KUKA System Technology KUKA Roboter GmbH

KUKA.PLC ProConOS 4-1 4.0

For KUKA System Software 8.2

Issued: 07.07.2011

Version: KST PLC ProConOS 4.0 V2 en

 KUKA.PLC ProConOS 4-1 4.0

© Copyright 2011
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub KST PLC ProConOS 4.0 en

Bookstructure: KST PLC ProConOS 4.0 V2.1
Label: KST PLC ProConOS 4.0 V2 en

2 / 35 Issued: 07.07.2011 Version: KST PLC ProConOS 4.0 V2 en

 Contents

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 Overview of KUKA.PLC ProConOS 4-1 ..................................................................... 7

3 Safety ............................................................................................................ 9
3.1 Safety measures for “single point of control” ............................................................. 9

4 Installation ................................................................................................... 11
4.1 System requirements ................................................................................................. 11
4.2 Installing or updating KUKA.PLC ProConOS 4-1 ...................................................... 11
4.3 Uninstalling KUKA.PLC ProConOS 4-1 ..................................................................... 11

5 Operation ...................................................................................................... 13
5.1 Controlling ProConOS by means of KRL ................................................................... 13
5.1.1 Calling up the status of ProConOS ....................................................................... 13
5.1.2 Powerfail status .................................................................................................... 13
5.1.3 Starting ProConOS ............................................................................................... 14
5.1.4 Stopping ProConOS ............................................................................................. 14

6 Configuration ............................................................................................... 15
6.1 Configuring a task priority .......................................................................................... 15
6.2 Configuring the ProConOS/Multiprog interface .......................................................... 16
6.3 Configurable ProConOS parameters ......................................................................... 16
6.3.1 PrioSvisor parameter ............................................................................................ 16
6.3.2 PRIOUSER parameter .......................................................................................... 17
6.3.3 PRIOSYSTEM parameter ..................................................................................... 17
6.3.4 PrioIdle parameter ................................................................................................ 18
6.3.5 KukaScheduling parameter .................................................................................. 18
6.3.6 KukaSettings/NrkTick parameter .......................................................................... 18
6.3.7 KukaSettings/ExempTask parameter ................................................................... 19
6.3.8 FileAccess_RootPath parameter .......................................................................... 19
6.3.9 WriteTsmOnStop parameter ................................................................................. 19
6.3.10 ProgramSize parameter ........................................................................................ 19
6.3.11 ReloadBootFileAtReconfig parameter .................................................................. 19
6.3.12 IgnoreDeinstalledIoDrv parameter ........................................................................ 19
6.3.13 WarmStartCheck parameter ................................................................................. 20
6.3.14 DELRETAIN parameter ........................................................................................ 20
6.3.15 AUTOARCHIVERETAIN parameter ..................................................................... 20
6.3.16 RETAINSIZE parameter ....................................................................................... 20
6.3.17 ProConOS_ROOTPATH parameter ..................................................................... 21
6.3.18 SIGNALFILES parameter ..................................................................................... 21
6.3.19 SIGNALFILEREAD parameter .............................................................................. 21

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 KUKA.PLC ProConOS 4-1 4.0

7 Diagnosis ...................................................................................................... 23
7.1 Displaying diagnostic data ......................................................................................... 23

8 KUKA Service ............................................................................................... 25

8.1 Requesting support ................................................................................................... 25
8.2 KUKA Customer Support ........................................................................................... 25

Index ............................................................................................................. 33

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 1 Introduction

1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and skills:
 Advanced KRL programming skills
 Advanced PLC programming skills
 Advanced knowledge of the robot controller system

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the KUKA System Software
 Documentation relating to options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe physical injury will occur, if no pre-
cautions are taken.

These warnings mean that death or severe physical inju-

ry may occur, if no precautions are taken.

These warnings mean that minor physical injuries may

occur, if no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures. These warnings do not refer to individual
hazards or individual precautionary measures.

Hints These hints serve to make your work easier or contain references to further
information.

Tip to make your work easier or reference to further information.

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 KUKA.PLC ProConOS 4-1 4.0

1.4 Trademarks

ProConOS and MULTIPROG are trademarks of KW-Software GmbH.

VxWorks is a trademark of Wind River Systems Inc.
Windows and Windows XP are trademarks of Microsoft Corporation.

1.5 Terms used

Term Description
KLI KUKA Line Interface. Connection to higher-level control
infrastructure (PLC, archiving)
Exception Exceptional treatment for a specific event.
KUKA.PLC Soft PLC for use in the robot controller.
Multiprog 5-35
WorkVisual Software that serves as an offline engineering system
for the software of KR C4-controlled robot systems.
SPOC Single Point of Control
Retentive data Data that are retained even when the PLC is reset.
Time slice Allocated time slot in which an application takes over the
CPU processing time.
Watchdog Function that monitors the max. allocated processing/
response time.

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 2 Product description

2 Product description

2.1 Overview of KUKA.PLC ProConOS 4-1

Description KUKA.PLC ProConOS 4-1 is a runtime system that is used by the technology
package KUKA.PLC Multiprog 5-35 to execute PLC applications on the robot
controller. ProConOS is compatible with the IEC standard 61131-3, and thus
employs standardized syntax and semantics. ProConOS can be configured by
means of an initialization file, and can be adapted flexibly to the requirements
of the robot system.

Fig. 2-1: Configuration overview

Item Description
1 KR C4:
 Windows operating system
 VxWorks real-time operating system
 ProConOS runtime system
2 Connection: KLI
3 External PC/laptop:
 Windows operating system
 MULTIPROG PLC development environment
 WorkVisual offline engineering system

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 KUKA.PLC ProConOS 4-1 4.0

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 3 Safety

3 Safety
This documentation contains safety instructions which refer specifically to the
software described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.

The “Safety” chapter in the operating and programming instructions

must be observed. Death to persons, severe physical injuries or con-
siderable damage to property may otherwise result.

Signal states can be changed by downloading the Multi-

prog project, via the control dialog in Multiprog or by
transferring them out of WorkVisual. It must be ensured that potentially haz-
ardous signals (e.g. the opening/closing of a gun) can only be executed if
AUT or AUT EXT mode is set and the safety gate is closed. For this, the sig-
nals must be mapped accordingly to the variables
bSPOC_UserSafetyActive and bSPOC_MotionEnabled.

3.1 Safety measures for “single point of control”

Overview If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
Components:
 Submit interpreter
 PLC
 OPC Server
 Remote control tools
 Tools for configuration of bus systems with online functionality
 KUKA.RobotSensorInterface
 External keyboard/mouse

The implementation of additional safety measures may be required.

This must be clarified for each specific application; this is the respon-
sibility of the system integrator, programmer or user of the system.

Since only the system integrator knows the safe states of actuators in the pe-
riphery of the robot controller, it is his task to set these actuators to a safe
state, e.g. in the event of an EMERGENCY STOP.

T1, T2 In the test modes, the components referred to above (with the exception of the
external keyboard/mouse) may only access the industrial robot if the following
signals have the following states:

Signal State required for SPOC

$USER_SAF TRUE
$SPOC_MOTION_ENABLE TRUE

Submit inter- If motions, (e.g. drives or grippers) are controlled with the Submit interpreter
preter, PLC or the PLC via the I/O system, and if they are not safeguarded by other means,
then this control will take effect even in T1 and T2 modes or while an EMER-
GENCY STOP is active.

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 KUKA.PLC ProConOS 4-1 4.0

If variables that affect the robot motion (e.g. override) are modified with the
Submit interpreter or the PLC, this takes effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
Safety measures:
 In the test modes, the system variable $OV_PRO must not be written to
by the Submit interpreter or the PLC.
 Do not modify safety-relevant signals and variables (e.g. operating mode,
EMERGENCY STOP, safety gate contact) via the Submit interpreter or
PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dan-
gerous state by the Submit interpreter or PLC.

OPC server, These components can be used with write access to modify programs, outputs
remote control or other parameters of the robot controller, without this being noticed by any
tools persons located inside the system.
Safety measures:
 KUKA stipulates that these components are to be used exclusively for di-
agnosis and visualization.
Programs, outputs or other parameters of the robot controller must not be
modified using these components.
 If these components are used, outputs that could cause a hazard must be
determined in a risk assessment. These outputs must be designed in such
a way that they cannot be set without being enabled. This can be done us-
ing an external enabling device, for example.

Tools for configu- If these components have an online functionality, they can be used with write
ration of bus access to modify programs, outputs or other parameters of the robot control-
systems ler, without this being noticed by any persons located inside the system.
 WorkVisual from KUKA
 Tools from other manufacturers
Safety measures:
 In the test modes, programs, outputs or other parameters of the robot con-
troller must not be modified using these components.

External These components can be used to modify programs, outputs or other param-
keyboard/mouse eters of the robot controller, without this being noticed by any persons located
inside the system.
Safety measures:
 Only use one operator console at each robot controller.
 If the KCP is being used for work inside the system, remove any keyboard
and mouse from the robot controller beforehand.

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 4 Installation

4 Installation

4.1 System requirements

Overview  KR C4
 PROFINET, PROFIBUS or Interbus
 Network connections (network switch, network cable, 100 Mbit network
card)

4.2 Installing or updating KUKA.PLC ProConOS 4-1

It is advisable to archive all relevant data before updating a software

package.

Precondition  Expert user group

 Software on KUKA.USB data stick

Only the KUKA.USB data stick may be used. Data may

be lost or modified if any other USB stick is used.

ProConOS OPC Server 2.1 is automatically installed during the in-

stallation of KUKA.PLC ProConOS 4-1.

Procedure 1. Plug in USB stick.

2. Select Start-up > Install additional software in the main menu.
3. Press New software. If a software package that is on the USB stick is not
displayed, press Refresh.
4. Mark the entry ProConOS 4-1 and press Install. Reply to the request for
confirmation with Yes. The files are copied onto the hard drive.
5. Repeat step 4 if another software package is to be installed from this stick.
6. Remove USB stick.
7. It may be necessary to reboot the controller, depending on the additional
software. In this case, a corresponding prompt is displayed. Confirm with
OK and reboot the robot controller. Installation is resumed and completed.

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

4.3 Uninstalling KUKA.PLC ProConOS 4-1

It is advisable to archive all relevant data before updating or uninstall-

ing a software package.

Precondition  Expert user group

Procedure 1. Select Start-up > Install additional software in the main menu. All addi-
tional programs installed are displayed.
2. Mark the entry ProConOS 4-1 and press Uninstall. Reply to the request
for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.

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

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 5 Operation

5 Operation

5.1 Controlling ProConOS by means of KRL

Description ProConOS can be controlled by means of KRL applications using the function
cIoCtl. The following functions can be executed:
 Start ProConOS
 Stop ProConOS
 Call up status of ProConOS
The function call returns a value of data type INT.

Syntax cIoCtl($Soft_Plc_Cmd, Function, Parameter, StrParameter, pRet)

Parameter Description
Function Function number
Parameter Function parameter (data type INT)
StrParameter Additional string parameter
pRet Return status (data type INT)

5.1.1 Calling up the status of ProConOS

Syntax cIoCtl($Soft_Plc_Cmd, 1003, 0, " ", tmpInt)

The value returned by the function is binary coded. However, at no time will
more than one bit be set.

The variable tmpInt must not be a runtime variable. It must be de-

clared in a .dat file.

Return values:

Value Designation Description

1 POWER ON ProConOS is started and no PLC pro-
gram is loaded.
2 RUN The PLC program is started.
4 STOP The PLC program is loaded and not
started.
8 HALT The PLC program has been stopped, e.g.
by a breakpoint.
32 LOADING The PLC program is being loaded.

5.1.2 Powerfail status

Syntax cIoCtl($Soft_Plc_Cmd, 1005, 0, " ", tmpInt)

The variable tmpInt must not be a runtime variable. It must be de-

clared in a .dat file.

Return values:

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 KUKA.PLC ProConOS 4-1 4.0

Value Description
1 Powerfail status is not active.
2 Powerfail status is active.

5.1.3 Starting ProConOS

Syntax cIoCtl($Soft_Plc_Cmd, 1013, argument, " ", tmpInt)

The variable tmpInt must not be a runtime variable. It must be de-

clared in a .dat file.

Argument Designation Description

0 Cold start All variable contents are deleted and
re-initialized.
1 Warm start All variable contents are deleted and
re-initialized, except for retentive data.
2 Hot start Variable contents are not deleted or
re-initialized.

Return value:

Value Description
0 ProConOS has been started.

5.1.4 Stopping ProConOS

Syntax cIoCtl($Soft_Plc_Cmd, 1014, 0, " ", tmpInt)

The variable tmpInt must not be a runtime variable. It must be de-

clared in a .dat file.

Return value:

Value Description
0 ProConOS has been stopped.

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 6 Configuration

6 Configuration

ProConOS is configured and operational following installation. Ways

of modifying the existing configuration are described below.

6.1 Configuring a task priority

Description The ProConOS priority model describes the fundamental relationships be-
tween the priorities and the various ProConOS tasks. The priority indicates a
precedence in the allocation of CPU computing time and the use of system re-
sources. The priority of tasks is defined in the initialization file ...Config\Us-
er\Common\ProConOS.xml.
Each task is assigned to a task range. The assignment is preset and cannot
be changed. Each task range is assigned a priority. The defined priority is as-
signed to the allocated task in this range. Each task range is represented by a
parameter in the initialization file. The value of the parameter defines the pri-
ority of the tasks located in this range.
The following task ranges are available:
 ProConOS Supervisor tasks (high-level tasks): This task range con-
tains all tasks which have a higher priority than the highest-priority user
task, for example robot tasks.
Default value of Supervisor tasks: 141
(>>> 6.3.1 "PrioSvisor parameter" Page 16)
 ProConOS User tasks and ProConOS Default task (ProConOS-level
tasks): This task range contains the PLC tasks and the Default task.
Default value of User tasks: 142 to 149
(>>> 6.3.2 "PRIOUSER parameter" Page 17)
 ProConOS Internal tasks:
Default value of Internal tasks: 200
(>>> 6.3.4 "PrioIdle parameter" Page 18)
 ProConOS System tasks (low-level tasks): Low Level tasks have a low-
er priority than the Default task.
Default value of System tasks: 218 to 223
(>>> 6.3.3 "PRIOSYSTEM parameter" Page 17)

Fig. 6-1

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 KUKA.PLC ProConOS 4-1 4.0

6.2 Configuring the ProConOS/Multiprog interface

Description A connection to ProConOS can be made via a network card in the robot con-
troller and an external Windows network. This connection can be established
using KLI: KLI can route any TCP/IP ports for the KR C, for VxWorks and for
external PCs. It is thus possible to access ProConOS from an external PC.

Fig. 6-2: Configuration overview

Item Description
1 KR C4:
 Windows operating system
 VxWorks real-time operating system
 ProConOS runtime system
2 Connection: KLI
3 External PC/laptop:
 Windows operating system
 MULTIPROG PLC development environment
 WorkVisual offline engineering system

6.3 Configurable ProConOS parameters

Description The parameters in the initialization file ...Config/User/Common/ProCo-

nOS.xml are described here. The parameter values are used to configure Pro-
ConOS during initialization.

6.3.1 PrioSvisor parameter

Description The value of this parameter specifies the priority of the ProConOS Supervisor
task. The ProConOS Supervisor task must have the highest priority of all Pro-
ConOS tasks. An example of a Supervisor task is exception handling. The ro-
bot controller must be restarted after the value of this parameter is changed.

The parameter value PrioSvisor must be greater than PRIOUSER.

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 6 Configuration

The value of the PrioSvisor parameter may be modified only in con-

sultation with KUKA Roboter GmbH.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

PrioSvisor = 0 Highest priority
PrioSvisor = 141 Default priority (default value)
PrioSvisor = 234 Lowest priority

6.3.2 PRIOUSER parameter

Description The value of this parameter specifies the priority of the ProConOS User tasks.
MULTIPROG allows the assignment of 15 priority levels, which can be
mapped on ProConOS by means of PRIOUSER. The priority defined via this
parameter corresponds to priority 1 in MULTIPROG. The default task has the
lowest priority level of the user tasks. The priority of the default task cannot be
defined, since it is calculated by ProConOS from the value of the PRIOUSER
parameter (DEFAULT TASK = PRIOUSER + 15). The default task receives
computing time if no other ProConOS task requires computing time.

The value of the PRIOUSER parameter must be greater than the val-
ue of the PrioSvisor parameter plus 1 (PRIOUSER ≥ PrioSvisor + 1).

The value of the PRIOUSER parameter may be modified only in con-

sultation with KUKA Roboter GmbH.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

PRIOUSER = 0 Highest priority
PRIOUSER = 151 Default priority (default value)
PRIOUSER = 235 Lowest priority

6.3.3 PRIOSYSTEM parameter

Description The value of this parameter specifies the priority of the ProConOS System
tasks. The functions of the ProConOS System tasks are communication with
MULTIPROG, debugging and memory management. System tasks receive
the lowest priority level. The robot controller must be restarted after the value
of this parameter is changed.

The value of the PRIOSYSTEM parameter is greater than or equal to

the value of the PRIOUSER parameter plus 16 (PRIOSYSTEM ≥
PRIOUSER + 16).

The value of the PRIOSYSTEM parameter may be modified only in

consultation with KUKA Roboter GmbH.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

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 KUKA.PLC ProConOS 4-1 4.0

Range of values Description

PRIOSYSTEM = 0 Highest priority
PRIOSYSTEM = 219 Default priority (default value)
PRIOSYSTEM = 250 Lowest priority

6.3.4 PrioIdle parameter

Description The value of this parameter defines the priority of two tasks which are used for
internal management purposes:
 one task that initializes and starts the ProConOS runtime system
 another task that saves the retentive data to the hard drive in the event of
a power failure (Powerfail)
The robot controller must be restarted after the value of this parameter is
changed.

The priority is freely selectable, but should be adjusted to suit the

overall system.

The value of the PrioIdle parameter may be modified only in consul-

tation with KUKA Roboter GmbH.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

PRIOINTERNAL = 0 Highest priority
PRIOINTERNAL = 190 Default priority (default value)
PRIOINTERNAL = 250 Lowest priority

6.3.5 KukaScheduling parameter

Description The value of this parameter defines which scheduling method is used.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True KUKA scheduling method is used (NrkTick).
False KW scheduling method is used (CPUCapMin /
CPUCapMax).

6.3.6 KukaSettings/NrkTick parameter

Description The value of this parameter defines the number of ticks within an interpolation
cycle (12 ms) if ProConOS tasks are active.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

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 6 Configuration

6.3.7 KukaSettings/ExempTask parameter

Description The name of the task that must not be adversely affected by the scheduling
(= continuous cycle access) is entered in this parameter.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name in the parameter.

6.3.8 FileAccess_RootPath parameter

Description A home directory relative to C:\KRC\ROBOTER is entered in this parameter.

The file access modules perform their file operations in this directory. If nothing
is entered in the parameter, the path ProConOS_RootPath is used.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the directory in the parameter.

6.3.9 WriteTsmOnStop parameter

Description The value of the parameter defines whether the TSMLog file is saved if the
PLC enters the Stop state.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True TsmLog is saved if the PLC enters the STOP
state.
False TsmLog is not saved if the PLC enters the STOP
state.

6.3.10 ProgramSize parameter

Description The value of the parameter defines the size (in bytes) of the application pro-
gram.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

6.3.11 ReloadBootFileAtReconfig parameter

Description The value of the parameter defines whether the boot file is reloaded after a re-
configuration.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True The boot file is reloaded after a reconfiguration.
False The boot file is not reloaded after a reconfigura-
tion.

6.3.12 IgnoreDeinstalledIoDrv parameter

Description The value of the parameter defines whether an error is signaled if the I/O driver
has been uninstalled, but is still active in the ProConOS configuration.

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 KUKA.PLC ProConOS 4-1 4.0

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True Error is not signaled.
False Error is signaled.

6.3.13 WarmStartCheck parameter

Description The value of the parameter defines whether the retentive data are checked for
CRC equality in the case of a HOT start.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True Check is carried out.
False No check.

6.3.14 DELRETAIN parameter

Description The value of this parameter defines whether the retentive data are deleted or
retained.
The robot controller must be restarted after the value of this parameter is
changed.

If retentive variables are inserted in the variable list, all of the subse-
quent variables are shifted. Thus with DELRETAIN = 1, the consis-
tency of the subsequent retentive variables cannot be ensured. New
variables should be inserted only at the end of the variable list.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True Retentive data are set to their initialization val-
ues (default value).
False Retentive data will be retained.

6.3.15 AUTOARCHIVERETAIN parameter

Description The value of this parameter defines whether the retentive data are saved in
the file when the robot controller is shut down.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Range of values Description

True The retentive data are saved (default value).
False The retentive data are not saved.

6.3.16 RETAINSIZE parameter

Description The value of this parameter defines the size of the area for the retentive data
in bytes. This size can be defined if necessary.

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 6 Configuration

If the value of the RETAINSIZE parameter is modified, these settings

must be reconfigured in Multiprog.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Value Description
4096 Default size 4096 bytes

6.3.17 ProConOS_ROOTPATH parameter

Description The path specified in this parameter defines the directory in which the ProCo-
nOS files are located. The directory must be read- and write-enabled.
The robot controller must be restarted after the path specification is changed.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name in the parameter.

Syntax Description
ProConOS_ROOTPATH = ProConOS Path relative to
C:\KRC\ROBOTER

6.3.18 SIGNALFILES parameter

Description The SIGNALFILES parameter is used to signal *.dat files to the ProConOS
system. These files are used to access I/O data symbolically. The parameter
is preset during setup with the following files:
 KRC\R1\System\$CONFIG.DAT
 KRC\STEU\MADA\$MACHINE.DAT
These files can be expanded.
The function is used by the following libraries:
 AutoExLib
 ExtensionLib

Procedure  Open the file ...\KRC\IRoboter\Config\User\Common\PROCONOS.xml in

a text editor and modify the parameter.

6.3.19 SIGNALFILEREAD parameter

Description The signal files in the parameter SIGNALFILES are read in accordance with
the entry SIGNALFILEREAD.

Procedure  Open the file ...Config\User\Common\ProConOS.xml in a text editor and

enter the name for the parameter.

Syntax Description
SIGNAL- The signal files are read once by ProConOS on
FILEREAD = START booting.
If the area after “=” is left blank or the parameter
is deleted, the signal files are read every time the
ProConOS program execution is started.

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 KUKA.PLC ProConOS 4-1 4.0

If Automatic External interface signals are reconfigured, ProConOS

must be stopped and restarted.

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 7 Diagnosis

7 Diagnosis

7.1 Displaying diagnostic data

Procedure 1. Select Diagnosis > Diagnostic monitor in the main menu.

2. Select the ProConOS module in the Module box.
Diagnostic data are displayed for ProConOS.

Description The following diagnostic data are displayed:

Name Description
Run status ProConOS status:
 SPS_ON: ProConOS is started and no
PLC program is loaded.
 SPS_RUN: The PLC program is started.
 SPS_STOP: The PLC program is loaded
and not started.
 SPS_DEBUGGED: The PLC program is
stopped.
 SPS_LOADING: The PLC program is
being loaded.
Ticks per second Ticks triggered per second by the PLC
ProConOS system tick Status of the ProConOS system ticks:
status
 1: OK
 0: Error
ProConOS system tick Consecutive counter of the ProConOS sys-
tem ticks
ProConOS RT tick ProConOS system ticks in seconds
Project status Internal status of the project
Default task cycle time Cycle time of the ProConOS default task (in
ms)
ProConOS project source  Exist: ProConOS project exists as a ZIP
code: ZIP name file on the target controller.
 None: ProConOS project does not exist
on the target controller.
Name of the boot project Name of the boot project
Project name Name of the ProConOS project
Project configuration Hardware configuration in the project
Resource name Name of the hardware resource
Number of errors Number of errors in the ProConOS error
memory
Pcos_Error(x) Error in the ProConOS memory. The first 10
errors are displayed with error code.
Number of user tasks Number of tasks defined by the user in the
ProConOS project
User_Task_Info(x) Information about a user task:
 Name
 Watchdog
 Type of task: event, cyclical, default
A maximum of 16 user tasks can be config-
ured.

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 KUKA.PLC ProConOS 4-1 4.0

Name Description
User_Task_Statistics(x) Statistics about a user task:
 Name
 Cycle time
 Delay
Number of system tasks Number of system tasks (max. 12)
Sys_Task_Info(x) Information about a system task:
 Name
 Priority
 Mode
 Current status
Kernel version Version of the ProConOS kernel
Firmware version KUKA firmware version of ProConOS
ProConOS root dir Directory entered in the
ProConOS_ROOTPATH parameter.
ProConOS file access dir Directory entered in the
FileAccess_RootPath parameter.
Configured program size Value entered in the ProgramSize parameter
Configured retain size Value entered in the RETAINSIZE parameter
Max. available memory Maximum contiguous block of memory avail-
block able in the system (in bytes)
Program memory Program memory available for ProConOS (in
bytes)
System data memory Memory available for system data (in bytes)
SPOC: UserSaveActive Status of the variable
bSPOC_UserSafetyActive:
 1: Not safe
 0: Safe
SPOC: MotionEnabled Status of the variable
bSPOC_MotionEnabled:
 1: Motion is enabled.
 0: Motion is not enabled.
Retain data valid  1: ProConOS data that were saved when
the system was shut down are valid.
 0: ProConOS data that were saved when
the system was shut down are not valid.
Exemp task Name of the task entered in the KukaSet-
tings/ExempTask parameter
Scheduling ticks Value entered in the KukaSettings/NrkTick
parameter
KRC signal read mode  each START: The signal files entered in
the SIGNALFILES parameter are read
every time ProConOS is started.
 each BOOT: The signal files entered in
the SIGNALFILES parameter are read
every time the controller is booted.

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 8 KUKA Service

8 KUKA Service

8.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

Information The following information is required for processing a support request:

 Model and serial number of the robot
 Model and serial number of the controller
 Model and serial number of the linear unit (if applicable)
 Version of the KUKA System Software
 Optional software or modifications
 Archive of the software
 Application used
 Any external axes used
 Description of the problem, duration and frequency of the fault

8.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

Australia Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
[email protected]
www.headland.com.au

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Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
[email protected]

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Automation Equipment (Shanghai) Co., Ltd.

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1808
Fax +86 21 6787-1805
[email protected]
www.kuka.cn

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
[email protected]
www.kuka-roboter.de

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 8 KUKA Service

France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India KUKA Robotics 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
[email protected]
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
[email protected]
www.kuka.it

Japan KUKA Robotics Japan K.K.

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
[email protected]

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
[email protected]

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 KUKA.PLC ProConOS 4-1 4.0

Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
[email protected]

Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]

Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
[email protected]

Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
[email protected]
www.kuka-roboter.at

Poland KUKA Roboter Austria GmbH

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
[email protected]

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 8 KUKA Service

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
[email protected]

Russia OOO KUKA Robotics Rus

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

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka-e.com

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South Africa Jendamark Automation LTD (Agency)

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

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
[email protected]
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

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USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036
Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
[email protected]
www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
[email protected]

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 Index

Index
A PRIOUSER 17
AUTOARCHIVERETAIN 20 PRIOUSER parameter 17
AUTOARCHIVERETAIN parameter 20 ProConOS_ROOTPATH 21
ProConOS_ROOTPATH parameter 21
C ProConOS/Multiprog interface, configuration 16
Configurable ProConOS parameters 16 Product description 7
Configuration 15 PROFIBUS 11
Configuring a task priority 15 PROFINET 11
Configuring the ProConOS/Multiprog interface ProgramSize 19
16 ProgramSize para 19
Controlling ProConOS by means of KRL 13
R
D ReloadBootFileAtReconfig 19
DELRETAIN 20 ReloadBootFileAtReconfig parameter 19
DELRETAIN parameter 20 RETAINSIZE 20
Diagnosis 23 RETAINSIZE parameter 20
Diagnostic data, displaying 23 Retentive data 6
Diagnostic monitor (menu item) 23
Documentation, industrial robot 5 S
Safety 9
E Safety instructions 5
Exception 6 Service, KUKA Roboter 25
SIGNALFILEREAD 21
F SIGNALFILEREAD parameter 21
FileAccess_RootPath 19 SIGNALFILES 21
FileAccess_RootPath parameter 19 SIGNALFILES parameter 21
Single point of control 9
I SPOC 6, 9
IgnoreDeinstalledIoDrv 19 Support request 25
IgnoreDeinstalledIoDrv parameter 19 System requirements 11
Installation 11
Interbus 11 T
Introduction 5 Target group 5
Terms used 6
K Time slice 6
KLI 6 Trademarks 6
KUKA Customer Support 25 Training 5
KUKA.PLC Multiprog 5-35 6
KUKA.PLC ProConOS 4-1, installing 11 W
KUKA.PLC ProConOS 4-1, uninstalling 11 WarmStartCheck 20
KukaScheduling 18 WarmStartCheck parameter 20
KukaScheduling parameter 18 Warnings 5
KukaSettings/ExempTask 19 Watchdog 6
KukaSettings/ExempTask parameter 19 WorkVisual 6
KukaSettings/NrkTick 18 WriteTsmOnStop 19
KukaSettings/NrkTick parameter 18 WriteTsmOnStop parameter 19

O
Operation 13
Overview, KUKA.PLC ProConOS 4-1 7

P
PrioIdle 18
PrioIdle parameter 18
PriosSvisor 16
PrioSvisor parameter 16
PRIOSYSTEM 17
PRIOSYSTEM parameter 17

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