then be restarted.

Depending on the keyboard layout

that has been set, or the actual key-
SAVE to CMOS and EXIT (Y/N)? Y board used, the “Y” and “Z” keys
may be reversed.

2.2 Installing the operating system

Place the CD--ROM with the operating system in the CD--ROM drive if you have not already
done so, and restart the system.
G If an operating system has already been installed on the hard drive, the message “Press
any key to boot from CD...” appears. If you now press a key, the setup program is
started. The existing operating system is overwritten.
G If there is no operating system installed on the hard drive, the setup program starts auto-
matically.

The operating system is installed in several steps:

G First of all, the hard drive is prepared for the installation of the operating system by
setting up two partitions. The first partition (drive “C:\”) has a defined capacity of 5 GB;
the remaining storage capacity is assigned to the second partition (drive “D:\). Both
partitions are then formatted.
G In the next step, the operating system is loaded and the system is restarted.
G The necessary KUKA drivers are now installed. Depending on the specific
configuration, the user may now be required to make certain entries. The system must
then be rebooted once again.
The operating system is now ready to use.

With a 733 MHz Celeron processor and a 48x CD--ROM drive, complete installation of the
operating system takes approximately 40 minutes.
The appearance and mode of operation of the operating system are influenced by the
configuration. They may therefore vary from the illustrations used in this documentation.

EinleitungBH5.2 08.03.00 en

10 of 24
 2 Operating system (continued)

2.3 Changing the boot sequence in the BIOS

Remember to reset the boot sequence to its original state. Call the BIOS settings by pressing
the Del key next time the system is started.

SOYO COMBO SETUP

Select the option “Boot Sequence”.

CPU Host/PCI Clock : 66/33 MHz CPU Warning Temperature : Disabled

CPU Frequency : x 6.5 = 433 MHz Current CPU1 Temperature: 57°C/136°F
SDRAM RAS-to-SAS Delay : 2 Current CPUFAN1 Speed : 0 RPM
SDRAM RAS Precharge Time : 2 Current CPUFAN2 Speed : 0 RPM
SDRAM CAS latency Time : 3 Vcore : 2.01 V +3.3 V : 3.48 V
+ 5 V : 4.97 V +12 V : 12.43 V
Boot Sequence : CDROM,C,A -12 V :-12.69 V -5 V : -5.14 V
Quick Power On Self Test : Enabled

ESC: Quit " # z !: Select Item

F1 : Help PU/PD/+/- : Modify
F5 : Old Values (SHIFT)F2 : Color
F7 : Load Setup Defaults

Use the “PgUp” and “PgDn” keys to select the parameter “C,A, SCSI”.
Boot Sequence : C,A,SCSI

SAVE & EXIT SETUP

To save the changes, select the menu item “SAVE & EXIT SETUP” in the main menu and
press the Enter key. Confirm the safety query with “Y”. The system will then be restarted.

Y Depending on the keyboard layout

that has been set, or the actual key-
SAVE to CMOS and EXIT (Y/N)? Y board used, the “Y” and “Z” keys
may be reversed.

EinleitungBH5.2 08.03.00 en

11 of 24
Installation

EinleitungBH5.2 08.03.00 en

12 of 24
 3 KUKA System Software (KSS)

3 KUKA System Software (KSS)

Insert the “KUKA System Software” CD into the CD--ROM drive.

The Windows settings strongly influence the appearance of the individual components.
They may therefore vary from the examples illustrated here.

If no version of KSS has previously been installed on the hard drive, skip the next section
and continue with “Installing the KUKA System Software manually”.

The following keys are required for navigation during installation of the KSS:

Key Designation Action

Opens the Start menu of the operating
Ctrl + Control + Escape system.
Not available in the user group “User”.

Arrow keys For selecting the desired entry

In the Start menu, this key opens the sub-

Enter key menu corresponding to the selected entry
or starts the selected program

Closes the current window and opens the

ESC key
previous one

Toggles to a different area in the Explorer

TAB key window where selections can then be
made

Deletes the element selected in the

Del Del key
Explorer

EinleitungBH5.2 08.03.00 en

13 of 24
Installation

3.1 Preventing an automatic start of the “KUKA System Software”

If a version of the KSS is already installed, this is automatically started when the robot system
is booted. To prevent this automatic start, proceed as follows:

Open the Windows Start menu

Hold the CTRL key down and press the ESC key.

Start Windows Explorer

Using the arrow keys, select the entry

“Programs” --> “Accessories” --> “Windows Explorer”
and press the Enter key.

EinleitungBH5.2 08.03.00 en

14 of 24
 3 KUKA System Software (KSS) (continued)

Prevent Startup

Using the arrow keys, select the path

“C:\ Documents and Settings \ All Users \ Start menu
\ Programs \ Startup”
and press the TAB key
Delete the “StartKRC” shortcut by pressing the Del key.

Restart the system

Then restart the system. Once the operating system has booted, you can continue with the
manual KSS setup.

EinleitungBH5.2 08.03.00 en

15 of 24
Installation

3.2 Installing the “KUKA System Software” manually

To install the KSS manually, open the Start menu and start Windows Explorer.

Starting the setup program

Using the TAB key and the arrow keys, select the CD--ROM drive. Use the TAB key to toggle
to the right--hand section of the window and select the entry “Setup.exe”. Then press the
Enter key.

Alternatively, you can load the setup

program via the Start menu and the
option “Run”. Enter “E:\Setup.exe” in
the command line and confirm this by
pressing Enter.

Depending on the hardware configuration, the CD--ROM drive may have been assigned
a drive letter other than “E:\” by the operating system. If this is the case, enter the corre-
sponding drive letter instead of “E”.

EinleitungBH5.2 08.03.00 en

16 of 24
 3 KUKA System Software (KSS) (continued)

Language selection
In the first step, you can choose the language in which texts are to be displayed during
installation.

Select the desired

language by pressing
the “#” and “"” arrow
keys and pressing the
space bar once to
highlight the option.
The selected language
is confirmed by press-
ing the Enter key.

If you wish to modify any of the settings, press the button “Back” to take you step--
by--step back through the previous dialog windows.
Pressing “Cancel” terminates the installation.

Welcome page
Please read the text in the welcome page.

The next window is

opened by pressing
“Next”.

EinleitungBH5.2 08.03.00 en

17 of 24
Installation

Copying the CD--ROM

Select the box
“Copying CD--ROM”
by pressing the
space bar if you
wish to copy the
contents of the
CD--ROM to the
hard disk.

This dialog window only appears if the software is being installed from the CD--ROM and
there is a second hard disk partition available. If the CD was already copied onto the hard
disk during an earlier installation, that copy will now be overwritten.

Virus scanner

Select the box

“Install Ikarus virus
scanner” by press-
ing the space bar if
you wish to install
this program in the
system.

EinleitungBH5.2 08.03.00 en

18 of 24
 3 KUKA System Software (KSS) (continued)

Entry of parameters
Select the desired
customer version.

Conversion
If there is an earlier version of the software already installed on the hard drive, data such as
machine data, Init files and programs can be converted.

Specify which data

are to be converted.

EinleitungBH5.2 08.03.00 en

19 of 24
Installation

Robot type
The robot type cannot be selected if the machine data from an earlier installation are
converted.

Select the robot type

to be used.

If your robot does not correspond with

the type suggested, activate the
“Browse” button using the “TAB” key and
press Enter.
Using the arrow keys, search in the
“MaDa” directory for the control cabinet
you are using (e.g. “KR C2”) and there
select the robot.

If the machine data loaded do not match the robot type, a corresponding error
message is generated when the controller is booted. The robot must not be moved
in this case.

EinleitungBH5.2 08.03.00 en

20 of 24
 3 KUKA System Software (KSS) (continued)

Options
Select the options
that are present in
your system. This
is also done using
the arrow keys and
the space bar.

Summary

Finally, a summary
of the setup settings
is displayed.
If all the settings are
correct, press the
Enter key. The
installation process
is now carried out.

EinleitungBH5.2 08.03.00 en

21 of 24
Installation

Restart

Windows must be
restarted on comple-
tion of the installa-
tion process.

The system is automatically configured when Windows is started. The “KUKA System
Software” is then started for the first time.

EinleitungBH5.2 08.03.00 en

22 of 24
 4 Automatic Software Update

4 Automatic Software Update

A new version of the control software can be installed with the KSS running.

Because of the operating system, a software update is only possible from Release 5.x
onwards. Older versions are not supported.

Place the CD with a new program version or service pack in the CD--ROM drive.
Setup Measure
Master
UnMaster
Software Update automatic
Service
Robot Data

The update CD must remain in the CD--ROM drive throughout the whole process.
Failure to do this will result in loss of data and incorrect installation.

A safety query appears in the message window.

Date: Wednesday, August 27, 2003 13:35:16

Source SSV No: 10
Perform a Software Update ?

Cancel
The software update is not carried out.
No

Yes The software update is carried out.

In the next stage the controller must be restarted.

C... Time No. Source Message
20:45:10 20 SSV To complete software update please REBOOT
20:45:10 4 Next boot will be a forced cold start.

Switch the controller off and wait until the computer unit has shut down completely. Only now
may the controller be switched back on again.

If errors occur during software update, you can view these in the display in the log file.

Once the update is complete the computer is run back down again. Only now may the CD
be removed from the drive. The controller is then restarted automatically.

EinleitungBH5.2 08.03.00 en

23 of 24
Installation

NOTES:

EinleitungBH5.2 08.03.00 en

24 of 24
 Index

A R
Automatic update, 5 Robot type, 20
B
BIOS settings, 7 S
Boot sequence, 8, 11 Software update, 23

C
Cabinet version, 6 U
Celeron, 6 Update, 5

D
Drive letter, 16 W
Windows Explorer, 14
H
Windows operating system, 6
Hard drive, 6
Windows Start menu, 14
Hard drive parameters, 9

I
Installing the KUKA System Software manually,
16
Installing the operating system, 10

K
KRC setup, 5
KSS, 13
KUKA System Software, 13
KUKA VGA, 6

L
Language, 17

M
Main memory, 6
Minimum requirements, 6
Motherboard, 6

O
Operating system, 5, 7
Options, 21

P
Processor, 6

Index -- i