151531401460

SOFTWARE
KR C2
KUKA.ArcTech Analog -- Configuration

Arc welding for power sources with analog reference voltage
Release 1.1
for KUKA System Software (KSS) Release 5.2, 5.3, 5.4, 5.5
Issued: 28 Juli 2008 Version: 00
ArcTechAnalog_Pro_R1.1 02.05.00 en 1 of 125

e Copyright 2008
KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim 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, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
2 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Operating convenience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Overview of the configurable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Additional safety instructions for “KUKA.ArcTech Analog” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Symbols and icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.2 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Graphical user interface (HMI) of the KUKA Control Panel (KCP) . . . . 11

3.1 Selecting the “Expert” user group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Configurable options ($CONFIG.DAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Configurable options (A10.DAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 “KUKA.ArcTech Analog” programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Overview of files for “KUKA.ArcTech Analog” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Adaptation to the periphery, configurable options . . . . . . . . . . . . . . . . . . 17

5.1 Digital outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1.1 Overview and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1.2 Index table for physical digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.3 Signal tables for digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.4 Examples of a signal configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.5 Index table for physical digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.6 Signal tables for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Customer--specific adaptation of weld sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2.1 Subroutines for weld commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2.2 Error handling routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Description of the weld commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.1 Controlling welding and wire feed with the status keys on the KUKA Control Panel . . . . . . 37
6.1.1 Manual activation and deactivation of the weld process (FLY ARC) . . . . . . . . . . . . . . . . . . . 37
6.2 Activating the welding package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3 Initialization (ARC--INIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.1 Checking the specified Submit routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.2 Setting the cyclical analog channel for ONLINE optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.3.3 Required setting for reduced velocity in T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3.4 Required settings for backward motion of a welding application . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 ARC ON command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4.1 Welding constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4.2 Gas preflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4.3 Configuration: monitoring the weld power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4.4 Configuration: robot motion start after weld start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4.5 Configuration of the weld modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.6 Configuration of the WELD start signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.7 Configuration of the error handling for an ignition failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4.8 Configuration of gas postflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.9 Configuration of necessary acknowledgement signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.10 Activating the ramp function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.11 Schematic sequence diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4.12 Ignition process signal flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.4.13 Activation of delayed weld process monitoring after ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.5 ARC SWITCH command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.5.2 Signal diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.5.3 Signal tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.6 ARC OFF command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.6.1 Signal tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.7 Burnfree options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.7.1 Configuration: burnfree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.7.2 Burnfree duration and number of burnfree attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.8 Burnback mode -- A_BB_MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.8.1 Burnback mode A_BB_MODE=#ACT_PAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.8.2 Burnback mode A_BB_MODE = #REDUCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Configuration of analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

7.1 Maximum number of analog outputs -- A_ACT_AN_MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1.1 Addressing of the analog outputs -- A_ANAOUT_NO[8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.2 Adaptation of analog outputs 1 and 2 specific to the power source . . . . . . . . . . . . . . . . . . . . 64
7.2.1 Number of characteristic points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2.2 Linear characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2.3 Non--linear characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 Weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.3 Two--dimensional weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.3.1 Creating the “Spiral” weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3.2 “Double 8” weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.4 Changing and creating patterns for mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.4.1 Changing existing weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.4.2 Creating your own weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.5 Notes on mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

8.5.1 Weave frequency, weave length, path velocity (travel speed) . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.5.2 Rotation of the weave plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9 Thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.1.1 Weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.1.2 Example of a signal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2 Combined mechanical and thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2.1 Combination possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2.2 Practical application possibilities (examples) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10 “KUKA.ArcTech Analog” settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10.1 Power source characteristic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.2 Configuration of the physical interface ($CONFIG.DAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2.1 Physical outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2.2 Configuration of the physical inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.3 Settings in the file A10.DAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11 Default data sets, resource distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

11.1 Setting the default data sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.2 KUKA.ArcTech Analog resource distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.2.1 Interrupt definitions at R1 level (all ARC versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.2.2 $CYCFLAG indices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.2.3 $TIMER indices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.2.4 Interrupt indices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
12 Fault situations and fault service functions . . . . . . . . . . . . . . . . . . . . . . . . 95

12.1 Ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12.1.1 Configuration: number of permissible ignition attempts ($CONFIG.DAT) . . . . . . . . . . . . . . . 95
12.1.2 Setting the ignition fault option ($CONFIG.DAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12.1.3 Special features of user--defined ignition fault service functions (#USR_START) . . . . . . . . 96
12.1.4 Ignition fault signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
12.2 Media faults of periphery faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
12.2.1 Configuring the monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
12.2.2 Ignoring temporary interrupts (A_SWINDL_OPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.3 Robot faults (IR_STOPMESS faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.3.1 Deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.3.2 Reactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12.3.3 Signal diagram for IR--STOPMESS or seam error fault situations . . . . . . . . . . . . . . . . . . . . . 100
12.4 TechStop faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.4.1 Description of the subroutine SPS.SUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.4.2 Interruption of the welding process after interpreter stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.4.3 Restart after an interpreter stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.4.4 Sequence diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
12.4.5 Details of the routine in the Submit interpreter (SPS.SUB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
12.5 Integration of the cleaner routine (torch cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12.6 Restart options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

12.6.1 Fault service functions defined by the user (#USR_SEAM) . . . . . . . . . . . . . . . . . . . . . . . . . . 109

12.6.2 Number of restart attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
12.6.3 Fault signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
12.6.4 Block selection response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
13 Customized messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

13.1 Message program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
14 Fault location, fault elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
15 Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

15.1 Message group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.2 Message time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.3 Message number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
15.4 Originator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
15.5 Message text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
15.6 List of error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
15.7 Standard error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1 Introduction
1 Introduction
This documentation has been created as a supplement to the documentation
[KUKA.ArcTech Analog -- Operation] for the Expert user group. In addition to basic
descriptions with accompanying schematic flow diagrams, it contains screenshots of
application tests and information on both standard routines and specific “KUKA.ArcTech
Analog” applications. This is intended to make parameter and hardware configuration and
the programming of arc welding applications easier.
At the expert level, the entire range of KRL commands are available to you. This requires
sufficient knowledge of the KRL programming language.
Texts in serif font are generally extracts from files, for example: DECL
A_TECH_STS_T A10_OPTION=#ACTIVE.
Passages in program listings that appear in bold type and/or are underlined indicate
that entries or changes can or must be made at these points.
Explanatory information on listings is shown in italics.
The syntax description of the KRL programming language is provided in the chapter
[Reference Guide]. Basic information on operation as well as the menu--guided creation
of programs at user level is provided in the documentation [KUKA.ArcTech Analog --
Operation].
1.1 System requirements

The technology packages have the following KRC controller and system software
requirements:
-- KUKA.ArcTech Analog KR C2, KUKA System Software (KRS) Rel. 5.2, 5.3, 5.4, 5.5
For more information, refer to the documentation [KUKA.ArcTech Analog -- Operation].

1.2 Operating convenience

G Manual control of the wire feed
G Manual control of the welding process
G “DryRun” function for quickly running over programmed seams without actually welding
G Welding ON/OFF, for activating/deactivating the welding process while applications are
running, including through--the--arc weave sensor (KUKA.ArcSense)
G Restart of the welding process after an interpreter stop and deactivation of the
peripheral interface signals
G Selection of any data set in a program with immediate start of the welding process
(configurable option)
G Automatic adaptation of the parameter lists following configuration and reboot
G Online optimization of velocity and weld parameters
G Integration of the “KUKA.ArcSense” weave sensor
1.3 Overview of the configurable functions

The “KUKA.ArcTech Analog” technology package also provides a range of options in addition
to the basic configuration.
G Adaptation of various welding equipment with analog reference voltages
G Quasi--simultaneous control of up to eight analog outputs
G Calibration of the weld voltage and wire feed according to the characteristic of the
welding equipment being used
G Adaptation of the parameters to the specific ignition process, for welding a seam in one
or more sections
G Different burnback options and burnfree option
G Various routines used for ignition faults, and monitoring of the ignition attempts
G Ignition repeats following faults, possible with ignition or weld parameters
G Variable ignition characteristics in fault situations
G Restart options in the event of faults
G Configurable user--specific strategies and routines in the event of faults
G Monitoring of welding faults, taking into account special welding processes (CO2)
G Selection of several defined patterns for mechanical weaving as well as the option of
configuring your own weave patterns
G Thermal weaving with synchronous variation of weld power and wire feed
G Manually switching the welding process and sensor function on and off
G Option of direct block selection within ARC SWITCH commands for continuing the
welding process
G Option of user--defined, cause--specific error messages during welding
G Option for adaptation and manipulation of parameter list labeling
G Ramp function for power and wire feed

2 Safety
2 Safety
WARNING!
Failure to observe these safety instructions could result in injury or a fatal accident
and/or damage to the robot system or other property!
G All pertinent safety regulations as well as the booklet [Safety and Installation
Instructions] are to be observed when working on the system.
G The KUKA safety chapter [KRC Safety, General] is supplied with the robot system and
must be read and understood before commencing work.
G The safety instructions in the KR C2 Operating Handbook must be observed.
2.1 Additional safety instructions for “KUKA.ArcTech Analog”

G Installation, exchange and service work on this technology package or individual
components thereof may only be performed by qualified personnel specially trained for
this purpose and acquainted with the risks involved.
G Follow the safety instructions provided by the manufacturer of the welding system used.
2.2 Liability
The “KUKA.ArcTech Analog” technology package has been designed, built, and
programmed using state--of--the--art technology and in accordance with the recognized
safety rules. Nevertheless, improper installation of this unit or its employment for a purpose
other than the intended one may constitute a risk to life and limb of operating personnel or
of third parties, or cause damage to or failure of the control cabinet, resulting in damage to
or failure of the entire robot system and other material property.
“KUKA.ArcTech Analog” may only be used in technically perfect condition in accordance with
its designated use and only by safety--conscious persons who are fully aware of the risks
involved in its operation. Connection and use must be carried out in compliance with this
documentation.
2.3 Designated use

“KUKA.ArcTech Analog” is a technology package for arc welding with power sources with
an analog reference voltage, for operation with a KUKA robot controller.

2.4 Symbols and icons

The safety symbols and icons described in the following are used in this documentation:
2.4.1 Safety symbols

Text passages indicated by these safety symbols are important for safety and must be
observed.
WARNING!
Exact compliance with these safety warnings is necessary for the prevention of
personal injury.
CAUTION!
Exact compliance with these safety warnings is necessary for the prevention of
damage to property.
2.4.2 Icons
Info
Indicates passages which are of particular significance or are useful for greater under-
standing.
See also
Indicates sections or chapters containing further information and explanations.
NOTE
Indicates sections with additional information on a particular subject and highlights special
features.

3 Graphical user interface (HMI) of the KUKA Control Panel (KCP)
3 Graphical user interface (HMI) of the KUKA Control Panel (KCP)

The most important settings and menu functions of “ArcTech Analog” are described in this
section.
Additional information on this can be found in the documentation [ArcTech Analog --
Operation].
3.1 Selecting the “Expert” user group

The “User” user group is initialized by default every time the system is started. You can
access the “Expert” user level from the “Configure” menu. From this menu, select the “User
group” item and press the “Expert” softkey. Enter your password when prompted to do so
and press the “Continue” softkey or the Enter key.
3.2 Configurable options ($CONFIG.DAT)

The configurable options described here affect the commands and influence the appearance
of the parameter lists. The variables are saved in the “$Config.dat” file.
Variable Value Meaning

A_ACT_AN_MAX 1 -- 8 Number of analog channels
(Default: 2)
A50_OPTION #DISABLED Display of the inline forms
#ACTIVE for TAST sensor (through--
arc seam tracking sensor,
(Default: #DISABLED) KUKA.ArcSense)
A_RAMP_OPTION TRUE Another parameter list
FALSE element is displayed:
configurable length [mm]
(Default: FALSE)
A_TH_WEAVE_OPT TRUE Appearance of the
FALSE parameter list page with
settings for thermal
(Default: FALSE) weaving
A_BB_MODE #ACT_PAR, Appearance of the
#REDUCE parameter list with a
separate burnback
(Default: #ACT_PAR) parameter for each weld
data set

3.3 Configurable options (A10.DAT)

The configurable options described here affect the commands and influence the appearance
of the parameter lists. The variables are saved in the “A10.dat” file. If the system is shut down
and rebooted using the variable RE_INITIALIZE=TRUE, the analog channels listed above
have new units and increments.

HIDE_BB_TIME TRUE Parameter list element for
FALSE burnback is no longer visible
in the weld data and crater
(Default: FALSE) filling parameter lists
RE_INITIALIZE=TRUE TRUE When set to TRUE, the
FALSE configured values shown in
the following tables will be
(Default: FALSE) taken over into the inline
forms or the parameter lists
next time the system is
booted.
Configuration: Analog channels

CHANNEL_INFO[1] {UNIT[]”volts”,STEP[]”0.1”} Analog channel 1 (weld
voltage, increment 0.1 ),
default: active
CHANNEL_INFO[2] {UNIT[]”m/min”,STEP[]”0.1”} Analog channel 2 (wire
feed, increment 0.1 m/s),
default: active
CHANNEL_INFO[3] {UNIT[]”%”,STEP[]”0.1”} Analog channel 3
(default: not active)
CHANNEL_INFO[4] {UNIT[]”s”,STEP[]”0.1”} Analog channel 4
CHANNEL_INFO[5] {UNIT[]”Hz”,STEP[]”0.1”} Analog channel 5
CHANNEL_INFO[6] {UNIT[]”ms”,STEP[]”0.1”} Analog channel 6
CHANNEL_INFO[7] {UNIT[]”ms”,STEP[]”0.1”} Analog channel 7
CHANNEL_INFO[8] {UNIT[]”s”,STEP[]”0.1”} Analog channel 8

4 “KUKA.ArcTech Analog” programs
4 “KUKA.ArcTech Analog” programs

4.1 Program structure
The block diagram in Fig. 1 shows the program structure of the robot controller with the
“KUKA.ArcTech Analog” technology package.
$CONFIG.DAT CELL.SRC
ARC WELDING
PACKAGE Autom./External
Global and
application data Organization
program
BAS.SRC P00.SRC IR_STOPM.SRC
Functions Functions for General

for robot Autom./ handling of
motion External robot faults
Handshake
Check Home
A10_INI.SRC A10.SRC FLT_SERV.SRC

.DAT .DAT .DAT
ArcTech Fault service
Arc welding functions
Analog functions
initialization defined by the
user
ARC_WEAVE.SRC A50.SRC ARC_MSG.SRC

.DAT
Definition and
parameters for A50 LIBO sensor Generation of
mechanical and functions user--defined
thermal weaving (through--the--arc error messages
seam tracking)
CLEANER.SRC A10_User.SRC
.DAT
-- Shutdown Customer--
-- Torch specific
cleaning after adaptation of
fault situation weld
sequences
(optional)
Fig. 1 “KUKA.ArcTech Analog” program structure

4.2 Overview of files for “KUKA.ArcTech Analog”

The files listed below are included with “KUKA.ArcTech Analog.”
$CONFIG.DAT Contains data specific to ArcTech Analog within the section
FOLD A10 GLOBALS
For additional entries, there is the file $CONFIG.DAT with the section
; User--defined Variables
A10.SRC Main program for arc welding with “KUKA.ArcTech Analog.”

A10.DAT Contains local data for the program “A10.SRC” and error message texts.
A10_INI.SRC “KUKA.ArcTech Analog” initialization program.

It sets the binary outputs to the initialization values.
-- Prepares the weld controller; activates the CYC flags;
sets the ARC variables;
-- defines the FIFO stack;
-- defines handling of faults in case of restarts.
A10_INI.DAT Contains local data for the program A10_INI.SRC as well as
error message data and, to a certain extent, configuration data.
FLT_SERV.SRC Program for user--defined fault strategies,

including ignition faults. Fault service function
(additional START error).
FLT_SERV.DAT Contains local data list for the program FLT_SERV.SRC.
ARC_MSG.SRC Routines for generation of user--specific error messages
ARC_WEAVE.SRC Definition of the patterns for mechanical and thermal weaving.

4 “KUKA.ArcTech Analog” programs (continued)
SPS.SUB
Program running at the controller level (PLC task) for monitoring and error handling in the
event of an interpreter stop.
Assured deactivation and reactivation after an interpreter stop.
This subroutine is used to manually control (by means of the left--hand KCP status keys) wire
feed (WFD) and welding (hot/cold) as well as switching off after an interpreter stop (red
“STOP” button).
The symbols illustrated below are to be found at various points in this documentation; they
indicate whether or not manual changes are permitted in the section of a file being described.
CLEANER.SRC
Torch cleaning package that can be integrated as an option (not included with
“KUKA.ArcTech Analog”); integration of cleaning device deactivation in the event of a fault
leading to an interpreter stop or robot STOPMESS reaction.


5 Adaptation to the periphery, configurable options
5 Adaptation to the periphery, configurable options

This section describes the definition of the interfaces from “KUKA.ArcTech Analog” to the
periphery, their specific adaptation as well as configurable options:
G Analog outputs Analog reference voltages from the robot controller to the
weld controller, e.g. weld voltage, wire feed;
G Digital outputs Digital control signals from the robot controller to the
weld controller -- e.g. “Gas preflow”, “Welding start”;
G Digital inputs Digital control signals from the weld controller to the
robot controller -- e.g. “Current flowing”, “Seam fault”.
Options in the form of index and signal tables are stored in variables that are defined in the
“FOLD ARCTECHANALOG GLOBALS” block in the “$config.dat” file. Settings that are
made are stored in that file. You can use an editor to set or change the values of the variables
in “$config.dat”.
Menu--prompted viewing and modification of the variable values is possible via the menu
“Monitor -- Variable -- Single.” The current value is shown when the variable name is entered.
This value can be changed.
A syntax check is not performed (for example, MIN and MAX values) when entries are
made using the menu function “Monitor -- Variable -- Single” or when the file is edited.
5.1 Digital outputs and inputs

5.1.1 Overview and purpose
The KRC interface is used to monitor safety and welding conditions (e.g. power source or
gas ready), and also to control the connected devices. A flexible concept is required in order
to be able to communicate with the wide range of different devices.
To facilitate this, all digital inputs and outputs of the physical interface can be freely configured
using the index table. A second table, the so--called signal table, enables the interlinking of
the physical inputs and outputs. This is necessary, for example, if a controller output is to
control different peripheral devices with different signal types (level, pulse) in parallel. This
so--called “induced addressing” uses two linking tables.
Physical
interface
Power source Controller

Gas
Periphery
Bus system Index table Linking with signal

assignment table
Fig. 2 Induced addressing -- linking tables

Index tables for configuring physical outputs and inputs

For the purpose of configuring the physical outputs and inputs, two index tables are
provided in the $config.dat file. The assignment of the electrical interface is defined here:
G Digital outputs FOLD ArcTech Outputs
A_WLD_OUT[ ] ...
Digital control signals from the robot controller to the
weld controller -- e.g. “Gas preflow”, “Welding start”...
G Digital outputs FOLD ArcTech Inputs
A_WLD_IN[ ] ...
Digital control signals from the weld controller to the
robot controller -- e.g. “Current flowing”, “Seam fault”,
In these index tables the assignment of the physical outputs and inputs is defined and
references are made to the corresponding signal tables of the controller.
This has the advantage that if the terminal assignments for the periphery are changed, all
that is needed is to alter the index tables accordingly.
Signal tables for linking digital inputs and outputs

The interface concepts are variable; this means that links between existing physical
inputs and outputs can be freely programmed in this signal table.
Configuring peripheral outputs and inputs by means of signal tables (“triple groups”) allows
processes to run synchronously. The option of setting or scanning several signals allows
various weld controllers to be adapted and timing to be optimized.
G Digital outputs A_O ...
Signal names of a group beginning with “A_O...”
designate digital outputs;
G Digital inputs A_I ...
Signal names of a group beginning with “A_I...”
designate digital inputs.
The signal table links (inputs and outputs) are preconfigured by the manufacturer so
it only remains necessary to adapt the index table to define the physical inputs and
outputs!

5 Adaptation to the periphery, configurable options (continued)
5.1.2 Index table for physical digital outputs

A total of 16 digital outputs (A_WLD_OUT[1] ... A_WLD_OUT[16]) are available; their
physical assignment (OUT_NRn) is freely definable. All “OUT_NR” array elements are set
to “0” at the factory, meaning they are inactive. For the purpose of assigning the physical
outputs, you can enter their corresponding numbers in the “FOLD ArcTech Outputs” index
table in the $config.dat file:
$config.dat ;FOLD ArcTech Outputs
DECL CTRL_OUT_T A_WLD_OUT[16]
A_WLD_OUT[1]={OUT_NR 0,INI FALSE,NAME_NAT[] “WELD_START “
A_WLD_OUT[2]={OUT_NR 0,INI FALSE,NAME_NAT[] “GAS PREFLOW “}
A_WLD_OUT[3]={OUT_NR 0,INI FALSE,NAME_NAT[] “WELD_MODE PS/MM”}
A_WLD_OUT[4]={OUT_NR 0,INI FALSE,NAME_NAT[] “CLEANER “}
A_WLD_OUT[5]={OUT_NR 0,INI FALSE,NAME_NAT[] “RECEIPT ERRORS “}
A_WLD_OUT[6]={OUT_NR 0,INI FALSE,NAME_NAT[] “ERROR MSG_SIGNAL”}
A_WLD_OUT[7]={OUT_NR 0,INI FALSE,NAME_NAT[] “START ERROR “}
A_WLD_OUT[8]={OUT_NR 0,INI FALSE,NAME_NAT[] “APPL_ERROR “}
A_WLD_OUT[9]={OUT_NR 0,INI FALSE,NAME_NAT[] “INTERPRETER-STOP”}
A_WLD_OUT[10]={OUT_NR 0,INI FALSE,NAME_NAT[] “ “}
A_WLD_OUT[15]={OUT_NR 0,INI FALSE,NAME_NAT[] “WFD + “}
A_WLD_OUT[16]={OUT_NR 0,INI FALSE,NAME_NAT[] “WFD - “}
Physical outputs Comment (signal name)
Initialization state
Fig. 3 Index table for physical digital outputs ($config.dat)
If you make any changes to the “NAME_NAT” comments (signal names) directly in the file
$CONFIG.DAT, please ensure that the string between the quotation marks (“ ”) has a
maximum length of 20 characters.
All “OUT_NR” array elements are set to “0” at the factory, meaning they are inactive. The
“INI” element defines the state to which the respective “OUT_NR” physical output is to be
set on initialization. The value “FALSE” sets the output to “LOW”, the value “TRUE” sets it
to “HIGH”.
Example of corresponding entries using the menu function “Monitor -- Variable -- Single”:
Variable Type Characteristics
Assignment of the physical output,
A_WLD_OUT[1].OUT_NR INT
e.g. “10” (default: 0)
State after initialization
(ARC--INIT command)
A_WLD_OUT[1].INI BOOL (default: FALSE)
FALSE = LOW
TRUE = HIGH
20 characters between “ ”; please
bear in mind that when making alter-
A_WLD_OUT[1].NAME_NAT[ ] STRING ations, any characters in the string not
overwritten (e.g. not visible in the
monitor window) will be retained.

The example illustrated in Fig. 4 shows the assignment of the physical outputs and the signal
states after initialization.
$config.dat ;FOLD ArcTech Outputs

A_WLD_OUT[1]={OUT_NR 10,INI FALSE,NAME_NAT[] “...”}
A_WLD_OUT[7]={OUT_NR 15,INI TRUE,NAME_NAT[] “...”}
State after
initialization:
Output 10
LOW (logic 0)
Output 15
HIGH (logic 1)
Fig. 4 Assignment of physical outputs and signal states after initialization
Array “A_WLD_OUT[n] INI” contains the initial value when the INIT routine is running before
reaching the block coincidence movement.

5.1.3 Signal tables for digital outputs

Definition
Configuring peripheral outputs with so--called “triple groups” allows processes to run
synchronously; depending on the way the system has been configured, several
configurations can be set or checked. This enables different weld power sources and
interface concepts to be adapted and the timing to be optimized.
Up to three outputs can be controlled and for each of these outputs the following parameters
can be defined.
Output parameters Characteristics
{NO ’H0’,PULS_TIME 0.0,STATE TRUE} Output disabled (ignored)
Address in the index table
(A_WLD_OUT[1]). *)
{NO ’H1’,PULS_TIME 0.0,STATE TRUE}
“TIME 0.0” = static signal with
HIGH level (logic 1)
(A_WLD_OUT[2]). *)
{NO ’H2’,PULS_TIME 0.0,STATE FALSE}
“TIME 0.0” = static signal with
LOW level (logic 0)
(A_WLD_OUT[9]). *)
{NO ’H9’,PULS_TIME 1.0,STATE TRUE}
“TIME 1.0” = pulse signal (1 s) with
HIGH level (logic 1)
(A_WLD_OUT[12]). *)
{NO ’HC’,PULS_TIME 0.5,STATE FALSE}
“TIME 0.5” = pulse signal (0.5 s) with
LOW level (logic 0)
*) The value for the “NO” element can be entered as a decimal number (without “H” for
HEX). Because of internal system requirements, this value is converted to the correspond-
ing hexadecimal value when the data are loaded into the controller.
Example: ...{NO ’10’...
becomes
...{NO ’HA’
If “NO” is set to “0” (zero), the output is deactivated and is ignored during execution of the
program.
Fig. 5 shows an example of a signal table from the file $config.dat for a digital output. The
A_O_MODE[1] element with the value ’H3’ refers to array 3 in the “DIGITAL OUTPUTS”
index table (A_WLD_OUT[16]) and thus to the physical output configured in it.

$config.dat ; outputs for MODE1 welding

DECL A_FCT_OUT_T A_O_MODE1[3]
A_O_MODE1[1]={NO ’H3’,PULS_TIME 0.0,STATE TRUE}
A_O_MODE1[2]={NO ’H0’,PULS_TIME 0.0,STATE FALSE}
A_O_MODE1[3]={NO ’H0’,PULS_TIME 0.0,STATE FALSE}
Signal name Pulse duration State (TRUE)

(“0.0” = static)
Index for addressing
in index table “A_WLD_OUT[ ]”
Fig. 5 Example of signal table for a physical digital output ($config.dat)
An output can be static (PULSE_TIME 0.0) or can be output in the form of a pulse, in which
case the pulse duration is programmed in seconds. For example, PULSE_TIME 0.3
corresponds to a pulse duration of 0.3 seconds.
Example of the entries using the menu function “Monitor -- Variable -- Single”:
Assignment to element in index table,
A_O_MODE1[1].NO INT
e.g. “1” (default: 0)
Pulse duration in seconds
A_O_MODE1[1].PULS_TIME REAL
Default: 0.0 (static)
Active state
A_O_MODE1[1].STATE BOOL
Default: FALSE
Signal states for digital outputs

The following table shows the possible states of the physical outputs resulting from the
setting of the initialization value in the “FOLD ArcTech Outputs” index table and after
activation.
Entry in index table Entry in signal table Physical output state after
“A_WLD_OUT[n].INI” “<Signal name>.NO” Initialization Activation
FALSE FALSE LOW LOW
FALSE TRUE LOW HIGH
TRUE FALSE HIGH LOW
TRUE TRUE HIGH HIGH

5.1.4 Examples of a signal configuration

The “outputs weld start” signal should be assigned to the physical output 10 of peripheral
connector X11. The signal level should be LOW at initialization and statically HIGH at the
start of welding.
In the “DIGITAL_OUTPUTS” index table, the designation (NAME_NAT) “WELD START” is
already entered in the first line A_WLD_OUT[1]. Assign the value “10” to the “OUT_NR”
variable and the value “FALSE” to the “INI” variable.
; outputs weld start Signal table

A_O_WLD_STRT[1]={NO ’H1’,PULS_TIME 0.0,STATE TRUE} NO ’H0’ =
Output
A_O_WLD_STRT[2]={NO ’H2’,PULS_TIME 0.0,STATE TRUE} disabled
A_O_WLD_STRT[3]={NO ’H0’,PULS_TIME 0.0,STATE TRUE}
Index table DIGITAL OUTPUTS

A_WLD_OUT[1]={OUT_NR 10,INI FALSE,NAME_NAT[] “...”
Output 10 WELD START HIGH

INI LOW
Fig. 6 Example of signal configuration with signal table and index table
In the “outputs weld start” signal table, assign the value “H1” to the “NO” variable in the first
line “A_O_WLD_STRT[1]”. The signal level should be static, so enter the value “0.0” for
“PULS_TIME”. Finally assign the value “TRUE” to the “STATE” variable. Any number of
signals can be assigned to each output.

Fig. 7 shows the linking of the A_WLD_OUT[1] output to the signals A_O_WLD_STRT[1]
(weld start) and O_FLT_ARC_ON[1] (fault during the ARC ON command):
; outputs weld start Signal table
; outputs fault while arc on Signal table

A_O_FLT_ON[1]={NO ’H1’,PULS_TIME 0.0,STATE FALSE}
A_O_FLT_ON[2]={NO ’H2’,PULS_TIME 0.0,STATE FALSE}
A_O_FLT_ON[3]={NO ’H7’,PULS_TIME 0.0,STATE TRUE}
DIGITAL OUTPUTS Index table

A_WLD_OUT[1]={OUT_NR 10,INI FALSE,NAME_NAT[] “WELD...”
Status table:
Initialization LOW
A_O_WLD_STRT[1] HIGH
Output 10 A_O_FLT_ON[1] LOW
The signal tables provide the option of defining up to three signals, i.e. of activating up to three
different physical outputs with different signal levels by means of one event.
In the event of absent or incorrect peripheral interface signals, entries in the index and signal
tables (addresses, value assignments) should always be checked first, before carrying out an
extensive search for faults in the hardware.

5.1.5 Index table for physical digital inputs

A total of 16 digital inputs (A_WLD_IN[1] ... [A_WLD_IN[16]) are available; their physical
assignment (IN_NRn) is freely definable. All “IN_NR” array elements are set to “0” at the
factory, meaning they are inactive. For the purpose of assigning the physical inputs, you can
enter their corresponding numbers in the “FOLD ArcTech Inputs” index table in the
$config.dat file:
$config.dat ;FOLD ArcTech Inputs
DECL CTRL_IN_T A_WLD_IN[16]
A_WLD_IN[1]={IN_NR 0,NAME_NAT[] “WELDER READY “}
A_WLD_IN[2]={IN_NR 0,NAME_NAT[] “ARC ESTABLISHED “}
A_WLD_IN[3]={IN_NR 0,NAME_NAT[] “SEAM_ERROR “}
A_WLD_IN[4]={IN_NR 0,NAME_NAT[] “CURRENT OVER “}
A_WLD_IN[5]={IN_NR 0,NAME_NAT[] “KEY SWITCH HOT/COLD “}
A_WLD_IN[6]={IN_NR 0,NAME_NAT[] “ “}
A_WLD_IN[7]={IN_NR 0,NAME_NAT[] “BURN FREE INP_SIGNAL”}
A_WLD_IN[10]={IN_NR 0,NAME_NAT[] “WATER AVAILABLE “}
A_WLD_IN[11]={IN_NR 0,NAME_NAT[] “GAS AVAILABLE “}
A_WLD_IN[12]={IN_NR 0,NAME_NAT[] “WIRE AVAILABLE “}
A_WLD_IN[13]={IN_NR 0,NAME_NAT[] “COLLECTION FAILURE “}
Physical inputs Comment (signal name)
Fig. 8 Index table for physical digital inputs
Assignment of the physical input, e.g.
A_WLD_IN[1].IN_NR INT
“2” (default: 0)
20 characters between “ ”; any char-
A_WLD_IN[1].NAME_NAT[ ] STRING
acters not overwritten will be retained.
All “IN_NR” array elements are set to “0” at the factory, meaning they are inactive.
If you make any changes to the “NAME_NAT” comments (signal names) directly in the
$config.dat file, please ensure that the string between the quotation marks (“ ”) has a
maximum length of 20 characters.
The following example illustrates the assignment of the physical inputs.

$config.dat ;FOLD ArcTech Inputs

A_WLD_IN[1]={IN_NR 2,NAME_NAT[] “WELDER READY “}
IN_NR 0 = input disabled Signals at:
Input 2
Input 12
In the example shown in Fig. 9, A_WLD_IN[1] is assigned to physical input no. 2 and
A_WLD_IN[2] to physical input no. 12.
5.1.6 Signal tables for digital inputs

Definition
Configuring peripheral inputs with so--called “triple groups” allows processes to run
synchronously; depending on the way the system has been configured, several
configurations can be set or checked.
Up to three inputs can be scanned. The following states can be checked for each of these
inputs:
Input parameter Characteristics

{NO ’H0’,STATE TRUE} Input disabled (ignored)
A HIGH signal is expected at the physical input
{NO ’H1’,STATE TRUE} referring to address 1 (H1) of the
I_WELD_CTRL[ ] index table.
A LOW signal is expected at the physical input
{NO ’H2’,STATE FALSE} referring to address 2 (H2) of the
I_WELD_CTRL[ ] index table.

The following example shows the signal table for a digital input. The A_I_WLD_COND[1].NO
element with the value ’H1’ refers to field 1 of the “FOLD ArcTech Inputs” index table
(A_WLD_IN[ ]) and thus to the physical input configured in it.
$config.dat ;inputs as condition before weld can start
DECL FCT_IN_T A_I_WLD_COND[3]
A_I_WLD_COND[1]={NO 1,STATE TRUE} ; source ok
A_I_WLD_COND[2]={NO 10,STATE TRUE} ; water available
A_I_WLD_COND[3]={NO 11,STATE TRUE} ; gas available
Signal name State

Index for addressing in
“A_WLD_IN[16]” index table
Fig. 10 Example of signal table for a digital input
Assignment of the physical input, e.g. “1”
A_I_WLD_COND[1].NO INT
(default: 0)
Active state
A_I_WLD_COND[1].STATE BOOL
Default setting: FALSE
The value for the “NO” element can be entered as a decimal number (without “H” for
HEX). Because of internal system requirements, this value is converted to the corres-
ponding hexadecimal value when the data are loaded into the controller, for example:
...{NO 10 ...
becomes
...{NO ’HA’ ...
The wait time for digital input signals is limited by the value of the “A_TIME_OUT1” variable.
$config.dat REAL A_TIME_OUT1=200.0 ; TIMEOUT for digital input
[10 ms * 200 -> 2.0 sec]
After this configurable wait time, the program is stopped and a corresponding error message
is displayed in the message window.
Entries using the menu function “Monitor -- Variable -- Single”:
Wait time 10 milliseconds [ms]
A_TIME_OUT1 REAL
For value 200 = [10 ms * 200] = 2000 ms = 2 s

Signal states for digital inputs

The signal tables provide the option of assigning up to three input signals to a condition. The
following example shows the “Inputs as condition before weld can start” signal table.
I_WELD_COND[1] here refers to the A_WLD_IN[1] field in the “FOLD ArcTech Inputs”
index table, in which the physical input 2 is defined by “IN_NR 2”. The system waits for a
HIGH signal at this input in accordance with the definition “STATE TRUE”.
Two other input signals are defined in this example as the second and third conditions that
have to be met before welding can be started.
; inputs as condition before weld can start
Signal table
A_I_WLD_COND[1]={NO 1,STATE TRUE}
A_I_WLD_COND[2]={NO 11,STATE TRUE}
A_I_WLD_COND[3]={NO 12,STATE FALSE} NO 0 = input disabled
;FOLD ArcTech Inputs Index table

A_WLD_IN[1]={IN_NR 2,NAME_NAT[] “WELDER READY...”}
A_WLD_IN[11]={IN_NR 12,NAME_NAT[] “2nd condition ...
A_WLD_IN[12]={IN_NR 17,NAME_NAT[] “3rd condition ...
Signals expected at:
Input 2
HIGH signal
Input 12
HIGH signal
Input 17
LOW signal
Fig. 11 Example of signal table for a digital input
Other signal tables may also contain references to the “ArcTech Inputs” index table.

5.2 Customer--specific adaptation of weld sequences

The files “A10_User.src” and “A10_User.dat” in the directory “C:\KRC\ROBOTER\KRC\R1\
TP\ArcTechAnalog” are available for the adaptation of commands in the “KUKA.ArcTech
Analog” technology package to specific process requirements, or for adaptation to specific
power sources, etc.
Editing the file “A10_User.src” requires sound knowledge of the KRL programming
language and the “KUKA.ArcTech Analog” technology package.
Following installation of the software, the directory “C:\KRC\ROBOTER\KRC\R1\TP” has

the attribute “Hidden”, i.e. it is not visible. In order to be able to access the files in this
directory, the Folder Options must be adapted accordingly (“Hidden files and folders” !
“Show hidden files and folders”).
The user can adapt and modify the subroutines in the file “A10_User.src” using a text editor.
In addition to this, a number of error handling routines are available.
Commands are divided into an advance run section and a main run section, with switching
of the weld parameters always occurring in the main run.
It is important to note that the advance run sections must not contain commands that trigger
an advance run stop.
5.2.1 Subroutines for weld commands

A10_USR_INIT
The routine “A10_USR_INIT” is called in the “ARC_INIT” command.
GLOBAL DEF A10_USR_INIT ()

;*************************
;* Call by ARC_INIT () *
;*************************
END ;(A10_USR_INIT)

A10_USR_PreArcOn
The routine “A10_USR_PreArcOn” is called in the advance run section of the “ARC ON”
command.
GLOBAL DEF A10_USR_PreArcOn

(WELD_MODE:IN,GAS_PRE_TIM:IN,ARC_CMD:IN)
;*************************
;* Call by Pre_Arc_ON *
;*************************
DECL A_CMD_T ARC_CMD ;Arc command type #ARC_START..
REAL GAS_PRE_TIM ;Gas preflow time
INT WELD_MODE ;Pulse or MigMag mode
END ;(A10_USR_PreArcOn)
A10_USR_START1
The routine “A10_USR_START1” can be called before any weld start, i.e. when the “ARC
ON” command is executed or in the case of a restart following a fault. The ignition data set
is accessed via “A_S_PARA_ACT” elements (file type A_STRT_T).
GLOBAL DEF A10_USR_START1(CMD:IN,ARC_CMD:IN)

;**********************************************************
;* Call by ARC_START before Weldstart-Signal activated *
;* or by other restart circumstances e.g. from interrupt *
;**********************************************************
INT CMD ;Arc condition (ARC_ON, from Techstop ...)
END ;(A10_USR_START1)
A10_USR_START2
The routine “A10_USR_START2” can be called before any weld start, i.e. when the “ARC
ON” command is executed or in the case of a restart following a fault.
GLOBAL DEF A10_USR_START2(CMD:IN,ARC_CMD:IN)

;********************************************************
;* Call by ARC_START after Weldstart-Signal activated *
;********************************************************
INT CMD ;Arc condition (ARC_ON, from Techstop ...)
END ;(A10_USR_START2)

A10_USR_PreArcSwi
The routine “A10_USR_PreArcSwi” is called in the advance run section of the “ARC SWI”
command.
GLOBAL DEF A10_USR_PreArcSwi(CMD:IN,WELD_MODE:IN,W:IN)

;********************************************
;* Call by PRE_ARC_SWI command *
;********************************************
DECL A_WELD_T W ;Weld set
DECL A_CMD_T CMD ;Arc command type #PRE_ARC_OFF,#PRE_ARC.
INT WELD_MODE ;Pulse or MigMag
END ;(A10_USR_PreArcSwi)
A10_USR_ArcSeam
The routine “A10_Usr_ArcSeam” can be called in the “ARC SWI” and “ARC OFF” commands
by means of the trigger integrated into the technology package, i.e. on the weld path to the
end point. The weld data set is accessed via “A_W_PARA_ACT” elements (file type
A_WELD_T).
GLOBAL DEF A10_USR_ArcSeam(ARC_CMD:IN)

;*************************************
;* Call by ARC_SWI-Trigger command *
;* Task on every welding seam *
;* access by A_W_PARA_ACT data *
;*************************************
DECL A_CMD_T ARC_CMD ;Arc command type #ARC_OFF,#ARC_SWI
END ;(A10_USR_ArcSeam)
A10_USR_PreArcOff
The routine “A10_USR_PreArcOff” is called in the advance run section of the “ARC OFF”
command.
GLOBAL DEF A10_USR_PreArcOff(CMD:IN,WELD_MODE:IN,W:IN)

;********************************************
;* Call by PRE_ARC_OFF command *
;********************************************
DECL A_WELD_T W ;Weld set
DECL A_CMD_T CMD ;Arc command type #PRE_ARC_OFF,#PRE_ARC.
INT WELD_MODE ;Pulse or MigMag
END ;(A10_USR_PreArcOff)

A10_USR_ArcOff1
The routine “A10_USR_ArcOff1” is called immediately before the weld start signal is with-
drawn in the “ARC OFF” command at the end of the seam. The end data set is accessed
via “A_E_PARA_ACT” elements (file type A_END_T).
GLOBAL DEF A10_USR_ArcOff1()

;****************************
;* Call by Finish_Seam *
;* before switch off welding*
;****************************
END ;(A10_USR_ArcOff1)
A10_USR_ArcOff2
The routine “A10_USR_ArcOff2” is called immediately before the weld start signal is with-
drawn in the “ARC OFF” command.
GLOBAL DEF A10_USR_ArcOff2()

;****************************
;* Call by Finish_Seam *
;* after switch off welding *
;****************************
END ;(A10_USR_ArcOff2)

5.2.2 Error handling routines

Submit interpreter task
Two error handling routines are available for the Submit interpreter task:
“A10_USR_PLC_INIT” and “A10_USR_PLC_Task”.
A10_USR_PLC_INIT
This routine is called in the initialization section of the Submit interpreter. The necessary
declarations must be made in the file “A10_User.dat”.
GLOBAL DEF A10_USR_PLC_INIT()

;*************************
;* Call by A10(#PLC_INIT *
;*************************
END ;(A10_USR_PLC_INIT)
A10_USR_PLC_Task
This routine is permanently called in a loop (Call by A10(#PLC_LOOP).
GLOBAL DEF A10_USR_PLC_Task()

;*************************
;* Call by A10(#PLC_LOOP *
;*************************
END ;(A10_USR_PLC_Task)
Robot error
A10_USR_IRSTOPMESS
This routine is called if the robot is switched off (IR_STOPMESS reaction, such as drives off,
safety gate open, etc.)
GLOBAL DEF A10_USR_IRSTOPMESS ()

;****************************
;* Call by IR_STOPMESS STOP *
;****************************
END ;(A10_USR_IRSTOPMESS)

Stop, interpreter stop

Three error handling routines are available for stops triggered by the interpreter or by
pressing a button:
“A10_USR_TechStop”, “A10_USR_TechstopSub1” and “A10_USR_TechstopSub2”.
A10_USR_TechStop
This routine is called in the event of a TechStop.
GLOBAL DEF A10_USR_TechStop ()

;****************************
;* Call by Tech_Stop *
;****************************
END ;(A10_USR_TechStop)
A10_USR_TechStopSub1
This routine is called immediately before the system is switched off in the event of a fault.
GLOBAL DEF A10_USR_TechstopSub1()

;****************************
;* Call by Techstop_Sub *
;****************************
END ;(A10_USR_TechstopSub1)
A10_USR_TechStopSub2
This routine is called immediately after the system is switched off in the event of a fault.
GLOBAL DEF A10_USR_TechstopSub2()

;****************************
;* Call by Techstop_Sub *
;* after switch off welding *
;****************************
END ;(A10_USR_TechstopSub2)

Seam error
A10_USR_SeamError
This routine is called in the event of a seam error.
GLOBAL DEF A10_USR_SeamError()

;****************************
;* Call by Seam_Error *
;****************************
END ;(A10_USR_SeamError)


6 Description of the weld commands
6 Description of the weld commands

6.1 Controlling welding and wire feed with the status keys on the KUKA Control Panel
After the menu function “Configure” -- “Status keys” -- “ArcTech Analog” has been activated,
the KCP provides a number of status keys specifically for “KUKA.ArcTech Analog”.
In addition, the robot controller allows the welding process to be switched on or off manually
with the left--hand status keys (hot/cold) while a welding program is running. It is also possible
to control wire feed and wire retraction manually. Ignition and welding are only possible when
the operating mode “DRY” is inactive (the status key “DRY” has not been pressed).
The states of the “HOT/COLD” status keys and the “wire forwards” and “wire backwards”
status keys are scanned cyclically during the endless loop. The submit interpreter recognizes
whether a key has been pressed in the course of a loop.
6.1.1 Manual activation and deactivation of the weld process (FLY ARC)
During a running welding process it is possible to switch welding on or off with the status key
HOT/COLD; the controller monitoring functions (as well as the keyswitch) remain active.
When it detects actuation of the status key HOT/COLD, the submit interpreter triggers a pulse
command, thereby triggering Interrupt 5 at the R1 level. The current status is used to detect
whether welding should be switched on or off.
Options
The following options are available for activation/deactivation of the weld process while a
welding program is running ($config.dat):
$config.dat DECL A_APPL_T A_APPLICAT=#THIN ;#thin,#thick
DECL A_BOOL_T A_STRT_BRAKE=#ACTIVE ;BRAKE option at ARC_START
(HPU control)
DECL A_BOOL_T A_END_BRAKE=#ACTIVE ; BRAKE option at ARC_OFF
(HPU control)
Corresponding entries using the menu function “Monitor -- Variable -- Single”:

Variable Value Characteristics
#THIN (default) Ignition without weld parameters
A APPLICAT
A_APPLICAT
#THICK Ignition with ignition parameters
#ACTIVE (default) Robot stops during the ignition process
A STRT BRAKE
A_STRT_BRAKE
#IDLE Ignition process executed without stop
#ACTIVE (default) Robot stops during the burnback process
A END BRAKE
A_END_BRAKE
#IDLE Burnback process executed without stop

Manual switch--off (COLD)

It is possible to switch off the welding process using the status key (COLD) in any phase of
a running welding program.
If the A_END_BRAKE=#ACTIVE option has been set, robot motion is interrupted during
burnback.
Manual switch--on (HOT)

To switch on (HOT) welding, the normal welding conditions must be satisfied. The torch may
only be activated on the weld path.
If the A_STRT_BRAKE=#ACTIVE option has been set, robot motion is interrupted during
ignition.
Controlling welding (HOT/COLD)

The two status keys HOT/COLD and DRY have a toggle function with reciprocal lockout. It
is not possible to switch directly from HOT (welding on) to DRY or vice versa.
The screenshot on the left shows the state Welding OFF, as indicated by the crossed--out
welding torch icon. In this state, the system only executes the motions of the welding program
and the weave motions. The robot will move at welding velocity, but welding will not be
performed.
Fast test run

Weaving is deactivated so the robot can run through the program at a relatively high velocity.
When the DRY status key is activated, the robot moves at a higher velocity. The weld process
and weaving are not executed. Any weaving that may have been programmed is
deactivated. The velocity is determined by the maximum permissible values for T1/T2.
When the “DRY” status key is activated, the robot moves at a higher velocity (in accordance
with the default setting DRY_RN_Vel Default = 0.15 m/s in the “$config.dat” file).
Wire feed and wire retraction

These keys can be used to position the welding wire when the weld keys are not active.
A physical output must be set for this in A_WLD_OUT[15] + [16].
;WIREFEED CONTROL
DECL FCT_OUT_T A_O_WRFEDP={NO 15,PULS_TIME 0.2,STATE TRUE}

DECL FCT_OUT_T A_O_WRFEDN={NO 16,PULS_TIME 0.2,STATE TRUE}
A_WLD_OUT[15]={OUT_NR 0,INI FALSE,NAME_NAT[ ] “WFD+ “}

A_WLD_OUT[16]={OUT_NR 0,INI FALSE,NAME_NAT[ ]”WFD-- “}
All status keys are deactivated in External mode (or if the Submit interpreter is stopped)
for safety reasons!

6 Description of the weld commands (continued)
6.2 Activating the welding package

The A10_OPTION must always be activated when executing “KUKA.ArcTech Analog”
applications.
DECL A_TECH_STS_T A10_OPTION=#ACTIVE; #active, #disabled
Variable Value for ArcTech Analog Characteristics

A10_OPTION #ACTIVE KUKA.ArcTech Analog
activated
#DISABLED (default) KUKA.ArcTech Analog
deactivated
6.3 Initialization (ARC--INIT)

All settings are checked when the ARC--INIT command is executed in order to ensure safe
operation. These include:
G The resetting of all weld technology outputs and analog outputs.
G Calculation of the welding rectifier characteristic.
G Checking of the offset override if an operating mode other than EXTERNAL is required
with an override <> 100%. If this is the case, the user is prompted to confirm this setting.
This query is not generated in External mode.
G Checking of further settings along with any necessary adaptation and transformation.
6.3.1 Checking the specified Submit routine

This check must be carried out in order to ensure safe operation of the Arc--specific softkeys
and a safe system response in the event of an interpreter stop.
Variable File Default Value

$PRO_I_O[ ] STEU/MADA/$CUS- /R1/SPS( ) /R1/SPS( )
TOM.DAT
6.3.2 Setting the cyclical analog channel for ONLINE optimizing

During ONLINE OPTIMIZING, the system checks that the cyclical analog channels are
activated, as information is written to these coefficients of the cyclical analog outputs.

A_WEAV_GEN[3] $CONFIG.DAT 3 3
0: Static analog channels

6.3.3 Required setting for reduced velocity in T1

The setting $RED_T1_OV_CP=FALSE, in conjunction with the variable PROC_IN_T1=TRUE,
enables welding in Test1 operating mode. Up to a certain velocity level, the velocity is then
identical to that in Test2 mode. Safety conditions are observed, i.e. the weld velocity can
never exceed the maximum permissible Test1 path velocity. The welding results would
otherwise be unusable.

$RED_T1_OV_CP steu\mada\ TRUE FALSE
$CUSTOM.DAT
6.3.4 Required settings for backward motion of a welding application

These settings can be made using the offline tool BW_INI.EXE during run time; this means
that although the program must be reselected, it is not necessary to reinitialize the HMI.

SET_TO_FALSE ..\KRC\RO- FALSE TRUE
BOTER\BACK-
WARD.INI
RESTORE ..\KRC\RO- AT_BWD AT_FWD
BOTER\BACK-
WARD.INI

6.4 ARC ON command

The “ARC ON” command contains the parameters for moving the welding torch (type of
motion, speed, etc.) from the home position to the start point of the seam, and all the ignition
parameters. The options set in the $CONFIG.DAT file are taken into account. While the
“ARC ON” program phase is being executed, the system constantly checks whether the weld
conditions are satisfied. “ARC ON” ends after ignition has been successfully completed.
The movement from the home position to the start point of the seam can be executed as a
“PTP”, “LIN” or “CIRC” motion. Approximation of the ignition position is not possible; the torch
is stopped exactly at the start of the seam. The point before the ignition position may,
however, be approximated.
6.4.1 Welding constraints

Program run mode
Welding is only possible in the $MODE_OP=#GO program run mode. All other operating
modes would be meaningless. Other settings for hot welding result in error messages.
Keyswitch with/without welding

A configured keyswitch can be used to prevent activation of an arc process.
The default setting of the software is configured without a keyswitch!
The keyswitch is always evaluated during ignition in the default configuration as long as the
ARC button has been set to ACTIVE.
DECL FCT_IN_T A_I_EN_W_EXT={NO 5, STATE TRUE}

(NO 5 refers to index A_WLD_IN[5] )
A_WLD_IN[5]={IN_NR 37, NAME_NAT[ ]”KEY SWITCH HOT/COLD”}

In External mode, an active welding symbol is expected on the KCP at all times. The external
keyswitch allows a cold run of the application at the next ignition process (even from a control
room). In all other operating modes, the state of the keyswitch is checked in the event of hot
welding and, where appropriate, a corresponding error message is generated.
The keyswitch can also be configured in such a way that the system can instantly be
switched off during operation.
Other welding conditions
Condition Variable
Robot on the path $ON_PATH=TRUE *
Process enabled PROC_ENABLE=TRUE
Options bits (general enable)
Process enabled in T1 PROC_IN_T1=TRUE
Options bits (only relevant in T1 mode)
Keyswitch See description “ARC ON”
ArcTech OPTION A10_OPTION=#ACTIVE
(default: #DISABLED)

Block coincidence $MOVE_BCO=FALSE*

Arc--specific status key A_HOT_WELD=#ACTIVE
(ICON symbol “hot”)
Robot on weld seam TECH_MOTION=TRUE
Program run mode $MODE_OP=#GO
*Set automatically during program execution.

The results of the welding conditions are reflected in the variables A_F_WLD_COND(#IDLE,
#ACTIVE).
6.4.2 Gas preflow

Every activation process is preceded by gas preflow. Depending on the gas preflow option
that has been set, this can be configured parallel to the motion, in particular the positioning
motion to the ignition position.
Condition Variable Meaning

A_PR_GAS_OPT TRUE (Default) Gas preflow “on the fly”
parallel to the positioning
motion to the ignition posi-
tion, with corresponding
FALSE gas preflow time
Gas preflow at the ignition
position
The ignition parameters, weld mode, and power source readiness are specified in the
advance run.

6.4.3 Configuration: monitoring the weld power source

This function checks that the power source is ready and that the cooling water and shielding
gas are available. A message is generated in the event of an error. This monitoring is ignored
when moving along seams with the torch deactivated (so--called “cold state”). It is configured
in the $CONFIG.DAT input group A_I_WLD_COND[ ]:
;input as condition before weld can start
DECL FCT_IN_T A_I_WLD_COND[3]
A_I_WLD_COND[1]={NO 1, STATE TRUE}; source ok

A_I_WLD_COND[2]={NO 10,STATE TRUE}; water available
A_I_WLD_COND[3]={NO 11,STATE TRUE}; gas available
In this example, physical inputs 1 (source ok), 10 (water available), and 11 (gas available)
are checked. The weld process is only enabled once all three inputs are set to HIGH. IN_NR
contains the physical input number for each.
A_WLD_IN[1]={IN_NR 1,NAME_NAT[ ]”WELDER_READY “}

A_WLD_IN[10]={IN_NR 10,NAME_NAT[ ]”WATER AVAILABLE “}
A_WLD_IN[11]={IN_NR 11,NAME_NAT[ ]”GAS AVAILABLE “}
6.4.4 Configuration: robot motion start after weld start

This signal group links the input conditions which, combined, enable robot motion. In this
example, the motion begins as soon as the “Current flowing” signal is present.
;inputs start moving
DECL FCT_IN_T A_I_STRT_MOV[3]
A_I_STRT_MOV[1]={NO ’H2’,STATE TRUE}

The condition in this example is met as soon as input no. 11 is set to HIGH. No other inputs
are checked.
A_WLD_IN[2]={IN_NR 11,NAME_NAT[ ]”ARC ESTABLISHED “}

6.4.5 Configuration of the weld modes

This signal group toggles the weld modes in all ArcTech commands (inline form settings: PS
or MM).
Mode1 (pulse, inline form: PS)
;outputs for MODE1 welding (--> Pulse)
DECL FCT_OUT_T A_O_MODE1[3]
A_O_MODE1[1]={NO ’H3’, PULS_TIME 0.0, STATE TRUE)

The link set out above sets physical output no. 7 to TRUE. No other outputs are activated.
A_WLD_OUT[3]={OUT_NR 7,INI FALSE,NAME_NAT[ ]”WELD MODE PS/MM “}
Mode2 (MIG / MAG, inline form: MM)

;outputs for MODE2 welding (--> Mig/Mag)
A_O_MODE2[1]={NO ’H3’, PULS_TIME 0.0, STATE FALSE)

The link set out above sets output no. 7 to FALSE. No other outputs are activated.
A_WLD_OUT[3]={OUT_NR 7,INI FALSE,NAME_NAT[ ]”WELD MODE PS/MM “}
6.4.6 Configuration of the WELD start signal

Once the ignition position has been reached and the gas preflow time has elapsed, the power
source is activated and the wire is fed and ignited. As soon as the “Current flowing” signal
is detected, the torch is moved away from the ignition position.
This signal group initiates the weld process. In this example, the gas preflow is activated in
parallel.
;outputs for weld start
DECL FCT_OUT_T A_O_WLD_STRT[3]
A_O_WLD_STRT[1]={NO ’H1’, PULS_TIME 0.0, STATE TRUE}

Physical output 2 activates the weld start while physical output 4 activates the gas flow.
A_WLD_OUT[1]={OUT_NR 2,INI FALSE,NAME_NAT[ ]”WELD START “}

A_WLD_OUT[2]={OUT_NR 4,INI FALSE,NAME_NAT[ ]”GAS PREFLOW “}

6.4.7 Configuration of the error handling for an ignition failure

Configuration: ignition failure
With this configuration, the weld start and gas flow are aborted in the event of an ignition
failure. It is also possible to set a corresponding ignition fault output for a connected PLC.
DECL FCT_OUT_T A_O_FLT_ON[3]
A_O_FLT_ON[1]={NO’H1’,PULS_TIME 0.0, STATE FALSE};reset weld

start
A_O_FLT_ON[2]={NO ’H2’,PULS_TIME 0.0, STATE FALSE};disconnect
gas
A_O_FLT_OM[3]={NO ’H7’,PULS_TIME 0.0, STATE TRUE};indicate igni-
tion fault
Three physical outputs are set here in parallel: output 3 to LOW, output 8 to LOW, and
output 9 to HIGH:
A_WLD_OUT[1]={OUT_NR 3, INI FALSE, NAME_NAT[ ]”WELD START “}

A_WLD_OUT[2]={OUT_NR 8, INI FALSE, NAME_NAT[ ]”GAS PREFLOW “}
A_WLD_OUT[7]={OUT_NR 9, INI FALSE, NAME_NAT[ ]”START ERROR “}
Configuration: general fault output

This signal indicates a general fault, irrespective of whether it is an ignition fault, a periphery
fault, or a seam fault.
DECL FCT_OUT_T A_O_FLT_SIGN={NO ’H6’,PULS_TIME 0.0,STATE TRUE}
In this example, the signal is switched through to output no. 8:
A_WLD_OUT[6]={OUT_NR 8, INI FALSE, NAME_NAT[]ERR MESSG_SIGNAL “}

6.4.8 Configuration of gas postflow

This signal group is permanently activated when the weld process has been deactivated in
order to enable shielding gas postflow. The gas postflow time is defined in the weld parameter
list of the last ARC OFF command.
;outputs gas post flow ends
DECL FCT_OUT_T A_O_POST_OFF[3]
A_O_POST_OFF[1]={’H2’,PULS_TIME 0.2, STATE TRUE}

The signal is generated here as a HIGH pulse at physical output no. 4:
A_WLD_OUT[2]={OUT_NR 4,INI FALSE, NAME_NAT[ ] “GAS PREFLOW “}

The postflow time is defined in the end crater parameter list.
6.4.9 Configuration of necessary acknowledgement signals

Power sources from certain manufacturers must be acknowledged before a new weld
process is started. An additional output can be configured in the KRC for this purpose:
;outputs acknowledge fault
DECL FCT_OUT_T A_O_ACK_FLT[3]
A_O_ACK_FLT[1]=(NO ’H5’,PULS_TIME 0.5,STATE TRUE}

A 0.5 s HIGH pulse is generated at physical output no. 9:
A_WLD_OUT[5]={OUT_NR 9, INI FALSE;NAME_NAT[ ]”RECEIPT ERRORS “}

6.4.10 Activating the ramp function

The ramp function (see Fig. 12) enables modification of the ignition and weld parameters
after the weld start. To do so, the variable:
A_RAMP_OPTION=TRUE (default: FALSE) must be modified in the $config.dat file.
In order to complete activation of the ramp function, the HMI then has to be reinitialized.
Ignition voltage/Wire feed

Ramps
WELDSET 1
WELDSET 2
Distance
Ramp length
Fig. 12 Ramp function
Setting the ramp length with the option active:
Ramp function Ramp function
Ramp length
Ramp length
0 to 25 mm
Select the ramp length so that the distance to the following point is long enough.
If the distance between the points is not long enough, the ramp will ”break” and the output will
take on unexpected values.
This function may not be used during sensor operation with “KUKA.ArcSense”
(TRACK command); here, the ramp length has to be set to 0 or the ramp function has
to be switched off (A_RAMP_OPTION=FALSE).
When welding with short distances between points, approximate positioning may no longer
be possible. The ramp function should also be deactivated in this case.

6.4.11 Schematic sequence diagram
ARC ON
Initialization
Options
(e.g. Output of
aluminum) ignition
parameters
PRE_ARC_ON( ) A_I_WLD_COND[ ]
Early gas
preflow A_O_GAS_PRE[ ]
A_I_EN_W_EXT[ ] Enabling test
Only with the option:
A_PR_GAS_OPT=TRUE
Ignition
A_O_ARC_FLT[ ]
A_O_MODE_n[ ] position
reached A_O_FLT_ON[ ]
A_O_FLT_SIGN[ ]
A_O_GAS_PRE[ ] Gas preflow
Messages
A_O_WLD_STRT[ ] Ignition
A_O_ACK_FLT[ ]
N
Ignition attempts
A_I_STRT_MOV[ ] Arc on according to
configuration
Y
A_O_POST_OFF[ ]
A_O_POST_ON[ ]
ARC_START( ) N
Ignition time
Weld process Monitoring is activated once the “Current

monitoring flowing” signal (A_I_STRT_MOV[ ]) has
been generated and the time defined in
activated
A_CTRL_DELAY has elapsed
End Process continued with the next

ARC ON data set
(ARC OFF or ARC SWITCH)
Fig. 13 ARC ON -- schematic sequence diagram

Input group Meaning

A_I_WLD_COND[ ] Weld enable (max. 3 inputs)
A_I_STRT_MOV[ ] “Current present” signal, enables continua-
tion of motion. (max. 3 inputs)
Output group Meaning

A_O_MODE1/2[ ] Weld mode (pulse or MigMag).
(max. 3 output)
A_O_GAS_PRE[ ] Gas preflow active (without Weld Start).
(max. 3 output)
A_O_WLD_STRT[ ] Weld start and Gas preflow active.
(max. 3 output)
A_O_FLT_SIGN[ ] Signal to the PLC in the event of a seam
fault or ignition fault. (max. 1 output)
A_O_FLT_ON[ ] Signal to the PLC in the event of an igni-
tion fault (max. 3 outputs)
A_O_POST_OFF[ ] Deactivation of the gas flow including post-
flow time (max. 3 outputs)
A_O_ACK_FLT[ ] Acknowledgement signal to the periphery
before repetition of the ignition process
6.4.12 Ignition process signal flow diagram

In the example shown in Fig. 14, a gas preflow time has been programmed in the “Start
parameters” list, shown here by means of the “Gas flow” graph (A_WLD_OUT[2]).
Start parameters Weld parameters
Wire feed setpoint value (channel 2)
Weld voltage setpoint value (channel 1)
Weld start (A_WLD_OUT[1])

Gas flow (A_WLD_OUT[2])
Gas preflow time Ignition time

Current flowing A_WLD_IN[2]
Fig. 14 Ignition process signal flow diagram

Beside it you see the signal for weld start (A_WLD_OUT[1]) -- this is the point in time at which
wire feed is activated -- followed by the “Current flowing” signal from the peripheral interface
(A_I_STRT_MOV[ ]), meaning that the arc is now established following successful ignition.
At the conclusion of the ignition time, a transition is made from the start parameters to the
weld parameters, as you can see from the curves for both analog channels (setpoint values
for weld voltage and wire feed -- channels 1 and 2). The weld parameters (W parameters)
are contained in the weld data set of the “ARC OFF” or “ARC SWITCH” command that follows
the “ARC ON” command.
6.4.13 Activation of delayed weld process monitoring after ignition
If an arc is established following ignition, the weld process monitoring function is activated
after a time delay set by means of the A_CTRL_DELAY variable. The “Current flowing” signal
(A_I_STRT_MOVL) from the weld power source is decisive for this. The default time is 1200
milliseconds.
The default time can be changed with the menu function “Monitor -- Variable -- Single”.
Variable Default (ms)
A_CTRL_DELAY 1200
To avoid disruptions, this value should not be too low. If the setting is too high, the peripheral
interface signals cannot be monitored during this time.
6.5 ARC SWITCH command

The “ARC SWITCH” command is always used between the “ARC ON” and “ARC OFF”
commands whenever the seam is divided into several sections with different motion and/or
weld parameters. Fig. 15 shows the schematic sequence diagram.
The command contains the motion and weld parameters for the current section of the seam,
including the parameters for mechanical and thermal weaving. The parameter sets can be
used repeatedly. The command is to be used if the seam is to be divided up into several seam
sections, even if the parameters do not need modification.
Functional principle
The ARC_SWI command switches from one weld data set to the next. In addition to
mechanical weaving, thermal weaving or the through--the--arc seam tracking sensor
(KUKA.ArcSense) can also be started here, or triggered for a new reference run. The weld
mode can be changed in the controller.

ARC SWITCH
Initialization
Preparation of Filling of FIFO buffer,

parameters for precalculation
PRE_ARC( )
welding,
mechanical
and thermal
weaving
Task at start of motion
on seam section
Weld mode
PS / MM
A_O_MODE1[]
A_O_MODE2[]
Output of
weld
Retrieve data from
parameters
FIFO buffer
WELD_ON_SEAM( )
Mechanical
weaving on *)
Thermal
weaving on *)
Activate cyclical
analog output
End ARC
SWITCH
Process continued with the

next data set (ARC OFF or
ARC SWITCH)
*) If configured accordingly
Fig. 15 ARC SWITCH sequence diagram

Input group Meaning

A_O_MODE1/2[ ] Configuration of the weld mode
(max. 3 inputs), PULSE or MIG/MAG
Approximate positioning should be used for motions in “ARC SWITCH” commands if exact
positioning between individual seam sections is not absolutely essential.
6.5.2 Signal diagrams

Switching weld parameters
Fig. 16 shows examples of the following:
G Weld start (ignition parameters, signals for weld start, current flowing, and gas flow)
G Weld parameters of weld data set 1 for the analog channels “Wire feed setpoint” and
“Weld voltage setpoint”
G Weld parameters of weld data set 2 for the analog channels “Wire feed setpoint” and
“Weld voltage setpoint”
Ignition
parameters Weld parameters
Weld data set 1 Weld data set 2
Wire feed setpoint value
Analog
channels
Weld voltage setpoint value
Weld start
Current flowing
Gas flow
Fig. 16 Diagram: switching weld parameters
You can recognize the changes to the analog channel setpoint values (wire feed, weld
voltage) during the transitions from “ignition parameters” to “weld data set 1”, as well as from
“weld data set 1” to “weld data set 2”.

Switching weld mode (PS / MM)

The diagram Fig. 17 additionally shows the weld mode switchover between weld data sets
1 and 2. Looking at the “MODE” graph, you can see the change from “PS” (pulse welding)
to “MM” (MIGMAG).
Ignition parameters
Weld parameters
Analog
Weld voltage setpoint value channels
Weld start
MODE (PS / MM)
Current flowing
Gas flow
Fig. 17 Diagram: switching weld mode (PS / MM)
Switching from constant values to thermal weaving

Switching from welding with constant values for weld voltage and wire feed (weld data set 1)
to “thermal weaving” (weld data set 2) is illustrated in Fig. 18.
You can see how the setpoints for voltage and wire feed change periodically when compared
with the values programmed in the W--parameter list. The “triangle” weave pattern is shown.
Ignition parameters
Weld parameters
(default) (thermal weaving)
Voltage setpoint value
Weld start
Current flowing
Gas flow
Fig. 18 Diagram: switching from constant values to thermal weaving

6.5.3 Signal tables

There are no specific additional signal tables for ARC SWITCH.
6.6 ARC OFF command

The command is available with LIN and CIRC variants. The weld command ARC OFF
contains motion and weld parameters for a single seam from the start of a weld to the end
of the seam, at which point the parameters for crater filling take effect.
A single seam therefore requires two commands: ARC_ON and ARC_OFF
If a seam consists of several seam sections with different motion and/or welding parameters,
the command ARC OFF is used for the last seam section. ARC_SWI commands are used
between ARC_ON and ARC_OFF.
Functionality:
To start with, the same actions are carried out in the motion to the seam end position as with
an ARC_SWI command. Once this position is reached, the end crater is filled, the wire
burnback is carried out, the welding torch is deactivated, and the gas postflow is initiated.
With the appropriate configuration, it is possible to force a burnfree procedure.
If a Track command (ARC_OFF with weave sensor) has been used, this is now deactivated
or the sensor offset is frozen.
Approximate positioning is not possible for “ARC OFF”; motions are exactly positioned to
each point.

6.6.1 Signal tables

A maximum of three signals can be defined for each table. These signal tables contain the
signal name, an index for addressing in the array, and the pulse duration, where
“PULS_TIME 0.0” designates a static output.
The relevant signal groups are described in the following.
Configuration: deactivation of welding (signal output)

This configuration deactivates the weld start once the end of the seam has been reached.
$config.dat ; outputs burn back starts
DECL A_FCT_OUT_T A_O_SEAM_END[3]
A_O_SEAM_END[1]={NO ’H1’,PULS_TIME 0.0,STATE FALSE}
A_WLD_OUT[1]={OUT_NR 0,INI FALSE;NAME_NAT[ ]”WELD START “}
Configuration: early gas postflow (signal output)

This signal enables postflow with extra shielding gas.
$config.dat ; outputs gas post flow starts
DECL FCT_OUT_T A_O_POST_ON[3]
A_O_POST_ON[1]={NO ’H2’,PULS_TIME 0.15,STATE TRUE}
Configuration: gas postflow (signal output)

This function corresponds to normal gas postflow (default).
$config.dat ; outputs gas post flow ends
DECL FCT_OUT_T A_O_POST_OFF[3]
A_O_POST_OFF[1]={NO ’H2’,PULS_TIME 0.2,STATE TRUE}

Configuration: current flow check (signal input)

Checks the current end signal or the deactivation mechanism of an intelligent power source
(e.g. with integrated burnback and burnfree options).
$config.dat ; inputs for weld in ended
DECL A_FCT_IN_T A_I_WELD_END[3]
A_I_WELD_END[1]={NO ’H4’,STATE FALSE}
A_WLD_IN[4]={IN_NR 0,NAME_NAT[ ]”CURRENT OVER “}
Configuration: wire free (signal input)

This input can be used to check whether or not the wire is still in contact with the component
following burnback. The burnfree option needs to be activated for this (see Section 6.7.1)
$config.dat ; inputs for test of burn free from workpiece
DECL A_FCT_IN_T A_I_BRN_FREE={NO 7,STATE TRUE}
A_WLD_IN[7]=IN_NR 0,NAME_NAT[ ]”BURN FREE INP_SIGNAL “}

6.7 Burnfree options

6.7.1 Configuration: burnfree
In cases when the wire does not separate from the workpiece at the end of the welding
process, the burnfree option can be used to attempt to bring about separation. This option
can only be used when welding controllers are used that are capable of supplying a
corresponding signal (BURN FREE INP_SIGNAL) to the robot controller.
The following settings are required to activate the burnfree option (which is not active in the
default configuration):
DECL A_BOOL_T A_BRN_FR_OPT=#ACTIVE ; Burnfree Option
Corresponding entry using the menu function “Monitor -- Variable -- Single”:

A_BRN_FR_OPT #ACTIVE Default: #IDLE
If the wire is not separated from the workpiece at the conclusion of the welding process, the
power source issues the A_I_BRN_FREE signal to the physical input (here A_WLD_IN[7]).
This triggers the process for burning the wire free.
The burnfree data must also be set. This variable is located in the A10.DAT file:
DECL A_ANA_SET_T8 A_BRN_FREE={CH1 26.0, CH2 8.0, CH3 0.0, CH4

0.0, CH5 0.0, CH6 0.0, CH7 0.0, CH8 0.0}
In this example, the burnfree voltage is set to 26.0 volts and the wire feed to 8 m/min in
channel 1. The other channels are not configured here and remain available for further
applications.
6.7.2 Burnfree duration and number of burnfree attempts
Corresponding entry using the menu function “Monitor -- Variable -- Single” in the
“$config.dat” file:
A_BRN_FREE_T 0.2 Pulse duration in seconds (default: 0.2)
A_BRN_FR_LIM 3 Number of burnback attempts (default: 3)

6.8 Burnback mode -- A_BB_MODE

It is possible to select between various burnback modes by means of the A_BB_MODE
variable.
DECL A_BB_TYPE A_BB_MODE=#ACT_PAR ;#REDUCE
The factory setting for A_BB_MODE is #ACT_PAR.
Corresponding entry using the menu function “Monitor -- Variable -- Single”:

#ACT_PAR (default) Standard
A_BB_MODE
A_BB_MODE
#REDUCE Seam--specific burnback parameters
6.8.1 Burnback mode A_BB_MODE=#ACT_PAR

With this option, burnback is carried out using the current values for wire feed and welding
voltage. If the crater filling time programmed in the parameter list >0, burnback is carried out
using the end crater parameters.
6.8.2 Burnback mode A_BB_MODE = #REDUCE

With this option, the wire feed channel (analog channel 2) is set to “0” before the process is
deactivated and, parallel to this, the active welding voltage (analog channel 1) is reduced by
a configurable factor.
This factor A_REDUCE=0.2 (DEFAULT) is located in the $CONFIG.DAT file and corresponds
to a reduction of 20%.

ARC OFF
Initialization
PRE_ARC( )
(advance run section) Preparation of Filling of FIFO buffer,
parameters for precalculation
welding,
mechanical
and thermal
weaving
Weld mode A_O_MODE [1]

PS / MM A_O_MODE[2]
Output of Synchronization with

weld robot motion, retrieve
parameters data from FIFO buffer
WELD_ON_SEAM( )
Robot Mechanical
motion weaving on *)
Thermal
weaving on *)
Calculation of
early activation of
gas postflow time
ADV. RUN STOP

A_O_POST_ON[ ]
Target position reached N

Crater time >0
FINISH_SEAM( ) Y
Output of
end crater
parameters
(EK time = end crater time)

(BB time = burnback time) [1--2]
*) If configured accordingly
Fig. 19 ARC OFF sequence diagram (page 1 of 2 pages)

[1--2]
FINISH_SEAM( )
Welding off A_O_SEAM_END[ ]
Burnback N
time
Y
A_WLD_ACTIV=#ACTIVE
Flag N
Gas postflow on
(Pulse command)
Initialization
$TIMER[2]
N A_I_WELD_END[ ]
Fault routine Arc off
Burnfree
option
A_O_POST_ON[ ]
Burnfree
A_O_POST_OFF[ ]
Wire free N
/ Cancel
Gas postflow
A_WLD_ACTIV=#IDLE
Initialization and A_COLD_SEAM=#IDLE
reset flags
End
ARC Off
Fig. 20 ARC OFF sequence diagram (page 2 of 2 pages)

Explanation of the variables:
Input groups
A_I_WELD_END[ ] Current end / power source deactivation
process
A_I_BRN_FREE Checks that wire is free or forces burnfree
if option is active
(A_BRN_FR_OPT=#ACTIVE)
Output groups
A_O_MODE1/2[ ] Weld mode (pulse/MigMag),
max. 3 outputs
A_O_POST_ON[ ] Early activation of gas postflow
(max. 3 outputs)
A_O_POST_OFF[ ] Configuration of gas postflow
(max. 3 outputs)
A_O_SEAM_END[ ] Initiates power source deactivation
A_O_FLT_SIGN[ ] Fault signal
A_O_ACK_FLT[ ] Acknowledge fault
A_O_WLD_STRT[ ] WELDSTART generated in event of forced
burnfree procedure
Standard mode, with end crater, burnback, and gas postflow

The diagram Fig. 21 shows the end parameters with end crater, burnback, and gas postflow.
Weld parameters STOP robot motion

End parameters
Burnback time
Crater time Gas postflow time

Analog
Weld voltage setpoint value channels
Weld start Gas flow
Current flowing
Fig. 21 Diagram: standard mode, with end crater, burnback, and gas postflow

On the left in the weld parameter range, the constant setpoint values for wire feed and weld
voltage are shown. In the following end parameter range, the setpoint values of the analog
reference voltages increase in accordance with the values programmed in the parameter list.
The end parameter range is divided into three sections:
G Crater time
G Burnback time and
G Postflow time
Wire feed is switched off at the falling edge of the “Weld start” signal. As a result, the arc goes
out, as can be seen from the falling edge of the “Current flowing” signal, which is delayed by
approximately 0.1 second.
In accordance with the parameter settings, gas flow is still maintained for a specific time.

7 Configuration of analog outputs
7 Configuration of analog outputs

Eight analog outputs are available. Two analog outputs are required for normal welding
applications. These are:
Weld voltage setpoint value (channel 1) Voltage setting -- Channel 1
Wire feed setpoint value(channel 2) Voltage setting -- Channel 2
The outputs 3 through 8 can be used as required.
7.1 Maximum number of analog outputs -- A_ACT_AN_MAX

The variable A_ACT_AN_MAX in $CONFIG.DAT defines the maximum number of analog
outputs used. A maximum of eight outputs can be defined; the default setting is two.
INT A_ACT_AN_MAX=2 ; Maximum number of analog channels
also influences user interface
Corresponding entry using the menu function Monitor - Variable - Modify:
Variable Default value (INT) Possible values

A_ACT_AN_MAX 2 up to 8
The value that is set influences the number of input boxes in the start, weld and end data
parameter lists. If you set the A_ACT_AN_MAX variable to a value >2, a correspondingly
greater number of channels (n--2) are available and thus more input boxes for setting
parameters.
Changes to the A_ACT_AN_MAX variable only become active after the system is restar-
ted or the HMI is reinitialized.
7.1.1 Addressing of the analog outputs -- A_ANAOUT_NO[8]

A maximum of eight analog outputs are available. The definition of the analog outputs
interface with allocation of the software channels to the hardware channels is made in the
declaration section DECL INT A_ANAOUT_NO[8] of the $CONFIG.DAT file.
DECL INT A_ANAOUT_NO[8] ; Indexed addressing of analog channels:
0 -> not used
A_ANAOUT_NO[1]=1 Channel 1 Assigned for weld voltage setpoint
A_ANAOUT_NO[2]=2 Channel 2 Assigned for wire feed setpoint
A_ANAOUT_NO[3]=3 Channel 3
A_ANAOUT_NO[4]=4 Channel 4 Can be configured if required.
A_ANAOUT_NO[5]=5 Channel 5 The value of the “A_ACT_AN_MAX” variable
A_ANAOUT_NO[6]=6 Channel 6 must be modified accordingly.

Corresponding entries using the menu function Monitor - Variable - Modify:

Variable Type Default setting, characteristics
A_ANAOUT_NO[1] INT Default 1 -- weld voltage setpoint
A_ANAOUT_NO[2] INT Default 2 – wire feed setpoint
A_ANAOUT_NO[3] ... [8] INT Freely available
Channel 1 is assigned by the manufacturer to the weld voltage parameters and channel 2
to the wire feed parameters. Channels 3 through 8 are not used and are thus freely available.
Analog outputs that are not required are deactivated by specifying “0”.
To activate further outputs, change the variable A_ACT_AN_MAX=n accordingly.
Channel numbering must be consecutive. In other words, channel 3 may only be assigned
if channels 1 and 2 are already used.
The analog outputs defined with A_ACT_AN_MAX must be addressed in the declaration
section DECL INT A_ANAOUT_NO[8].
For example, if A_ACT_AN_MAX has the value 4, A_ANAOUT_NO[1] ... A_ANAOUT_NO[4]
may not have the value 0.
7.2 Adaptation of analog outputs 1 and 2 specific to the power source

For each analog output and welding mode used, the relationship between the programmed
parameters and the physical setpoint values of the analog reference voltages (for example,
weld voltage and wire feed) must be defined.
To calibrate the setpoint values for weld voltage and wire feed, the respective characteristics
of the welding controller being used must be known. The value for VAL in the block DECL
A_ANA_DEF_T A_ANA_DEF[2,8,5] of the file $CONFIG.DAT must be between 0
(minimum value) and 1 (maximum value). Corresponding to the scaling used in the following
examples (VAL1.0 ≙ 10 volts), this results in a variation range of 0 to 10 volts of the analog
control voltage for the welding controller.
The characteristics of a welding controller described in the following are examples.

7 Configuration of analog outputs (continued)
7.2.1 Number of characteristic points

A linear characteristic is determined by two points. In the case of a non--linear characteristic,
the relationship between parameters and control voltage can be defined with five points.
The number of required characteristic points required must be entered in the block DECL
INT A_ANA_MAX_D[2,8] of the file $CONFIG.DAT for each analog channel used.
A_ANA_MAX_D[1,1]=2
Mode Number of characteristic points
Channel
In the following example, two characteristic points (corresponding to a linear characteristic)

each are defined for channels 1 (voltage) and 2 (wire feed) for mode 1 (pulse welding) and
for mode 2 (MIGMAG) welding.
DECL INT A_ANA_MAX_D[2,8] ;maximum number of points to define

a controller line
A_ANA_MAX_D[1,1]=2 Mode 1; Channel 1; 2 characteristic points
...
...
Corresponding entry using the menu function Monitor - Variable - Modify:

Variable Type Characteristics ,default setting
A_ANA_MAX_D[1,1] INT Mode 1; channel 1; 2 characteristic points (default)
A_ANA_MAX_D[1,2] INT Mode 1; channel 2; 2 characteristic points (default)
If only one welding mode (either pulse or MIGMAG) is going to be used, we recommend
making all configuration entries and parameter settings for mode 1 and mode 2 identical
in the $CONFIG.DAT file.
In this way you ensure that accidentally switching from the welding mode “PS” to “MM” or
vice versa while programming inline forms does not result in errors.

7.2.2 Linear characteristic

The following example (channel 1, set weld voltage) is based on a linear characteristic with
the values:
Control voltage Weld voltage setpoint
Point
(volts) (volts)
1 0.369 0
2 8.062 80
The next example shows the characteristic with assignment of the parameters PARA and VAL
in the file $CONFIG.DAT. PARA is the value Voltage for the weld voltage (S, W and E
parameter lists), and VAL corresponds to 1/10 of the analog control voltage.
VAL U (volts)
1.00 10.000
0.8062 8.062 2
VAL 1.0 ≙ 10 volts
0.0369 0.369 1 PARA

0
0 80 (volts)
DECL A_ANA_DEF_T A_ANA_DEF[2,8,5] ($CONFIG.DAT)
;WELD_Mode,Channel,Points of controller line
;Mode1 Channel1 command value
A_ANA_DEF[1,1,1]={PARA 0.0,VAL 0.0369}
A_ANA_DEF[1,1,2]={PARA 80.0,VAL 0.8062}
Fig. 22 Voltage characteristic (example) -- Channel 1, characteristic points (1,2)
A further example shows a linear characteristic for the wire feed (channel 2). Here, the value
(VAL) of 0.0631 at characteristic point 1 corresponds to a control voltage of 0.631 volts,
resulting in a wire feed rate of 50 inch/min and the value (VAL) 0.9511 at characteristic point
2 corresponds to a control voltage of 9.511 volts for a wire feed rate of 770 inch/min.
Control voltage Wire feed
Point
(volts) (inches/minute)
1 0.631 50
2 9.511 770
The next example shows the corresponding characteristic with assignment of the
parameters PARA and VAL in the file $CONFIG.DAT. In this case PARA is the Wire Feed
value for the wire feed rate in inch/min (S, W and E parameter lists); “VAL” corresponds to
1/10 of the analog control voltage.

7 Configuration of analog outputs (continued)
VAL U (volts)
1.00 10.000
0.9511 9.511 2
0.0631 0.631 1
PARA
0 50 770 (inches/minute)
...
;Mode1 Channel2 wire feed [IPM]
A_ANA_DEF[1,2,1]={PARA 50.0,VAL 0.0631}
A_ANA_DEF[1,2,2]={PARA 770.0,VAL 0.9511}
Fig. 23 Wire feed characteristic (example) -- Channel 2, characteristic points (1,2)
Parameters are set for the individual characteristic points in the block DECL A_ANA_DEF_T
A_ANA_DEF... of the $CONFIG.DAT file. In the above example with two characteristic
points, the following must be entered for channel 1 (voltage) and channel 2 (wire feed):
DECL A_ANA_DEF_T A_ANA_DEF[2,8,5] ;WELD_Mode,Channel,
Points of controller line
(For the weld voltage)
A_ANA_DEF[1,1,1]={PARA 0.0,VAL 0.0369}
A_ANA_DEF[1,1,2]={PARA 80.0,VAL 0.8062}
A_ANA_DEF[1,1,3]={PARA 40.0,VAL 0.0} (*)
A_ANA_DEF[1,1,4]={PARA 41.0,VAL 0.0} (*)
A_ANA_DEF[1,1,5]={PARA 42.0,VAL 0.0} (*)
...
(For the wire feed)
;Mode1 Channel2 wire feed [IPM]
A_ANA_DEF[1,2,1]={PARA 50.0,VAL 0.0631}
A_ANA_DEF[1,2,2]={PARA 770.0,VAL 0.9511}
A_ANA_DEF[1,2,3]={PARA 1001.0,VAL 0.0} (*)
A_ANA_DEF[1,2,4]={PARA 1002.0,VAL 0.0} (*)
A_ANA_DEF[1,2,5]={PARA 1003.0,VAL 0.0} (*)
...
Explanation
A_ANA_DEF[1,1,2]={PARA 80.0,VAL 0.8062}

Mode
Channel Weld voltage setpoint
Characteristic point 1/10 control voltage
(*)If, as in this example, the number of characteristic points (A_ANA_MAX_D[...,...])

had been defined as 2, the values contained in the lines A_ANA_DEF[...,...,3] through
A_ANA_DEF[...,...,5] would have no effect. These values are set by the program to
values that are greater than the highest value (of characteristic point 2 in this case).

The parameters of the characteristic points must be entered in ascending order.
Example of the entry of the characteristic parameters PARA and VAL with the menu function
Monitor - Variable - Modify:
Variable Type Characteristics, value
A_ANA_D_DEF[1,1,2].PARA REAL Value for “PARA”, e.g.: 80.0
A_ANA_D_DEF[1,1,2].VAL REAL Value for “VAL”, e.g.: 0.8062
7.2.3 Non--linear characteristic

In the case of non--linear characteristics, several characteristic points (max. 5) must be
defined as shown in the following example:
VAL U (volts)
1.00 10,00
0.85 8.50 5
0.72 7.20 4
0.50 5.00 3
0.26 2.60 2
0.02 0.20 1 PARA

0
0 6.5 24 51 80 (volts)
A_ANA_DEF[1,1,1]={PARA 0.0,VAL 0.02}
A_ANA_DEF[1,1,2]={PARA 6.5,VAL 0.26}
A_ANA_DEF[1,1,3]={PARA 24.0,VAL 0.5}
A_ANA_DEF[1,1,4]={PARA 51.0,VAL 0.72}
A_ANA_DEF[1,1,5]={PARA 80.0,VAL 0.85}
Fig. 24 Voltage characteristic (example) -- 5 characteristic points (1,5)
DECL INT A_ANA_MAX_D[2,8]

A_ANA_MAX_D[1,1]=5
Accordingly, the following must be entered for channel 1 in the block DECL A_ANA_DEF_T
A_ANA_DEF[ ] of the file $CONFIG.DAT:
DECL A_ANA_DEF_T A_ANA_DEF[2,8,5] ;WELD_Mode,Channel,Points of
controller line
A_ANA_DEF[1,1,1]={PARA 0.0,VAL 0.02}
A_ANA_DEF[1,1,2]={PARA 6.5,VAL 0.26}
A_ANA_DEF[1,1,3]={PARA 24.0,VAL 0.5}
A_ANA_DEF[1,1,4]={PARA 51.0,VAL 0.72}
A_ANA_DEF[1,1,5]={PARA 80.0,VAL 0.85}

8 Mechanical weaving
8 Mechanical weaving
8.1 Fundamentals
In mechanical weaving, the torch moves across the seam and is thus superposed on the
continuous--path motion of the robot arm. The torch can also be rotated in the weave plane
(but not the weave plane itself if a through--the--arc seam tracking sensor is being used or
a Track command is being executed).
Mechanical weaving is executed in the coordinate system TTS (tool--based technological
system). The weave function is thus not dependent on whether welding is by the “forehand”
or “backhand” technique. A deliberately inclined position of the torch for asymmetrical
distribution of the heat has, in principle, no effect on the weaving.
The tool must be calibrated in 6D mode, with the +x direction of the tool in the tool
coordinate system corresponding to the wire outlet.
Undesirable effects may otherwise result, such as a rotation of the weave plane by
90 degrees, for example.
The coordinate system “TTS” (tool--based technological system)

The tool--based moving frame or TTS (tool--based technological system) is defined as
follows:
X axis Unit vector in direction of path tangent.
Unit vector in direction of vector product of path tangent and X axis of tool
Y axis
coordinate system.
Z axis Unit vector in direction of vector product of path tangent and Y axis.
Z axis
Y axis
X axis
Xwz
Fig. 25 The tool--based technological system TTS (tool--based moving frame)
The TTS is calculated every time a CP motion is executed. If the X axis of the tool
coordinate system and the path tangent are parallel, the TTS cannot be generated. This
triggers dynamic braking and the error message “TTS NOT EXISTING”.
In this case, a corresponding reorientation of the tool is required as well as reprogramming
of the motion.

8.2 Weave patterns

The weave patterns shown in Fig. 26 and Fig. 27 are included with “KUKA.ArcTech Analog”:
s
Weave amplitude
Weave length
Weld direction
s
No weave
Triangle
Double triangle
Trapezoid
Double trapezoid
Unsym.trapezoid
Spiral *)
Double 8
Fig. 26 Weave patterns for mechanical weaving (1 of 2)
*) In order to achieve circular weave motions with the Spiral weave pattern selected, the
weave amplitude needs to be half the set weave length.

8 Mechanical weaving (continued)
Edge weave
bottom Weave length
Weld direction
z x
s
y
Edge weave top Weave length
Weld direction
Fig. 27 Weave patterns for mechanical weaving (2 of 2)
Block selection response

Weaving is deactivated at every block selection as mechanical weaving can force the robot
into critical motions. Reactivation is however assured.

Example of weave pattern definition in the “ARC_WEAVE.SRC” file

The value for X can be between 0.0 and 1.0. Xn=1.0 corresponds to the weave length entered
in the W--parameter list 2/4 (Mechanical Weaving), i.e. the length over which a pattern is
executed.
The value for Y can be between --1.0 and 1.0. Yn=1.0 corresponds to the lateral deflection
(weave amplitude -- zero to peak) entered in the W--parameter list 2/4 (Mechanical Weaving).
The weave length X, the lateral deflection Y, and the angle of the torch in relation to the
welding plane can be programmed for each weave pattern in the W--parameter list 2/4
“Mechanical Weaving” with menu prompting.
SWITCH FIGUR
n = Control points (CPNUM)
CASE 1 ;triangle
IF A_FG_MECH1>0 THEN Y 2
$TECH[A_FG_MECH1].FCT.ORDER=1 1
$TECH[A_FG_MECH1].FCT.CPNUM=4
$TECH[A_FG_MECH1].FCT.CPS1.X1=0.0
$TECH[A_FG_MECH1].FCT.CPS1.Y1=0.0 0.5 0.75 1.0 X
$TECH[A_FG_MECH1].FCT.CPS1.X2=0.25 0.0 0.25
1 4
$TECH[A_FG_MECH1].FCT.CPS1.Y2=1.0
$TECH[A_FG_MECH1].FCT.CPS1.X3=0.75 3
$TECH[A_FG_MECH1].FCT.CPS1.Y3=--1.0 --1
ENDIF
Fig. 28 Definition of a weave pattern
The value for X can be between 0.0 and 1.0. Xn=1.0 corresponds to the weave length entered
in the W--parameter list 2/4 (Mechanical Weaving), i.e. the length over which a pattern is
executed.
The value for Y can be between --1.0 and 1.0. Yn=1.0 corresponds to the lateral deflection
(weave amplitude -- zero to peak) entered in the W--parameter list 2/4 (Mechanical Weaving).
The weave length X, the lateral deflection Y, and the angle of the torch in relation to the
welding plane can be programmed for each weave pattern in the W--parameter list 2/4
“Mechanical Weaving” with menu prompting.
8.3 Two--dimensional weaving

Weave patterns such as triangular and trapezoidal patterns result from the lateral deflection
of the torch during motion along the seam. Complex patterns are possible by means of a
second function generator that causes the torch to weave in the welding direction (X axis).

Two practical functions (for thin sheet welding, for example), namely spiral weaving and
figure--eight weaving, are already included in the technology package. You can also develop
your own patterns. The following diagram illustrates the mode of operation of the function
generator using the example of spiral weaving.
Lateral deflection (amplitude) 1)

$TECH[A_FG_MECH1].FCT.CPS1.Xn = x (0.0 ... 1.0) (Y)
$TECH[A_FG_MECH1].FCT.CPS1.Yn =y (--1.0 ... 1.0)
(WEAV_DEF.SRC)
(--Y’) (Y’)
Deflection in the direction of the path 2)
$TECH[A_FG_MECH2].FCT.CPS1.Xn = x (0.0 ... 1.0)
$TECH[A_FG_MECH2].FCT.CPS1.Yn =y (--1.0 ... 1.0) (--Y)
Path tangent, X axis Torch

Lateral deflection
(amplitude) 1)
Weave width
Weave length
1) Lateral deflection (amplitude) = half weave width
2) Deflection in direction of path = ¦ weave length
Fig. 29 Two--dimensional weaving
The magnitude of the deflection in the welding direction (...FCTCTRL.SCALE_IN) in

relation to the weave length (W.WEAVLEN_MECH) is set in the file “A10.SRC” at a ratio of 1:1.
The lateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for half the
weave width (W.WEAVAMP_MECH).
IF A_WEAV_GEN[N]>0 THEN
$TECH_C[A_WEAV_GEN[N]].FCTCTRL.SCALE_IN=W.WEAVLEN_MECH
$TECH_C[A_WEAV_GEN[N]].FCTCTRL.SCALE_OUT=W.WEAVAMP_MECH
ENDIF
The “Weave amplitude” value is defined as “zero to peak”, i.e. it corresponds to half the
weave width (peak to peak).
8.3.1 Creating the “Spiral” weave pattern

Fig. 30 shows creation of the “Spiral” weave pattern. As a result of the superposition of a
lateral weave motion “sin(x)” with an orthogonally--acting weave motion (in welding direction)
of the same frequency “cos(x)”, the torch describes a motion in the form of a circle (with the
same amplitude) or of an ellipse (with different amplitudes).

The spiral form results because the torch is moved by the amount of the weave length (from
X=0 to X=1) during one period (360°) in the direction of welding.
Superposition of sine and cosine Without continuous--path With continuous--path

motion motion
0 Weld direction
0 1
1
sin(x) cos(x)
Fig. 30 Creating the “Spiral” weave pattern

Fig. 31 shows the curve shapes of the function generators derived from the sine function.
This is approximately a sine for the lateral deflection ($TECH[A_FG_MECH1]...) and a
cosine for the deflection in the direction of the path ($TECH[A_FG_MECH2]...). The
corresponding control point parameters are stored under CASE6;spiral in the
“Arc_weave.src” file. The spiral pattern results from the superpositioning of these two
motions.
Lateral deflection (amplitude) Deflection in the

Y Y direction of the path
2 3
1 1
$TECH[A_FG_MECH1]... 3’ 4’
(X 1 ... 6 ; Y 1 ... 6)
6 X
0
1 1,0
$TECH[A_FG_MECH2]...
(X 1 ... 6 ; Y 1 ... 6) X
--1 0
4 5 1,0
Y Resulting spiral
1
2 3
2’ 3’
(--Y’) (Y’)
1 6, 6’ X --1
0 1’ 2’ 5’ 6’
1’
5’ 4’
--1
Weave length 5 4
Fig. 31 ”Spiral” weave pattern -- control points

The control points for the “Spiral” weave pattern are defined in the “Arc_weave.src” file. The
parameters for the lateral deflection are stored in the first block (...MECH1...).
CASE 6 ;spiral
IF A_FG_MECH1>0 THEN
$TECH[A_FG_MECH1].FCT.ORDER=1
$TECH[A_FG_MECH1].FCT.CPS1.Y4=-1.0
ENDIF
The second block (A_FG_MECH2...) contains the parameters for the deflection in the
direction of the welding path:
ENDIF

8.3.2 “Double 8” weave pattern

An additional weave pattern in the form of an asymmetrical “figure--eight” is defined in the
“Arc_weave.src” file. This pattern results from the superposition of a lateral weave motion
with an orthogonally--acting weave motion in the direction of welding with double frequency.
Lateral deflection Deflection in the Resulting figure--eight
(amplitude) direction of the path
Y Y Y
3 2 6 4
1 0,5 1
2 4 2
3
5 9 3 7 9 5 9
0 X 0 X 0 X
1 1 5 1
8 6
6 8
--1 --0,5 --1
7 4 8 7
$TECH[A_FG_MECH1]... $TECH[A_FG_MECH2]... Weave length
(X 1 ... 6 ; Y 1 ... 6) (X 1 ... 6 ; Y 1 ... 6)
Fig. 32 “Double 8” weave pattern

8.4 Changing and creating patterns for mechanical weaving

User--defined weave patterns are possible in “Arc_weave.src” and can be programmed
directly on the user interface (Listbox--Inhalt_Anw.Def).
8.4.1 Changing existing weave patterns

You can adapt the weave patterns defined in the “Arc_weave.src” file to your own
requirements by changing the number of control points and their parameters.
You want to shift the “Triangle” pattern -- contained in the “Arc_weave.src” file -- by 180° in
the phase angle. This might be necessary as a result of the combined application of
mechanical and thermal weaving.
The settings for the “Triangle” weave pattern are contained in the “Arc_weave.src” file:
CASE 1 ;triangle
ENDIF
This is shown graphically in Fig. 33.
Y
2
1
0.25 0.5 0.75 1.0

0.0 X
1 4
3
--1
Fig. 33 Changing an existing weave pattern

In order to achieve a phase shift of 180°, it is merely necessary to change the parameters
for control points Y2 and Y3. The required changes have been made in the following list and
are underlined for ready identification.
CASE 1 ;triangle (phi = 180 degrees)

ENDIF
Y
3
1
1 0.25 0.5 0.75 1.0

0.0 X
4
2
--1
Fig. 34 Changing an existing weave pattern

8.4.2 Creating your own weave patterns

The following example shows the practical approach for creating your own weave patterns.
A weave pattern is to be created as a combination of a trapezoid and a triangle.
It is recommendable to start by drawing the desired pattern. A range from 0.0 to 1.0 for the
path “X” covered within a period and ± for the lateral deflection “Y” are predefined.
Y
2 3
1
0.0 0.2 0.4 0.6 0.8 1.0

X
1 4 6
5
--1
Fig. 35 Creating your own weave patterns
The first value for X must be 0 (zero) and the last value must be 1. Multiple X values that
are identical cannot be used. The deflection should always begin at 0 in order to prevent
unnecessary acceleration.
The number of control points determined (CPNUM) as well as the X and Y values can be
entered, for example, in the block “CASE 8 ;default as minimums and flag for beginning” of
the WEAVDEF.SRC file, as shown in the following.
CASE 8 ;Trapezoid - Triangle

$TECH[A_FG_MECH1].FCT.CPNUM=6 Number of control points
$TECH[A_FG_MECH1].FCT.CPS1.X1=.0 Value X for control point 1
$TECH[A_FG_MECH1].FCT.CPS1.Y1=.0 Value Y for control point 1
$TECH[A_FG_MECH1].FCT.CPS1.X2=.2 Value X for control point 2
$TECH[A_FG_MECH1].FCT.CPS1.Y2=1.0 Value Y for control point 2
$TECH[A_FG_MECH1].FCT.CPS1.X3=.4 ...
$TECH[A_FG_MECH1].FCT.CPS1.Y3=1.0 ...
$TECH[A_FG_MECH1].FCT.CPS1.X4=.6
$TECH[A_FG_MECH1].FCT.CPS1.Y4=.0
$TECH[A_FG_MECH1].FCT.CPS1.X5=.8
$TECH[A_FG_MECH1].FCT.CPS1.Y6=.0
ENDIF

8.5 Notes on mechanical weaving

The quality of a seam welded with mechanical weaving is influenced by a variety of physical
and mechanical factors, such as the mechanical play in the gears, axis torsion, robot
position, path tangent, etc. In addition, interdependencies with the interpolation cycle as well
as the set robot--specific $Filter value also exist.
The weave motion is superposed on the path motion. In the case of weave patterns such as
“Trapezoid” or “Spiral”, this leads to an irregular welding speed during a period. This can vary
between the set path velocity and a multiple of it, depending on the relation of the weave
length (frequency) to the lateral deflection (amplitude).
The maximum weave frequency for mechanical weaving is – depending on the robot type
concerned – influenced by several factors, for example by the resonant frequency of the
“robot/tool” mechanical unit. Weave frequencies of up to 3 Hz (corresponding, for example,
to a weave length of 3.33 mm at a travel speed of 0.6 m/min) are possible without causing
problems, according to previous experience.
With higher weave frequencies, undesirable effects are liable to result under certain
circumstances (depending on the tool design and/or tool orientation). With weave
frequencies > 4 Hz, the motion characteristics of the robot should therefore be individually
tested in each case.

8.5.1 Weave frequency, weave length, path velocity (travel speed)
Of significance for the correct functioning of the robot is the weave frequency, which
results from the programmed path velocity (travel speed) and the weave length. The
following relationships exist between these parameters:
Path velocity [m/min] ¯ 1000

Weave frequency f = [Hz]
Weave length [mm] ¯ 60
Path velocity [m/min] ¯ 1000
Weave length s = [mm]
Weave frequency [Hz] ¯ 60
Weave frequency [Hz] ¯ Weave length [mm] ¯ 60 [m/min] *)
Path velocity v =
1000
Fig. 36 Weave frequency -- Weave length -- Weld velocity
These relationships are depicted graphically in the nomogram shown in Fig. 37.
Weave length s Weave frequency f

[mm] [Hz]
12 0.3 0.5 0.75 1.0 1.25 1.5 2.0 2.5
11 3.0
10
3.5
9
4.0
8
7
5.0
6
5 6.5
4
3
2
1.5
0
.1 .2 .3 .4 .6 .7 .8 .9 .1 .2 .3 .4 .6 .7 .8 .9
0 0.5 1.0 1.5 2.0
Weld velocity v m/min *)
For weave frequencies > 4 Hz,
see explanation in text. Non--permissible range
Fig. 37 Relationship between weave frequency -- weave length -- weld velocity

*) The weld velocity can also be entered in the inline forms in inch/min (after consultation with
KUKA). The unit m/min is always used for internal storage and calculations, however.

8.5.2 Rotation of the weave plane

In certain applications it may be necessary to rotate the weave plane (e.g. to improve the
distribution of heat). The range of possible settings is --180 to +180 degrees, so the weave
pattern can start on either the left--hand or right--hand side of the path.
90 degrees
Weave amplitude
Torch plane
Torch
Mechanical weaving
Weave Angle Weave plane

Component (weave angle)
plane
Weave angle 0 degrees
Fig. 38 Rotation of the weave plane


9 Thermal weaving
Thermal weaving may not be used in conjunction with the “KUKA.ArcSense” through--the--
arc tracking sensor option.
9.1 Fundamentals
In conventional welding processes, the values for the weld voltage and the wire feed rate
remain constant. Thermal weaving can be used for certain applications. The weld voltage
and the wire feed rate are periodically and synchronously altered in this instance, thus
producing a seam with weld metal that varies periodically according to these changes.
The robot--specific “Thermal weaving” mode has nothing in common with the “Pulsing”
option offered by welding equipment.
A precondition for the “Thermal weaving” function is that the value of the variable
A_TH_WEAVE_OPT is set to TRUE.

FALSE Thermal weaving deactivated (default).
Thermal weaving activated. The parameter list
A_TH_WEAVE_OPT is expanded to include the page: Thermal
TRUE
weaving settings, Analog channels, Weave
length, and Weave pattern.
In order to ensure synchronization between mechanical and thermal weaving, the variable
$TECH_ANA_OFF[B] must be set to TRUE in \STEU\MADA\$CUSTOM.DAT.
9.1.1 Weave patterns

Two patterns (triangle and trapezoid) are predefined by the manufacturer, with the possibility
of two further user--defined patterns. These are defined in the parameter list (thermal
weaving) under the settings
G Usr. def. pattern 1
G Usr. def. pattern 2

9 Thermal weaving (continued)
Thermal weaving
Triangle Trapezoid
(Triangle) (Trapezoid)
Length Length
Weld voltage (1 period) Weld voltage (1 period)
(volts) (volts)
Max. voltage Max. voltage
(setting in (setting in
“Wn”, page 1) “Wn”, page 1)
Min. voltage Min. voltage
Weld direction Weld direction
Wire feed Wire feed

(inches/minute) (inches/minute)
Max. feed Max. feed
Min. feed Min. feed

Weld direction Weld direction
Fig. 39 Thermal weaving

9.1.2 Example of a signal diagram
Ignition parameters
Weld parameters
(default) (Thermal weaving)
Weld start
Current flowing
Gas flow
Fig. 40 Example of signal flow diagram
9.2 Combined mechanical and thermal weaving

Mechanical and thermal weaving can be combined for use together. With the same weave
length (frequency), the function generators for mechanical weaving and the periodic change
of the weld voltage and wire feed have synchronous phases.
9.2.1 Combination possibilities

By defining the control point coordinates X and Y in the file WEAV_DEF.SRC as the situation
requires, you can define any phase shift and relationship you desire between the frequencies
(weave lengths) for mechanical and thermal weaving.
Two combination possibilities are shown in Fig. 41. In the combination shown in diagram a),
the frequency and the phase angle for mechanical and thermal weaving are the same. In
diagram b), the frequency for thermal weaving is double the mechanical weave frequency,
and the phase relation is 270° (--90°).

a) Combination with the same frequency b) Combination with different frequency

(weave length) and phase angle and phase angle
Weave plane Weave plane
Mechanical Y (1 period) Mechanical Y i
(1 period)
weaving (1.0) weaving (1.0)
X X
(0.0) (0.0)
(0°) (0°)
(--1.0) (--1.0)
--Y --Y
Thermal weaving Thermal weaving

Same frequency (weave Double frequency (half mechanical weave
length), same phase angle length), phase angle 270° (--90°)
Weld voltage Weld voltage
(volts) (volts)
Max. voltage Max. voltage
Y (1.0) Y (1.0) (0°)
(0°)
Min. voltage Min. voltage (-- 90°)
--Y (--1.0) --Y (--1.0)
X X
Weave
length
Wire feed Wire feed
(inches/minute) (inches/minute)
Max. feed Max. feed
Y (1.0) Y (1.0)
Min. feed Min. feed
--Y (--1.0) --Y (--1.0)
X X
Direction of path Direction of path
(X axis) (X axis)
Fig. 41 Examples of combining mechanical and thermal weaving

9.2.2 Practical application possibilities (examples)

Fig. 42 shows the practical application of combined triangular and trapezoidal weaving taken
from the lefthand side in the example above. By synchronizing the mechanical and thermal
weave curves, the weld voltage and the wire feed rate are greater on the side of the thicker
sheet than on that of the thin sheet.
+
Max. voltage, Max. voltage,
max. wire feed max. wire feed
Min. voltage, Min. voltage,

-- wire feed
min. min. wire feed
Mechanical: Triangle ϕ = 0° Mechanical weaving Trapezoid ϕ = 0°
Thermal: Triangle ϕ = 0° Thermal weaving Trapezoid ϕ = 0°
Fig. 42 Combining triangular and trapezoidal weaving
If the phase of the thermal weave curve is shifted by 180° in relation to the mechanical weave
curve, the combination shown in Fig. 43 will result:
+
Max. voltage,
max. wire feed
Min. voltage,
-- min. wire feed
Thermal: Triangle ϕ = 0° Thermal weaving Trapezoid ϕ = 0°
Here, either the thermal weave curve or the mechanical weave curve can be changed in the
“WEAV_DEF.SRC” file.
Fig. 44 shows another possible combination.

+ Max. voltage,
max. wire feed Max. voltage,
max. wire feed
Min. voltage,
0 Min. wire 0
feed
Max. voltage,
Min. voltage, max. wire feed
min. wire feed
Thermal: Double triangle ϕ = 270° Thermal weaving Double triangle ϕ = 270°
Compared to the mechanical weave frequency, the thermal weave frequency is twice as high
and shifted in phase by 270° 〈--90°). In this way, the weld voltage and wire feed rate change
in the course of one period according to the curves shown. In the areas of maximum
mechanical lateral deflection, welding is executed using the parameters entered in the
W--parameter list 1/4 “Primary Weld” (max. voltage and wire feed) whereas the parameters
entered in the W--parameter list 3/4 “Thermal Weaving” (min. voltage and wire feed) are used
in the area of the weld root.
Fig. 45 shows another example in which the thermal weave frequency is twice as high as the
mechanical weave frequency and shifted in phase by 90°.
+
Max. voltage, Min. voltage,
max. wire feed min. wire feed
Max. voltage,
0 Max. wire 0
feed
Min. voltage,
Min. voltage, min. wire feed
min.
-- wire feed
Thermal: Double triangle ϕ = 90° Thermal weaving Double triangle ϕ = 90°
In the area of the weld root, welding is executed using the parameters entered in the
W--parameter list 1/4 “Primary Weld” (max. voltage and wire feed), while the parameters
entered in the W--parameter list 3/4 “Thermal Weaving” (min. voltage and wire feed) are used
in the areas of maximum mechanical lateral deflection.

10 “KUKA.ArcTech Analog” settings

10.1 Power source characteristic settings
$config.dat INT A_ACT_AN_MAX=2 ;Maximum of analog channels to see parameterlists
In the following section, the setting A_ACT_AN_MAX=2 (default setting) is assumed.
The characteristic curves are assumed to be linear. These are configured identically for both
PULSE and MIGMAG.
DECL INT A_ANA_MAX_D[2,8]
;maximum number of points to define a controller line
A_ANA_MAX_D[1,1]=2 (DEFAULT)
A_ANA_MAX_D[1,2]=2 (DEFAULT)
A_ANA_MAX_D[2,1]= 2 (DEFAULT)
A_ANA_MAX_D[2,2]= 2 (DEFAULT)
DECL A_ANA_DEF_T A_ANA_DEF[2,8,5]

;WELD_Mode,Channel,Points of controller line 1:pulse/2:MigMag
A_ANA_DEF[1,1,1]={PARA 0.0,VAL 0.0}; 0..80 volts

A_ANA_DEF[1,1,2]={PARA 80.0,VAL 1.0}
;Mode1 Channel2 wire feed [m/min]
A_ANA_DEF[1,2,1]={PARA 0.0,VAL 0.0} ;0..25 m/min
A_ANA_DEF[1,2,2]={PARA 25.0,VAL 1.0}
A_ANA_DEF[2,1,1]={PARA 0.0,VAL 0.0};0..80 volts
A_ANA_DEF[2,1,2]={PARA 80.0,VAL 1.0}
;Mode2 Channel2 wire feed [m/min]
A_ANA_DEF[2,2,1]={PARA 0.0,VAL 0.0};0..25 m/min

A_ANA_DEF[2,2,2]={PARA 25.0,VAL 1.0}

10 “KUKA.ArcTech Analog” settings (continued)
10.2 Configuration of the physical interface ($CONFIG.DAT)

10.2.1 Physical outputs
IO-Mapping of physical outputs
A_WLD_OUT[1]={OUT_NR 33,INI FALSE,NAME_NAT[] ”WELD_START ”}
A_WLD_OUT[2]={OUT_NR 34,INI FALSE,NAME_NAT[] ”GAS PREFLOW ”}
A_WLD_OUT[3]={OUT_NR 0,INI FALSE,NAME_NAT[] ”WELD_MODE PS/MM ”}
A_WLD_OUT[4]={OUT_NR 0,INI FALSE,NAME_NAT[] ”CLEANER ”}
A_WLD_OUT[5]={OUT_NR 0,INI FALSE,NAME_NAT[] ”RECEIPT ERRORS ”}
A_WLD_OUT[6]={OUT_NR 0,INI FALSE,NAME_NAT[] ”ERR MESSG_SIGNAL”}
A_WLD_OUT[7]={OUT_NR 0,INI FALSE,NAME_NAT[] ”START ERROR ”}
A_WLD_OUT[8]={OUT_NR 0,INI FALSE,NAME_NAT[] ”APPL_ERROR ”}
A_WLD_OUT[9]={OUT_NR 0,INI FALSE,NAME_NAT[] ”INTERPRETER-STOP”}
A_WLD_OUT[10]={OUT_NR 0,INI FALSE,NAME_NAT[] ” ”}
A_WLD_OUT[15]={OUT_NR 0,INI FALSE,NAME_NAT[] ”WFD + ”}
A_WLD_OUT[16]={OUT_NR 0,INI FALSE,NAME_NAT[] ”WFD - ”}
10.2.2 Configuration of the physical inputs

Relating to this configuration (only the current is monitored!)
DECL FCT_IN_T A_FLT_CYCFLG[4]

A_FLT_CYCFLG[1]={NO 13,STATE TRUE } ;e.g. collection failure
A_FLT_CYCFLG[2]={NO 2,STATE TRUE} ;e.g. current
A_FLT_CYCFLG[3]={NO 11,STATE TRUE} ;e.g. gas
A_FLT_CYCFLG[4]={NO 10,STATE TRUE} ;e.g. water
Configuration of error collection as indication of operational readiness, of current flow for start
of robot motion, and of seam fault.
;FOLD IO-Mapping of physical inputs

A_WLD_IN[1]={IN_NR 33,NAME_NAT[] ”WELDER READY ”}

A_WLD_IN[2]={IN_NR 34,NAME_NAT[] ”ARC ESTABLISHED ”}
A_WLD_IN[3]={IN_NR 0,NAME_NAT[] ”
”}
A_WLD_IN[4]={IN_NR 0,NAME_NAT[] ”CURRENT OVER ”}
A_WLD_IN[5]={IN_NR 0,NAME_NAT[] ”KEY SWITCH HOT/COLD ”}
A_WLD_IN[6]={IN_NR 0,NAME_NAT[] ” ”}
A_WLD_IN[7]={IN_NR 0,NAME_NAT[] ”BURN FREE INP_SIGNAL”}
A_WLD_IN[10]={IN_NR 0,NAME_NAT[] ”WATER AVAILABLE ”}
A_WLD_IN[11]={IN_NR 0,NAME_NAT[] ”GAS AVAILABLE ”}
A_WLD_IN[12]={IN_NR 0,NAME_NAT[] ”WIRE AVAILABLE ”}
A_WLD_IN[13]={IN_NR 0,NAME_NAT[] ”COLLECTION FAILURE ”}

10.3 Settings in the file A10.DAT

Settings for COLD START
BOOL RE_INITIALIZE=TRUE
;TRUE: TPARC.DLL forced to new initialization MIN/MAX and control-
ler line parameters
Units and increments in the parameter lists:
CHANNEL_INFO[1]={UNIT[] ”volts”,STEP[] ”0.1”}

CHANNEL_INFO[2]={UNIT[] ”m/min”,STEP[] ”0.1”}
After the above settings have been made, the HMI has to be reinitialized or a cold start has
to be forced.

10 “KUKA.ArcTech Analog” settings (continued)

11 Default data sets, resource distribution

11.1 Setting the default data sets
In the case of an ignition data set, programming is carried out via an ARC_ON command in
which the name “DEFAULT” is entered instead of data set “S”. In the case of weld data sets
or end data sets, this name is to be used in the ARC_OFF or ARC_SWI command. If changes
are made here, the data sets in the $CONFIG.DAT file listed below are also modified.
Advantage of this procedure: as soon as a new program is generated, the data manipulated
here are preset with exactly these values. The power source and welding wire diameter can
be adapted.
The following data can, of course, also be changed directly in the $CONFIG.DAT file.
Ignition DEFAULT data set
DECL A_STRT_T A10BDEFAULT={GAS_PRE_T 0.1,START_T 0.2,ANA1

24.0,ANA2 450.0,ANA3 0.0,ANA4 0.0,ANA5 0.0,ANA6 0.0,ANA7
0.0,ANA8 0.0}
End DEFAULT data set
DECL A_END_T A10EDEFAULT={END_TI 0.1,BURNBACK_T 0.05,GAS_POST_T

0.2,ANA1_E 22.0,ANA2_E 400.0,ANA3_E 0.0,ANA4_E 0.0,ANA5_E
0.0,ANA6_E 0.0,ANA7_E 0.0,ANA8_E 0.0}
Weld DEFAULT data set
DECL A_WELD_T A10WDEFAULT={VEL 0.5,ANA1 22.5,ANA2 430.0,ANA3

0.0,ANA4 0.0,ANA5 0.0,ANA6 0.0,ANA7 0.0,ANA8 5.0,WEAVFIG_MECH
’H0’,WEAVLEN_MECH 14.0,WEAVAMP_MECH 2.0,WEAVANG_MECH 0.0,WEAV-
FIG_THER ’H0’,ANA1_THERM 0.0,ANA2_THERM 0.0,WEAVLEN_THER
4.0,BURNBACK_T 0.3

11 Default data sets, resource distribution (continued)
11.2 KUKA.ArcTech Analog resource distribution
The resources described in Sections 11.2.2, 11.2.3 and 11.2.4 can be customized.
11.2.1 Interrupt definitions at R1 level (all ARC versions)

Program ;FOLD ARCTECH ANALOG_INI
FOLD “INI” IF A10_OPTION==#ACTIVE THEN
INTERRUPT DECL A_Arc_Control_Intr WHEN
$CYCFLAG[A_CycFlagIndex1]==FALSE DO A10 (#APPL_ERROR)
INTERRUPT DECL A_Arc_Swi_Intr WHEN A_ARC_SWI==#ACTIVE
DO A10 (#ARC_SEAM)
INTERRUPT DECL A_Arc_HPU_Intr WHEN A_FLY_ARC==TRUE
DO A10 (#HPU_ARC)
INTERRUPT ON A_Arc_HPU_Intr
A10_INI ( )
ENDIF
;ENDFOLD (ARCTECH ANALOG_INI)
11.2.2 $CYCFLAG indices

$config.dat CycFlagIndex1=2 ;indexed cycflags
INT A_CycFlagindex2=4 Seam fault monitoring
INT A_CycFlagIndex3=5 Seam fault monitoring
11.2.3 $TIMER indices

$config.dat TimerIndex1=15 Ignition process monitoring
INT A_TimerIndex2=16 Gas postflow monitoring
11.2.4 Interrupt indices

$config.dat INT A_Arc_Control_Intr=4 ;ISR index Seam control
INT A_Arc_Swi_Intr=7 ;ISR index Arc_SWI command
INT A_Arc_HPU_Intr=5 ;ISR index HPU Statuskey

12 Fault situations and fault service functions

If a welding or robot fault occurs during ignition or welding, the welding process is interrupted.
Due to the variety of causes and types of faults, different fault service functions are required.
In addition to the standard measures included in the technology package, the user can
configure fault service functions tailored to specific requirements.
Types of faults and causes

A distinction is made between application--specific seam faults caused by peripheral
equipment and faults attributable to the robot controller (e.g. IR_STOPMESS faults).
The possible causes of faults may be, for example:
G Ignition and seam faults resulting from unreliable operating states of the torch and/or
welding equipment;
G Media faults (e.g. shielding gas, welding wire, cooling);
G Ignition and seam faults resulting from workpiece characteristics (dirt, gap, etc.);
G Controller faults (e.g. IR_STOPMESS faults, EMERGENCY STOP actuation);
G Operator control function “Interpreter STOP”
12.1 Ignition faults

12.1.1 Configuration: number of permissible ignition attempts ($CONFIG.DAT)
Number of ignition attempts before an ac-
A_MAX_RETRY 3 (default)
knowledgement message is generated
12.1.2 Setting the ignition fault option ($CONFIG.DAT)

The ignition process is repeated with the torch
position unchanged and with the same start
#RESTART (default) parameters until either ignition is successful
or the value programmed in A_MAX_RETRY
(default: 3) is reached.
A_S_ERR_OPT In accordance with the procedure defined in
FLT_SERV.SRC, the torch moves away from
the component between ignition attempts until
#USR_START
either ignition is successful or the value pro-
grammed in A_MAX_RETRY (default: 3) is
reached.
A status message appears in the message window after every ignition attempt. If the number
of ignition attempts (value defined in A_MAX_RETRY) is exceeded, an acknowledgement
message appears.

12 Fault situations and fault service functions (continued)
12.1.3 Special features of user--defined ignition fault service functions (#USR_START)

The fault service function #USR_START is used to call up the fault routine program
FLT_SERV.SRC, which then calls up specific fault service functions.
The selection of the fault service function to be used is made in the file $CONFIG.DAT by
means of the variable “A_FLT_SV_FCT” (default setting: 0):
INT A_FLT_SV_FCT=0 ; Number of user-defined FLT_SERV subroutine

A_FLT_SV_FCT 0 (default) Definition of the fault service function
The entry A_FLT_SV_FCT=0 corresponds to the “CASE 0” fault service function in the
FLT_SERV.SRC file. This procedure is suitable, for instance, for cutting through insulating
oxide layers (for example during aluminum welding) when the wire contacts the workpiece
in order to allow a fault--free ignition process in a restart.
SWITCH A_FLT_SV_FCT
;===========================================
; FAULT SERVICE FUNCTION (additional START-Error )
;===========================================
CASE 0
IF A10_OPTION ==#ACTIVE THEN
IF ARC_ON_FLT==#ACTIVE THEN
MOVE_TCP ({X --20.0,Y 0.001,Z 0.001} )

IF ((A_RETRY_COUNT< A_MAX_RETRY) OR (A_S_ERR_OPT<>#USR_START))
THEN
MOVE_TCP ({X 20.0,Y --0.001,Z --0.001} )
ENDIF
ELSE
MOVE_TCP ({X -20.0,Y 0.001,Z 0.001} )
ENDIF
ENDIF
;*****************
; local subroutine
;*****************
DEF MOVE_TCP (TCP_IN :IN )
DECL TCP_TYP TCP_IN
F=$NULLFRAME
F.X=TCP_IN.X
F.Y=TCP_IN.Y
F.Z=TCP_IN.Z
LIN $POS_ACT:F
END

The following illustration shows the mode of operation.

Allow clearance from
possible obstacles!
*) Depending on the position of the

X axis in the tool coordinate system
Gas nozzle axis
*)
*) *)
X
MOVE _TCP({X-20.0,Y1.0,Z1.0}) LIN POS_RET
Fig. 46 Fault service function -- torch retraction
If this fault service function is implemented, it is essential to make sure that there
is sufficient clearance for the torch to be retracted.
If this is not possible, reduce the distance “X” accordingly -- MOVE_TCP ({X -20.0,Y
1.0,Z 1.0} ).
When torch angles are measured, the position of the gas nozzle axis (tip of the torch) is
the crucial value for establishing a proper reference plane (important, for example, in
mechanical weaving).
The tool must be calibrated in such a way that the current nozzle with the protruding
wire corresponds to the +X direction in the tool coordinate system. Otherwise, there
is the risk of a collision with the workpiece.
12.1.4 Ignition fault signals
Output group Meaning

A_O_FLT_SIGN[ ] Signal to the PLC in the event of a seam
fault or ignition fault. (max. 1 output)
A_O_FLT_ON[ ] Signal to the PLC in the event of an ignition
fault (max. 3 outputs)
A_O_ACK_FLT[ ] Acknowledgement signal to the periphery
before repetition of the ignition process

12.2 Media faults of periphery faults

Seam faults are application--specific faults. Monitoring devices in the peripheral equipment
and robot controller recognize incorrect function sequences (for example, an interruption in
the weld current) and generate the corresponding fault signals that are then evaluated by the
robot controller.
During the initialization phase, the corresponding CYCFLAGS are activated in the
ARC_INIT command. By means of this routine, whose mode of operation is comparable to
that of an autonomous programmable controller, the welding process is constantly monitored
following proper ignition and a delay time set with the variable A_CTRL_DELAY.
Variable Value
A_CTRL_DELAY 1200 ms (default) Monitoring delay
12.2.1 Configuring the monitoring functions

The following configuration example shows the assignment of A_FLT_CYCFLG[1]...[4]
to the input table (digital inputs). In this example the following peripheral interface signals are
monitored:
-- Group fault
-- Current fault
-- Gas fault
-- Water fault
Configuration: Monitoring functions
DECL FCT_IN_T A_FLT_CYCFLG[4]
A_FLT_CYCFLG[1]={NO 13,STATE TRUE} ;e.g. group fault

A_FLT_CYCFLG[2]={NO 2,STATE TRUE} ;e.g. current
A_FLT_CYCFLG[3]={NO 11,STATE TRUE} ;e.g. gas
A_FLT_CYCFLG[4]={NO 10,STATE TRUE} ;e.g. water

A_WLD_IN[10]={IN_NR 0,NAME_NAT[] “WATER AVAILABLE “}
A_WLD_IN[11]={IN_NR 0,NAME_NAT[] “GAS AVAILABLE “}
A_WLD_IN[13]={IN_NR 0,NAME_NAT[] “GROUP FAULT “}
The available peripheral interface signals depend on the type of welding controller being used.
The entered signal states (STATE “TRUE” or “FALSE”) must each correspond to the set
“GOOD” status that exists during troublefree operation.

12.2.2 Ignoring temporary interrupts (A_SWINDL_OPT)

Another configurable option, A_SWINDL_OPT, allows you to ignore temporary interruptions
in current, such as those that can occur during “harsh” welding operations (for example, in
CO2 processes). After the time elapses that has been set with A_SWINDL_TIM, the state of
the $CYCFLAG is read again. If the fault state still exists after this set time, the deactivation
procedure is executed. Otherwise the process is continued.
Configuration using the menu function Monitor - Variable - Modify
($CONFIG.DAT):
A_SWINDL_OPT #ACTIVE (default) #IDLE = deactivated
A_SWINDL_TIM 0.05 (default) Wait time in seconds
12.3 Robot faults (IR_STOPMESS faults)

This term refers to all faults triggered by the robot system itself. Examples include:
G Drives OFF
G Operating mode switchover
G Enabling switches
G EMERGENCY STOP
G Faulty program (e.g. division by 0)
Voltage dips in the mains voltage supply are also monitored using this interrupt routine.
12.3.1 Deactivation
Once the robot fault is detected, the fault signal A_O_FLT_SIGN[ ] is set during welding.
If a torch cleaning process activated by the flag A_CLEANER=#ACTIVE is detected at the
same time, this is deactivated in accordance with the signal group A_O_FLT_APPL[ ].
The current is disconnected, shielding gas continues to flow and the mechanical weaving is
interrupted. The fault signal A_O_FLT_APPL[ ] is also set (only in the case of hot welding).
The weld fault counter is incremented and an error message is generated; this message is
deleted once it has been manually acknowledged. A_O_ACK_FLT[ ] also triggers an
acknowledgement pulse and repositions the robot to $POS--RET.

12.3.2 Reactivation
Acknowledgement of the error message results in reactivation. Depending on the option set
(A_APPLICAT=#THICK or A_APPLICAT=#THIN) ignition or weld parameters are then
generated. The relevant weave process is reactivated along with the weave sensor if one
is being used. Ignition is always accompanied by gas preflow.
12.3.3 Signal diagram for IR--STOPMESS or seam error fault situations

Fig. 47 shows the signals generated when a seam fault occurs:
Weld parameters Ignition parameters Weld parameters

Application errors “Error message” signal A_O_FLT_SIGN[ ]
A_O_FLT_APPL[ ] Acknowledge fault A_O_ACK_FLT[ ]
Weld start
Current flowing Gas flow Current flowing
Fig. 47 Signals in the event of seam faults
Within this sequence, you can see on the left the falling edge of the “Current flowing” signal
(A_I_STRT_MOV[ ]) coming from the welding peripheral interface. The result is that the
robot controller generates the fault signal A_O_FLT_APPL[ ] as well as the signal used for
the fault message on the control panel, A_O_FLT_SIGN[ ]. Then the “Gas flow” signal
(A_WLD_OUT[2]) is also canceled.
Acknowledging the message triggers the pulse A_O_ACK_FLT[ ], thus resetting the fault
signal. In the diagram, you can recognize the restart process after the fault has been
acknowledged. An ignition process begins using the set ignition parameters with the signals
“Gas flow” (A_WLD_OUT[2]) and “Weld start” (A_WLD_OUT[1]). The peripheral interface
signal “Current flowing” (A_I_STRT_MOV[ ]) shows that ignition was successful; the
process is continued with the set weld parameters.

12.4 TechStop faults

These include, for example, pressing the red Stop button on the KCP. The robot is
immediately brought to a standstill on the path and the process is stopped. If the Start key
is pressed again, an Interrupt is triggered that reactivates the process (and weaving if
applicable).
Triggering is carried out by means of a pulse command at the A_FLY_ARC signal which may,
under certain circumstances, need to be allocated to a different IO range (default: $OUT[
817]).
12.4.1 Description of the subroutine SPS.SUB

The subroutine SPS.SUB is a program (PLC task) that runs at the controller level. This
assures reliable switching off and on following an interpreter stop.
With the aid of this subroutine, manual wire feed (WFD) and welding (hot/cold) are
controlled by means of the left--hand KCP status keys, the welding process is interrupted as
a result of an interpreter stop (red “STOP” button pressed), and the process is restarted.
12.4.2 Interruption of the welding process after interpreter stop

An interpreter stop (also called “TECH STOP”) is triggered by pressing the “STOP” button
located on the left of the KUKA Control Panel. This operator action -- not to be confused with
the “IR_STOPMESS” fault resulting from a fault situation (see Section 12) -- stops the robot
(ramp--down braking) and, if the welding process is active, terminates welding and interrupts
the flow of gas. The corresponding routine at the controller level is triggered by means of
Interrupt 21.
A corresponding signal (A_O_IR_STOP) is given for the duration of an interpreter stop
command that occurs during the welding process, and is reset when the state that caused
the signal is terminated. This is configured in the file $CONFIG.DAT.
; output for interpreter stop
DECL FCT_OUT_T A_O_IR_STOP={NO ’H9’,PULS_TIME 0.0,STATE TRUE}
The physical output to the periphery is also configured in the file $CONFIG.DAT:
;Digital outputs
;----------------------------------
A_WLD_OUT[9]={OUT_NR 9,INI FALSE,NAME_NAT[] “INTERPRETER-STOP”}
Physical digital output
In this example A_O_IR_STOP.NO is a reference to A_WLD_OUT[9].

Variable Value
A O IR STOP NO
A_O_IR_STOP.NO 9

Fig. 48 shows the control signals for weld start, current flowing, and gas flow when an
interpreter stop is triggered with a subsequent restart. The interpreter stop signal
(A_O_IR_STOP) is also shown. The change from the weld parameters to the ignition
parameters and back again is evident from the characteristics of the analog signals for the
wire feed setpoint and voltage setpoint.
Weld parameters Ignition parameters Weld parameters

Interpreter stop signal
(A_O_IR_STOP)
Voltage setpoint
value
Weld start Weld start
Gas
Current flowing flow Current flowing
Fig. 48 Signals in the event of interpreter stop
Characteristic features of an interpreter stop:

G If the welding process is performed with thermal weaving, the setpoint values for wire feed
and weld voltage that are current at the time of the interpreter stop are retained until the
restart.
G The counter for the number of ignition attempts is set to zero.
G The outputs to the periphery are deactivated by means of the configured group
A_O_DISBL_P if the welding process was active at the time of the interpreter stop
(A_WLD_ACTIV=#ACTIVE) and/or gas was flowing (A_GAS_FLOW=#ACTIVE).
12.4.3 Restart after an interpreter stop

If the welding process was interrupted by an interpreter stop, it can be restarted by pressing
the green start button on the KUKA Control Panel. If the process was interrupted during
welding (A_HOT_WELD=#ACTIVE), ignition is immediate.
The ignition process is initiated either with the programmed ignition parameters or weld
parameters, depending on how the option A_APPLICAT (“#THICK” or “#THIN”) is set. When
the thick plate range is set (A_APPLICAT=THICK), ignition is always with the ignition
parameters. In this way, with thermal weaving a normal ignition process is ensured even if
the values for weld voltage and wire feed were at the minimum point of the weave curve at
the time of the interpreter stop.
The restart described above is not possible if another fault situation or fault service function
is active at the same time, or has not been properly concluded.

12.4.4 Sequence diagram

On the following pages the functioning of the PLC subroutine is shown in the form of a
sequence diagram.
Start
...SPS.SUB
Selection of CELL programs

(AUTOMATIC EXTERNAL)
Routine only for

N A10 option
TRUE POWER UP
Set variables to default setting

PRE_INIT( )
START LOOP
Folds contain
program calls or
Folds of other program codes
technology packages
Endless loop
(LOOP)
N A10 option
TRUE
PLC task See diagram

A10--specific “Detail from
...SPS.SUB”
END LOOP
End
Fig. 49 Sequence diagram: mode of operation of the PLC subroutine

12.4.5 Details of the routine in the Submit interpreter (SPS.SUB)
Detail from
PLC task
“...SPS.SUB”
Stop key pressed &

weld command
active & gas flow / Program N
weld power source STOP
active
Y
Reset ignition
retry counter Set flag “Hot weld” A_TCHSTP_STS=
A--HOT_T_STOP = #ACTIVE #IDLE
R1 interpreter N
active
Restart after interruption of the
welding process due to Y
interpreter stop (no other fault
service function active) A_TSTOP_CONT=
#ACTIVE
A_HOT_T_STOP= A_TSTOP_CONT=
#ACTIVE #IDLE
A_RETRY_COUNT=0
Initiation of a restart
WELD_AGAIN( ) (Only detection of
status key activation)
Program active N “HOT/COLD”

status key
pressed
“HOT/COLD” status “Key pressed” flag:

key enabled A_ISR_ACTION=#IDLE
“Triggering” flag
State of “HOT/COLD” A_OLD_WELD Detail from
status key saved =A_HOT_WELD “...SPS.SUB”
continued 1/2
Fig. 50 Sequence diagram: Submit interpreter routine (page 1 of 3)

Detail from
“...SPS.SUB”
continued 1/2
Manual wire N
Precondition: Welding inactive, feed
wire feed enabled
Y
Status key
N
+ or --
pressed
Pulse command Pulse command

“Wire feed” “Wire retract”
“HOT”
status key N
pressed
Y
Preconditions:
-- manual welding enabled Programmed
-- restart process after N
weld command
interpreter stop not active. active
-- weld process not active.
Y
Pulse command Trigger ISR 5 (R1):

for signal declaration in A_FLY_ARC=TRUE
$CONFIG.DAT
Flag:
Marking the running A_ISR_ACTION
interrupt = #ACTIVE
Detail from
“...SPS.SUB”
continued 2/3

Detail from
“...SPS.SUB”
continued 2/3
“COLD” N
Precondition: status key
ignition routines pressed
inactive
Y
Welding
N
and/or gas
flow active
Trigger ISR5:
A_FLY_ARC=TRUE
Marking the running Flag

interrupt A_ISR_ACTION=#ACTIVE
Refreshing of the
function
generator data
End
PLC task

12.5 Integration of the cleaner routine (torch cleaning)

As long as the flag fulfils the condition A_CLEAER=#ACTIVE, the signal group
A_O_DISBL_P[n] will be deactivated in every fault situation (periphery fault, robot fault, or
Tech stop fault).
Configuration: deactivation of torch cleaning: ($CONFIG.DAT)
DECL FCT_OUT_T A_O_DISBL_P[3]
A_O_DISBL_P[1]={NO ’H4’,PULS_TIME 0.0,STATE FALSE}

A_WLD_OUT[4]={OUT_NR 0,INI FALSE,NAME_NAT[] “CLEANER “}
Example of a cleaner program

&ACCESS RO
&COMMENT Cleaner program
DEF CLEANER ( )
;---------------------------------------------
; $OUTs[n] have to have links to the A10 configuration
; A_O_DISBL_P[3]- OUTPUT-Group: indexed addressing to
; the group DECL CTRL_OUT_T A_WLD_OUT[16]
; Flag: A_CLEANER is an identifier to switch off
; the running CLEANER program
;---------------------------------------------
INTERRUPT DECL 3 WHEN $STOPMESS==TRUE DO IR_STOPM ( )

INTERRUPT ON 3
A_CLEANER=#ACTIVE
; $OUT[n] ; sprayer
; WAIT SEC
; $OUT[n] ; rotating knife
; WAIT SEC
; $OUT[n] ; reamer addressing
; WAIT SEC
A_CLEANER=#IDLE
END ; ( CLEANER )

12.6 Restart options

Possible approaches when faults occur during the weld start include, for example:
G Unlimited number of restart attempts.
The restart process is repeated until it is successful.
G Limited number of restart attempts.
After the set number of ignition attempts has been completed (A_MAX_RETRY), the
current process is continued to the end in the “cold” mode (ARC OFF) and without
mechanical weaving (if it was programmed).
G User--defined subroutines, for example cutting through insulating oxide layers.
The fault service function to be used is defined in the file $CONFIG.DAT by means of the
variable A_RESTRT_OPT. #LIM_RESTART is the default setting. The acknowledgment
message “Seam error” is generated when weld faults occur. Error messages are generated
in accordance with the “user--defined messages” template.
;Restart Mode at seam error
DECL A_RESTART_T A_RESTRT_OPT=#LIM_RESTART (default)
Configuration using the menu function “Monitor -- Variable -- Modify” and description of
the characteristics:
The restart attempts are carried out with the
torch position unchanged and with the same
parameters until either ignition is successful
#LIM_RESTART or the value programmed in A_MAX_RETRY
(default) (default: 3) is reached.
If the number of weld faults (>A_MAX ER-
ROR) is exceeded, an acknowledgement
message is generated.
The number of restart attempts is unlimited.
However, if more ignition faults occur during
a restart attempt than programmed in
#RESTART
A_MAX_RETRY, the procedure is terminated.
A corresponding message is displayed on
the control panel.
A_RESTRT_OPT The weld process is not restarted. The torch
is moved to the ARC OFF position on the
current seam. Only then can the next
#COLD_SEAM
ARC ON command be started.
If no restart occurs, the A_O_FLT_APPL[ ]
signal remains active.
The torch moves away from the component
between ignition attempts in accordance
with the procedure defined in the file
FLT_SERV.SRC.
#USR_SEAM This procedure is repeated until either igni-
tion is successful or the value programmed
in A_MAX_RETRY (default: 3) is reached.
A corresponding message is displayed on
the control panel.
Using the Trigger function, various values can be assigned to the variable A_FLT_SV_FCT
depending on the robot motion. The purpose of this is to assign appropriate fault service
functions to different working ranges of the robot.

12.6.1 Fault service functions defined by the user (#USR_SEAM)

The particular feature here is that the robot remains positioned away from the seam so that
the seam or welding wire can be reworked by the operator. Once the error message has been
acknowledged the robot is repositioned and ignition process is carried out.
The file FLT_SERV.SRC contains a fault service function with the designation “CASE 0” as
well as five other examples (CASE 1 ... 5) that can be freely configured.
The fault service function to be used is selected using the variable A_FLT_SV_FCT. The
value “0” is the default setting for “CASE 0”.
FAULT SERVICE FUNCTION (additional START error)

CASE 0
IF ARC_ON_FLT==#ACTIVE THEN
INTERRUPT OFF 3 ; IR_STOPMESS()
MOVE_TCP ({X -20.0,Y 1.0,Z 1.0} ) Applies to ignition faults only.
INTERRUPT ON 3
ELSE In the case of an error during
welding,
MOVE_TCP ({X -50.0,Y 1.0,Z 1.0} ) the torch is moved back
by X=50 mm *)
HALT
LIN POS_RET The torch is moved back to the
ENDIF start position.
The robot stops 50 mm away from the seam. This makes it possible to work on the wire
without having to move the robot away.
If this fault service function is implemented, it is essential to make sure that there
is sufficient clearance for the torch to be retracted.
If this is not possible, reduce the distance “X” accordingly -- MOVE_TCP ({X -50.0,Y
1.0,Z 1.0} ).

12.6.2 Number of restart attempts

The number of permissible restart attempts is programmed with the variable A_MAX_RETRY.
(default value = 3)
12.6.3 Fault signals

Configuration: general fault signal ($CONFIG.DAT)
; output for fault message
DECL FCT_OUT_T A_O_FLT_SIGN={NO ’H6’,PULS_TIME 0.0,STATE TRUE}
A_WLD_OUT[6]={OUT_NR 0,INI FALSE,NAME_NAT[] “ERR MESSG_SIGNAL”}

Configuration: application fault signal ($CONFIG.DAT)
; output for fault application error message
DECL FCT_OUT_T A_O_FLT_APPL={NO ’H8’,PULS_TIME 0.0,STATE TRUE}
A_WLD_OUT[8]={OUT_NR 0,INI FALSE,NAME_NAT[] “APPL_ERROR “}
12.6.4 Block selection response

If the $CONFIG variable is set to A_HOT_SELECT=#ACTIVE (default= #IDLE), the weld
process is started in the middle of the seam in the event of a block selection to an
ARC_SWITCH or TRACK_SWITCH command with sensor as long as the weld conditions
are met. Weaving is initially switched off for the motion and is reinitialized if necessary.

13 Customized messages
In addition to the standard error messages, the KCP can also display customized information
in the message window. The message texts and the signal inputs to which they are linked
can be determined by the customer. This results in enhanced operating convenience and
simpler location of faults. This type of error message is only generated for periphery faults.
13.1 Message program

When the file ...\R1\TP\ArcTechAnalog\ARC_MSG.SRC is opened, the window shown in
Fig. 53 is displayed.
Fig. 53 ARC_MSG.SRC program

13 Customized messages (continued)
When the fold PREPARED SYSTEM INPUTS is opened, the window shown in Fig. 54 is
displayed.
Fig. 54 ARC_MSG.SRC program -- FOLD “PREPARED SYSTEM INPUTS”
The system inputs in question are the signal groups defined in A_FLT_CYCFLAG for weld
seam monitoring.
In the event of a fault, a bit--coded fault marker is generated in the variable TMP_WLD_CTRL
in order to generate a cause--specific message after deactivation. Four inputs are
preprogrammed in $CONFIG.DAT:
These four configured inputs can trigger a periphery error:
A_FLT_CYCFLAG[1]={NO 13,STATE TRUE}; group fault

A_FLT_CYCFLAG[2]={NO 2,STATE TRUE}; current
A_FLT_CYCFLAG[3]={NO 11,STATE TRUE}; gas
A_FLT_CYCFLAG[4]={NO 10,STATE TRUE}; water
In addition to the four predefined messages, other prepared messages (e.g. for KPI systems)
are displayed when the fold USER ERROR MESSAGES is opened. The length of the text may
not exceed 7 characters!
You can enter your own texts from line S_MSG[5]...... (Fig. 55) onwards. The length of
the text must be entered in the structure at “LENGTH.”

Fig. 55 ARC_MSG.SRC program -- entering your own text
Fig. 56 ARC_MSG.SRC program -- FOLD “Coding of fault information”
Fig. 56 shows how the fault information is coded in the variable TMP_WLD_CTRL_B. The
position of the set bit in the bit sequence (from the right) determines which text is generated.
The bit sequence B00100000 thus refers to error message S_MSG[6]... in USER ERROR
MESSAGES. The total number of bits which can be set in this way is 12. The bit sequence
B100000000000 thus refers to the message S_MSG[12]....

13 Customized messages (continued)
Fig. 57 shows an example of a dynamically generated error message.
Fig. 57 Example of a dynamically generated error message

14 Fault location, fault elimination
For additional information on fault location and fault elimination when operating with the
“KUKA.ArcSense” option, see the [KUKA.ArcSense] documentation.
Fault Cause Remedy

Error message “Interrupt -- A10 option not set -- Set A10_OPTION
not defined” -- ARC_INI has not been -- Stop PLC*)
executed -- Set PLC*)
-- Boot system with
ARC.INI
FLT_SERV program: INIT section must be *) PLC has to be
Function cannot be taught, deactivated by turning it deselected. (The command
or messages such as ori- into a comment BAS(#INIT_MOV) is
entation velocity have not executed exclusively for
been programmed teaching purposes (and
then deactivate it again by
turning it into a comment).)
Wire feed keys have no No A10_Option or wire Set A10_OPTION=#AC-
effect feed not configured TIVE
Incorrect Submit module Set $PRO_I_O[ ]=
“/R1/SPS()”
A10_Option or wire feed Set A10_OPTION=
not configured #ACTIVE
Incorrect configuration of A_WLD_OUT[15].OUT_Nr
the wire feed keys (feed) or
A_WLD_OUT[16].OUT_Nr
(retract) must be set to a
value other than zero
Short ignition pulse “Current flowing” signal Increase value of $CON-
followed by error may be suspended briefly FIG.DAT A_TIME_OUT1
message: Current not in the event of an unstable (n * 10 ms)
established ignition process
Seam faults with a Caused by seam fault Check A_FLT_CYC-
customized error message monitoring FLAG]1..4] and
generated, e.g. A_WLD_IN[ ] structure
“CURRENT”, following a
short and successful
ignition
Weaving not possible $TECH_OPTION possibly STEU/$CUSTOM.DAT:
not activated Set $TECH_OPTION to
TRUE
Heat distribution in thermal Values in the parameter list Switch the default weld
weaving on the wrong side for weld voltage and wire values and the thermal
feed have been switched weaving parameter list
with those for thermal values back again
weaving

14 Fault location, fault elimination (continued)
Fault Cause Remedy

Spiral weaving results in Weave pattern only Set weave amplitude to
strange weave patterns vaguely resembles a spiral half weave length, and
observe frequency
dependence and amplitude
Absence of phase Heat distribution on the Set $CUSTOM.DAT:
synchronization during workpiece material some- $TECH_ANA_FLT_OFF[3]
thermal weaving times sporadic and =TRUE; the weave motion
changeable filtering is manipulated
Thermal weaving has no A static analog value is Activate cyclical analog
effect generated channels.
A_WEAV_GEN[3]=3
Reinitialize HMI; restart
Submit and application
program
Wire feed keys pressed. With some power sources, Once activation of the wire
Wire is fed at unsuitable the analog channel for wire feed key has been
speed feed must first be set. detected, set
If this has been adapted to A_TH2_ACT_G=0 in the
the wire feed channel using PLC and set
$ANOUT[2], this may A_TH2_ACT_O to a
nonetheless remain without velocity--proportional value
effect if cyclical analog between 0.0 and 0.1. A
channels have been used. value < 0.2 is suitable here
Default setting: (i.e. 20% of the max. wire
A_WEAV_GEN[3]=3 feed velocity).
This is a customer--specific
adaptation.
After a short, successful The monitoring delay value -- Set the variable
ignition process the error has been set too low. A_CTRL_DELAY in
message “Seam fault” or a $CONFIG.DAT to a
programmed customized higher value (default:
message is generated. 1200 [ms])
-- Check the configuration:
the signal to be monitored
on the seam is missing.
*) Depending on whether the “KUKA.ArcSense” option has been installed and activated.

15 Error messages / troubleshooting

Messages of all categories are displayed in the message window. These can be either
informative messages that do not need to be acknowledged or messages that have to be
acknowledged.
A message consists of the following items of information, for example:
Message group
Message time
Message number
Originator
Message text
15.1 Message group

Info messages
provide the operator with explanatory information, for example, if an illegal key has been
pressed.
Operational messages
signal the status of the system that has led to a control reaction, e.g. Emergency Stop. The
message is cleared once its cause has been eliminated. In some cases, a secondary signal
that has to be acknowledged is set for reasons of safety.
Acknowledgement messages
indicate a situation that must in all instances be recognized and acknowledged with the
acknowledge key. They are often a consequence of an operational message. An
acknowledgement message stops a motion or prevents further operation.
Dialog messages
require confirmation by the operator (“Yes” or “No” softkeys). The message is cleared after
it has been confirmed.
15.2 Message time

The message time indicates the time at which the message was generated.

15 Error messages / troubleshooting (continued)
15.3 Message number

With the aid of the message number, the corresponding cause, effect, and remedy can
quickly be located in the list of error messages.
15.4 Originator
The origin of the error is indicated in this field.
15.5 Message text

The text of the error message is shown here.
15.6 List of error messages

To make it easier to find error messages in the following list, the message number is shown
first, unlike on the display. By referring to this message number, it is possible to obtain further
information on an error and the appropriate remedial action. This information is subdivided
into:
Message text
is the actual text of the error message as displayed.
Cause
gives a detailed description of the cause of the error.
Monitor
indicates when the message is generated.
Effect
describes how the controller reacts to the error.
Remedy
describes what action the user can take to eliminate the error.

15.7 Standard error messages
1 Message text Missing SPS or A10_OPTION disabled
Cause Submit interpreter is not running (stopped or canceled, or variable

$PRO_I_O[ ] in $STEU/CUSTOM.DAT is incorrect)
Monitor ARC_INIT, advance run file of the KRC--ON command
Effect Welding not possible
Remedy Select Submit and configure $PRO_I_O[ ]:
/R1/SPS( )
3 Message text Variable ANAOUT_NO[n] must be <>0
Cause With A_ACT_AN_MAX <>2, the value needs to be <>0 up to this number
of array variables (induced addressing of the analog channels)
Monitor ARC_INIT
Effect ARC_INIT is not executed, not even in cold or dry run
Remedy Correct the array A_ANAOUT ($CONFIG.DAT)
4 Message text Confirm override 100%
Cause Weld program executed with < >100% override (acceleration ramps are
not so steep); monitor in TEST1/2 and Automatic mode
Monitor ARC.INI
Effect The program enquires whether this has been forgotten
Remedy Answer dialog
5 Message text Backward.ini: SET_TO_FALSE=TRUE and RESTORE=AT_FWD necessary
Cause Settings in Backward.ini are incorrect

Monitor ARC_INIT
Effect Message is generated to prevent malfunction during backward motion
Remedy Correct Backward.ini (using offline tool BW_INI.exe; correction is
also possible during run time)
6 Message text Option $RED_T1_OV_CP=FALSE in $CUSTOM.DAT necessary
Cause Option set incorrectly (STEU/$CUSTOM)

Monitor ARC_INIT
Effect It is not possible to move at weld velocity in T1 mode. Once this setting
has been corrected, it is possible to weld just as fast in T1 mode as in
T2/AUT/EXT modes provided that the safety conditions are met.
Remedy Set option

7 Message text Process not enabled: A_PROC_ENABLE
Cause Option is deactivated (disabled for unauthorized personnel)

Monitor ARC_INIT
Remedy Set variable back to default value:
A_PROC_ENABLE=TRUE ($CONFIG.DAT)
8 Message text Controller characteristics configuration error
Cause Characteristic incorrectly defined

Monitor ARC_INIT
Effect Correction vital
Remedy Set the configuration correctly:
Cancel Submit --> Reselect --> Cold start necessary
Set A10.DAT: REINITIALIZE=TRUE before cold start
9 Message text Cyclic analog channels are necessary for online optimizing
Cause No cyclical analog outputs are active

Monitor ARC_INIT
Effect Thermal weaving and online optimizing not possible
Remedy A_WEAV_GEN[3]=3 then cold start necessary
10 Message text RUN Mode necessary for welding
Cause Program run mode is not set to RUN and welding is to be carried out
Monitor Advance run section of ARC_ON command or ARC_INIT
Effect Program remains in this loop as long as hot welding is meant to be
taking place and the program run mode has not been set to #GO
Remedy Correct the program run mode or activate a cold or dry run
11 Message text Power source not ready
Cause Power source readiness not detected (signal group A_I_WLD_COND[])

Monitor Ignition attempt only carried out in hot mode
Remedy Check the configuration of A_I_WLD_COND[ ] and A_WLD_OUT[ ] and
ensure that the power source is switched on

12 Message text Current not established
Cause No weld current detected during the timeout following the ignition
attempt.
Monitor After every ignition attempt
Effect Welding is not possible
Remedy Check A_I_STRT_MOV[ ] signal configuration and A_WLD_OUT[ ]
signal table
Check components, gap, and dirt
13 Message text 1. 2.3..... Retry of start procedure
Cause An ignition error has occurred

Monitor Failure of ARC_ON command
Effect Weld process deactivated, renewed ignition attempt
Remedy -- Check A_I_STRT_MOV[ ] signal configuration and A_WLD_OUT[ ]
signal table
-- Check components, gap, and dirt
14 Message text Too many retries: continuing cold
Cause Too many failed ignition attempts

Monitor Failure of ARC_ON command
Effect Weld process deactivated
Remedy Check components, gap, and dirt
15 Message text “Current flowing” signal still active
Cause Current off signal not detected within the configured timeout
(A_TIME_OUT) (only if burnfree option is not active)
Monitor ARC OFF command
Effect Process is deactivated anyway
Remedy Check the signal group A_I_WLD_END[ ]
16 Message text Wire still connected to work piece!
Cause Burnfree input not detected (only if burnfree option not active)
Monitor ARC OFF command
Effect Acknowledgement message appears so that burnback can also be
optimized if required. This is intended to be seen as an optimization
Remedy It may also be appropriate to modify the variable #QUIT to #NOTIFY in
A10.DAT (do not configure this input for applications where cycle times
are critical!)

17 Message text Burn free procedure repeated
Cause The burnfree procedure was repeated with the burnfree option
activated
Monitor ARC_OFF in burnfree routine
Effect Message serves as information for the user
Remedy Optimize burnback and check burnfree configuration if message appears
frequently
Adapt A_BRN_FREE data set in A10.DAT
18 Message text Burn free retry limit exceeded
Cause Number of burnfree attempts specified in A_BRN_FR_LIM exceeded

Monitor Burnfree procedure in ARC_OFF
Effect Acknowledgement message as aid for the user
Remedy Adapt A_BRN_FREE data set in A10.DAT (check burnfree parameters)
19 Message text Welding deactivated in step mode
Cause Welding active but program run mode is invalid. Program run mode
#GO necessary
Monitor Before every ignition process
Effect Torch cannot be activated
Remedy Adapt the program run mode
20 Message text Welding not possible in T1 mode
Cause The variable A_PROC_IN_T1 was set to FALSE, which deactivated

welding in mode T1
Monitor In every ARC command
Remedy Set variable A_PROC_IN_T1 ($CONFIG.DAT) to TRUE
21 Message text Wrong state of WELDING keyswitch
Cause While the technology--specific softkey is set to “Welding On”, a different

state has been detected for the keyswitch
Monitor In advance run of ARC ON command
Effect Program remains stopped, welding not possible
Remedy Change keyswitch position or softkey state

22 Message text Wrong state of WELDING keyswitch
Cause A setting has been detected in T1 / T2 mode which would allow

immediate welding if the HOT button were pressed
Monitor Advance run section of the ARC ON command (irrespective of whether
welding is set for cold or hot)
Effect Program remains stopped, welding not possible
Remedy Adapt icon or keyswitch position
23 Message text Active sensor simulation --> Path deviation of the robot
Cause Sensor driver is set to simulation mode (Service mode!)

Monitor A50_SENSOR_ON
Effect Robot deviating from programmed path --> risk of crash
Remedy A robot will never be delivered in this operating mode. If this is not the case,
please contact KUKA Roboter GmbH Technical Support
24 Message text Sensor offset is still available
Cause Sensor offset has been frozen

Monitor A50.SDC, ARC OFF, or TRACK OFF command if message is active
(message only appears in T1/T2 mode)
Effect Sensor offset remains in place. PTP motions are not permissible in this
state as it is impossible to predict where the robot will move
Remedy As this is not a fault, but merely a mixed effect, the user need only be aware
of this possible situation


Index
Symbols A_WLD_IN[ ], 25
#ACT_PAR, 58 A_WLD_OUT[ ], 19
#COMPLETE, 58 A_WLD_OUT[1], 50, 100
#USR_SEAM, 109 A_WLD_OUT[1].INI, 19
$CONFIG.DAT, 11, 14 A_WLD_OUT[1].NAME_NAT[ ], 19
$CYCFLAG indices, 94 A_WLD_OUT[1].OUT_NR, 19
$TECH[A_FG_MECH1], 72 A_WLD_OUT[2], 49, 100
$TECH_ANA_OFF[B], 83 A10.DAT, 12, 14
$TIMER indices, 94 A10.SRC, 14, 73
A10_INI.DAT, 14
A10_INI.SRC, 14
A
A10_USR_ArcOff1, 32
A_ACT_AN_MAX, 63
A10_USR_ArcOff2, 32
A_ANA_DEF[2,8,5], 64
A10_USR_ArcSeam, 31
A_ANA_MAX_D[ ], 65
A10_USR_INIT, 29
A_ANA_MAX_D[1,1], 68
A10_USR_IRSTOPMESS, 33
A_ANAOUT_NO[ ], 64
A10_USR_PLC_INIT, 33
A_APPLICAT, 37, 102
A10_USR_PLC_Task, 33
A_BB_MODE, 58
A10_USR_PreArcOff, 31
A_BRN_FR_OPT, 57
A10_USR_PreArcOn, 30
A_CLEAER=#ACTIVE, 107
A10_USR_PreArcSwi, 31
A_CTRL_DELAY, 50, 98
A10_USR_SeamError, 35
A_END_BRAKE, 37
A10_USR_START1, 30
A_FLT_CYCFLG[ ], 98
A_FLT_SV_FCT, 96, 109 A10_USR_START2, 30
A_GAS_FLOW, 102 A10_USR_TechStop, 34
A_HOT_WELD, 102 A10_USR_TechStopSub1, 34
A_I_BRN_FREE, 57 A10_USR_TechStopSub2, 34
A_I_STRT_MOV[ ], 50, 100 Adaptation of analog outputs 1 and 2, 64
A_I_WELD_END[ ], 56 Adaptation to the periphery, 17
A_MAX_RETRY, 110 Addressing of the analog outputs, 63
A_O_ACK_FLT[ ], 100 Approximate positioning, 54
A_O_DISBL_P, 102 ARC OFF sequence diagram, 59, 60
A_O_FLT_SIGN, 100 ARC ON -- schematic sequence diagram, 48
A_O_IR_STOP, 101 ARC SWITCH sequence diagram, 51
A_O_IR_STOP_NO, 101 ARC_INIT, 29
A_O_POST_OFF[ ], 55 ARC_MSG.SRC, 14, 111
A_O_POST_ON[ ], 55 ARC_WEAVE.SRC, 14
A_O_SEAM_END[ ], 55 Arc_weave.src, 77
A_PR_GAS_OPT, 42 ARCSPS.SUB, 15
A_RESTRT_OPT, 108
A_STRT_BRAKE, 37
A_SWINDL_OPT, 99
B
A_SWINDL_TIM, 99 Burnback, 58
A_TH_WEAVE_OPT, 83 Burnback mode, 58
A_WLD_ACTIV, 102 Burnback parameters, seam--specific, 58
Index -- i
Index
C I
Changing existing weave patterns, 77 Ignition faults, 95
Characteristic, voltage, 68 Ignoring temporary interrupts, 99
Cleaner routine, 107 IN_NR, 25
Combined mechanical and thermal weaving, Index table for physical digital inputs, 25
85 Index table for physical outputs, 19
Configurable options, 17 Index tables, 18
Configuring the monitoring functions, 98 Interpreter stop, 101
Control points (CPNUM), 72 Interrupt 21, 101
Creating your own weave patterns, 79 Interrupt 5, 37
Current flowing, 50 Interrupt indices, 94
Customer--specific adaptation of weld se-
quences, 29 K
Customized messages, 111
Keyswitch, 41
KRL programming language, 7
D
Digital inputs, 18 L
Digital outputs, 18 Lateral deflection (weave amplitude), 72
Double 8, 70 Linear characteristic, 66
E M
Error handling routines, 33 Manual activation and deactivation of the weld
process, 37
Max. no. of analog outputs, 63
F Maximum weave frequency, 80
FAULT SERVICE FUNCTION, 96 Motion characteristics of the robot, 80
Fault service functions, 95, 109
Fault situations, 95 N
FCTCTRL.SCALE_IN, 73 NAME_NAT, 19, 25
FCTCTRL.SCALE_OUT, 73 Non--linear characteristic, 68
Figure--eight weave pattern, 76 Notes on mechanical weaving, 80
Figure--eight weaving, 70 Number of characteristic points, 65
FLT_SERV.DAT, 14
FLT_SERV.SRC, 14, 96
P
FLY ARC, 37
PARA (characteristic analog output), 66
Path velocity, 80
G Program structure, 13
Graphical user interface of the KUKA Control PULS_TIME, 21
Panel, 11 PULSE_TIME 0.0, 22
Index -- ii
Index
R T
Through--the--arc seam tracking, 13
Resonant frequency, 80
Tool--based technological system TTS, 69
Resource distribution, 94
Trapezoidal weaving, 70
Restart after an interpreter stop, 102 Triangular weaving, 70
Robot error, 33 Triple groups, 18, 21, 26
Robot motion interrupted, 38 Two--dimensional weaving, 72
Rotation of the weave plane, 81 Types of faults and causes, 95
V
S VAL (characteristic analog output), 66
Voltage, 66
Seam error, 35 Voltage characteristic, 66
Signal states for digital outputs, 22
Signal tables, 55 W
Signal tables for digital inputs, 26 Weave frequency, 80
Signal tables for digital outputs, 21 Weave frequency nomogram, 81
Weave length, 72, 80
Signal tables for digital outputs and inputs, 18
Weave patterns (mechanical weaving), 70
Spiral weave pattern, 73
Weave patterns, changing, 77
Spiral weaving, 70 Weave patterns, creation, 79
SPS.SUB, 101 Weave patterns, thermal weaving, 83
STATE, 21 Weaving, mechanical and thermal, 69
Status key ”DRY”, 38 Weaving, mechanical and thermal combined,
85
Submit interpreter task, 33
Weaving, two--dimensional, 72
Submit routine, 39 Weld process monitoring, 50
Subroutines for weld commands, 29 Weld voltage, 66
Switching from constant values to thermal Wire feed, 37, 66
weaving, 53 Wire feed characteristic, 67
Index -- iii

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SOFTWARE

KUKA.ArcTech Analog -- Configuration

Issued: 28 Juli 2008 Version: 00

ArcTechAnalog_Pro_R1.1 02.05.00 en 1 of 125

KUKA Roboter GmbH

2 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en

3 Graphical user interface (HMI) of the KUKA Control Panel (KCP) . . . . 11

4 “KUKA.ArcTech Analog” programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Adaptation to the periphery, configurable options . . . . . . . . . . . . . . . . . . 17

6 Description of the weld commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ArcTechAnalog_Pro_R1.1 02.05.00 en 3 of 125

6.3.3 Required setting for reduced velocity in T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7 Configuration of analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en

10 “KUKA.ArcTech Analog” settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

11 Default data sets, resource distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

12 Fault situations and fault service functions . . . . . . . . . . . . . . . . . . . . . . . . 95

ArcTechAnalog_Pro_R1.1 02.05.00 en 5 of 125

12.6.1 Fault service functions defined by the user (#USR_SEAM) . . . . . . . . . . . . . . . . . . . . . . . . . . 109

13 Customized messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

14 Fault location, fault elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

15 Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en

1.1 System requirements

For more information, refer to the documentation [KUKA.ArcTech Analog -- Operation].

ArcTechAnalog_Pro_R1.1 02.05.00 en 7 of 125

1.2 Operating convenience

1.3 Overview of the configurable functions

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2.1 Additional safety instructions for “KUKA.ArcTech Analog”

2.3 Designated use

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2.4 Symbols and icons

2.4.1 Safety symbols

10 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en

3 Graphical user interface (HMI) of the KUKA Control Panel (KCP)

3.1 Selecting the “Expert” user group

3.2 Configurable options ($CONFIG.DAT)

Variable Value Meaning

ArcTechAnalog_Pro_R1.1 02.05.00 en 11 of 125

3.3 Configurable options (A10.DAT)

Variable Value Meaning

Configuration: Analog channels

Variable Value Meaning

12 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en

4 “KUKA.ArcTech Analog” programs

BAS.SRC P00.SRC IR_STOPM.SRC

Functions Functions for General

A10_INI.SRC A10.SRC FLT_SERV.SRC

ARC_WEAVE.SRC A50.SRC ARC_MSG.SRC

Fig. 1 “KUKA.ArcTech Analog” program structure

ArcTechAnalog_Pro_R1.1 02.05.00 en 13 of 125

4.2 Overview of files for “KUKA.ArcTech Analog”

A10.SRC Main program for arc welding with “KUKA.ArcTech Analog.”

A10_INI.SRC “KUKA.ArcTech Analog” initialization program.

FLT_SERV.SRC Program for user--defined fault strategies,

ARC_MSG.SRC Routines for generation of user--specific error messages

ARC_WEAVE.SRC Definition of the patterns for mechanical and thermal weaving.

14 of 125 ArcTechAnalog_Pro_R1.1 02.05.00 en