Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
R30iB Plus Profinet I-Device and Safety (CP1604) Configuration with
Firmware 2.7
1. Overview
The following step-by-step instructions describe how to configure the I-Device function. In addition to the I/O
controller configuration, the I-Device function must also have the I/O device configuration. Figure 1.1 below lists
the SIEMENS Configuration tools required on the PC. The two most important software pieces are SIMATIC STEP
7 Professional V14.0 SP1 Upd4 or up and SIMATIC STEP 7 Safety V14.0 SP1 Upd4 or up. The other software items
are loaded by default with TIA Portal software. Note that STEP 7 V14 is also called TIA Portal.
Figure 1.1 Installed Software
2. CP1604 S/W and H/W Requirements
Table 2.1 lists all S/W and H/W ordering information.
Ordering item
Ordering information
V9.10P/05 or later
 J709 PROFINET I/O G2
 J731 PROFINET Safety
 J744 PROFINET CP16XX FW. (Free)
Input 2048 Bytes
Output 2048 Bytes
Note: It could be higher with high speed COMM CPU. See the formula.
Robot Software
Max I/O Size
Motherboard (Wide-mini)
Ordering specification : A05B-2600-J075
PROFINET board
CP1604 with order number : 6GK1 160-4AA01
FW: 2.7.2
Table 2.1 Ordering information for CP1604 (R-30iB Plus)
PROFINET board firmware
I/O Size Computation:
(Total bytes of input data of IOC and IOD) + (Total bytes of output data of IOC and IOD) + [8 x (The number of the
submodules of IOC and IOD) < 800 bytes]
The total input/output = ~3000/3000 if there are only a few submodule.
The total input/output = ~2048/2048 with 36 submodules.
Please order Motherboard C (with high speed communication CPU) if I/O size is more than 2048/2048.
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PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Note: J709 PROFINET I/O G2 can’t coexist with options J930 PROFINET I/O or R834 Dual Chan. Profinet (Molex
Variant).
The current firmware (FW) can be verified using system variable $PNG2_DIAG.$FW_VERSION
If your firmware is not correct, update your firmware to 2.7.2. Firmware comes with the media and option J744
(free) needs to be ordered. Contact FANUC CRC at www.fanucamerica.com or 1-888-FANUC-US to get the
appropriate CP1604 FW. All variants of firmware exist on the media (in the J744 folder). Pick pn2720.fwl which is
FW 2.7.2. Follow the instructions below to install the firmware.
2.1. Once you have the firmware, please copy it to USB aka UD1:, and plug it into the robot front panel
USB port.
2.2. Go to CTRL start by pressing and holding PREV and NEXT key while cycling power.
2.3. Select Controlled start (#3) and press ENTER, which performs a CTRL start.
2.4. Press MENU 00PROFINET Setup, that displays the screen as shown in Figure 1.2.
2.5. Cursor down to item #4 and change the path if it is not right. In this case, ud1:\pn2720.fwl.
2.6. Cursor up to item #4 (Download Firmware), and press ENTER.
2.7. It displays, This operation may take 7 minutes. Choose F4 [YES] if you are ready.
2.8. It displays, Please wait… (7 minutes) and alarm PRIO-633 PNIO: Updating Firmware is posted. Please
wait until another alarm PRIO-634 PNIO: FW Updated is posted and the TP prompt says, Firmware
download successful.
2.9. Perform a complete power cycle on the board. A robot power cycle performs a power cycle on the
CP1604 board too. If there is an external 24V power supply, disconnect the power supply before
cycling power on the robot. Reconnect the power supply after it is back online. Note that Robot is still
at CTRL start. So press FNCT+ COLD to get to COLD start.
2.10. Alternatively, the TIA portal can be used to update the firmware. Please see step 4.7.
Figure 2.1 Firmware Update
3. H/W Configuration for CP1604
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PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Configure the Robot as IO-Device (CP1604) and F-Device and SIEMENS PLC (F1516F3) as I-Controller and FHost.
3.1. Open the TIA Portal V14.
3.2. Click on “Create new project” as shown in Figure 3.1.
Figure 3.1 Create Project
3.3. Fill in the project name and path, then click Create as shown in Figure 3.2. A new project will be
created successfully.
Figure 3.2 Locate Path
3.4. If there are no devices (which is the case for a fresh project), click “Configure a device” as shown in
Figure 3.3.
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PROFINET H/W: CP1604 FW 2.7.2.0
Figure 3.3 Configure Device
3.5. Click “Add new device” (Figure 3.4)
Figure 3.4 Add New Device
3.6. Click on PC Systems and navigate to PC Station (Figure 3.5), and click ADD.
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PROFINET H/W: CP1604 FW 2.7.2.0
Figure 3.5 Navigate to PC Systems
3.7. “Project View” opens as shown below. Navigate to the CP1604 module on the “Catalog” tree in the
right pane. Make sure you select the correct CP1604 version (V2.7).
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PROFINET H/W: CP1604 FW 2.7.2.0
Figure 3.6 Drag and Drop CP1604 Module
3.8. Drag and drop the 6GK1 160-4AA01 module to PC Station on left pane (Figure 3.7).
Figure 3.7 Select CP1604 Module
3.9. Right click on the device (CP 1604) as shown in Figure 3.8 or the name on the left tree as shown in
Figure 3.9, and select properties.
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Figure 3.8 Select Properties
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Figure 3.9 Select Properties
3.10. Navigate to the General tab Operating Mode, and check I/O Device and Use manually assigned
submodules as shown in Figure 3.10.
3.11. Navigate to I-Device Configuration, add safety and I/O modules. In this case, 8 Bytes safety, 64 Bytes
IN and 64 Bytes OUT as shown in Figure 3.14.
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Figure 3.10 Select I/O Device
3.12. Click on “Add New” under Transfer Area (Figure 3.11), and type “Safety I/O” or whatever you want to
call the Safety module as shown in Figure 3.12. Under Type, select the F-PS for “Safety I/O.” By default,
1 Byte appears under the Length column. Now, modify it as appropriate, 8 bytes in this case. Manually
configure Submodule ID to 0x1001-0x1008 for 1-8 Bytes respectively as shown in Figure 3.12. Note that
it adds Input and Ouput modules automatically. Now, you can click on Safety I/O in left sub-menu and
see Safety configuration as shown in Figure 3.13. It allows you to enable PROFIenergy if you intend to
use it, but it is not used in this example.
Figure 3.11 Add I/O Modules
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Figure 3.12 Add Safety Module
Figure 3.13 Safety Module Properties
3.13. Click on “Add New” under Transfer Area, and type “Input” or whatever you want to call the Input
module as shown in Figure 3.14. Under Type, select the CD for “I/O Module.” By default, 1 Byte appears
under Length column..
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PROFINET H/W: CP1604 FW 2.7.2.0
Figure 3.14 Add Input Module
Note the arrow in Figure 3.14, from left to right () indicates that it is the input module. Also address
starting with ‘I’ is another indication. If you click on the arrow, it can be of three types.
Type
Input
Output
Bidirectional
Arrow
Address
→
I XXXX… i.e. I 4116
←
Q XXXX… i.e. Q
↔
Adds two addresses for I
XXXX and Q XXXX
Table 3.1 I/O Modules
Type
CD
TM
F-PS
Description
I/O Module
Transfer Module
Safety I/O Module
Table 3.2 I/O Module Type
Click on Input under I-device communication, and change the Input length to 64 if not change in step 3.13 as
shown in Figure 3.15. ‘I’ indicates the input type as discussed earlier.
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Figure 3.15 Change Input Size
3.14. Similarly, add the output module as shown in Figure 3.14 i.e. 64 bytes output. ‘Q’ indicates the output
type as discussed in Table 3.1.
3.15. Set the Ethernet information as shown in Figure 3.16. Go to PROFINET Interface  Ethernet addresses.
Under the IP Protocol section, set up the IP address and subnet mask as appropriate. Under the
PROFINET section, uncheck the PROFINET device name is set directly at device and Generate PROFINET
device name automatically, then configure PROFINET device name i.e. cp1604.
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Figure 3.16 Ethernet Configuration
3.16. Set the catalog information as shown in Figure 3.17. Check Enable customization in the Customization
section. Now the other items become editable. Fill in all information as listed in Table 3.3.
Item Name
Value
PROFINET Vendor ID
PROFINET Device ID
Article no
Product family
Manufacturer Name
Product Name
Name of the GSD
bitmap file
1B7
E
1A05B-2600-J709
Robot Controller
FANUC
R30iB_Plus_Safe
GSDML-01B7-000DR2000iB165FV910_CP1604V27
Table 3.3 I/O Module Type
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Figure 3.17 Enable customization
3.17. Select Export Software Release as shown in Figure 3.17.
Note: The bitmap file as specified under catalog information must be in the same directory as the GSDML file is
located when it was imported into the TIA Portal.
3.18. Press OK, and compile the project as shown in Figure 3.18. If everything is good, then it will compile
successfully as shown in Figure 3.19.
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Figure 3.18 Compile Project
Figure 3.19 Compilation Successful
3.19. The Export button is activated. Press Export in Operating Mode (Figure 3.20).
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Figure 3.20 Export GSDML File
3.20. Locate the folder where the Bit Map file is located and save the newly created GSDML file. Note that
file name is created based on GSDML specification. It is advised not to change the file name except the
product name of your choice explained in step 3.16.
Figure 3.21 Save GSDML File
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PROFINET H/W: CP1604 FW 2.7.2.0
4. Download H/W Configuration to CP1604
Note that Robot controller is at COLD start. Download the hardware configuration to CP1604. Right click on
CP1604 and select Download to Device then Hardware Configuration as shown in Figure 4.1.
Figure 4.1 Download Hardware Configuration
4.1. The screen shown below will be displayed (Figure 4.2). Press Start search and it will find all accessible
devices in the network. Select the CP1604 card in the list, and press Load.
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Figure 4.2 Find Accessible Devices
4.2. At this point, if you do not see any red warnings in Figure 4.3, then you are good to proceed. Press
Load. Otherwise, fix any issues, and return to this screen.
Figure 4.3 Load Preview
4.3. It may take few minutes until this window (Figure 4.4) goes away.
Figure 4.4 Load in Progress
Note: I renamed this project to cp1604_safe_fw2.7 because it has to exist with an IOD project which has the same
name. Please do not confused with project file name.
4.4. If the load fails, it is likely it didn’t allow changing the name and IP. It happens when the device is in a bad
state. In this case, CP1604 needs to be factory reset. Right click on the device, and select Online &
Diagnostics as shown in Figure 4.5.
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Figure 4.5 Online and Diagnostic
4.5. Now select Modules and go to the Operating Mode tab. First, select Stop Module, and then it can be
reset to the factory by selecting Reset to Factory Settings option as shown below in Figure 4.6.
4.6. Please restart the load process as step 4.1-4.3.
4.7. Please note the green option in Figure 4.6 called Firmware update. CP1604 firmware can be updated
using this feature as mentioned in step 2.10 as other alternative.
4.8. Note that the IP address and Profinet names can also be assigned to CP1604 (using Online &
Diagnostics) if you chose not to do so in step 3.15.
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Figure 4.6 Reset to Factory
4.9. Finally, the load completes. Refer to the Info window as shown in Figure 4.7 as an example. If there
are any issues, you can find them displayed here.
Figure 4.7 Load Completed
4.10. Go to COLD start by pressing FCTN + COLD. Navigate to MENU  SETUP  PROFINET  General.
Now change Start mode to RUN if not already. You can see the Device and Vendor ID populated as
they were filled during device configuration in step 3.16. At this point, CP1604 is ready to talk to the
I/O controller.
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Figure 4.8 Load Completed
4.11. You can navigate through each module configured from this process. Click on F3 [other] and select IDevice as shown in Figure 4.9
Figure 4.9 Select I-Device
4.12. Now press ENTER when cursor is on <Detail> at 2 Transfer areas as shown in Figure 4.10.
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Figure 4.10 Transfer Area
4.13. Now you can see all modules 1-8 populated (Figure 4.11). Comments for each modules can be added
in below screen.
Figure 4.11 I-Device Modules
4.14. Press F2 [detail] to see Module 1 as shown in Figure 4.12. Similarily, press next to see F4[next]
module and so on as shown in Figure 4.13 through Figure 4.19.
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Figure 4.12 Module 1 (Safety)
Figure 4.13 Module 2 (Input)
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Figure 4.14 Module 3 (Output)
Figure 4.15 Module 4
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Figure 4.16 Module 5
Figure 4.17 Module 6
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Figure 4.18 Module 7
Figure 4.19 Module 8
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5. Configure F-Device with SIEMENS S7-1500F PLC
Please note that this configuration can be added in project created in step 3. Let’s create a new project to talk to
CP1604 as I-Device. Create a new project as explained earlier in the TIA portal. Fill in the project details, and
press Create.
Figure 5.1 Create Project
5.1. The project view will open. Drag and drop the appropriate I/O controller from the H/W catalog. In this
example, it is SIEMENS CPU S7-1500F and model is 6ES7 516-3FN01-0AB0 with FW 2.0. You can find
this detail from the SIEMENS PLC manual.
Figure 5.2 Drag and Drop PLC
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5.2. At this step, CP1604 has to be added but the new GSDML file is not installed yet. So let’s install a new
GSDML file that was created in Section -3. Go to Options, then select Manage general station
description files (GSD) as shown Figure 5.3.
Figure 5.3 Install GSD
5.3. Select the appropriate file that says, Not yet installed, and press Install.
Figure 5.4 Select and Install GSD
5.4. It takes few seconds to install and update the H/W catalog. Newly added CP1604 appears under: Other
filed devices PROFINEY I/O  PLCs and CPs  FANUC  Robot Controller  R30iB_Plus_Safe.
Note that Red items shown here are configured in step 3.16 i.e. Vendor name  Product family 
Product name. Drag and drop R30iB_Plus_Safe.
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Figure 5.5 Add CP1604
5.5. Assign the interface. Assuming the Ethernet cable is connected to Port 1 of PLC. See Figure 5.6 and
Figure 5.7.
Figure 5.6 Select the Interface_1
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Figure 5.7 Assign the Interface
5.6. Now, right click on the PLC and go to properties as shown in Figure 5.8. Set High limit for Fdestination addresses to 300 as robot default address is 200 (Figure 5.9).
Figure 5.8 PLC Properties
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Figure 5.9 Set F-Parameters
5.7. Fill the correct IP and PROFINET information as shown in Figure 5.10. It includes the IP address, Subnet
mask and profinet name. These are important pieces of information.
Figure 5.10 IP Protocol and PROFINET Information (PLC)
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5.8. Now, set up passwords for various access levels to avoid warnings since this project contains a safety
program. Let’s set up a display password under PLC_1  Right Click  Properties  General
Display  Password as shown in Figure 5.11.
5.9. Let’s set up a password for access level under PLC_1  Right Click  Properties  General
Protection and Security  Access Level  Full access incl. fail-safe (no protection)  Password
as shown in Figure 5.12.
5.10. Finally, set up a password for a safety program under Safety Administration  Access Protection 
Setup as shown in Figure 5.13.
Figure 5.11 Setup Display Password
Figure 5.12 Access Level Password Setup
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Figure 5.13 Password Setup for Safety Program
5.11. Similarly, make sure the IP protocol and PROFINET information is correct for CP1604 as it was
configured at step 3.15. If not, please correct it (Figure 5.14).
Figure 5.14 IP Protocol and PROFINET Information (CP1604)
5.12. It’s time to fill in CRC which is generated by robot when DCS apply is done. Now go to MENU 0
6TYPE DCS. Press F2, [APPLY] if any changes are pending. Please refer to the Dual Check Safety
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Operator’s manual if you do not know the apply process. Now go to PROFINET Safety page and look for
item #4, F_Address and F_iPar_CRC Calculation which are the F_Dest_Add and CRC to be filled in the
project. These are 200 and C181B3 respectively in this example. Please note that CRC may be empty or
wrong, if any changes are pending. Please click on Safety I/O under the Network View tab on right pane.
Fill in F_Dest_Add to 200 (Robot has F_Dest_Add 200 by default), and next fill C181B3 as noted earlier
from robot in F_iPar_CRC box as shown in Figure 5.15.
Figure 5.15 Assign CRC
5.13. Save and compile the project as shown in Figure 5.16 and Figure 5.17.
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Figure 5.16 Compile H/W and S/W
Figure 5.17 Compile H/W and S/W
5.14. If there are no errors, create the reintegration logic. Open up PLC_1  Program Blocks 
Main_Safety_RTG1[FB1] program, and change Language to LAD.
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Figure 5.18 Change the Language to LAD
5.15. Now, drag Normally Open Contact to the ladder on network below. Click on “??.?” and look for
F00000_cp1604 in the drop down as shown in Figure 5.19.
Figure 5.19 Drag Normally Open Contact to Network
5.16. Now select ACK_REQ under F00000_cp1604 as shown in Figure 5.20.
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Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Figure 5.20 Select ACK_REQ
5.17. Now, drag the Assignment operator to the network and select F00000_cp1604.ACK_REI this time using
procedure shown in Figure 5.19 - Figure 5.20. Acknowledge for reintegration is ready in Figure 5.22.
Compile again as shown in Figure 5.23.
Figure 5.21 Drag Assignment operator
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Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Figure 5.22 Acknowledgement for reintegration
Note: Please note that this PLC programming example is just a proposal; and actual re-integration strategy should
be reviewed with customer’s safety officer.
Figure 5.23 Recompile
5.18. The safety program is ready to be downloaded. Please download the program to the safety PLC.
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Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Figure 5.24 Download to device
5.19. Press the search button that shows all accessible devices. In this example, there is only one that is PLC.
Select the device, and press Load.
Figure 5.25 Select PLC
5.20. At this stage, it prompts you to check if everything is good to load to the device. Under password
section, you need to enter the password which you created in step 5.9. There is a protection warning
which is OK for now. Press Load again.
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Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Figure 5.26 Load Verification
5.21. The load results screen appears once the project is downloaded successfully. Now start all modules by
pressing the Finish button (Figure 5.26).
Figure 5.27 Start Devices
5.22. If everything goes well, the screen shown below shows all checks passed and loading completed
without errors/warnings (Figure 5.28).
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Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Figure 5.28 Loading Completed
5.23. You can check that all devices got the correct IP addresses and names are being shown in online
diagnostics as configured earlier (Figure 5.29).
Figure 5.29 Online and Diagnostics
5.24. Go ONLINE and both devices can be seen checked green under network view. It shows both devices
are talking successfully as shown in Figure 5.30.
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Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
Figure 5.30 Devices Online
5.25. At this point, all LEDs on PLC and CP1604 are green. Now let’s verify on the robot if safety I/O
exchange started. Go to MENU  SYSTEM  0  6  TYPE  Status  PROFINET
F3[other]Safety. If everything is OK, Safety I/F Status shows RUNNING and Frame count
continues incrementing as shown in Figure 5.31.
Figure 5.31 Frame Count
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Doc: Profinet Safety User Guide v1.0
Software Version: V910P/05 and up
H/W Version: R30iB Plus
Modified: 04/16/2018
PROFINET Variant: SIEMENS
PROFINET H/W: CP1604 FW 2.7.2.0
6. Tips and Tricks
6.1. Make sure to use a fixed IP V4 address on the ONE and SAME subnet / as all the PROFINET equipment
you are working with / for the Ethernet adapter of your PC.
6.2. Use TIA V14 SP1 UPD4, or above as noted earlier in the guide.
6.3. It is always advised to have a clear and fixed list of PROFINET names and IP’s for all your equipment on
the network before starting engineering work.
6.4. Please make sure you have complete H/W and F/W information of the equipment you are trying to
use. Even the slightest variance can cause the devices not to communicate. Make sure you have
EXACT hardware references, and the EXACT versions of FW installed on all the different modules, out
of the HW catalogue.
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