KR C4 EtherCAT KSS VSS 82 83 84 85 86 en

Controller Option
KR C4 EtherCAT
Configuration
For KUKA System Software 8.2, 8.3, 8.4, 8.5 and 8.6
For VW System Software 8.2, 8.3 and 8.6
Issued: 26.04.2019
KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6
V2
KUKA Deutschland GmbH
KR C4 EtherCAT
© Copyright 2019
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 KUKA Deutschland 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 soft-
ware 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 regu-
lar 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
Translation of the original documentation
Publication: Pub KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6 (PDF) en
PB11696
Book structure: KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6 V2.1
BS10800
Version: KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6 V2
2/109 | www.kuka.com KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6 V2 | Issued: 26.04.2019
KR C4 EtherCAT
Contents
1 Introduction.............................................................................................. 5
1.1 Target group.......................................................................................................... 5
1.2 Industrial robot documentation.............................................................................. 5
1.3 Representation of warnings and notes................................................................. 5
1.4 Trademarks............................................................................................................ 6
1.5 Terms used............................................................................................................ 6
2 Product description................................................................................. 7
2.1 Intended use.......................................................................................................... 8
3 Safety......................................................................................................... 9
4 Configuration............................................................................................ 11
4.1 Overview................................................................................................................ 11
4.2 Preparing device description files......................................................................... 12
4.3 Inserting the KUKA Extension Bus in the project................................................ 12
4.4 Entering the IP address of the KUKA Line Interface........................................... 13
4.5 Modifying bus driver settings................................................................................ 13
4.5.1 Master settings tab................................................................................................ 14
4.6 Inserting devices manually.................................................................................... 14
4.7 Automatically inserting devices (bus scan).......................................................... 15
4.7.1 2-stage bus scan................................................................................................... 16
4.8 Configuring devices............................................................................................... 16
4.8.1 “General” tab......................................................................................................... 17
4.8.2 “Process data objects” tab.................................................................................... 18
4.8.3 Modules tab........................................................................................................... 19
4.9 Configuring File Access over EtherCAT............................................................... 20
4.10 Writing the alias address to devices.................................................................... 20
4.11 Checking and modifying the topology.................................................................. 21
4.11.1 “Topology” tab........................................................................................................ 22
5 Operation.................................................................................................. 25
5.1 Decoupling/coupling devices................................................................................. 25
5.2 Activating/deactivating bus errors......................................................................... 25
5.3 Restarting the bus system.................................................................................... 26
5.4 Executing queries / changes................................................................................. 27
5.4.1 Querying the bus error status of SYS-X44.......................................................... 27
5.4.2 Querying whether EtherCAT slave is configured as a decouplable device........ 28
5.4.3 Querying whether a decouplable device is enabled or disabled......................... 28
5.4.4 Querying the operating mode of the EtherCAT slave.......................................... 28
5.4.5 Querying the timeout period for the coupling/decoupling of devices.................. 28
5.4.6 Changing the timeout period for the coupling/decoupling of devices.................. 29
5.4.7 Querying the number of configured devices........................................................ 29
5.5 Accessing EtherCAT SDO via KRL...................................................................... 29
5.5.1 Access via CANopen over EtherCAT (CoE)........................................................ 30
5.5.2 Access via File Access over EtherCAT (FoE)...................................................... 34
5.5.3 Access via vendor-specific protocol over EtherCAT (VoE).................................. 45
KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6 V2 | Issued: 26.04.2019 www.kuka.com | 3/109
KR C4 EtherCAT
5.5.4 Access via ADS over EtherCAT (AoE)................................................................. 48
6 Diagnosis.................................................................................................. 59
6.1 Displaying diagnostic data.................................................................................... 59
6.1.1 KUKA Extension Bus (SYS-X44).......................................................................... 59
6.2 Device diagnosis................................................................................................... 60
6.3 Topology diagnosis................................................................................................ 61
7 Messages.................................................................................................. 65
7.1 Information about the messages.......................................................................... 65
7.2 System messages from module: CrossMeld (KSS)............................................. 65
7.2.1 KSS13008.............................................................................................................. 65
7.2.2 KSS13011.............................................................................................................. 66
7.2.3 KSS13012.............................................................................................................. 69
7.2.4 KSS13013.............................................................................................................. 78
7.2.5 KSS13015.............................................................................................................. 79
7.2.6 KSS13016.............................................................................................................. 81
7.2.7 KSS13018.............................................................................................................. 83
7.2.8 KSS13020.............................................................................................................. 87
7.2.9 KSS13021.............................................................................................................. 92
7.2.10 KSS13068.............................................................................................................. 93
7.2.11 KSS13080.............................................................................................................. 97
8 KUKA Service........................................................................................... 101

8.1 Requesting support............................................................................................... 101
8.2 KUKA Customer Support...................................................................................... 101
Index 109
KR C4 EtherCAT
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 field buses
• Knowledge of WorkVisual
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts in KUKA.Xpert
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.
KR C4 EtherCAT
This warning draws attention to procedures which serve to prevent or rem-

Introduction
edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.
1.4 Trademarks
EtherCAT® is a registered trademark and patented technolo-

gy, licensed by Beckhoff Automation GmbH, Germany.
1.5 Terms used
Term Description
ADS Automation Device Specification
Field bus-independent standard from Beckhoff Automa-
tion GmbH for communication between devices
CAN Controller Area Network
ESI EtherCAT Slave Information
File format for description of EtherCAT devices
FSoE Fail Safe over EtherCAT
Protocol for transferring safety-relevant data via Ether-
CAT in conjunction with an FSoE master and an FSoE
slave
KLI KUKA Line Interface
Ethernet interface of the robot controller (not real-time-
capable) for external communication.
SDO Service Data Objects
PLC Programmable Logic Controller
WorkVisual Configuration software from KUKA for field bus configu-
ration
KR C4 EtherCAT
Product description
2 Product description
EtherCAT is an Ethernet-based field bus suitable for real-time require-
ments.
Compatibility
KR C4 EtherCAT is compatible with the following field buses:

• KR C4 PROFINET 2.0 to 2.3 and 3.0 to 3.2
• KUKA.PROFINET® M/S 4.0, 4.1 and 5.0
• KUKA.PROFINET® -/S 4.1 and 5.0
• KR C4 EtherNet/IP 1.0, 1.1 and 2.0
• KUKA.EtherNet/IP™ M/S 3.1 and 4.1
• KR C4 PROFIBUS
• KR C4 PROFIBUS CP 5614 1.0 and 2.0
• KR C4 DeviceNet
• KR C4 Interbus 1.0, 1.1 and 2.0
• KUKA.INTERBUS M/S 3.0
• EtherCAT Bridge
• EtherCAT bridge FSoE
• VARAN slave
Functions
The following functions and device classes are supported:

• EtherCAT IO (cyclical communication)
• Slot-based devices (Modular Device Profile)
• Devices that are not slot-based
• CANopen over EtherCAT
• File Access over EtherCAT
• Vendor-specific over EtherCAT (KUKA System Software 8.5 or higher)
• ADS over EtherCAT (KUKA System Software 8.5 or higher)
• Gateway devices (for converting EtherCAT to other field buses)
‒ PROFIBUS
‒ DeviceNet
‒ EtherCAT Bridge
‒ VARAN slave
• Decouplable devices (KUKA System Software 8.5 or higher)
Limitations
The following functions and device classes are not supported, for exam-
ple:
• Servodrive over EtherCAT
• Ethernet over EtherCAT
• Slave-to-slave communication
• Creation and configuration of process data objects
• Modification of the configuration of process data objects
• Advanced settings (e.g. watchdog, timeout, mailbox protocol)
• Distributed Clocks
• Oversampling
Product description KR C4 EtherCAT
Fail Safe over EtherCAT can only be used in conjunction with EtherCAT
Bridge FSoE for connection to a safety controller. Further information
can be found in the EtherCAT bridge FSoE (master/master) documen-
tation.
Configuration
KR C4 EtherCAT is configured on a laptop or PC. The following software

is required for configuration:
• WorkVisual 6.0
The requirements for installation of WorkVisual are contained in the
WorkVisual documentation.
Device types
The following device types are used with KR C4 EtherCAT:

• Master: A higher-level controller that controls all the components of a
system.
• Slave: A field device subordinated to a master. A slave consists of
one or more modules.
System limits
• Maximum number of EtherCAT slaves: 128

• Size of the process data: EtherCAT frame ≤ 1536 bytes
2.1 Intended use
Use
KR C4 EtherCAT is intended solely for the configuration and diagnosis of

EtherCAT bus modules on the KUKA Extension Bus using the KU-
KA.WorkVisual software.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. The manufacturer cannot be held liable for any
damage resulting from such use. The risk lies entirely with the user.
Examples of such misuse include:
• Configuration of EtherCAT bus modules not in accordance with the
specified parameters
KR C4 EtherCAT
Safety
3 Safety
This documentation contains safety instructions which refer specifically to
the product described here. The fundamental safety information for the in-
dustrial robot can be found in the “Safety” chapter of the operating or as-
sembly instructions for the robot controller.
WARNING
The “Safety” chapter in the operating instructions or assembly instruc-
tions of the robot controller must be observed. Death to persons, severe
injuries or considerable damage to property may otherwise result.
Safety KR C4 EtherCAT
KR C4 EtherCAT
Configuration
4 Configuration
4.1 Overview
Step Description
1 Configure the higher-level controller with the manufacturer’s
configuration software.
Note: This step only needs to be carried out if a higher-lev-
el controller is being used. The required device description
file must be obtained from the device manufacturer.
The interface to the higher-level controller can be routed,
for example, via EtherCAT Bridge or EtherCAT Bridge
FSoE. Further information can be found in the EtherCAT
Bridge or EtherCAT Bridge FSoE documentation.
2 Prepare device description files.
(>>> 4.2 "Preparing device description files" Page 12)
3 Insert KUKA Extension Bus into project.
(>>> 4.3 "Inserting the KUKA Extension Bus in the project"
Page 12)
4 Enter the IP address of the KUKA Line Interface (optional).
(>>> 4.4 "Entering the IP address of the KUKA Line Inter-
face" Page 13)
Note: The IP address of the KLI is required for online func-
tions such as the bus scan or device diagnosis.
5 Modify bus driver settings (optional).
(>>> 4.5 "Modifying bus driver settings" Page 13)
6 Insert EtherCAT devices manually or automatically into the
bus.
(>>> 4.6 "Inserting devices manually" Page 14)
(>>> 4.7 "Automatically inserting devices (bus scan)"
Page 15)
7 Configure the EtherCAT devices.
(>>> 4.8 "Configuring devices" Page 16)
8 Configure File Access over EtherCAT (optional).
(>>> 4.9 "Configuring File Access over EtherCAT"
Page 20)
9 Write alias address to devices (optional).
(>>> 4.10 "Writing the alias address to devices" Page 20)
10 Check the topology in the Topology editor and modify it if
necessary.
(>>> 4.11 "Checking and modifying the topology" Page 21)
11 Map the inputs and outputs in WorkVisual.
12 Transfer the bus configuration from WorkVisual to the robot
controller.
Configuration KR C4 EtherCAT
Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation. Information about procedures in the configuration
software of the higher-level controller can be found in the
documentation for this software.
4.2 Preparing device description files
WorkVisual requires the associated device description files for the configu-
ration of EtherCAT. The files can be downloaded from the website of the
vendor.
Precondition
• There is no project open.
Procedure
1. Select the menu sequence File > Import / Export. A window opens.
2. Select Import device description file. and click on Next >.
3. Click on Search.... Another window opens.
4. Select the file format EtherCAT ESI.
5. Navigate to the directory in which the device description files are loca-
ted.
6. Select the files to be imported and click on Open. A list is displayed
of the device description files that are to be imported.
7. Confirm with Next >. A list is displayed of the devices that are to be
imported.
8. Click on Finish. The devices are imported.
9. Close the window.
The following applies to device description files that contain a reference

to further files: Only the file that contains the references must be impor-
ted. The files to which the references refer are automatically imported.
All files must be in the same directory. If a file could not be found, this
is indicated by a message.
4.3 Inserting the KUKA Extension Bus in the project
Precondition
• A project is open.
• The robot controller has been set as the active controller.
Procedure
1. Expand the tree structure of the robot controller on the Hardware tab
in the Project structure window.
2. Right-click on Bus structure and select Add… from the context
menu.
3. A window opens. Select the entry KUKA Extension Bus (SYS-X44)
and confirm with OK. The entry is inserted in the tree structure.
KR C4 EtherCAT
Configuration
4.4 Entering the IP address of the KUKA Line Interface
Description
In order to be able to perform online functions (e.g. bus scan, diagnosis),

the IP address of the KLI must be entered.
Precondition
• KUKA Extension Bus (SYS-X44) is inserted.
Procedure
1. Right-click on the KUKA Extension Bus (SYS-X44) entry on the

Hardware tab in the Project structure window.
2. Select Settings… from the context menu. The Settings… window
opens.
3. Select the Master settings tab.
4. Enter the IP address of the KLI and confirm with OK.
4.5 Modifying bus driver settings
This functionality is only available for robot controllers with version 8.5
or higher.
Description
The bus driver settings can be modified.
Precondition
Procedure

opens.
3. Select the Master settings tab.
(>>> 4.5.1 "Master settings tab" Page 14)
4. Modify the desired settings and confirm with OK.
4.5.1 Master settings tab
Fig. 4-1: Master settings tab
Box Description
Bus cycle time Update time of the bus instance
• 1 … 12 ms
Default value: 4 ms
Topology refresh Update time of the typology
time
• 100 … 5000 ms
Default value: 1000 ms
Restart after error • Automatic: Following an error, the bus in-
stance is automatically rebooted.
• Manual: Following an error, the bus in-
stance is not rebooted.
Default setting: Manual
4.6 Inserting devices manually
Precondition
Procedure
2. Right-click on EtherCAT under the KUKA Extension Bus (SYS-X44)
entry and select Add… from the context menu. A window opens.
3. If a bus device is to be added: Continue with step 4.
If a bus coupler is to be added: Select the bus coupler, e.g. EK1100
EtherCAT coupler (2A E-Bus), and confirm with OK. The bus coupler
is inserted in the tree structure.
Further modules can be inserted under a bus coupler (e.g. input or
output terminals, gateways, etc.).
4. Select the EtherCAT device used and confirm with OK. The device is
inserted in the tree structure.
5. If further devices are to be inserted, repeat steps 2 to 4 for these de-
vices.
KR C4 EtherCAT
Configuration
4.7 Automatically inserting devices (bus scan)
Description
The bus devices can be inserted automatically. For this, the user can start
a scan in WorkVisual to determine which devices are connected to the re-
al bus. The corresponding devices are then inserted automatically into the
bus structure in WorkVisual.
Only for system software versions lower than 8.5: Before the search is
started, the bus must contain at least one bus device so that the bus
boots in the correct operating mode (PreOp).
Precondition
• The IP address of the KUKA Line Interface is entered.
• Network connection to the real robot controller
• The devices are connected to the real robot controller.
• Only for system software versions lower than 8.5: A bus device is in-
serted into the bus.
Procedure
2. Right-click on the KUKA Extension Bus (SYS-X44) entry and select
Connect from the context menu. The connection is established.
3. Right-click on the KUKA Extension Bus (SYS-X44) entry again and
select Scan Topology… > EtherCAT from the context menu. The
Topology Scan Wizard window is opened.
4. Click on Next > to start the scan. When the scan is completed, Work-
Visual displays all the devices found in the window on the left. Each
device is represented by a number (= product code).
5. Select a device. In the window on the right, WorkVisual displays a list
of the device description files which have the same product code.
These are usually different versions of the same device description
file.
6. If the list contains a number of device description files, scroll down the
list and check if the file of the device that is actually used is selected.
If a different file is marked, select the option Manual selection and
select the correct file.
7. Repeat steps 5 and 6 for all devices shown.
8. Click on Next > to confirm the assignment.
9. To assign the devices, click on Finish.
10. Only for slot-based devices:
a. Transfer the project to the robot controller.
b. Repeat steps 3 and 4. When the scan is completed, WorkVisual
displays the device modules found in the window on the left.
c. Click on Finish. The modules are now present on the Modules
tab.
4.7.1 2-stage bus scan
Description
The 2-stage bus scan only has to be carried out for devices which require
the process data objects to be uploaded.
Precondition
• Network connection to the real robot controller
• The devices are connected to the real robot controller.
• Only for system software versions lower than 8.5: A bus device is in-
serted into the bus.
• The bus is in PreOp operating mode.
Procedure
2. Right-click on the KUKA Extension Bus (SYS-X44) entry in the tree
structure and select Connect from the context menu. The connection
is established.
Scan Topology… > EtherCAT from the context menu. The Topology
Scan Wizard window is opened.
4. Click on Next > to start the scan. When the scan is completed, Work-
Visual displays all the devices found in the window on the left. Each
device is represented by a number (= product code).
5. Select a device. In the window on the right, WorkVisual displays a list
of the device description files which have the same product code.
These are usually different versions of the same device description
file.
6. If the list contains a number of device description files, scroll down the
list and check if the file of the device that is actually used is selected.
If a different file is marked, select the option Manual selection and
select the correct file.
7. Repeat steps 5 and 6 for all devices shown.
8. Click on Next > to confirm the assignment.
9. To assign the devices, click on Finish. A message is displayed indi-
cating that the bus scan must be performed again.
10. Check whether the process data objects have been uploaded.
11. Transfer the project to the robot controller and activate it.
12. Open the project from the robot controller in WorkVisual.
13. Repeat steps 1 to 10.
4.8 Configuring devices
Precondition
KR C4 EtherCAT
Configuration
• Devices are inserted into the bus.
Procedure
2. Right-click on the device and select Settings… from the context
menu. A window opens with the device settings.
3. Make the desired settings on the General tab.
(>>> 4.8.1 "“General” tab" Page 17)
4. If the Distributed clocks tab is present: Deactivate the distributed
clocks.
5. Make the desired settings on the Process data objects tab.
(>>> 4.8.2 "“Process data objects” tab" Page 18)
6. If the Modules tab is present, modify the desired parameters.
(>>> 4.8.3 "Modules tab" Page 19)
7. Save the settings by selecting OK.
4.8.1 “General” tab
Fig. 4-2: General tab
Addresses
Box Description
EtherCAT address The EtherCAT address is assigned automatical-
ly. The address can be changed using the Top-
ology tab.
(>>> 4.11 "Checking and modifying the topolo-
gy" Page 21)
EtherCAT alias Alias address for decouplable devices, e.g. tool
changer
The alias address is required for coupling/
uncoupling decouplable devices during opera-
tion. The alias address can be changed using
the Topology tab.
(>>> 4.11 "Checking and modifying the topolo-
gy" Page 21)
Device identification
Box Description
Check vendor ID • Check box active: The manufacturer ID is
checked when booting up the device.
• Check box not active: The manufacturer
ID is not checked.
Check product code • Check box active: The product number is
checked when booting up the device.
• Check box not active: The product num-
ber is not checked.
Check revision num- Procedure for checking the revision number of
ber the device. The revision numbers that can be
selected depend on the device.
• OFF: The revision number is not checked.

• EQ: A check is made to see if the revision
number matches.
• LW_EQ: A check is made to see if the low-
order 16 bits of the revision number match.
The default setting is read from the device de-
scription file.
4.8.2 “Process data objects” tab
Fig. 4-3: “Process data objects” tab (example)
Box Description
Use • Check box active: The process data object is
used.
• Check box not active: The process data object is
not used.
SM Another Sync Manager can be assigned to the process
data object.
The settings on this tab depend on the device used. Further information
about the settings can be found in the manufacturer’s documentation for
the device.
KR C4 EtherCAT
Configuration
4.8.3 Modules tab
Fig. 4-4: “Modules” tab (example)
Item Description
1 Slots on the device
The number of slots displayed depends on the device selected.
The number of slots displayed is always the maximum number
possible for the device.
There are 2 possible methods for assigning a module to a slot:
• Select the desired group in the module window. Click on the

desired module in the group and drag it onto a compatible
slot. If the module is marked, the compatible slots are high-
lighted in orange.
• Assign a module to a next available slot: Select the desired
group in the module window and double-click on the desired
module.
2 Parameter window
Displays the module-specific parameters. The values of the pa-
rameters can be changed.
3 Search box
The search box can be used to search for modules. The search
is a full-text search.
4 Module window
The modules are divided into groups.
5 Module description
Describes the module type and properties.
6 Parameter description
Describes the parameters that can be set in the parameter win-
dow.
For devices that are not slot-based, only the parameter window and the
parameter description are shown on this tab.
The parameters on this tab depend on the device used. Further informa-
tion about the parameters can be found in the manufacturer’s documen-
tation for the device.
4.9 Configuring File Access over EtherCAT
Description
File Access over EtherCAT can be used to load files from a device or to
save them on a device.
Precondition
• The device supports the File Access over EtherCAT function.

• The device is connected and active.
• The device is inserted into the bus.
Procedure
Load file from the device:

2. Right-click on the device and select Connect from the context menu.
The connection to the device is being established.
3. Right-click on the device again and select Functions > Upload file
from the context menu.
4. A window opens. Navigate to the location of the file to be loaded by
the device.
5. Enter a name and click on Save.
Save file to device:
3. Right-click on the device again and select Functions > Download file
from the context menu.
4. A window opens. Navigate to the location of the file to be saved on
the device.
5. Select the file and click on Save.
4.10 Writing the alias address to devices
Description
With WorkVisual, the alias address can be written directly to a device. If

the alias address of a device matches the alias address that has been
configured for this device, the device can be used as a decouplable de-
vice.
Precondition

• WorkVisual:
KR C4 EtherCAT
Configuration
‒ A project is open.
‒ The robot controller has been set as the active controller.
‒ The device is inserted into the bus.
• Real robot controller:
‒ User group “Expert” or higher
‒ T1 mode
‒ The safety controller does not give a drives enable signal.
‒ This status can be brought about in the following way: trigger
an EMERGENCY STOP.
‒ This status can be checked as follows: In the status bar, click
on the Drives status indicator. The Motion conditions window
opens. The Drives enabled from Safety box must be gray. It
must not be green.
Information about the status bar can be found in the operat-
ing and programming instructions for the system software.
Procedure
3. Right-click on the device again and select Functions > Assigning
alias address... from the context menu. The Alias address assign-
ment window opens. The current alias address of the device is dis-
played in the Alias address box.
4. Modify the address as desired and confirm with OK.
5. Restart the device.
4.11 Checking and modifying the topology
Description
If devices are inserted into the bus, WorkVisual connects the devices au-
tomatically. As WorkVisual does not know the real bus configuration, a
check must be carried out to determine whether the connections match
this configuration. If this is not the case, the connections must be modified
accordingly. The topology is not modified following subsequent modifica-
tions to the bus configuration. As a result, a check must be carried out to
determine whether the connections match in this case as well.
Precondition
• Devices are inserted into the bus.
Procedure

opens.
3. Select the Topology tab.
(>>> 4.11.1 "“Topology” tab" Page 22)
4. Make the desired modifications:

• Delete invalid connections: Right-click on the connection and
select Delete.
Alternatively: Select the connection and press the “Del” key.
• Insert missing connections: Click on a connection and hold down
the mouse button. Drag the mouse pointer to another connection
and release the mouse button.
• Rearrange the devices using Drag&Drop. This serves to increase
the clarity of the Topology tab. It has no effect on the bus.
• Select the individual devices and modify the desired properties,
e.g. the alias address, in the Properties window.
5. Click on OK.
4.11.1 “Topology” tab
Fig. 4-5: “Topology” tab (example)
Item Description
1 Permanent connection
A solid line indicates a permanent connection between 2 devi-
ces.
2 Device
The number specifies the physical address of the device.
When a device is selected, the properties of the device, e.g. the
address and alias address, are displayed in the Properties win-
dow. Some of the properties can be changed. For decouplable
devices, it essential for an alias address to be assigned.
Note: These properties are saved in the WorkVisual project and
on the robot controller, but not on the device itself. If, for exam-
ple, the alias address is modified here, this has no effect on the
alias address on the device. When coupling and decoupling the
device, the alias address displayed here is compared with the
alias address on the device in order to identify the device un-
ambiguously.
KR C4 EtherCAT
Configuration
Item Description
3 Connection
Each device can have up to 4 connections. Connection A is the
designation for the input. The number and designation of the
outputs (connections B, C and D) depend on the design of the
device. The input of every device must be connected to the out-
put of a device that is in the line topology. The connections
must match the real topology.
An output can only be connected to an input. No cyclical de-
pendencies are possible.
4 Decouplable connection
A dotted line indicates a decouplable connection between 2 de-
vices.
5 The device is sending one or more messages.
6 Message area
The message area shows if a device has an invalid address or
alias address. The message area can be collapsed in order to
enlarge the graphic display area. The message area is only dis-
played if messages are active.
Button Description
Print Prints the graphic.
If one or more devices are selected, only those devi-
ces are printed.
KR C4 EtherCAT
Operation
5 Operation
5.1 Decoupling/coupling devices
or higher.
Description
Decouplable devices have the following properties:

• After booting or reconfiguration, a decouplable device is not automati-
cally integrated into the bus. The device remains in the INIT state, but
this does not trigger an error.
• After a restart of the bus system or a reboot of the robot controller,
the state that the decouplable device had before the restart is re-
stored.
• If a decouplable device is coupled and is then disconnected from the
bus without first decoupling it, this triggers a bus error.
• If an attempt is made to couple a decouplable device that is not
present on the bus, this does not trigger a bus error.
Precondition
• An alias address has been written to the decouplable device.

(>>> 4.10 "Writing the alias address to devices" Page 20)
• The alias address of the decouplable device has been stored in Work-
Visual. (>>> 4.11 "Checking and modifying the topology" Page 21)
KRL syntax
Decoupling:
ioRet = ioCtl("SYS-X44", 60, Device address)
Coupling:
ioRet = ioCtl("SYS-X44", 50, Device address)
Return values
The following return values are possible for ioRet:

Value Meaning
0 The device was successfully decoupled/coupled.
<> 0 An error occurred during execution of the function. The return
value is an error code.
5.2 Activating/deactivating bus errors
or higher.
Description
Bus errors can be disabled and re-enabled using IOCTL functions. As

standard, bus errors are enabled. This leads to a stop and/or inhibits ac-
tive commands if a bus error occurs.
Disabling bus errors is possible for one or more bus instances. If bus er-
rors are disabled, the response is as follows:
Operation KR C4 EtherCAT
• Bus error: No stop and/or inhibition of active commands

• Bus error: No error message in the message window of the smartHMI
• The following message is displayed in the message window of the
smartHMI:
KRC IO bus error suppression active for bus instance: {Bus instance}
{Bus instance}{Bus instance}
• If an error has already occurred for a bus instance, it is not possible
to re-enable bus errors.
Whether or not a bus error has occurred can be read in this case via the
system variable $IOBUS_INFO[].
Enabling and disabling can be carried out via the smartHMI or the KRL
program.
Procedure
On the smartHMI:
1. Select the menu sequence Display > Variable > Single.
2. In the Name box, enter:
• To disable: =IOCTL("KRC->SYS-X44", 1, 1)
• To enable: =IOCTL("KRC->SYS-X44", 1, 0)
3. Confirm by pressing the Enter key.
In the KRL program:
• Enter the following:
‒ To disable: retVal=IOCTL("KRC->SYS-X44", 1, 1)
‒ To enable: retVal=IOCTL("KRC->SYS-X44", 1, 0)
Return values for retVal:
Value Meaning
0 IOCTL function executed successfully
-4 Enabling not permissible because a bus error has occurred
-3 IOCTL function contains an incorrect parameter
-1 The specified bus driver or bus name was not found
5.3 Restarting the bus system
or higher.
Description
After a bus error, the bus system can be restarted using IOCTL function
12.
KRL syntax
INT ioRet
ioRet = ioCtl("SYS-X44", 12, 0)
Return values
KR C4 EtherCAT
Operation
Value Meaning
0 Restart of the bus system was successful.
-1 Restart of the bus system failed.
5.4 Executing queries / changes
or higher.
Description
IOCTL functions can also be used to make queries or changes. Parame-

ters are required for some queries and changes. If no parameter is re-
quired, “0” is entered as the parameter in the syntax.
Syntax
INT ioRet
ioRet = ioCtl("SYS-X44", '[IOCTL function]', [Parameter])
Overview
Query Function Parameters

Bus error status of SYS-X44 H8001 -
EtherCAT slave is configured as a de- H8003 Device address
couplable device.
Decouplable device enabled/disabled H8004 Device address
Operating mode of the EtherCAT slave H8005 Device address
Timeout period for the coupling/decou- H8009 -
pling of devices
Number of configured devices H8109 -
Change Function Parameters

Timeout period for the coupling/decou- H8008 Timeout period
pling of devices in ms
5.4.1 Querying the bus error status of SYS-X44
Syntax
INT ioRet
ioRet = ioCtl("SYS-X44", 'H8001', 0)
Return values

Value Meaning
0 SYS-X44 is OK
<> 0 There is an active bus error.
5.4.2 Querying whether EtherCAT slave is configured as a decouplable de-

vice
Syntax
INT ioRet
ioRet = ioCtl("SYS-X44", 'H8003', Device address)
Return values

Value Meaning
-1 Device address not found / general error
0 EtherCAT slave is not configured as a decouplable device.
1 EtherCAT Slave is configured as a decouplable device.
5.4.3 Querying whether a decouplable device is enabled or disabled
Syntax
INT ioRet
Return values

Value Meaning
0 EtherCAT slave is disabled.
1 EtherCAT slave is enabled.
5.4.4 Querying the operating mode of the EtherCAT slave
Syntax
INT ioRet
Return values

Value Meaning
0 EtherCAT slave is not in the operating mode OPERATIONAL.
1 EtherCAT slave has no error and is in the operating mode
OPERATIONAL.
5.4.5 Querying the timeout period for the coupling/decoupling of devices
Syntax
INT ioRet
KR C4 EtherCAT
Operation
Return values

Value Meaning
-1 General error
> 0 Current timeout period in ms
5.4.6 Changing the timeout period for the coupling/decoupling of devices
As standard, the timeout period for the coupling/decoupling of devices is

5000 ms.
Syntax
INT ioRet
ioRet = ioCtl("SYS-X44", 'H8008', Timeout period in ms)
Return values

Value Meaning
0 New timeout period has been set
<> 0 An error occurred during execution of the function.
5.4.7 Querying the number of configured devices
The number also includes all decouplable devices that are not currently
connected to the bus.
Syntax
INT ioRet
Return values

Value Meaning
-1 General error
> 0 Number of configured devices
5.5 Accessing EtherCAT SDO via KRL
or higher.
Overview
EtherCAT SDO can be accessed via KRL in the following ways:
• Access via CANopen over EtherCAT (CoE)

(>>> 5.5.1 "Access via CANopen over EtherCAT (CoE)" Page 30)
• Access via File Access over EtherCAT (FoE)
(>>> 5.5.2 "Access via File Access over EtherCAT (FoE)" Page 34)
• Access via vendor-specific protocol over EtherCAT (VoE)
(>>> 5.5.3 "Access via vendor-specific protocol over EtherCAT (VoE)"
Page 45)
• Access via ADS over EtherCAT (AoE)
(>>> 5.5.4 "Access via ADS over EtherCAT (AoE)" Page 48)
5.5.1 Access via CANopen over EtherCAT (CoE)
Read access
Function signature: “krl_ECat_Sys_X44_CoE_Read”

Function call: CWRITE($FCT_CALL, State, Mode,
"krl_ECat_Sys_X44_CoE_Read", Slave address, CoE index, CoE
subindex, Buffer, Data length, Timeout, CoE access, Return value)
Write access
Function signature: “krl_ECat_Sys_X44_CoE_Write”

"krl_ECat_Sys_X44_CoE_Write", Slave address, CoE index, CoE
subindex, Buffer, Data length, Timeout, CoE access, Return value)
Description
Parameter Description
Slave address [IN] Physical address of the slave
Data type: INT
CoE index [IN] The parameter can be used to read or write to
the entire CoE object.
Data type: INT
CoE subindex [IN] The parameter can be used to read or write to
individual values of the CoE object.
Data type: INT
Buffer [OUT] Buffer for the data to be read or written
Data type: CHAR array
Data length [IN/OUT] [IN]: Maximum length of the data to be read (in
bytes)
[OUT]: Actual length of the data read (in bytes)
Data type: INT
Timeout [IN] Maximum time for the access (in ms)
Data type: INT
CoE access [IN] Access to an individual element or to the entire
group
For access to the entire group: CoeObjSu-
bIdx=0
Data type: BOOL
KR C4 EtherCAT
Operation
Return value [OUT] Value that is returned after the function call
Data type: INT
Return value Description

Stat.Msg_No = -10 The function call contains too few or too
many parameters. The function call must con-
tain 8 parameters.
Stat.Msg_No = -11 The parameter Slave address has the wrong
data type or is not in the valid range of val-
ues (UShort).
Stat.Msg_No = -12 The parameter CoE index has the wrong
ues (UShort).
Stat.Msg_No = -13 The parameter CoE subindex has the wrong
ues (UChar).
Stat.Msg_No = -14 The parameter Buffer has the wrong data
type or the value of the parameter Data
length is too great.
Stat.Msg_No = -15 The parameter Data length has the wrong da-
ta type or a value ≤ 0.
Stat.Msg_No = -16 The parameter Timeout has the wrong data
type or a value ≤ 0.
Stat.Msg_No = -17 The parameter CoE access has the wrong
data type.
Stat.Msg_No = -18 The parameter Return value has the wrong
data type.
Stat.Msg_No = -30 No connection can be established to the
SDO interface of the KUKA Extension Bus.
Stat.Msg_No = -31 The specified physical address of the slave
cannot be assigned to a slave.
Stat.Msg_No = -32 The CoE interface of the KUKA Extension
Bus is not initialized.
Stat.Msg_No = -33 The CoE interface contains an impermissible
combination of parameters
Stat.Msg_No = -34 The CoE interface of the KUKA Extension
Bus signals an execution error at the pro-
gramming interface
Stat.Ret1 = #DATA_OK The data were read/written successfully.
Example 1
Read access to an individual index
1 DECL INT physAddr

2 DECL STATE_T State
3 DECL MODUS_T Mode
4 DECL CHAR sBuffer[128]
5 DECL INT nAtemRet, nDataLen
6 BOOL bTemp
7
8 nAtemRet = 'H98110000'
9 nDataLen = 128
10 bTemp = StrCopy(sBuffer[], " ")

11 IF (NOT bTemp) THEN
12 HALT
13 ENDIF
14
15 CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_CoE_Read",
1004, 'H1008', 0, sBuffer[], nDataLen, 200, FALSE, nAtem-
Ret)
16 IF (State.Ret1 <> #DATA_OK) THEN
17 IF (State.Msg_No == -34) THEN
18 HALT
19 ELSE
20 HALT
21 ENDIF
22 ELSE
23 HALT
24 ENDIF
25
26 END
Line Description
1 … 6 Declaration of the required variables
8 … 9 Initialization of the variables that are used in the function
call
10 Buffer is cleared
11 … 13 If an error occurs while the buffer is being cleared, the
program is stopped.
15 Function is called
Here the name of the slave with the physical address
1004 is read.
16 … 18 If read access fails, an error code is generated. This is
contained in the variable nAtemRet. The error code can
be transformed into an English text using the function
CWRITE(..."krl_ECat_ApiErrorTxt"...).
19 If read access fails because the transfer parameters for
the CWrite call are not correct, a different error code is
generated. The relevant description can be found in the
table of error codes.
22 If read access was successful, the read value is con-
tained in the KRL variable sBuffer.
Example 2
Read access to a complete index

2 DECL MODUS_T Mode
5 DECL INT nVendorId
6 DECL INT nProdCode
7 DECL INT nRevNr
8 DECL INT nSerNr
9 DECL INT nNumSubIdx
10 DECL CHAR bySubIdx[2]
11 DECL INT OFFSET
12 BOOL bTemp
KR C4 EtherCAT
Operation
13
14 nAtemRet = 'H98110000'
15 nDataLen = 128
16 bTemp = StrCopy(sBuffer[], " ")
17 IF (NOT bTemp) THEN
18 HALT
19 ENDIF
20
21 CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_CoE_Read",
1004, 'H1018', 'H0', sBuffer[], nDataLen, 200, TRUE, nA-
temRet)
23 AtemErrMsg(nAtemRet)
24 HALT
25 ELSE
26 nVendorId='H1', nProdCode='H1', nRevNr='H1',
nSerNr='H1'
27 bySubIdx[1]="X", bySubIdx[2]="X"
28 OFFSET=0
29 CAST_FROM(sBuffer[],OFFSET,bySubIdx[1], bySu-
bIdx[2],nVendorId,nProdCode,nRevNr,nSerNr)
30 nNumSubIdx=bySubIdx[1]
31 KrlMsgStringXInt("CoE-Rd(0x1018): '"'%1'"' -> %2",
"Num. Sub-Index", nNumSubIdx)
"Vendor-ID", nVendorId)
"Procuct-Code", nProdCode)
34 KrlMsgStringXInt("CoE-Rd(0x1018): '"'%1'"' -> %2", "Re-
vision-Nr.", nRevNr)
35 KrlMsgStringXInt("CoE-Rd(0x1018): '"'%1'"' -> %2", "Se-
rial-Nr.", nSerNr)
36 ENDIF
37 END
Line Description
call
16 Buffer is cleared
17 … 19 If an error occurs while the buffer is being cleared, the
program is stopped.
The entire CoE object is read here.
contained in the variable nAtemRet. The error code can
be transformed into an English text using the function
CWRITE(..."krl_ECat_ApiErrorTxt"...).
25 … 35 If read access was successful, a message is generated.
This contains the values that have been read.
Example 3
Write access to an individual index

2 DECL MODUS_T Mode
3 DECL INT nAtemRet
5 DECL INT OFFSET, nNewVal

6
7 nAtemRet = 'H98110000'
8 nNewVal = 'H0815'
9 Offset=0
10 CAST_TO(sBuffer[],OFFSET, nNewVal)
11 IF (Offset == 4) THEN
12 CWRITE($FCT_CALL,State, Mode,
"krl_ECat_Sys_X44_CoE_Write", 1004,'H3004', 'H1', sBuff-
er[], 4, 200, FALSE, nAtemRet)
13 IF (State.Ret1 - #DATA_OK) THEN
15 HALT
16 ELSE
17 KrlMsgStringXInt("CoE-Wr(): '"'%1'"' -> ATEM-Ret=%2",
"CoE_Write(0x3004:01)", nAtemRet)
18 ENDIF
19 ELSE
20 HALT
21 ENDIF
Line Description
call
10 The contents of the variable nNewVal are copied byte by
byte to the variable sBuffer[]. The value of the variable
Offset indicates the array position at which the copying
operation begins.
In this example, the variable Offset has the value zero;
therefore, after execution of the function, the variable
sBuffer[] contains the values {'H00', 'H00', 'H08', 'H15'}.
CoE index 0x3004 and CoE subindex 0x01 are written
here.
contained in the variable nAtemRet.
16 … 17 If read access was successful, a message is generated.
This contains the values that have been written.
19 … 20 If an error occurs during execution of the function
CAST_TO() in line 10, the program is stopped. Alterna-
tively, generation of a message can be programmed
here.
5.5.2 Access via File Access over EtherCAT (FoE)
There are 2 types of access via FoE:

• Access to the file contents transferred as parameters (CHAR array).
• Access to the directory in which the file is stored in the file system.
The type of access varies depending on how many parameters are used
and which ones. The function call itself is identical for both types.
Read access (file contents)
Function signature: “krl_ECat_FoE_Read”
KR C4 EtherCAT
Operation
"krl_ECat_FoE_Read", Slave address, File name, Buffer, Data
length, Password, Timeout, Return value, Return value FoE)
Description
Data type: INT
File name [IN] Name of the file
It is not possible to specify the directory.
Buffer [OUT] Buffer for the file contents
The data are read to this buffer.
bytes). The length corresponds to the size of
the CHAR array of the parameter Buffer.
Data type: INT
Password [IN] Password for access to the file contents
Data type: INT
Data type: INT
Data type: INT array
Return value FoE Return value of the FoE interface
[OUT]
The return value consists of an error code and
an error text. The error code is an integer val-
ue (bytes 1 … 4). This is followed by an error
text with a maximum length of 80 characters.
This contains the description of the error code.
Length: 84 bytes

tain 8 parameters.
ues (UShort).
Stat.Msg_No = -12 The parameter File name has the wrong data
type.
type or the data length of the parameter Data
length does not correspond to the size of the
CHAR array.

Stat.Msg_No = -15 The parameter Password has the wrong data
type.
data type.
Stat.Msg_No = -18 The parameter Return value FoE has the
wrong data type or the number of elements ≠
84.
Stat.Msg_No = -32 The FoE interface of the KUKA Extension
Stat.Msg_No = -33 The FoE interface contains an impermissible
combination of parameters.
Stat.Msg_No = -34 The SDO interface of the KUKA Extension
gramming interface.
Stat.Ret1 = #DATA_OK The contents of the file were read successful-
ly.
Write access (file contents)
Function signature: “krl_ECat_FoE_Write”

"krl_ECat_FoE_Write", Slave address, File name, Buffer, Data
length, Password, Timeout, Return value, Return value FoE)
Description
Data type: INT
File name [IN] Name of the file
It is not possible to specify the directory.
Buffer [IN] Buffer containing the file contents
Data length [IN] Length of the data to be written (in bytes). The
length corresponds to the size of the CHAR ar-
ray of the parameter Buffer.
Data type: INT
Password [IN] Password for access to the file contents
Data type: INT
KR C4 EtherCAT
Operation
Data type: INT
Data type: INT array
[OUT]
Length: 84 bytes

tain 8 parameters.
ues (UShort).
type.
type or the data length of the parameter Data
length does not correspond to the size of the
CHAR array.
type.
data type.
84.
gramming interface.

Stat.Ret1 = #DATA_OK The contents of the file were written success-
fully.
Read access (directory)
Function signature: “krl_ECat_FoE_Read”

"krl_ECat_FoE_Read", Slave address, File name, Data length,
Password, Timeout, Return value, Return value FoE)
Description
Data type: INT
File name [IN] Name of the file with specification of the direc-
tory to which the read file is to be written
Data length [OUT] Actual length of the data read (in bytes)
Data type: INT
Password [IN] Password for access to the directory
Data type: INT
Data type: INT
Data type: INT
[OUT]
Length: 84 bytes

tain 7 parameters.
ues (UShort).
type.
ta type.
type.
KR C4 EtherCAT
Operation
data type.
84.
gramming interface.
Stat.Ret1 = #DATA_OK The file was read successfully.
Write access (directory)
Function signature: “krl_ECat_FoE_Write”

"krl_ECat_FoE_Write", Slave address, File name, Data length,
Password, Timeout, Return value, Return value FoE)
Description
Data type: INT
File name [IN] Name of the file with specification of the direc-
tory in which the file to be written is located
Data length [IN] Actual length of the data written (in bytes)
Data type: INT
Password [IN] Password for access to the directory
Data type: INT
Data type: INT
Data type: INT
[OUT]
Length: 84 bytes

tain 7 parameters.
ues (UShort).
type.
ta type.
type.
data type.
84.
gramming interface.
Stat.Ret1 = #DATA_OK The file was written successfully.
Example 1
Read access to the file contents

2 DECL MODUS_T Mode
5 DECL CHAR sFoeRet[84]
6 DECL INT nFoeRet, OFFSET
KR C4 EtherCAT
Operation
7 DECL CHAR sFoeRetTxt[80]
8
9 nAtemRet = 'H98110000'
10 Wait for StrCopy(sBuffer[], " ")
11 Wait for StrCopy(sFoeRet[], " ")
12 nDataLen = StrDeclLen(sBuffer[])
13
14 CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_FoE_Read",
1001, "XData.txt", sBuffer[], nDataLen, 0, 2000, nAtem-
Ret, sFoeRet[])
17 nFoeRet = -1
18 OFFSET=0
19 CAST_FROM(sFoeRet[],OFFSET,nFoeRet,sFoeRetTxt[])
20 KrlMsgStringXInt("FoE-Read() Fehler: '"'%1'"' - %2",
sFoeRetTxt[], nFoeRet)
21 HALT
22 ELSE
23 KrlMsgStringXInt("FoE-Read(): '"'%1'"' <-- ApiRet=%2",
"Read XData.txt ... OK", nAtemRet)
24 ENDIF
Line Description
9 Initialization of the variables that are used in the function
call
10 Clears the buffer to which the file contents are read
11 Clears the buffer for the return value of the FoE interface
12 Determines the maximum length of the buffer for the file
contents from the declaration of the variable sBuffer[]
The contents of the file XData.txt are read here from the
slave.
17 … 18 Initialization of the variables nFoeRet and Offset. This is
necessary for the function CAST_FROM() in line 19 to
work correctly.
19 Evaluation of the return value of the FoE interface in the
event of an error
The function CAST_FROM() transfers the error code and
error text from the variable sFoeRet[] to the variables
nFoeRet and sFoeRetTxt[]. The error code (INT) is trans-
ferred to the variable nFoeRet, the error text (CHAR[]) to
the variable sFoeRetTxt[].
20 A message is generated in the event of an error. This
contains the error code and the error text.
21 If an error occurs during execution of the function
CAST_FROM() in line 19, the program is stopped.
23 If read access was successful, a message is generated.
Example 2
Read access to a directory

2 DECL MODUS_T Mode
7
8 nAtemRet = 'H98110000'
9 nDataLen = 0
11
12 CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_FoE_Read",
1001, "Log/YData.txt", nDataLen, 0, 2000, nAtemRet,
sFoeRet[])
15 nFoeRet = -1
16 OFFSET = 0
18 KrlMsgStringXInt("FoE-Read() Fehler: '"'%1'"' - %2",
19 HALT
20 ELSE
21 KrlMsgStringXInt("FoE-Read(): '"'%1'"' <-- ApiRet=%2",
"Read Log/YData.txt ... OK", nAtemRet)
22 ENDIF
Line Description
call
Here the file YData.txt is read from the “Log” directory of
the slave.
work correctly.
event of an error
Example 3
Write access to the file contents
KR C4 EtherCAT
Operation
2 DECL MODUS_T Mode
8
9 nAtemRet = 'H98110000'
10 Wait for StrCopy(sBuffer[], "test data for FoE test")
12 nDataLen = StrLen(sBuffer[])
13
"krl_ECat_Sys_X44_FoE_Write", 1001, "XData.txt", sBuff-
er[], nDataLen, 0, 2000, nAtemRet, sFoeRet[])
17 nFoeRet = -1
18 OFFSET=0
20 KrlMsgStringXInt("FoE-Write() Fehler: '"'%1'"' - %2",
21 HALT
22 ELSE
23 KrlMsgStringXInt("FoE-Write(): '"'%1'"' <-- ApiRet=%2",
"Write XData.txt ... OK", nAtemRet)
24 ENDIF
Line Description
call
10 Writes the text “test data for FoE test” to the buffer
12 Determines the actual length of the data in the buffer
Here data are written to the file XData.txt from the slave.
15 … 16 If write access fails, an error code is generated. This is
work correctly.
event of an error
23 If write access was successful, a message is generated.
Example 4
Write access to a directory

2 DECL MODUS_T Mode
8
9 nAtemRet = 'H98110000'
11
"krl_ECat_Sys_X44_FoE_Write", 1001, "Log/YData.txt", 0,
2000, nAtemRet, sFoeRet[])
15 nFoeRet = -1
16 OFFSET=0
18 KrlMsgStringXInt("FoE-Write() Fehler: '"'%1'"' - %2",
19 HALT
20 ELSE
21 KrlMsgStringXInt("FoE-Write(): '"'%1'"' <-- ApiRet=%2",
"Write Log/YData.txt ... OK", nAtemRet)
22 ENDIF
Line Description
call
Here the file YData.txt is written to the “Log” directory of
the slave.
13 … 14 If write access fails, an error code is generated. This is
work correctly.
event of an error
KR C4 EtherCAT
Operation
5.5.3 Access via vendor-specific protocol over EtherCAT (VoE)
Read access
Function signature: “krl_ECat_Sys_X44_VoE_Read”

"krl_ECat_Sys_X44_VoE_Read", Slave address, Buffer, Data
length, Timeout, Return value)
Description
Data type: INT
Buffer [OUT] Buffer for the data to be read
Data type: INT
Data type: INT
Data type: INT

tain 5 parameters.
ues (UShort).
data type.
gramming interface.
Stat.Ret1 = #DATA_OK The data were read successfully.
Write access
Function signature: “krl_ECat_Sys_X44_VoE_Write”

"krl_ECat_Sys_X44_VoE_Write", Slave address, Buffer, Data
length, Timeout, Return value)
Description
Data type: INT
Buffer [OUT] Buffer for the data to be written
Data length [IN] Length of the data to be written (in bytes).
Data type: INT
Data type: INT
Data type: INT

tain 5 parameters.
ues (UShort).
data type.
gramming interface.
Stat.Ret1 = #DATA_OK The data were written successfully.
Example 1
Read access

2 DECL MODUS_T Mode
KR C4 EtherCAT
Operation
5
6 nAtemRet = 'H98110000'
7 nDataLen = 128
9
10 CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_VoE_Read",
1004, sBuffer[], nDataLen, 200, nAtemRet)
13 HALT
14 ELSE
15 KrlMsgStringXInt("VoE-Rd(): '"'%1'"' <-- Len=%2",
sBuffer[], nDataLen)
16 ENDIF
Line Description
call
8 Clears the buffer to which the data are read
Here data are read from the slave with the physical ad-
dress 1004.
11 … 13 If read access fails, the program is stopped and an error
code is generated. This is contained in the variable nA-
temRet.
Example 2
Write access
DECL STATE_T State

DECL MODUS_T Mode
DECL INT nAtemRet
DECL CHAR sBuffer[128]
DECL INT OFFSET, nSerVal
nAtemRet = 'H98110000'
Wait for StrCopy(sBuffer[], "test")
CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_VoE_Write",
1004, sBuffer[], StrLen(sBuffer[]), 200, nAtemRet)
IF (State.Ret1 <> #DATA_OK) THEN
AtemErrMsg(nAtemRet)
HALT
ELSE
KrlMsgStringXInt("VoE-Wr(): '"'%1'"' -> ATEM-Ret=%2",
"VoE_Write", nAtemRet)
ENDIF
Line Description
7 Initialization of the variable nAtemRet that is used in the
function call
8 Clears the buffer to which the data are written
Line Description
Here the string “test” is written to the slave with the phys-
ical address 1004.
11 … 13 If write access fails, the program is stopped and an error
temRet.
5.5.4 Access via ADS over EtherCAT (AoE)
Read access (slave net ID)
Function signature: “krl_ECat_Sys_X44_AoE_GetSlaveNetId”

"krl_ECat_Sys_X44_AoE_GetSlaveNetId", Slave address, AoE
target net ID, Return value)
Description
Data type: INT
AoE target net ID Addresses the desired device
[OUT]
Data type: INT

tain 3 parameters.
ues (UShort).
Stat.Msg_No = -12 The parameter AoE target net ID has the
wrong data type or fewer than 6 array ele-
ments.
data type.
Stat.Msg_No = -34 The AoE interface of the KUKA Extension
gramming interface.
Stat.Ret1 = #DATA_OK The slave net ID was read successfully.
KR C4 EtherCAT
Operation
Read access
Function signature: “krl_ECat_Sys_X44_AoE_Read”

"krl_ECat_Sys_X44_AoE_Read", Slave address, AoE target net ID,
AoE target port, AoE group index, AoE index offset, Buffer, Data
length, Timeout, Return value AoE)
Description
Data type: INT
AoE target net ID [IN] Addresses a specific device
AoE target port [IN] Addresses a specific service on the device
Data type: INT
AoE group index [IN] The parameter can be used to read the entire
AoE group.
Data type: INT
AoE index offset [IN] The parameter can be used to read individual
values of the AoE group.
Data type: INT
Buffer [OUT] Buffer for the data to be read
Data type: INT
Data type: INT
Return value AoE Return value of the AoE interface
[OUT]
The return value is a CHAR array with 12
bytes, containing 4-byte values:
• AoE response error code (bytes 1-4)

• AoE command result code (bytes 5-8)
• Result code of the programming interface
(bytes 9-12)

tain 9 parameters.
ues (UShort).

ments.
Stat.Msg_No = -13 The parameter AoE target port has the wrong
ues (UShort).
Stat.Msg_No = -14 The parameter AoE group index has the
wrong data type.
Stat.Msg_No = -15 The parameter AoE index offset has the
wrong data type.
Stat.Msg_No = -19 The parameter Return value AoE has the
ments.
Stat.Msg_No = -33 The AoE interface contains an impermissible
gramming interface.
Stat.Ret1 = #DATA_OK The data were read successfully.
Write access
Function signature: “krl_ECat_Sys_X44_AoE_Write”

"krl_ECat_Sys_X44_AoE_Write", Slave address, AoE target net
ID, AoE target port, AoE group index, AoE index offset, Buffer, Da-
ta length, Timeout, Return value AoE)
Description
Data type: INT
Data type: INT
KR C4 EtherCAT
Operation
AoE group index [IN] The parameter can be used to write to the en-
tire AoE group.
Data type: INT
AoE index offset [IN] The parameter can be used to write to individ-
ual values of the AoE group.
Data type: INT
Buffer [IN] Buffer for the data to be written
Data length [IN] Length of the data to be written (in bytes).
Data type: INT
Data type: INT
[OUT]

(bytes 9-12)

tain 9 parameters.
ues (UShort).
ments.
ues (UShort).
wrong data type.
wrong data type.
ments.

gramming interface.
Stat.Ret1 = #DATA_OK The data were written successfully.
Read and write access
Function signature: “krl_ECat_Sys_X44_AoE_ReadWrite”

"krl_ECat_Sys_X44_AoE_ReadWrite", Slave address, AoE target
net ID, AoE target port, AoE group index, AoE index offset, Buffer,
Data length Write, Data length Read, Timeout, Return value AoE)
Description
Data type: INT
Data type: INT
AoE group index [IN] The parameter can be used to read or write to
the entire AoE group.
Data type: INT
AoE index offset [IN] The parameter can be used to read or write to
individual values of the AoE group.
Data type: INT
Buffer [IN/OUT] Buffer for the data to be read and/or written
Data length Write [IN] Length of the data to be written (in bytes)
Data length Read [IN/ [IN]: Maximum length of the data to be read (in
OUT] bytes). The length corresponds to the size of
Data type: INT
Data type: INT
KR C4 EtherCAT
Operation
[OUT]

(bytes 9-12)

tain 10 parameters.
ues (UShort).
ments.
ues (UShort).
wrong data type.
wrong data type.
length Write or Data length Read is too great.
Stat.Msg_No = -17 The parameter Data length Write has the
wrong data type or a value ≤ 0.
Stat.Msg_No = -18 The parameter Data length Read has the
wrong data type or a value ≤ 0.
ments.
gramming interface.

Stat.Ret1 = #DATA_OK The data were read and/or written successful-
ly.
Example 1
Read access to slave net ID

2 DECL MODUS_T Mode
3 DECL INT nAtemRet
4 DECL CHAR sAdsNetId[6]
5 DECL CHAR sAdsNetIdString[64]
6 DECL INT OFFSET
7
8 nAtemRet = 'H98110000'
9 Wait for StrCopy(sAdsNetId[], " ")
10
11 CWRITE($FCT_CALL, State, Mode, "krl_ECat_Sys_X44_AoE_Get-
SlaveNetId", 1001, sAdsNetId[], nAtemRet)
13 KrlMsgStringXInt("AoE-Net-ID Read() Fehler: '"'%1'"' -
%2", "Read ... Fehler", nAtemRet)
14 HALT
15 ELSE
16 OFFSET = 0
17 SWrite(sAdsNetIdString[], STATE, OFFSET, "Net-ID =
%i.%i.%i.%i.%i.%i",sAdsNetId[1], sAdsNetId[2], sAdsNe-
tId[3], sAdsNetId[4], sAdsNetId[5], sAdsNetId[6])
18 KrlMsgStringXInt("AoE-Net-ID Read(): '"'%1'"' <-- ApiR-
et=%2", sAdsNetIdString[], nAtemRet)
19 ENDIF
Line Description
8 Initialization of the variable nAtemRet that is used in the
function call
9 Clears the buffer for the slave net ID
Here the net ID is read from the slave with the physical
address 1001.
12 … 14 If read access fails, the program is stopped and an error
temRet.
16 Initialization of the variable OFFSET. This is necessary
for the function SWrite() in line 17 to work correctly.
17 The function SWrite() writes the text string for the AoE
target net ID to the variable sAdsNetIdString[] so that it
can be indicated in the message in line 18 (e.g.
"11.2.3.4.5.6").
Example 2
Read access
KR C4 EtherCAT
Operation
3 DECL MODUS_T Mode
4 DECL INT nDataLen
7 DECL CHAR sAoeRet[12]
8 DECL INT OFFSET, nAoeResponseRet, nAoeCmdRet, nAtemRet
9
10 nAtemRet = 'H98110000'
11 nAoeResponseRet = 0
12 nAoeCmdRet = 0
14 Wait for StrCopy(sAoeRet[], " ")
15 GetSlaveNetId(1001, sAdsNetId[])
16 nDataLen = StrDeclLen(sBuffer[])
17
18 CWRITE($FCT_CALL, State, Mode,
"krl_ECat_Sys_X44_AoE_Read", 1001, sAdsNetId[], 55, 1234,
22, sBuffer[], nDataLen, 200, sAoeRet[])
20 OFFSET = 0
21 CAST_FROM(sAoeRet[], OFFSET, nAoeResponseRet, nAoeCm-
dRet, nAtemRet)
23 HALT
24 ELSE
25 KrlMsgStringXInt("AoE-Rd(): '"'%1'"' <-- Len=%2",
sBuffer[], nDataLen)
26 ENDIF
Line Description
call
13 Clears the buffer to which the data are read
14 Clears the buffer for the return value of the AoE interface
15 Reads the slave net ID of the slave with the physical ad-
dress 1001
16 Determines the maximum length of the buffer from the
declaration of the variable sBuffer[]
At AoE target port 55 of the slave with the physical ad-
dress 1001, AoE group index 1234 is read with AoE in-
dex offset 22.
19 … 23 Evaluation of the return value of the AoE interface in the
event of an error
The return value of the AoE interface consists of 3 inte-
ger variables. The function CAST_FROM() transfers the
values of the 3 variables in the correct sequence to the
variables nAoeResponseRet, nAoeCmdRet and nAtem-
Ret. The program is stopped in the event of an error.
Example 3
Write access

2 DECL MODUS_T Mode
3 DECL INT nDataLen
8
9 nAtemRet = 'H98110000'
11 nAoeCmdRet = 0
12 Wait for StrCopy(sBuffer[], "ADS test")
15 nDataLen=StrLen(sBuffer[])
16
"krl_ECat_Sys_X44_AoE_Write", 1001, sAdsNetId[], 55,
1234, 22, sBuffer[], nDataLen, 200, sAoeRet[])
19 OFFSET = 0
dRet, nAtemRet)
22 HALT
23 ELSE
24 KrlMsgStringXInt("AoE-Wr(): '"'%1'"' <-- Len=%2",
"Write...OK", nDataLen)
25 ENDIF
Line Description
call
12 Writes the text “ADS test” to the buffer
dress 1001
15 The length of the buffer sBuffer[] is defined in the varia-
ble nDataLen
The write access is performed at the slave with the phys-
ical address 1001. The contents of the buffer are written
to AoE group index 1234 with AoE index offset 22 at
AoE target port 55 of the slave.
event of an error
KR C4 EtherCAT
Operation
Line Description
Example 4
Write and read access

2 DECL MODUS_T Mode
3 DECL INT nMaxRdDataLen, nDataWrLen
8
9 nAtemRet = 'H98110000'
11 nAoeCmdRet = 0
12 Wait for StrCopy(sBuffer[], "Write test")
13 nDataWrLen = StrLen(sBuffer[])
16 nMaxRdDataLen = 128
17
18 CWRITE($FCT_CALL,State, Mode, "krl_ECat_Sys_X44_AoE_Read-
Write", 1001, sAdsNetId[], 55, 1234, 22, sBuffer[], nDa-
taWrLen, nMaxRdDataLen, 200, sAoeRet[])
20 OFFSET = 0
dRet, nAtemRet)
23 HALT
24 ELSE
25 KrlMsgStringXInt("AoE-Rd/Wr(): '"'%1'"' <-- Len=%2",
sBuffer[], nMaxRdDataLen)
26 Halt
27 ENDIF
Line Description
call
12 Writes the text “Write test” to the buffer
13 The length of the buffer sBuffer[] to which data are to be
written is defined in the variable nDataWrLen
dress 1001
16 The maximum length of the buffer for the data that are to
be read is defined in the variable nMaxRdDataLen
First a write access is performed at the slave with the
physical address 1001. The contents of the buffer are
written to AoE group index 1234 with AoE index offset 22
at AoE target port 55 of the slave. The answer is then
read from the same AoE target port.
Line Description
event of an error
25 … 26 If the write and read access was successful, a message
is generated and the program is stopped.
KR C4 EtherCAT
Diagnosis
6 Diagnosis
6.1 Displaying diagnostic data
The diagnostic data can also be displayed in WorkVisual. Information

about procedures in WorkVisual is contained in the WorkVisual docu-
mentation.
Procedure
1. Select Diagnosis > Diagnostic monitor in the main menu.

2. Select the desired module in the Module box.
Diagnostic data are displayed for the selected module.
Description
Diagnostic data can be displayed for the following modules:
• KUKA Extension Bus (SYS-X44)
6.1.1 KUKA Extension Bus (SYS-X44)
Name Description
Master OK Operating state of the entire EtherCat master stack
• OK: EtherCAT master and slaves are OK.

• ERROR: Error in EtherCAT operation
Current master status Current operating mode of the master
• Init: The EtherCAT slave is initialized. The EtherCAT

slave is in this state after being switched on.
• PreOP: Mailbox communication is possible; process
data communication is not yet possible.
• BootStrap: An update of the EtherCAT slave firmware
is possible.
• SafeOP: Mailbox and process data communication is
possible; the EtherCAT slave outputs, however, are
still in a safe state. The input data are already upda-
ted cyclically.
• OPERATIONAL: The EtherCAT slave copies the out-
put data of the EtherCAT master to its outputs. Proc-
ess data and mailbox communication is possible.
• Unknown: The state of the EtherCAT master is un-
known.
Slaves in requested state • OK: All EtherCAT slave modules have reached the
operating state requested by the EtherCAT master.
• ERROR: Not all EtherCAT slave modules have
reached the operating state requested by the Ether-
CAT master.
Master in requested state • OK: The EtherCAT master has reached the requested
operating state.
• ERROR: The EtherCAT master is not in the requested
operating state.
Diagnosis KR C4 EtherCAT
Name Description
Master has detected network con- • OK: A connection has been established between the
nection network card of the EtherCAT master and the first
EtherCAT slave.
• ERROR: The network connection between the net-
work card of the EtherCAT master and the first Ether-
CAT slave has been terminated.
Number of slaves found Number of EtherCAT slaves detected by the EtherCAT
master
Number of ECat slaves config- Number of EtherCAT slaves configured
ured
Bus capacity utilization (%) Utilization of the bus capacity
Number of Tx frames Number of EtherCAT telegrams sent via the network
Number of Rx frames Number of EtherCAT telegrams received via the network
Number of lost Frames Number of EtherCAT telegrams lost
Counter: Response out of time Number of EtherCAT telegrams not received in time
Counter: Response repeatedly Number of EtherCAT telegrams not received in time (re-
out of time peatedly and one directly after the other)
Counter: Not all slaves operation- Counter for the bus cycles in which not all EtherCAT
al slaves were in the OPERATIONAL state.
Counter: Stack error Number of bus errors
Counter: Stack restarts after error Number of bus restarts that were successfully carried out
after a bus error.
Current send-to-send time (µs) Current time between 2 “Send” calls from EtherCAT tele-
grams
Example: 4000 µs
Current receive-to-receive time Current time between 2 “Recv” calls from EtherCAT tele-
(µs) grams
Example: 4000 µs
Maximum send-to-send time (µs) Maximum time between 2 “Send” calls from EtherCAT
telegrams
Example: 6000 µs
Maximum Recv-To-Recv time (µs) Maximum time between 2 “Recv” calls from EtherCAT
telegrams
Example: 8000 µs
Link layer: Interface name Name of the network interface for the stack instance
Example: virtual4
EtherCat slave EtherCAT slave with slave ID, name and state of the
slave
6.2 Device diagnosis
Precondition

(>>> 4.4 "Entering the IP address of the KUKA Line Interface"
Page 13)
KR C4 EtherCAT
Diagnosis
Procedure
2. Right-click on the KUKA Extension Bus (SYS-X44) entry in the tree
structure and select Connect from the context menu.
3. Repeat step 2 with the bus coupler, gateway and/or device.
4. Right-click on the gateway or device and select Diagnosis... from the
context menu. The CANopen over EtherCAT window is opened.
Description
The service data objects (SDO) are displayed in the CANopen over
EtherCAT window. These data form the communication channel for the
transfer of parameters to a device (e.g. programming of the encoder reso-
lution). The parameters are device-specific; further information about this
can be found in the manufacturer’s documentation for the device.
The parameters contain at least the following properties:
Property Description
Index number Serves to uniquely identify all parameters. The index
number is divided into a main index and a subindex
(example: 1018:05). The main index is located before
the colon and the subindex after the colon.
Name More comprehensible, self-explanatory text
Value May be a text, a number or another parameter index.
Only the main indices are displayed if the CANopen over EtherCAT win-
dow is opened. Clicking on Update loads the subindices and displays
them.
Fig. 6-1: CANopen over EtherCAT window (example)
6.3 Topology diagnosis
This functionality is only available for robot controllers with version 8.6.
Precondition
• The devices to be diagnosed are connected and active.
Procedure
1. In the main menu, select Diagnosis > EtherCAT topology. The

EtherCAT topology window opens.
2. In the selection box, select which KUKA bus is to be displayed.

3. Select the desired device in the tree structure. Information about the
selected device is displayed beneath the tree structure.
4. Following modifications to the bus structure or devices, press Refresh.
Description
In the topology diagnosis, the bus structure is represented as a tree struc-

ture that reflects the wiring sequence. Information about every device in
the bus structure is displayed together with any error messages.
Fig. 6-2: “EtherCAT topology” window
Item Description
1 Selection of the KUKA bus
• KUKA Controller Bus (KCB)

• KUKA Extension Bus (SYS-X44)
• KUKA System Bus (SYS-X48)
2 Bus structure
• The LED indicates the status of the device: (>>> "LEDs"

Page 63)
• The icon indicates the status of the configuration or type of
device: (>>> "Icons" Page 63)
KR C4 EtherCAT
Diagnosis
Item Description
3 Tabs with information about the device
• Info tab:
Information about the device is displayed here, e.g. name,
address, status, etc.
• Error tab:
This tab is only displayed if errors have occurred on the de-
vice. The errors that have occurred are displayed here in
detail.
• Log tab:
This tab is only displayed if a KUKA bus is selected. The
messages from the LOG file are displayed here. The mes-
sages can be filtered by message type (Info, Warning, Er-
ror).
The messages can also be deleted. For this, press Delete.
4 Link to Error tab
LEDs
LED Description
The device is operational.
The device signals an error, but the module is still opera-

tional.
The device is defective and must be exchanged.
The device has been configured, but is not connected.
Icons
Icon Description
The device is configured in the project and present in the
network.
The device is not configured in the project, but present in
the network.
The device is configured in the project, but not present in
the network.
The device is a decouplable device.
KR C4 EtherCAT
Messages
7 Messages
7.1 Information about the messages
The “Messages” chapter contains selected messages. It does not cover all
the messages displayed in the message window. For the listed messages,
all known causes and solutions are specified – even if these are not rele-
vant in the context of this documentation.
7.2 System messages from module: CrossMeld (KSS)
7.2.1 KSS13008
Message code KSS13008

Message text <{Instance name}> Ethercat bus error. {Additional parameter} {Addi-
tional parameter}
Message type Status message
Effect No braking reaction
No interlock of motions or commands
Possible cause(s) Cause: Bus error has occurred (>>> Page 65)
Solution: Reboot the robot controller (>>> Page 65)
Cause: Bus error has occurred
Description
A bus error was detected, precise localization of the error is ongoing.

When this is complete and the error has been found, the message is
cleared and replaced by another message.
If it was not possible to execute any of the EtherCAT commands for local-
ization, then it was not possible to localize the error. In this case, the
message remains active and the additional parameter “Job-Task Error” is
displayed in the message.
The procedure for checking if localization has failed is as follows:
Checking instructions
• Check whether the additional parameter “Job-Task Error” is displayed

in the message.
Solution: Reboot the robot controller
Precondition
• User group Expert
Procedure
1. In the main menu, select Shutdown.
Messages KR C4 EtherCAT
2. Press Reboot control PC.

3. Confirm the request for confirmation with Yes. The system software is
shut down and then restarted.
NOTICE
The main switch on the robot controller must not be operated if the KSS
has been exited with the option with restart and the reboot has not yet
been completed. System files may otherwise be destroyed.
7.2.2 KSS13011

Message text <{Bus ID}> Error reading configuration file [{XML file name}]
Possible cause(s) Cause: Configuration file for initialization missing (>>> Page 66)
Solution: Reload WorkVisual project (>>> Page 67)
Cause: Configuration file for initialization missing (>>> Page 67)

Solution: Update the KUKA System Software from the USB stick
(>>> Page 67)
Cause: Configuration file for initialization missing (>>> Page 68)

Solution: Update KUKA System Software from network
(>>> Page 68)
Cause: Configuration file for initialization missing
Description
The configuration file detailed in the message is not available. The file is
required for initializing the bus instance.
The method for restoring the file depends on whether the file is a user file
or system file:
• If the configuration file is a user file: Reload the WorkVisual project.
• If the configuration file is a system file: Update the KUKA System Soft-
ware. The update can be carried out with the version of the KUKA
System Software that is already installed.
The procedure for checking whether the file is a user file or a
system file is as follows:
• Find out which directory contains the file:

‒ User files: C:\KRC\Roboter\Config\User
‒ System files: C:\KRC\Roboter\Config\System
KR C4 EtherCAT
Solution: Reload WorkVisual project
Messages
Description
The WorkVisual project must be transferred to the robot controller again.
Precondition
• User group “Expert”

• T1 or T2 mode
• Network connection to the robot controller
Procedure
1. Load the active project from the robot controller.

2. Transfer the project back from WorkVisual to the robot controller and
activate it.
Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.
Description
or system file:

Solution: Update the KUKA System Software from the USB stick
NOTICE
A non-bootable USB stick must be used.
We recommend using a non-bootable KUKA stick. Data may be lost if a
stick from a different manufacturer is used.
Precondition
• “Expert” user group

• T1 or T2 mode
• No program is selected.
• USB stick with the software to be installed
‒ ZIP files must be unzipped.
‒ There must be no other files in the directory in which the individual

files are located.
Procedure
1. Plug in USB stick.

2. In the main menu, select Start-up > Software update > Automatic.
3. A request for confirmation is displayed, asking if the update should be
carried out. Confirm by pressing Yes.
The following message is now displayed in the message window: To
complete software update, please REBOOT computer!
4. Select Shutdown in the main menu and then the option Reboot con-
trol PC (Reload files is not necessary).
5. Confirm the request for confirmation with Yes. The robot controller is
rebooted and performs the update.
The robot controller then reboots again.
6. Once the robot controller has rebooted for the second time, the USB
stick can be removed.
The updated System Software is now available.
Description
or system file:

Solution: Update KUKA System Software from network
Description
In the case of an update from the network, the installation data are copied
to the local drive D:\. If there is already a copy of a system software ver-
sion present on D:\, that copy will now be overwritten.
Installation is started on completion of the copying operation.
Precondition
For the preparation:

• T1 or T2 mode
KR C4 EtherCAT
Messages
For the procedure:
• T1 or T2 mode
Preparation
Configure the network path from which the update installation is to be car-
ried out:
1. In the main menu, select Start-up > Additional software.
2. Press New software.
3. Press Configure.
4. Select the Installation path for KRC update via the network box.
Press Path selection.
5. Select the desired network path (= the directory in which the Set-
up.exe file is located). Press Save.
6. The selected path is now displayed in the Installation path for KRC
update via the network box.
Press Save again.
7. Close the window.
It is only necessary to configure the network path once. It remains

saved for subsequent updates.
Procedure
1. In the main menu, select Start-up > Software update > Net.
2. A request for confirmation is displayed, asking if the update should be
carried out. Confirm by pressing Yes.
Depending on the network utilization, the procedure may take up to
15 min.
3. A message is displayed, indicating that a cold start will be forced next
time the system is booted. Switch the controller off.
4. Wait until the computer has shut down completely. Then switch the
controller back on.
5. Once the update has been completed, the computer is automatically
shut down and rebooted.
7.2.3 KSS13012

Message text <{Bus ID}> Error during ECat stack initialization [{Reason} {Reason
2}]
Possible cause(s) Cause: RDC instead of micro-RDC in the WorkVisual project

(>>> Page 70)
Solution: Correct the configuration with WorkVisual. (>>> Page 70)
Cause: Invalid configuration in WorkVisual on SYS-X42

(>>> Page 70)
Cause: Incorrect connection between KPC and CCU

(>>> Page 71)
Solution: Exchange the faulty cabling (>>> Page 72)
Cause: EtherCAT not connected correctly to Office PC

(>>> Page 72)
Solution: Exchange the faulty cabling (>>> Page 75)
Cause: No power supply at bus coupler EK1100 via X55

(>>> Page 75)
Solution: Establish correct connection (>>> Page 76)
Cause: Return contacts are incorrectly wired (>>> Page 77)

Cause: RDC instead of micro-RDC in the WorkVisual project
Description
In order to be able to function correctly, a micro-RDC must be configured

for the robot. An RDC is configured in the project.
The procedure for checking whether the project contains an RDC is
as follows:
1. Open project in WorkVisual.

2. Select the Hardware tab in the Project structure window.
3. Open the Controller components node.
4. Check whether the entry Resolver Digital Converter (RDC) is
present.
Solution: Correct the configuration with WorkVisual.
Procedure
• Correct the configuration with WorkVisual.
Cause: Invalid configuration in WorkVisual on SYS-X42
Description
The configuration in the KUKA Controller Bus (KCB) is faulty, e.g.

• Incorrect structure of the topology
• Device (KSP) hardware is not available, but device is configured in
WorkVisual
• Device (KSP) hardware is available, but device is not configured in
WorkVisual
• EMD is not defined as Disconnectable
• Two devices have the same name
KR C4 EtherCAT
Messages
Fig. 7-1: Example of a controller bus
• Check whether the bus structure configured in WorkVisual matches

the actual bus structure.
Procedure

More detailed information can be found in the WorkVisual documen-
tation, in the chapter "Configuration".
Cause: Incorrect connection between KPC and CCU
Description
The cabling of the KUKA Controller Bus (KCB) is faulty.

The cabling is carried out as follows:
• CCU (X31)
• Cable W166356
• KPC
Fig. 7-2: X31 interface on CCU
Inspection instructions
1. Check whether the plug connection is correctly connected. Particular

attention must be paid to:
• Pins pushed in
• Corrosion
• Scorched contacts
• Connector insert pushed back
• Connector on correct slot
2. Check whether the plug connection still conducts electricity. Particular
• Cross-connection of individual wires
• Short-circuit of individual wires with the ground conductor
• Correct wiring in accordance with circuit diagram
Solution: Exchange the faulty cabling
Procedure
• Connect the cabling correctly and exchange if necessary.
Cause: EtherCAT not connected correctly to Office PC
Description
EtherCat (KUKA Extension Bus KEB) is connected to the socket for the
KUKA System Bus (KSB) on the Office PC.
The procedure for checking whether the error is caused by an incor-
rectly connected interface is as follows:
1. Check whether the message parameters are as follows:

• Bus ID: SYS-X44
KR C4 EtherCAT
Messages
• Reason: isNetworkLinkConnected()
• Reason 2: KSB: not connected
2. Check whether the KSB interface on the motherboard has been used
for the KUKA Extension Bus.
3. Check, e.g. by swapping with another cable, whether the cable is
functioning correctly.
Overview
Fig. 7-3: Motherboard D2608-K interfaces
1 Connector X961, power supply DC 24 V

2 Connector X962, PC fan
3 LAN Dual NIC – KUKA Controller Bus
4 LAN Dual NIC – KUKA Line Interface
5 Field bus cards, slots 1 to 7
6 LAN Onboard – KUKA System Bus
7 8 USB 2.0 ports
Overview

4 LAN Dual NIC – KUKA Controller Bus
5 LAN Dual NIC – KUKA System Bus
6 4 USB 2.0 ports
7 DVI-I (VGA support possible via DVI on VGA adapter). The user
interface of the controller can only be displayed on an external
monitor if no active operator control device (smartPAD, VRP) is
connected to the controller.
8 4 USB 2.0 ports
9 LAN Onboard – KUKA Option Network Interface
10 LAN Onboard – KUKA Line Interface
Overview

(optional, inside PC, depending on variant)
4 LAN Onboard – KUKA Controller Bus
6 2 USB 2.0 ports
7 2 USB 3.0 ports
8 DVI-I
9 4 USB 2.0 ports
VGA support is possible via DP on VGA adapter. The user interface of

the controller can only be displayed on an external monitor if no active
operator control device (smartPAD, VRP) is connected to the controller.
KR C4 EtherCAT
Messages
Overview

3 LAN Onboard – KUKA Controller Bus
5 2 USB 2.0 ports
6 2 USB 3.0 ports
7 DVI-D
8 Display port
9 4 USB 2.0 ports
VGA support is possible via DP on VGA adapter. The user interface of

the controller can only be displayed on an external monitor if no active
operator control device (smartPAD, VRP) is connected to the controller.
Solution: Exchange the faulty cabling
Procedure
• Connect the cabling correctly and exchange if necessary.
Cause: No power supply at bus coupler EK1100 via X55
Description
The power supply for the EK1100 is routed via interface X55.
The power can be supplied either directly from an external source to con-
tacts 5/6, or by jumpering the internal voltage (contacts 7/5 and 8/6) on
X55.
Fig. 7-7: Connector pin allocation X55
Fig. 7-8: Contact diagram, view from contact side
The procedure for checking whether there is a fault in interface X55

is as follows:
1. Check whether the following parameters are displayed in the message:

• Bus ID = SYS-X44
• Reason = isNetworkLinkConnected()
• Reason 2 = KSB: not connected
2. Check whether the power supply is connected correctly to X55.
Solution: Establish correct connection
Precondition
• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The controller has been shut down.
• The power cable is de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.
KR C4 EtherCAT
Messages
• Observe the ESD guidelines.
Procedure
• Exchange the defective cable or rectify contact problem.
Cause: Return contacts are incorrectly wired
Description
Return contacts Q5 and Q6 on contactor U2 are incorrectly wired.

The procedure for checking whether the return contacts are incor-
rectly wired is as follows:
1. In the main menu, select Diagnosis > KrcDiag.

A KrcDiag is created.
2. Switch to the Windows interface.
3. Switch to the directory C:\KUKA\KRCDiag.
4. Unzip the current KRCDiag.
5. Open the file KRCDiag.log.
6. Check whether the “Driver state” for CIB Safety Module (SION-CIB)
is 0x3000.
11:13:51 BASIC iHnf1 11:13:53.285 : safe-

Appl(1): handle | driver | slave | driver
state | name
11:13:51 BASIC iHnf1 11:13:53.285 : safe-
Appl(1): in out | index | address | read |
write |
11:13:51 BASIC iHnf1 11:13:53.285 : safe-
Appl(1): -----------+--------+---------+------------
+------------+--------------
11:13:51 BASIC iHnf1 11:13:53.285 : safe-
Appl(1): 3 3 | 2 | 1020 | 0
| 0 | KUKA Power Pack 3 20A (KPP3)
11:13:51 BASIC iHnf1 11:13:53.285 : safe-
Appl(1): 4 4 | 3 | 1021 | 0
| 0 | KUKA Servo Pack 64A (KSP)
11:13:51 BASIC iHnf1 11:13:53.285 : safe-
Appl(1): 6 6 | 13 | 8508 | 0x1000 |
0 | KRC4 Roboter Primary
11:13:51 BASIC iHnf1 11:13:53.286 : safe-
Appl(1): 1 1 | 5 | 1 | 0x3000
| 0 | CIB Safety Modul (SION-CIB)
11:13:51 BASIC iHnf1 11:13:53.286 : safe-
Appl(1): 2 2 | 15 | 2 | 0
| 0 | Resolver Digital Converter (RDC)
11:13:51 BASIC iHnf1 11:13:53.286 : safe-
Appl(1): 15 14 | 18 | 0 | 0
| 0 | Safety Diagnose
11:13:51 BASIC iHnf1 11:13:53.286 : safe-
Appl(1): 16 17 | 20 | 0 | 0
| 0 | VIO Positionen
11:13:51 BASIC iHnf1 11:13:53.286 : safe-
Appl(1): 0 0 | 21 | 13330 | 0
| 0 | Box 2 (SION-KCP)
11:13:51 BASIC iHnf1 11:13:53.286 : safe-
Appl(1): 18 18 | 25 | 0 | 0
| 0 | SharedKCP Diagnose
11:13:51 BASIC iHnf1 11:13:53.286 : safe-

Appl(1): 11 12 | 22 | 0 | 0
| 0 | KCP3 Local
Precondition
WARNING
Procedure
7.2.4 KSS13013

Message text <ECat> Error creating Ethercat stack instances
Possible cause(s) Cause: Too little memory (>>> Page 78)

Solution: Contact KUKA Support (>>> Page 78)
Cause: Too little memory
Description
The system does not have enough memory available for execution.
Solution: Contact KUKA Support
Description
Contact the relevant KUKA Support department to rectify errors.
KR C4 EtherCAT
Messages
7.2.5 KSS13015

Message text <{Bus ID}> Ethercat bus scan error. Device: {Incorrect device} [{Ad-
ditional info}]
Possible cause(s) Cause: Device is connected to the wrong connection

(>>> Page 79)
Solution: Connect device to the correct connection (>>> Page 80)
Cause: The force/torque sensor has a different vendor ID than ex-

pected (>>> Page 80)
Solution: Adapt the configuration of the joint/torque sensor in Work-
Visual (>>> Page 80)
Cause: Field bus configuration for hardware that is not present

(>>> Page 80)
Solution: Only configure the hardware that is actually installed
(>>> Page 81)
Cause: Device is connected to the wrong connection
Description
The configured device is not connected to the same connection as the ac-
tual device.
The procedure for checking which connection has been configured is
as follows:
Precondition
• Project is open in WorkVisual.

Settings… from the context menu. The Settings… window opens.
4. Check the configured connection to see if it matches the connection
the device is connected to.
KR C4 EtherCAT
Solution: Connect device to the correct connection

Messages
Procedure
• Connect the device to the connection that was configured for the de-
vice.
Cause: The force/torque sensor has a different vendor ID than expected
Description
Several ForTTran SG 500-20 force/torque sensors from early production

series have a different vendor ID than that indicated in the device descrip-
tion file Kuka ForTTran.xml. The sensor is recognized as an incorrect de-
vice after it has been added during commissioning.
1. Check whether the sensor KUKA ForTTran SG 500-20is displayed for

the parameter Device: in the error message.
2. Check whether the following code is displayed for the parameter Addi-
tional info: Bus-DEV.: ATI / P-Code=0x26483053.
Solution: Adapt the configuration of the joint/torque sensor in WorkVisual
Description
Adapt the configuration of the joint/torque sensor ForTTran SG 500-20 in

WorkVisual such that the vendor ID is not requested.
Precondition

Procedure
1. Set the robot controller as the active controller.

3. Right-click on the joint/torque sensor ForTTran SG 500-20 and select
Settings... from the context menu. A window opens.
4. To remove the check mark, click on the check box on the General tab
under Check vendor ID.
5. Save the setting and close the window.
6. Transfer the project to the robot controller.
Description
The field bus configuration does not correspond to the hardware that is
actually installed, e.g. a different field bus card has been configured than
the one that is installed in the controller.
KR C4 EtherCAT
Messages
• Compare the configuration with the hardware that is actually installed

(field bus card, gateway, bus coupler, I/O modules).
• Check whether the installed hardware has been correctly installed and
connected and that no connecting cable is defective.
The procedure for checking whether the connecting cable is defec-
tive is as follows:
1. Check whether the connectors are correctly connected. Particular at-

tention must be paid to:
• Pins pushed in
• Corrosion
• Socket pushed back
2. Check whether the cable is mechanically damaged. Causes of squash-
ed cables or wires can include the following:
• Cable straps too tight
• Clips too tight
• Trapped when closing a cover
• Bend radius too tight
3. Check whether the cable still conducts electricity. Particular attention
must be paid to:
Procedure
• Limit the configuration to the hardware components that are actually

installed; if necessary, exchange hardware components for those that
are required.
7.2.6 KSS13016

Message text <{Bus ID}> missing reception of network frames [{Details}]
Possible cause(s) Cause: Bus cycle time too short (>>> Page 82)
Solution: Modify variable or parameter (>>> Page 82)
Cause: Network cable defective or not connected correctly

(>>> Page 82)
Solution: Exchange network cable or connect it correctly
(>>> Page 83)
Cause: Bus cycle time too short
Description
The configured bus cycle time is too short. This can result in EtherCAT
telegrams not being answered or being answered too late.
Configuration file
Directory C:\KRC\ROBOTER\Config\User\Common
File ECAT_SYS_X44.xml
Parameter BusCycleTimeMs
The procedure for checking which value is configured is as follows:
Precondition

• Windows interface (CTRL+ESC)
1. Select the file in the Navigator and press Open. The file is displayed
in the editor.
2. Search for the variable or parameter and check the value.
Solution: Modify variable or parameter
Precondition
• User group Expert
Depending on the configuration and the system software used, higher

user rights may be required.
Procedure
1. Select the file in the Navigator and press Open. The file is displayed
in the editor.
2. Search for the corresponding point in the file and modify the value.
3. Save and close the file.
Description
The network cable is defective or the plug connection is incorrect.

The procedure for checking whether the network cable and connec-
tors are correctly connected is as follows:
KR C4 EtherCAT
Messages
1. Check that the network cables are correctly connected and fitted se-
curely.
2. Interchange the network cables.
Procedure
• Exchange network cable or connect it correctly.
7.2.7 KSS13018

Message text <{Bus ID}> Error during ECat stack initialization. Device: {Faulty de-
vice} [{Additional information}]
Possible cause(s) Cause: Field bus configuration for hardware that is not present
(>>> Page 83)
(>>> Page 84)
Cause: KSP defective (>>> Page 84)

Solution: Exchange the KSP (>>> Page 85)
Description
The field bus configuration does not correspond to the hardware that is
actually installed, e.g. a different field bus card has been configured than
the one that is installed in the controller.
• Compare the configuration with the hardware that is actually installed

(field bus card, gateway, bus coupler, I/O modules).
• Check whether the installed hardware has been correctly installed and
connected and that no connecting cable is defective.
The procedure for checking whether the connecting cable is defec-
tive is as follows:
1. Check whether the connectors are correctly connected. Particular at-

tention must be paid to:
• Pins pushed in
• Corrosion
• Socket pushed back
2. Check whether the cable is mechanically damaged. Causes of squash-
ed cables or wires can include the following:
• Cable straps too tight
• Clips too tight
• Trapped when closing a cover
• Bend radius too tight
3. Check whether the cable still conducts electricity. Particular attention
must be paid to:
Procedure
• Limit the configuration to the hardware components that are actually

installed; if necessary, exchange hardware components for those that
are required.
Cause: KSP defective
Description
The KSP / KSP_SR has detected a hardware error.

The example and the checking instructions refer to the KR C4. The
checking instructions may differ for the Product Family KR C4 compact,
KR C4 smallsize, etc.
Examples:
• Ground fault
• Overvoltage
• Undervoltage
• Overcurrent
• Internal error
• Brake voltage:
Precondition
WARNING
The robot controller is energized (50-600 V) when it is switched on. This
voltage can cause life-threatening injuries on contact. Work and meas-
urements on the electrical equipment may only be carried out by spe-
cially trained personnel.
KR C4 EtherCAT
Messages
1. Restart the drive bus: menu sequence Main menu > Shutdown >
Drive bus OFF / ON.
2. Check KSP device status LED group.
Overview
Fig. 7-9: KSP LED display
1 LED group: axis control 3 LED group: communication

status
2 LED group: KSP device sta-
tus
Device status
Red LED Green LED Meaning

Off Off No power supply to the control
electronics
On Off Fault in the KSP
Off Flashing No communication with the control-
ler
Off On Communication with the controller
Solution: Exchange the KSP
Precondition
CAUTION
If removal is performed immediately after the robot controller has
been shut down, the heat sink surface temperatures are likely to be
high and could result in burn injuries. Protective gloves must be
worn.
WARNING

• Wait 5 minutes until the intermediate circuit has discharged.
WARNING
The following components may remain energized (50-780 V) up to 5
minutes after the robot controller has been switched off:
‒ the KPP
‒ the KSPs
‒ connections for motor connector X20 and connected motor ca-
bles
‒ the intermediate circuit connecting cables
This voltage can cause life-threatening injuries.
Procedure
1. Unlock connectors X20 and X21 of the data cables. Unplug all con-
nections to the KSP.
NOTICE
Unplugging the data cable connectors without first unlocking them
damages the connectors. Unlock the connectors before unplugging
them.
Fig. 7-10: Unlocking connectors X20 and X21
1 Connector unlocked 3 Connector X21 plugged in

and locked
2 Connector locked 4 Connector X20 plugged in
and unlocked
2. Slacken the Allen screws.

CAUTION
The KSP weighs approx. 10 kg. When removing or installing the
KSP, care must be taken to avoid injury by crushing. Protective
gloves must be worn.
KR C4 EtherCAT
Messages
3. Lift the KSP slightly, tilt the top forwards and lift the KSP out of the
support bracket.
4. Insert the new KSP into the support bracket, hook it on at the top and
tighten the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable
labeling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
setup of the robot must be configured using WorkVisual.
Fig. 7-11: KSP fastening
1 Allen screws 3 Support bracket

2 Rear panel of cabinet
7.2.8 KSS13020

Message text <{Bus ID}> Ethercat bus error. Device: {Details} [{Details}]
Possible cause(s) Cause: Device is connected to the wrong connection

(>>> Page 88)
Solution: Connect device to the correct connection (>>> Page 88)
Cause: Contact problem or incorrect plug connection on the RDC

(>>> Page 88)
Solution: Install the correct plug connections (>>> Page 90)
Cause: Device is incorrectly configured (>>> Page 90)


(>>> Page 91)
Solution: Connect socket X32 correctly or exchange it
(>>> Page 92)
Cause: Device is connected to the wrong connection
Description
The configured device is not connected to the same connection as the ac-
tual device.
The procedure for checking which connection has been configured is
as follows:
Precondition

4. Check the configured connection to see if it matches the connection
the device is connected to.
Solution: Connect device to the correct connection
Procedure
• Connect the device to the connection that was configured for the de-
vice.
Description
Contact problem or incorrect plug connection on the RDC, e.g. X20 (EMD
connection) and X19 (KCB OUT) are interchanged.
KR C4 EtherCAT
Messages
Connections
Fig. 7-12: Overview of RDC connections
Connect-
Item Description
or
1 X1 Resolver connection, axis 1
9 X13 EDS connection, memory card, RDC
10 X20 EMD
11 X19 KCB OUT
12 X18 KCB IN
13 X17 EMD power supply
14 X15 Power supply IN
15 X16 Power supply OUT (next KCB device)
The procedure for checking whether the plug connections on the
RDC are connected correctly is as follows:

• Pins pushed in
• Corrosion

Solution: Install the correct plug connections
Precondition
WARNING
Procedure
• Install the correct plug connection.
Cause: Device is incorrectly configured
Description
The configured device does not match the device that is actually connec-
ted. One or more configuration parameters are, for example, set incorrect-
ly.
The procedure for checking how the device has been configured is
as follows:
Precondition

3. Check the settings on the tabs to see if they match the connected de-
vice.
Procedure
KR C4 EtherCAT
Messages
Description
Contact problem or incorrect plug connection on the RDC, e.g. X20 (EMD
connection) and X19 (KCB OUT) are interchanged.
Connections
Fig. 7-13: Overview of RDC connections
Connect-
Item Description
or
9 X13 EDS connection, memory card, RDC
10 X20 EMD
11 X19 KCB OUT
12 X18 KCB IN
13 X17 EMD power supply
14 X15 Power supply IN
15 X16 Power supply OUT (next KCB device)
The procedure for checking whether the plug connections on the
RDC are connected correctly is as follows:

• Pins pushed in
• Corrosion
Solution: Connect socket X32 correctly or exchange it
Description
Eliminate the contact problem at socket X32 on the RDC box.
Procedure
1. When plugging the X32 connector into the RDC box, push it against
the inlay of the socket from inside.
2. Exchange the socket on the RDC box if the problem persists.
7.2.9 KSS13021

Message text <{Bus ID}> Ethercat network error. {Details} [{Details}]
Possible cause(s) Cause: Network cable defective or not connected correctly

(>>> Page 92)
(>>> Page 93)
Cause: CIB Safety Module (SION-CIB) missing in WorkVisual

project (>>> Page 93)
Description
The network cable is defective or the plug connection is incorrect.

The procedure for checking whether the network cable and connec-
tors are correctly connected is as follows:
KR C4 EtherCAT
Messages
1. Check that the network cables are correctly connected and fitted se-
curely.
2. Interchange the network cables.
Procedure
• Exchange network cable or connect it correctly.
Cause: CIB Safety Module (SION-CIB) missing in WorkVisual project
Description
The CIB Safety Module (SION-CIB) has been deleted from the WorkVisual
project. However, the project does not generate an error when transferred
to the controller even though the project cannot run on the controller.
The procedure for checking whether the error is caused by an in-
complete WorkVisual project is as follows:
• Check whether SION-CIB is present in the WorkVisual project under

Controller components and under Bus structure > KUKA System
Bus (SYS-X48) > EtherCAT.
Procedure
7.2.10 KSS13068

Message text <{Bus instance}> EtherCAT device {Device name} is not connected
to bus.
Possible cause(s) Cause: Device is not connected (>>> Page 94)

Solution: Connect device (>>> Page 94)
Cause: EM8905-1001 I/O module not configured (>>> Page 94)

Cause: Incorrect connection between SIB and the safety interface

(>>> Page 96)
KR C4 EtherCAT
Cause: Device is not connected

Messages
Description
The device is present in the configuration but is not connected to the bus.
The procedure for checking which connection the device has to be
connected to is as follows:
Precondition

4. Check which connection is configured for the device.
Solution: Connect device
Procedure
• Connect the device to the connection that has been configured.
Cause: EM8905-1001 I/O module not configured
Description
The Agilus 2 can be ordered with different internal energy supply systems
(with and without I/O module). The catalog element without I/O module is
the only one available in WorkVisual. If the Gigabit data cable (X74) var-
iant is available, then the EM8905-1001 I/O module is required in WorkVi-
sual.
The procedure for checking whether the configuration contains er-
rors is as follows:
1. Check whether position 5 (X74) is available at customer interface A1.
KR C4 EtherCAT
Messages
Fig. 7-14: Customer interface A1, AIR CTR GIG
1 MEMD connection X32

2 PURGE venting connection (optionally for IP67)
Max. pressure: 0.3 bar
Air, oil-free, dry, filtered
according to: ISO 8573.1-1, 1.2 to 16.2
3 Air line connection AIR1 (valve unit)
Outside diameter: 4 mm
4 Fuse for I/O and power supply (F41-F3A)
5 CAT5e data cable connection X74
Gigabit Ethernet (1000 Base-T)
6 Air line connection AIR2
Outside diameter: 6 mm
7 Connection for external axis A8 (XP8.1)
8 Connection for external axis A7 (XP7.1)
2. Check if the I/O module EM8905-1001 I/O module is available in

WorkVisual under Device view > Bus structure > KUKA Controller Bus
(KCB).
If the Gigabit data cable (X74) variant is available, then the
EM8905-1001 I/O module is required in WorkVisual.
Procedure

KR C4 EtherCAT
Cause: Incorrect connection between SIB and the safety interface

Messages
Description
The connection between SIB (Safety Interface Board) and the safety inter-
face is defective.
The cabling is carried out as follows:
for X11:
• CCU X302
• W188678
• SIB (X250 and X258)
• X252 and X253
• W187758 and W187757
• Connector panel (X11)
for XS2/XS3:
• CCU X302
• W188678
• SIB (X250 and X258)
• X252 and X253
• W194205 and W194210
• Connector panel (XS2 and XS3)
Standard connections
Fig. 7-15: Standard SIB connections
Con-
Item Description
nector
1 X250 SIB power supply
2 X251 Power supply for additional components
3 X252 Safe outputs
4 X253 Safe inputs
5 X254 Safe inputs
6 X258 KUKA System Bus IN
KR C4 EtherCAT
Messages
Con-
Item Description
nector
7 X259 KUKA System Bus OUT
The procedure for checking whether the connection is correct is as
follows:
1. Check whether the connectors of the cable are connected firmly

enough.
2. Check whether pins are bent when connected.
Precondition
WARNING
Procedure
7.2.11 KSS13080

Message text <{Bus instance}> Ethercat device: '{Device names}' cannot be star-
ted. {Reason}
Possible cause(s) Cause: Device is incorrectly configured (>>> Page 98)

Cause: Incorrect terminal configured in WorkVisual (>>> Page 98)

Cause: The device is defective. (>>> Page 99)

Solution: Exchange device (>>> Page 99)
KR C4 EtherCAT
Cause: Device is incorrectly configured

Messages
Description
The configured device does not match the device that is actually connec-
ted. One or more configuration parameters are, for example, set incorrect-
ly.
The procedure for checking how the device has been configured is
as follows:
Precondition

3. Check the settings on the tabs to see if they match the connected de-
vice.
Procedure
Cause: Incorrect terminal configured in WorkVisual
Description
The configuration on SYS-X44 (KUKA Extension Bus) is faulty if the phys-

ical mapping does not match the mapping in WorkVisual. Example: The
terminal EL3204-0160 (corresponds to version 160) has been installed.
However, the terminal EL3204-0000 (corresponds to version 0) has been
configured in WorkVisual.
The procedure for checking whether there is a faulty configuration is
as follows:
1. Check whether the bus connections have been plugged in correctly.

2. Check whether the configured terminal matches the terminal that is ac-
tually installed.
3. Check whether the parameter EL3204 4Ch. Ana. Input PT100 (RTD)
is displayed in the message.
Procedure

KR C4 EtherCAT
Cause: The device is defective.
Messages
Description
The device cannot be started because it is defective.
1. Disconnect the device that is assumed to be defective.

2. Connect a device that is identical and fully functional.
3. If the function test is successful, the device is defective.
Solution: Exchange device
Procedure
• Disconnect the defective device and replace it with a fully functional

device.
KR C4 EtherCAT
KUKA Service
8 KUKA Service
8.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
8.2 KUKA Customer Support
Availability
KUKA Customer Support is available in many countries. Please do not

hesitate to contact us if you have any questions.
Argentina
Ruben Costantini S.A. (Agentur)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
KUKA Service KR C4 EtherCAT
Australia
KUKA Robotics Australia Pty Ltd
45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
info@kuka-robotics.com.au
www.kuka-robotics.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.
Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
info@kuka-roboter.com.br
www.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 Robotics China Co., Ltd.
No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
info@kuka-robotics.cn
www.kuka-robotics.com
KR C4 EtherCAT
KUKA Service
Germany
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka.com
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 India Pvt. Ltd.
Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
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 Japan K.K.
YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
info@kuka.co.jp
Canada
KUKA Robotics Canada Ltd.
2865 Argentia Road, Unit 4-5
Mississauga
Ontario L5N 8G6
Canada
Tel. +1 905 858‑5852
Fax +1 905 858-8581
KUKAFocusCenter@KUKARobotics.com
www.kukarobotics.ca
Korea
KUKA Robotics Korea Co. Ltd.
RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com
Malaysia
KUKA Robot Automation (M) Sdn Bhd
South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
info@kuka.com.my
KR C4 EtherCAT
KUKA Service
Mexico
KUKA de México S. de R.L. de C.V.
Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
www.kuka-robotics.com/mexico
Norway
KUKA Sveiseanlegg + Roboter
Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no
Austria
KUKA CEE GmbH
Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 732 784 752 0
Fax +43 732 793 880
KUKAAustriaOffice@kuka.com
www.kuka.at
Poland
KUKA CEE GmbH Poland
Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka.com
Portugal
KUKA Robots IBÉRICA, S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
info.portugal@kukapt.com
www.kuka.com
Russia
KUKA Russia OOO
1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
support.robotics.ru@kuka.com
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 CEE GmbH
Linz, Zweigniederlassung Schweiz
Heinrich Wehrli-Strasse 27
5033 Buchs
Switzerland
Tel. +41 62 837 43 20
info@kuka-roboter.ch
Slovakia
KUKA CEE GmbH
organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
support.robotics.cz@kuka.com
Spain
KUKA Iberia, S.A.U.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
comercial@kukarob.es
KR C4 EtherCAT
KUKA Service
South Africa
Jendamark Automation LTD (Agentur)
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 Automation Taiwan Co. Ltd.
1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
info@kuka.com.tw
Thailand
KUKA (Thailand) Co. Ltd.
No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
HelpdeskTH@kuka.com
Czech Republic
KUKA Roboter CEE GmbH
organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
support.robotics.cz@kuka.com
Hungary
KUKA HUNGÁRIA Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
USA
KUKA Robotics Corporation
51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
CustomerService@kuka.com
www.kuka.com
United Kingdom
KUKA Robotics UK Ltd
Great Western Street
Wednesbury West Midlands
WS10 7LL
United Kingdom
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk
KR C4 EtherCAT
Index K
KLI.....................................................................6
KUKA Customer Support............................. 101
A KUKA Extension Bus, inserting..................... 12
ADS...................................................................6 KUKA Service...............................................101
Alias address, writing to devices................... 20
L
B LED group: KSP device status......................85
Bus driver settings, modifying........................13
Bus errors, activatingBus errors,
deactivating.....................................................25 M
Bus scan, 1-stage.......................................... 15 Messages........................................................65
Bus scan, 2-stage.......................................... 16 Modules (tab)..................................................19
Bus system, restarting....................................26 Motherboard D2608-K.................................... 73
Motherboard D3076-K.................................... 73
Motherboard D3236-K.................................... 74
C Motherboard D3445-K.................................... 75
CAN.................................................................. 6
Configuration...................................................11
O
Operation........................................................ 25
D
Device description files, preparing.................12
Device diagnosis............................................ 60 P
Devices, configuring....................................... 16 PLC................................................................... 6
Devices, inserting (automatic)........................15 Process data objects (tab).............................18
Devices, inserting (manual)............................14 Product description...........................................7
Diagnosis........................................................ 59
Diagnosis, topology........................................ 61
Diagnostic data, displaying............................ 59 S
Diagnostic data, KUKA Extension Bus..........59 Safety................................................................9
Diagnostic monitor (menu item).....................59 Safety instructions............................................ 5
Documentation, industrial robot....................... 5 Scanning, bus.................................................15
SDO.................................................................. 6
Standard SIB, connections............................ 96
E Support request............................................ 101
ESI.................................................................... 6
T
F Target group..................................................... 5
File Access over EtherCAT, configuring........ 20 Terms used....................................................... 6
FSoE................................................................. 6 Topology, checking......................................... 21
Topology, diagnosis........................................ 61
Topology, modifying........................................ 21
G Trademarks....................................................... 6
General (tab).................................................. 17
U
I Use, intended................................................... 8
Insertion, devices (automatic)........................ 15
Insertion, devices (manual)............................ 14
Intended use.....................................................8 W
Introduction....................................................... 5 Warnings........................................................... 5
IP address of KLI, entering............................13 WorkVisual........................................................ 6

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Controller Option

Version: KR C4 EtherCAT KSS/VSS 8.2, 8.3, 8.4, 8.5, 8.6 V2

5.5.4 Access via ADS over EtherCAT (AoE)................................................................. 48

8 KUKA Service........................................................................................... 101

1.1 Target group

This documentation is aimed at users with the following knowledge and

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

These warnings contain references to safety-relevant information or gen-

This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

EtherCAT® is a registered trademark and patented technolo-

1.5 Terms used

KR C4 EtherCAT is compatible with the following field buses:

The following functions and device classes are supported:

KR C4 EtherCAT is configured on a laptop or PC. The following software

The following device types are used with KR C4 EtherCAT:

• Maximum number of EtherCAT slaves: 128

2.1 Intended use

KR C4 EtherCAT is intended solely for the configuration and diagnosis of

Any use or application deviating from the intended use is deemed to be

Information about procedures in WorkVisual is contained in the WorkVi-

4.2 Preparing device description files

• There is no project open.

The following applies to device description files that contain a reference

4.3 Inserting the KUKA Extension Bus in the project

In order to be able to perform online functions (e.g. bus scan, diagnosis),

1. Right-click on the KUKA Extension Bus (SYS-X44) entry on the

4.5 Modifying bus driver settings

The bus driver settings can be modified.

1. Right-click on the KUKA Extension Bus (SYS-X44) entry on the

4.5.1 Master settings tab

Fig. 4-1: Master settings tab

4.6 Inserting devices manually

4.7.1 2-stage bus scan

4.8 Configuring devices

4.8.1 “General” tab

Fig. 4-2: General tab

• OFF: The revision number is not checked.

4.8.2 “Process data objects” tab

Fig. 4-3: “Process data objects” tab (example)

Fig. 4-4: “Modules” tab (example)

• Select the desired group in the module window. Click on the

4.9 Configuring File Access over EtherCAT

• The device supports the File Access over EtherCAT function.

Load file from the device:

4.10 Writing the alias address to devices

With WorkVisual, the alias address can be written directly to a device. If

• The device is connected and active.

4.11 Checking and modifying the topology

1. Right-click on the KUKA Extension Bus (SYS-X44) entry on the

4. Make the desired modifications:

4.11.1 “Topology” tab

Fig. 4-5: “Topology” tab (example)

5.1 Decoupling/coupling devices

Decouplable devices have the following properties:

• An alias address has been written to the decouplable device.

The following return values are possible for ioRet:

5.2 Activating/deactivating bus errors