Configuring SINAMICS S110 PROFINET Telegram on KUKA KR C4 in KRL

1. Architecture Overview

A SINAMICS S110 (single-axis positioning drive from the SINAMICS S family) coupled to a KUKA KR C4 compact controller over PROFINET IO is a heterogeneous cell in which:

• The KR C4 is the PROFINET IO Controller (PN-IO-Controller) and runs the KUKA PROFINET stack configured from WorkVisual.
• The SINAMICS S110 (CU305 PN or CU310 PN + PM340) is the PROFINET IO Device (PN-IO-Device) configured from STARTER, SCOUT, or Startdrive in TIA Portal.
• KRL (KUKA Robot Language) consumes the process data through $Config.dat / $IOSYS.ini symbolic I/O and does not parse Siemens telegrams natively.

The S110 is positioned as a simple, fast, accurate basic positioning drive for machine axes per the official product description on PI (PROFIBUS & PROFINET International) – SINAMICS S110 product finder.

2. Prerequisites

• KUKA KR C4 compact controller, KSS 8.3.x or later. PROFINET stack option enabled (standard on compact variants).
• KUKA KR 6 robot arm.
• SINAMICS S110 with Control Unit CU305 PN or CU310 PN + PM340 power module.
• SINAMICS firmware ≥ 4.4 (recommended 5.1 for current GSDML-V2.3x family).
• KUKA.WorkVisual ≥ 4.0 (current V8.x release train).
• SINAMICS STARTER ≥ 4.5 or Startdrive V15.1+ inside TIA Portal V16.
• GSDML for SINAMICS S110 (e.g. GSDML-V2.31-Siemens-Sinamics_S110-xxxxxxxx.xml) imported into both WorkVisual and STARTER.
• One managed PROFINET switch (recommended) or direct line topology if the S110 is the only slave.

3. Installing the GSDML and Adding the S110 in WorkVisual

1. Open WorkVisual and load the KR C4 project.
2. Options → GSDML Files → Import… and browse to the S110 GSDML.
3. In the catalog tree open PROFINET IO → Drives → Siemens AG → SINAMICS → SINAMICS S110.
4. Drag the device into the topology under the KR C4 PROFINET master port.
5. Assign a PROFINET device name (e.g. s110-a1) and IP address (e.g. 192.168.1.10).
6. Open the slot configuration. Default slots on the S110 PROFINET interface:
   - Slot 0: DAP
   - Slot 1: Telegram (default Standard Telegram 1)
   - Slot 2: Supplementary data / measurement / extended modules

4. Telegram Type Selection

The S110 supports the standard Siemens telegrams (predefined process-data layouts designed for use with SIMATIC blocks like SINAMICS_S, LAcycCom, DriveLib) plus the Free Telegram 999 (a freely configurable user-defined telegram). KRL does not interpret Siemens telegram structures directly; it only reads/writes the bytes that WorkVisual maps into $IN[n] / $OUT[n].

Selection guidance for KR C4 + KRL

• Standard Telegram 3 or 5 – choose when the KRL program needs OFF1/OFF2/OFF3, enable, ramp-function generator enable, a 16-bit speed setpoint, and a 32-bit actual-position feedback (G1_XIST1).
• Standard Telegram 110 / 111 – choose when driving the S110 in MDI (Manual Data Input) mode from the KRL submit interpreter, where traversing blocks are written cyclically.
• Free Telegram 999 – choose when the KRL data width does not match any standard layout, or when you need custom connector routing (e.g. adding KPC gain, XERR position error, or removing the speed word entirely).

5. Configuring Free Telegram 999 in STARTER

1. Open the S110 in STARTER online or offline.
2. Navigate to Communication → PROFINET → Telegram configuration.
3. Delete the default telegram and insert Telegram 999.
4. Define the PZD mapping by adding signals:
   - Outputs (ctrl → drive): STW1 (r2050[0]), STW2, NSOLL_A, optional XERR, KPC.
   - Inputs (drive → ctrl): ZSW1 (p2051[0]), ZSW2, NIST_A, G1_XIST1, G1_XIST2.
5. Compile and download to the S110.
6. Back in WorkVisual refresh the slot. The slot length must match the configured telegram length exactly, otherwise the AR (Application Relationship) will fail to establish.

6. PROFINET Address Assignment in WorkVisual

After telegram selection, open the S110 device view and inspect the I/O addresses tab. A typical default layout for Telegram 3 on the KR C4:

• Input start address: IB 256 (18 bytes = 9 words)
• Output start address: QB 256 (10 bytes = 5 words)

Record these offsets; they are referenced from $Config.dat and from the WinPZAd tool during commissioning.

7. Mapping the PROFINET Words into KRL

The KRL runtime reads/writes $IN[n] and $OUT[n] words. Inside $Config.dat declare symbolic aliases:

; ===== Inputs (drive → controller) =====
DECL GLOBAL SIGNAL S110_ZSW1     $IN[256]    ; Status Word 1
DECL GLOBAL SIGNAL S110_ZSW2     $IN[257]    ; Status Word 2
DECL GLOBAL SIGNAL S110_NIST     $IN[258]    ; Actual speed N2
DECL GLOBAL SIGNAL S110_G1XIST1  $IN[259]    ; Encoder 1 actual position (low)
DECL GLOBAL SIGNAL S110_G1XIST1H $IN[260]    ; Encoder 1 actual position (high)

; ===== Outputs (controller → drive) =====
DECL GLOBAL SIGNAL S110_STW1     $OUT[256]   ; Control Word 1
DECL GLOBAL SIGNAL S110_STW2     $OUT[257]   ; Control Word 2
DECL GLOBAL SIGNAL S110_NSOLL    $OUT[258]   ; Speed setpoint (N2)
DECL GLOBAL SIGNAL S110_XSETP    $OUT[259]   ; Position setpoint low
DECL GLOBAL SIGNAL S110_XSETPH   $OUT[260]   ; Position setpoint high

Bit-of-word pattern in KRL

KRL has no native bit-of-word operator equivalent to Siemens DB1.DBX0.0. Use a wrapper integer pattern in a submit interpreter so the cycle is deterministic:

DECL GLOBAL INT giSTW1 = 0

; Set OFF1 = 1  (bit 0)
giSTW1 = giSTW1 BOR (1 BSH 0)
; Clear OFF2 = 1  (bit 1) – keep 1 to prevent coast stop
giSTW1 = giSTW1 BOR (1 BSH 1)
; Enable operation = 1  (bit 3)
giSTW1 = giSTW1 BOR (1 BSH 3)
; Acknowledge fault rising edge  (bit 7)
giSTW1 = giSTW1 BOR (1 BSH 7)

$OUT[256] = giSTW1

Read ZSW1 back the same way using BAND (bitwise AND) and BSH (bit shift):

liStatus = $IN[256]
bReady   = ((liStatus BAND (1 BSH 1)) <> 0)   ; bit 1 = "ready to switch on"
bFaulted  = ((liStatus BAND (1 BSH 3)) <> 0)   ; bit 3 = "fault present"
bInSetpoint=((liStatus BAND (1 BSH 6)) <> 0)   ; bit 6 = "switch on inhibited active"

8. Example KRL Motion Driver

The following minimal pattern issues a steady setpoint and monitors drive status. Treat it as a reference skeleton, not as production code.

; ----- enable and command motion -----
giSTW1 = 0
giSTW1 = giSTW1 BOR (1 BSH 0)        ; /OFF1 = 1
giSTW1 = giSTW1 BOR (1 BSH 1)        ; /OFF2 = 1
giSTW1 = giSTW1 BOR (1 BSH 3)        ; Enable operation
giSTW1 = giSTW1 BOR (1 BSH 4)        ; Ramp-function generator enable
$OUT[256] = giSTW1

$OUT[258] = 1500                     ; NSOLL_A in LU  (scaling: p2000 = reference speed)
WAIT SEC 0.05

; ----- read feedback -----
liStatus = $IN[256]
bOpEnabled = ((liStatus BAND (1 BSH 2)) <> 0)   ; ZSW1 bit 2 = "operation enabled"

IF NOT bOpEnabled THEN
  ; Drive refused enable. Inspect ZSW1 bits 0..3 and ZSW2 fault bits.
  ERR_SYSTEM("S110 not enabled, status=" << liStatus)
  HALT
ENDIF

9. PROFINET Topology and AR Bring-up

The recurring field problem – "only the S110 is visible in WorkVisual topology, controller and S110 are not connected" – is almost always caused by one of the following:

1. PROFINET master not activated on the KR C4. In WorkVisual go to the controller node, open the PROFINET master settings, and confirm the port is enabled and the project has been transferred with a cold restart.
2. PROFINET name mismatch. The S110 was named in STARTER (e.g. s110-a1) but the KR C4 project uses a different name. DCP will not establish neighbour relations unless both sides agree.
3. Topology cable not drawn. In the topology editor drag a connection from the KR C4 PN port to the S110 PN port 1. Saving the topology forces port-based LLDP neighbours and turns off the requirement for name assignment in some cases.
4. Firmware / GSDML version mismatch. The GSDML must declare firmware that matches the S110. If the S110 ships with a newer firmware than the GSDML supports, the controller will reject the device with F01910 at AR start.

10. Verification Checklist

1. Power S110 and KR C4. S110 PROFINET LEDs: green LINK + green RX/TX.
2. On the KUKA SmartHMI: Diagnostics → PROFINET → IO Devices. S110 should show AR established and Data exchange.
3. In STARTER online: the S110 project must show the green online indicator with cyclic traffic.
4. Write $OUT[256] = 16#047E from KRL and read back $IN[256]. ZSW1 should mirror STW1 bits per the Siemens control-word state machine.
5. Run a small jog motion through the external axis and verify $IN[259..260] (G1_XIST1) increments in the expected direction and resolution.

11. Diagnostic Word and Bit Reference

12. Troubleshooting Matrix

13. Safety Considerations

The PROFINET-integrated SINAMICS S110 supports PROFIsafe for Safety Integrated functions such as STO, SS1, SOS, and SLS. The safety connection is normally terminated in the KUKA safety controller (if the relevant KUKA option is licensed), not in KRL. The control bits OFF1, OFF2, OFF3 mapped into $OUT[…] are non-safety operator commands. Functional stop categories F-F0/F-F1 must be implemented via PROFIsafe or hard-wired safe inputs on the S110 (e.g. F-DI on CU310 PN). For additional background on integrated positioning with Safety Integrated, see the Siemens Application Note SINAMICS S: Positioning of a S110 using S7-300/400 with PROFINET/PROFIBUS and Safety Integrated.

14. Alternative: KUKA.CNC Sinumerik

If the application is a CNC-style machining process with the KR C4 acting as a SINUMERIK 840D sl emulation, the KUKA.CNC Sinumerik option package lets the KRL runtime consume SINUMERIK telegrams natively and uses the Siemens PLC blocks (FB379, FB380, etc.) for axis control. For a single external positioning axis driven from a robot motion program, the WorkVisual + $Config.dat approach covered above is the simpler and more common path. Choose KUKA.CNC only when the S110 must behave like a SINUMERIK-managed spindle or path axis.

15. Reference Architecture Diagram

16. State Machine Reference

17. Scaling Formulas

Speed setpoint and feedback use the N2 (16-bit) scaling defined in the S110 parameters. Convert between physical speed and the raw 16-bit value with:

n_raw = round(n_phys / p2000 × 16384)

with p2000 = reference speed (default 3000 rpm). For position feedback, the G1_XIST1 32-bit counter is scaled by the load gear / motor encoder resolution per p2900 family parameters.

FAQ