Computer Unit

2 Motherboard

2.1 Motherboard interfaces

COM1 COM2 LPT1

for mouse connection for serial interface for printer connection
(9--pin) (25--pin) (25--pin)

Floppy disk drive

for 3.5“ disks

Hard disk
for data storage in
the PC

CD--ROM drive
for CD’s

Pentium
Power supply unit
Voltage supply for all
PC components

Motherboard
27 V

Data cable (ribbon cable): from power module

Supply cable:

Fig. 36 Motherboard interfaces

2.1.1 Serial interface

The serial interfaces are used to connect a mouse, (serial) printer or other serial peripheral
device. On a serial interface, the data is transferred on only one line (one channel) in
sequence, i.e. in serial mode. These interfaces have either a 9--pin or a 25--pin port and are
labelled COM1 (1st serial interface) and COM2 (2nd serial interface).

2.1.2 Parallel interface

The parallel interfaces are used for connecting a (parallel) printer or other parallel peripheral
devices. On a parallel interface, the data is transferred simultaneously on eight lines (eight
channels) in parallel. This interface has a 25--pin port (female) and is designated LPT1 (1st
parallel interface).

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 2 Motherboard (continued)

2.2 Motherboard properties

The motherboard (also: “main board”) is the central board in a PC system. The processor,
the main memory (RAM) and interfaces to all PC components are all located on the mother-
board. Furthermore, the motherboard determines the type of bus system used and characte-
rizes it in terms of the PC performance category to which it belongs.

The processor (CPU):

The CPU (Central Processing Unit) controls all operations and sequences of a process and
is the most important chip on the motherboard. Directly or indirectly, the processor is
connected to every other component in the PC. Address and data lines are available to the
CPU for this purpose. Intel Pentium CPUs with processor clock rates of 166 MHz and Cele-
ron 400 MHz have been used in the KR C1 A. The standard specification currently supplied
is Celeron 400 MHz. The current standard specification delivered is 166 MHz.

The main memory (Random Access Memory)

In the KR C1 A ≥64 MB of RAM are installed as standard. Unlike the mass memory devices
(HDD, FDD and CD--ROM), which can store their data permanently, the main memory is a
volatile memory, i.e. all the contents of the main memory are lost when the power supply is
switched off.

The bus systems

The bus is the central communication line of the computer. The various functional areas such
as interfaces, controller or graphics card are coordinated via the bus. The bus consists of
a number of lines and a special controller circuit that governs data traffic on these lines. A
distinction can be drawn between the address bus and the data bus: with the address bus,
specific memory areas or ports can be designated to receive or transmit data. These data
are then transported over the data bus.

The cache memory

The cache memory (a special buffer memory), unlike the simple buffer memory, can work
in both directions (read/write cache) and has a degree of intelligence that enables it to hold
certain data ready for use even before they are requested.

The chipset of the motherboard

The chipset is a group of highly complex ICs that are strictly matched to one another and act
as the auxiliary unit for controlling and monitoring the PC system. These components are
integrated on the motherboard and support the processor e.g. in accessing the main memory
and organizing the data bus or address bus. They also contain the bus controller, cache
controller and memory controller and various other monitoring and control units.

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Computer Unit

2.3 Types of motherboard in the KR C1 A

According to the motherboard manufacturer, the boards listed below can be equipped
with different processor types. However, KUKA Roboter GmbH assembles, tests and
delivers the individual motherboards only in accordance with the following table. No
warranty can be provided for any other configuration.

Intel Pentium processor

Motherboard Celeron
166 MHz
400 MHz
HOT--579 X
SY71ZB+ X
GA--6LA7 X

All motherboards have a sticker on the side of ISA slot 4 (the slot nearest the outer edge
of the board) bearing the name of the board. An angled mirror or a CD (which can be used
as a mirror) is useful for looking at this on an installed board. On some motherboards, the
name of the board is printed on the board itself.

2.3.1 Special features (distinctive features) of the individual motherboard types

Name of the motherboard

printed on the board

SOYO chip set

Three ISA slots

Fig. 37 Motherboard SY7IZB+ (SOYO)

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 2 Motherboard (continued)

SIMM memory banks

VIA chip set

Three ISA slots

Motherboard name sticker on the side

of the first ISA slot

Fig. 38 HOT--579 motherboard (Shuttle)

INTEL chip set

Name of the motherboard

printed on the board

Two ISA slots

Fig. 39 GA--6LA7 motherboard (Gigabyte)

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Computer Unit

2.4 Motherboard hardware configurations

2.4.1 Motherboard configuration SY--7IZB+ (SOYO)

Fig. 40 Motherboard SY7IZB+ (SOYO)

Configuring the clock rate and the processor voltage

G The processor voltage and the clock rate are not configured using jumper settings on
the motherboard.
G The settings are made in the BIOS setup, in the so--called [SOYO COMBO SETUP].
G The first time the computer is booted, the boot procedure is interrupted by pressing the
<Del> key and the BIOS setup window appears.
G First of all, select the option [LOAD SETUP DEFAULTS]; the SETUP then loads the
basic BIOS settings giving the motherboard an optimal basic configuration.
G Once this process is complete you can select the option [SOYO COMBO SETUP]. This
activates a selection window listing the processors suitable for the motherboard.
G To the left of the CPU frequencies are a number of buttons. Select the button next to
the entry corresponding to your processor (400MHz (66x6.0)).
G In the main menu, select the item [SAVE & EXIT SETUP]. Confirm the process by pres-
sing <ENTER> to save the settings that have been made and end the BIOS SETUP.
The computer then continues the boot process.
G Your motherboard is now configured for the processor.

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 2 Motherboard (continued)

2.4.1.1 Motherboard configuration Shuttle HOT--579

Motherboard configuration Shuttle HOT--579

PENTIUM JP4 JP5 JP6 JP11 JP12 JP13 JP33 JP33 JP33 JP33 JP33
2--3 2--3 1--2 1 3 5 7 9
manual manual manual manual manual

166 / 66 MHz* open closed closed closed closed closed closed closed closed closed open
* REG jumper over D--S

On--board AT--power
supply connection

On--board AT--power
Parallel supply connection
JP17 program- interface
ming voltage for Two serial PS/2 mouse Keyboard
Programmable EEPROM Flash EPROM interfaces connection connection
Flash BIOS Infrared connection

USB connection

Delete JP19 CMOS

3 ISA slots

4 PCI slots

Connections for
on--board EIDE
controller
Connections for on--board
floppy disk controller

VIA VT580VPC chip

set

JP11, JP12, JP13, JP14

system clock rate setting

JP31 AT/ATX power

supply selection
ZIF socket 7

On--board voltage
controller allows auto-
matic setting of the
CPU voltage
JP33
CPU voltage automatic JP4, JP5, JP6
or manual setting CPU multiplier
On--board 1MB/512kB pipelined
HDD burst cache
KEYLOCK 1 EPMI LED+

Two DIMM
Four SIMM
+ SPEAKER RESET PWR ON
Jumper REG2: closed
G Intel Pentium P54C
D
S
Fig. 41 HOT--579 motherboard (Shuttle)

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2.4.1.2 Motherboard configuration Gigabyte GA--6LA7

Motherboard configuration Gigabyte GA--6LA7 (DIP switches for CPU frequency)

PENTIUM SW1 SW2 SW3 SW4
Celeron
400 MHz on on on off
Motherboard configuration Gigabyte GA--6LA7 (Jumpers for board frequency)
PENTIUM JP6 JP5 JP4
Celeron
66 MHz 1--2 1--2 1--2

DIP switches

Jumpers

Fig. 42 Motherboard GA--6LA7 (Giga-

byte)

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 2 Motherboard (continued)

2.5 Exchanging the motherboard

A defective motherboard is counted together with the swing frame as a single
exchange part and is therefore not exchanged separately.

2.6 Exchanging the RAM memory modules

(1) Lever the lateral clips on the RAM sockets carefully to the sides with a small screw-
driver. Tilt the memory modules backwards and remove.
(2) The new memory modules are tilted slightly backwards, placed into the groove in the
RAM socket and pushed forwards until they lock into place.
Polarity reversal is not possible as the memory modules possess a characteristic
groove on one side making it physically impossible to insert them the wrong way round.

When using Simm modules, the sockets in a memory bank must always be fitted in
pairs with identical modules.
Simm modules (72--pin, 5 V) and Dimm modules (168--pin, 3.3 V) must not be used at
the same time.
For further information please refer to the user manual provided by the motherboard
manufacturer (delivered with the robot controller).

2.7 Exchanging the swing frame

(1) Switch off the robot controller and wait until the battery--backed shutdown storage
procedure is terminated.
(2) Remove the cover plate on the back of the swing frame (for this you will require a Phillips
screwdriver).
(3) Disconnect the mouse and keyboard if applicable. Disconnect power supply and PE
connections.
(4) Disconnect cable connections to the KVGA, MFC and DSE--AT.
(5) Release the cable clip bracket.
(6) Depending on the version, either slacken cable harness screws or open the cable strap
and place the cable harness carefully to one side.
(7) Unscrew safety logic.
(8) Lift the swing frame vertically and remove.
(9) Reattach the cover plate on the back of the swing frame.
(10) Package the swing frame and send it to KUKA Roboter GmbH with a detailed descrip-
tion of the fault.
(11) The swing frame is installed by reversing the above sequence.

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Computer Unit

2.8 Motherboard function test

2.8.1 Boot the computer using a boot disk
(1) Connect a PC loudspeaker to the “SPEAKER” or “SPK” interface (bottom left) on the
motherboard (not included as part of the robot controller package!).

Since the motherboard generates acoustic signals (beeps) in the event of a malfunction,
a PC loudspeaker can be very useful for locating faults.
A loudspeaker is not necessary for normal robot operation as the acoustic signals are
not noticeable in any case because of the noise of the production processes.
(2) Insert boot disk and switch on the robot controller.
(3) Pay attention to the following messages on the display and acoustic signals from the
loudspeaker:
-- is there a display on the screen?
-- can a short beep (boot signal) be heard from the loudspeaker?
-- is the CPU clock correctly displayed (e.g. “PENTIUM--S CPU at 166MHz”)?
-- is the main memory correctly counted (e.g. Memory Test: 32768K OK)?
-- after the main memory has been counted, the “NumLock”, “CapsLock” and “Scroll
Lock” LEDs on the keyboard light up briefly (these LEDs may be labelled diffe-
rently!).
-- does the system automatically detect the hard drive? (This is only carried out if
the setting “AUTO” has been made in the BIOS setup, in the menu “STANDARD
CMOS SETUP”, under the menu item “HARD DISKS” “TYPE”.)
Message: Detecting HDD Primary Master ...
-- does the system detect the CD--ROM drive?
Message: Found CDROM: FX400E
-- are any BIOS error messages generated?
(4) As soon as the main memory has been counted, press the “Del” or “Backspace” key
on the external keyboard in order to make the necessary settings in the BIOS setup for
booting the system from a boot disk.
-- Check or set the date and time in the menu “STANDARD CMOS SETUP”.
-- In the menu “STANDARD CMOS SETUP”, under the menu item “HARD DISKS”,
set “TYPE” to “AUTO”.
-- In “BIOS FEATURES SETUP”, switch the option “Boot Sequence” to “A,C”.
-- Save the settings and exit the BIOS setup using the BIOS function “SAVE & EXIT
SETUP”. The computer boots again.
(5) Repeat point (3).

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 2 Motherboard (continued)

(6) As soon as the window “System Configurations” appears, in this case for a Shuttle--
HOT 579 motherboard, interrupt the boot procedure by pressing the “Pause” key on the
external keyboard and check the settings.

(7) After checking the settings, press “Enter” to resume the boot procedure.
(8) Windows 95 is booted.
Message: Windows 95 booting ...

2.8.2 Boot the computer from the hard drive

If the system runs up correctly, the following boot sequence is observed:
G Boot procedure as when booting from floppy disk — see Section 2.8.1, points (3), (6)
and (8)
G The LPVXWIN.VXD driver for the real--time operating system VxWorks is loaded
G The Windows 95 Desktop appears
G The file CROSS.EXE is booted
G The FTP server KUKAFTPD is called
G Memory is reserved for VxWIN
G KUKA GUI is loaded
G KUKA GUI is initialized
G KUKA GUI appears

2.8.3 Confirm the function check by checking the functioning of other components
G Check the functioning of the following components:
-- KCP, drive servos, KPS 600, MFC, DSE--IBS
-- IBS card, if present
Refer to the relevant sections in this chapter.

The robot must be subjected, by means of a motion program, to at least 30 minutes

continuous operation, in order to preclude the risk of runtime or thermally induced errors.

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