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KSS 41 END en

software kuka
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100% found this document useful (2 votes)
729 views702 pages

KSS 41 END en

software kuka
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 702

SOFTWARE

KR C...

Operating Handbook

KUKA System Software (KSS)


Release 4.1

Issued: 22 Nov 2004 Version: 07


ÜbersichtBHR4.1.7 12.03.07 en

1 of 4
e Copyright 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.

PD Interleaf

ÜbersichtBHR4.1.7 12.03.07 en

2 of 4
1 Introduction

Contents

1 Introduction
1. Foreword
2. How to use this documentation
3. Service requests

2 Safety
1. Liability
2. Designated use
3. Safety symbols
4. Safety measures
5. Safety labeling
6. Planning and construction
7. Installation, operation and other work
8. ESD directives
9. Applied directives and standards

3 Operator Control
1. Running up / shutting down the controller
2. The KUKA Control Panel KCP
3. Coordinate systems
4. Jogging the robot
5. Navigator
6. Executing, stopping and resetting a program
7. Monitor
8. Menu structure

4 Start-- up
1. Robot mastering / unmastering
2. Calibration
3. Calibration -- External kinematics
4. Robot name

ÜbersichtBHR4.1.7 12.03.07 en

3 of 4
Operating Handbook

The gray sections refer to documentation in the Programming Handbook

5 Configuration
1. Configuring the system
2. Configuring the system, expert
3. Automatic External

6 User Programming
1. Program editing
2. Program commands

7 Expert Programming
1. General information on KRL programs
2. Variables and declarations
3. Motion programming
4. KRL assistant
5. Program execution control
6. Input/output instructions
7. Subprograms and functions
8. Interrupt handling
9. Trigger -- Path--related switching actions
10. Data lists
11. External editor

8 Additional Functions
1. Standard programs

9 Applications

10 Appendix
1. Glossary
2. Operating Handbook history from V4.1.5 --> V4.1.6
3. Overall index

ÜbersichtBHR4.1.7 12.03.07 en

4 of 4
PRODUCT DOCUMENTATION

(V)KR... / (V)KR C... / KL...

Introduction

Issued: 16 Nov 2004 Version: 00

RobsysEinleitung 11.04.00 en
1 of 16
e Copyright 2004

KUKA Roboter GmbH


Zugspitzstr. 140
D--86165 Augsburg
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 16
RobsysEinleitung 11.04.00 en
Contents

1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 How to use this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


2.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Text styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Cross references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Service requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Device type and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Software version numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 We value your opinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Service centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Introduction

RobsysEinleitung 11.04.00 en
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1 Foreword

1 Foreword

This document is part of the operating instructions.

The KUKA Robot Group documentation is there to assist you in the following areas:
G Working with the products from the KUKA Robot Group
G Working with the product documentation
G Help with service requests

RobsysEinleitung 11.04.00 en
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Introduction

2 How to use this documentation


The KUKA Robot Group documentation contains:
G Safety symbols
G Icons
G Text styles

2.1 Safety symbols


Text passages indicated by the following safety symbols are relevant to safety and must be
observed.

WARNING
Following these safety warnings carefully can prevent personal injury.

CAUTION
Following these safety warnings carefully can prevent material damage.

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2 How to use this documentation (continued)

2.2 Icons
Text passages indicated by the following icons facilitate handling of the robot system.

NOTE
Indicates special features for particular attention.

Tip
Indicates recommendations and advice to make your work easier.

See also
Indicates sections or chapters containing further information and explanations.

Info
Indicates passages which are of particular significance or are useful for greater under-
standing.

Example
Indicates practical examples that can be implemented in the robot system.

Modifications or entries required


Indicates process steps requiring operator entries.

Modifications or entries not permissible


Indicates process steps in which operator entries are not permissible.

RobsysEinleitung 11.04.00 en
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Introduction

2.3 Text styles

Font style Meaning


Text in [square brackets] Indicates cross references
Text in “quotation marks” Indicates softkeys, status keys, keys and boxes
(e.g. in forms)
Bold Indicates particular features
Serif Indicates extracts from program listings
Italics Explain program listings
Serif bold or underlined Indicates operator entries in program listings

2.4 Cross references


The following cross reference designations are used in the documentation:
G Handbook (HB) refers to another handbook in the operating instructions.
Example: [HB: Robot].
G Main chapter (MC) refers to a main chapter within a handbook.
Example: [MC: Introduction].
G Chapter (Ch.) refers to a subdivision of a main chapter.
Example: [Ch.: How to use this documentation].
G Section refers to a subdivision of a chapter.
Example: [Section: Safety symbols].

... instructs the operator to press a program key (menu key or softkey) on the KCP.
<Function>
The currently valid function of the key is displayed on the screen.

... instructs the operator to press a menu key and a submenu key on KCP.

RobsysEinleitung 11.04.00 en
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3 Service requests

3 Service requests
The KUKA Robot Group documentation offers a wealth of information on operation and
provides assistance with troubleshooting.
Your local service center is available at all times to deal with any service requests going
beyond the scope of this documentation (see Section 3.4).

You should report any faults to the service center responsible within one hour of their
occurrence.

The following information is required for processing a service request:


G Model and serial number of the robot
G Model and serial number of the linear unit (optional)
G Model and serial number of the controller
G Version numbers of the software
G Memory dump (archive) from the controller
G Application used
G External axes used
G Description of the problem, duration and frequency of the fault

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Introduction

3.1 Device type and serial number


Check the type and serial number of all affected system parts using the identification plates.
The identification plates are located in the following positions:

Fig. 1 Robot identification plate

Fig. 2 Linear unit identification plate

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3 Service requests (continued)

Fig. 3 (V)KR C2 control cabinet identification plate

Fig. 4 KR C3 (table version) controller identification plate

Fig. 5 KR C3 (rack version) controller identification plate

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Introduction

3.2 Software version numbers


The version numbers of the software are displayed on the KCP screen by pressing the menu
key “Help/Info”.

Fig. 6 Version numbers of the software

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3 Service requests (continued)

3.3 We value your opinion


These operating instructions have been carefully tailored to the product they accompany.
Despite regular checks, errors cannot be entirely precluded.
For this reason, we cannot guarantee that this documentation is totally free from errors.

If you have any questions about the documentation (suggestions, corrections), please send
them to one of the following addresses:
Fax: +49 821 797 1087
e--mail: [email protected]

RobsysEinleitung 11.04.00 en
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Introduction

3.4 Service centers


Argentina
Ruben Costantini S. A. (Agency) Tel.: +54--35 64 / 42 10 33
Luis Angel Huergo 13 20 Fax: +54--35 64 / 42 88 77
Parque Industrial E-- Mail: [email protected]
2400 San Francisco (CBA), Argentina

Australia
Marand Precision Engineering Pty. Ltd (Agency) Tel.: +61--3 / 85 52 06 00
153 Keys Road Fax: +61--3 / 85 52 06 05
Moorabbin, Victoria 31 89 E-- Mail: [email protected]
Australia

Austria
KUKA Roboter GmbH Tel.: +43--732 / 78 47 52
Vertriebsbüro Österreich Fax: +43--732 / 79 38 80
Regensburger Strasse 9/1 E-- Mail: [email protected]
A -- 4020 Linz Internet: http://www.kuka--roboter.at

Belgium
KUKA Automatisering + Robots N.V. Tel.: +32--11 / 51 61 60
Centrum Zuid 1031 Fax: +32--11 / 52 67 94
B -- 3530 Houthalen E-- Mail: [email protected]
Belgium Internet: http://www.kuka.be

Brazil
KUKA Roboter do Brasil Ltda. Tel.: +55--11 / 64 13 49 00
Rua Dom Feliciano no 63 Fax: +55--11 / 64 11 15 65
Cidade Satélite, Guarulhos E-- Mail: [email protected]
CEP 07224 240
São Paulo, SP Brasil

China
KUKA Automation Equipment Tel.: +86--21 / 58 66 51 39
(Shanghai) Co.,Ltd. Fax: +86--21 / 58 66 75 71
Part B, Ground Floor, No. 211, Fu te Road (North) E-- Mail: [email protected]
Waigaoqiao Free Trade Zone
Shanghai 200 131, China

France
KUKA Automatisme + Robotique SAS Tel.: +33--1 / 69 31 66 00
Techvallée Fax: +33--1 / 69 31 66 01
6, Avenue du Parc E-- Mail: [email protected]
F -- 91140 Villebon s/Yvette Internet: http://www.kuka.fr

Germany Tel.: 0190 / 88 19 26


Service--Stützpunkt:
KUKA Roboter GmbH Fax: +49--821 / 797 -- 10 87
Zugspitzstraße 140 E-- Mail: [email protected]
D -- 86165 Augsburg Internet:: www.kuka--roboter.de

RobsysEinleitung 11.04.00 en
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3 Service requests (continued)

India
Sieflex Robotics (Agency) Tel.: +91 (44) / 624 14 12
54, Industrial Estate, Ambattur Fax: +91 (44) / 26 25 87 57
Madras -- 600 058 E-- Mail: [email protected]
India

Hungary
KUKA Robotics Hungaria Kft. Tel.: +36--24 / 50 16 09
2335 Taksony Fax: +36--24 / 47 70 31
Fö út 140 E-- Mail: [email protected]

Italy
KUKA Roboter Italia S.p.A. Tel.: +39--0 11 / 959 50 13
Via Pavia 9/a -- int. 6 Fax: +39--0 11 / 959 51 41
I -- 10098 Rivoli (TO) E-- Mail: [email protected]
Internet: http://www.kuka.it

Korea
KUKA Robot Automation Korea, Co. Ltd. Tel.: +82--31 / 496--99 37
4 Ba 806 Sihwa Ind. Complex / 496--99 38
Sung--Gok Dong, Ansan City Fax: +82--31 / 496--99 39
Kyunggi Do, 425--110 Korea E-- Mail: [email protected]

Malaysia
KUKA Robot Automation Sdn Bhd Tel: +60--3 / 80 61--06 13
South East Asia Regional Office / 80 61--06 14
24, Jalan TPP 1/10, Taman Industri Puchong Fax: +60--3 / 80 61--73 86
47100 Puchong, Selangor, Malaysia E-- Mail: [email protected]

Mexico
KUKA de Mexico S. de R.L. de C.V. Tel.: +52--55 / 52 03 84 07
Rio San Joaquin #339, Local 5 Fax: +52--55 / 52 03 81 48
Colonia Pensil Sur E-- Mail: [email protected]
C.P. 11490 Mexico D.F.

Norway
KUKA Svetsanläggningar + Tel.: +47--61 / 13 34 22
Robotar AB Avd. Norway Fax: +47--61 / 18 62 00
Hadelandsveien 2 E-- Mail: [email protected]
Postbox 17
NO--2801 Gjövik, Norway

Portugal
KUKA Sistemas de Automatización S.A. Tel.: +351--21 / 238 80 83
Urbanização do Vale do Alecrim, Lote 115--B Fax: +351--21 / 238 80 86
2950 Palmela, Portugal E-- Mail: [email protected]

Russia Tel.: +7--84 82 / 39 12 49


KUKA-- VAZ Engineering
445633 Togliatti / 37 05 64
Jushnoje Chaussee, 36 VAZ, PTO Fax: +7--84 82 / 73 67 30
Tx: +7--21 41 06
E-- Mail: [email protected]

RobsysEinleitung 11.04.00 en
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Introduction

South Africa
Jendamark Automation LTD (Agency) Tel.: +27--41 / 391 47 00
76a York Road, North End Fax: +27--41 / 373 38 69
Port Elizabeth 6000 Internet: http://www.jendamark.co.za
South Africa

Spain
KUKA Sistemas de Automatización, S.A. Tel.: +34--93 / 814 23 53
Pol. Industrial Fax: +34--93 / 814 29 50
Torrent de la Pastera E-- Mail: [email protected]
Carrer del Bages s/n Internet: http://www.kuka--e.com
E -- 08800 Vilanova i La Geltrú (Barcelona)

Sweden
KUKA Svetsanläggningar + Robotar AB Tel.: +46--31 / 72 66 200
A. Odhners gata 15 Fax: +46--31 / 72 66 201
S--42130 Västra Frölunda E-- Mail: [email protected]

Switzerland
KUKA Roboter Schweiz AG Tel.: +41--17 / 44 90 90
Riedstrasse 7 Fax: +41--17 / 44 90 91
CH--8953 Dietikon E-- Mail: [email protected]
Internet: http://www.kuka--roboter.ch

Taiwan
KUKA Robot Automation Taiwan Co., Ltd. Tel.: +886--3 / 437 19 02
136, Section 2, Fax: +886--3 / 283 00 23
Huanjung E. Road E-- Mail: [email protected]
Jungli City, Taoyuan, Taiwan 320 Internet: www.kuka.com.tw

Thailand
KUKA Robot Automation (M)Sdn Bhd Tel.: +66--2 / 750 27 37
Thailand Office Fax: +66--2 / 661 23 55
c/o Maccall System Co. Ltd. E-- Mail: [email protected]
49/9--10 Soi Kingkaew 30, Kingkaew Road Internet: http://www.kuka--roboter.de
Tt. Rachatheva, A. Bangpli
Samutprakarn, 10540 Thailand

U.K.
KUKA Welding Systems + Robot Ltd. Tel.: +44--121 / 58 50 800
Hereward Rise, Halesowen Fax: +44--121 / 58 50 900
UK--West Midlands B62 8AN GB E-- Mail: [email protected]

U.S.A.
KUKA Robotics Corp. Tel.: +1--866 / 873 58 52
22500 Key Drive Fax: +1--(586) / 569 20 87
Clinton Township E-- Mail: [email protected]
Michigan 48 036 USA Internet: http://www.kukarobotics.com

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Index

A I
Application, 9 Icons, 6, 7
Example, 7
Info, 7
Modifications or entries not permissible, 7
B Modifications or entries required, 7
Bold, 8 Note, 7
See also, 7
Tip, 7
Identification plate
C
KR C3, 11
Caution, 6 Linear unit, 10
Ch., 8 Robot, 10
Controller, 9 Identification plates, 10
Info, 7
Controller serial number, 9
Italics, 8
Cross reference
Ch., 8
K
HB, 8
KUKA Robot Group, 5
MC, 8
Section, 8
Cross references, 8 L
Linear unit, 9

D M
Description of the problem, 9 Material damage, 6
MC, 8
Device type, 10
Memory dump, 9
Menu key, 8
Modifications or entries not permissible, 7
E Modifications or entries required, 7
Example, 7
External axes, 9 N
Note, 7

F P
Foreword, 5 Personal injury, 6
Frequency of the fault, 9 Program key, 8

Q
H Quotation marks, 8

HB, 8
Help with service requests, 5 R
How to use this documentation, 6 Robot serial number, 9

Index -- i
Index

S
Safety symbols, 6
Caution, 6
Warning, 6
Section, 8
See also, 7
Serial number, 10
Serif, 8
Serif bold, 8
Service centers, 14
Service requests, 9
Softkey, 8
Software version numbers, 12
Square brackets, 8
Submenu key, 8

T
Text emphasis, 6
Text style
Bold, 8
Italics, 8
Quotation marks, 8
Serif, 8
Serif bold, 8
Square brackets, 8
Text styles, 8
Tip, 7

V
Version numbers of the software, 9

W
Warning, 6
Working with the product documentation, 5

Index -- ii
SAFETY

ROBOT SYSTEM

General

All Robot Types KR


Robot Controller KR C2 or Higher

Issued: 12 Mar 2004 Version: 00


SicherheitKRC 02.04.00 en

1 of 24
e Copyright 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.

PD Interleaf

SicherheitKRC 02.04.00 en

2 of 24
Contents

1 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.1 User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Installed equipment, attachments and conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Safety instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6.1 Restricted envelope – working space limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6.2 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6.2.1 External EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6.3 Enabling switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.3.1 External enabling switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.4 Guard interlock (operator safety) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 Emergency axis override device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Safety labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Planning and construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14


6.1 Foundations and substructures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Load ratings of the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3 Safety (exclusion) zones and working zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Collision protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.5 Counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.6 Tool change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.7 Safety mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.8 Interface characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.9 EMERGENCY STOP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.10 Presetting of outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.11 Tooling and additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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General

6.12 Laser systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17


6.13 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7 Installation, operation and other work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18


7.1 Mains connection conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3 Protection from dirt and UV radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.5 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.7 Shut--down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.8 Additional remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

8 ESD directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Handling ESD modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.3 Packaging suitable for ESDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

9 Applied directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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1 Liability

Valid for all robot types KR


robot controller KR C2 or higher

The primary purpose of this Doc. Module is the safety of the user
and operating personnel when using the device described below.

1 Liability
The device described in these operating instructions is an industrial robot -- called “robot
system” in the following text --, consisting of robot, connecting cables and control cabinet.
The robot system -- the subject matter of these operating instructions -- has been built
in accordance with state--of--the--art standards and the recognized safety rules.
Nevertheless, improper use of the robot system 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 the robot system and to other
material property.
The robot system 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. Use of the robot system is subject to compliance
with these operating instructions and with the manufacturer’s declaration* supplied
together with the robot system. Any functional disorders affecting the safety of the
robot system must be rectified immediately.
The design and rating of the mechanical and electrical equipment of the robot system is
based on the EC machinery directives together with their annexes and associated standards.
Harmonized standards were taken into account with regard to the safety of the robot system:
The electrical part of the robot system additionally conforms to the “EC low voltage directive”
and the directive on “Electromagnetic compatibility”.
A list of the applied directives and standards can be found in the chapter “Applied directives
and standards”.

* The manufacturer’s declaration is to be found in the control cabinet.

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General

2 Designated use
The robot system is designed exclusively for the applications specified in the robot
Doc. Module “Technical Data”.
Using the robot system for any other or additional purpose is considered contrary
to its designated use. The manufacturer cannot be held liable for any damage
resulting from such use. The risk lies entirely with the user.
Operating the robot system within the limits of its designated use also involves
continuous observance of these operating instructions with particular reference to
the maintenance specifications.
The software employed is matched to the applications specified by the
customer/user and has been thoroughly tested. In the event that the functions
contained in the software are not executed without interruption, the chapter “Error
Messages/Troubleshooting” must be consulted to remedy this condition. This also
applies to malfunctions occurring during service, set--up, programming and start--up
activities.
The robot system may not be put into operation until it is ensured that the functional
machine or plant into which the robot system has been integrated conforms to the
specifications of the EC directives.
No liability can be accepted if these directions are disregarded.
If the user provides items of equipment and the like which do not constitute part of
the KUKA Roboter GmbH contract and these parts are integrated into the periphery
of the robot system by KUKA Roboter GmbH on behalf of the user, KUKA Roboter
GmbH cannot be held liable for any resulting damage. Any risk associated with these
parts (mechanical, pneumatic and electrical) lies entirely with the user.
These operating instructions consist of the following parts: · robot
· control cabinet
· software
They constitute an integral part of the robot system supplied by KUKA Roboter
GmbH, whose serial numbers for robot and control cabinet can be noted from the
manufacturer’s declaration.

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3 Safety symbols

3 Safety symbols
The following safety symbols are used in these operating instructions:

This symbol is used where failure to fully and accurately observe operating
instructions, work instructions, prescribed sequences and the like could result in
injury or a fatal accident.

This symbol is used where failure to fully and accurately observe operating
instructions, work instructions, prescribed sequences and the like could result in
damage to the robot system.

This symbol is used to draw attention to a particular feature. Observance of the note will
generally result in facilitation of the work concerned.

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General

4 Safety measures
The mechanical and electrical equipment of the robot system for which these operating
instructions, prescribed by the manufacturer, have been issued meets the requirements of
the standard concerning the safety of industrial robots. The technical features and possible
mounting positions of this robot system are presented in detail in these operating instructions
and in the relevant specifications for the robot and control cabinet.

Improper use of the robot system or its employment for a purpose other than the
intended one may cause
-- danger to life and limb
-- danger to the robot system and other assets of the user and
-- danger to the efficient working of the robot system or its operator.

The associated operating instructions therefore contain numerous safety instructions, which
also apply to applications and to the use of accessories and supplementary equipment
supplied by KUKA Roboter GmbH.
Every person involved with installation or exchange, adjustment, operation, maintenance or
repair of the robot system must have read and understood these operating instructions,
particularly the Doc. Module “Safety, General”, paying special attention to the passages
marked with the symbol , which are of paramount importance.

Passages marked with the symbol are of paramount importance. These passages
contain switch--off procedures and other safety precautions serving to protect operating
personnel. Particular attention must be devoted to them when any work concerning for
example, transportation, installation, operation, conversion and adjustment, adaptation,
maintenance or repair is carried out.

The robot system must be switched off before exchange, adjustment, maintenance
and repair in accordance with the regulations contained in these operating
instructions, i.e. the main switch on the robot control cabinet must be turned to
“OFF” and secured with a padlock to prevent unauthorized persons from switching
it on again.

Voltages in excess of 50 V (up to 600 V) can be present in the KPS, the KSDs and
the intermediate--circuit connecting cables up to 5 minutes after the control cabinet
has been switched off!

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4 Safety measures (continued)

4.1 Personnel
Installation, exchange, adjustment, operation, maintenance and repair must be performed
only as specified in these operating instructions and only by qualified personnel specially
trained for this purpose and acquainted with the risks involved.
The user is recommended to have personnel assigned for this work complete an
application--specific KUKA Roboter GmbH training course.
The user and operating personnel must ensure that only authorized personnel are permitted
to work on the robot system. The user must clearly set out what the responsibilities of
operating personnel actually entail and give them the authority to refuse to carry out
instructions from third parties which are contrary to safety procedures.

4.1.1 User
The responsibilities involved in operation of the robot system and in all other work performed
on the robot system or in its immediate vicinity must be clearly defined and observed by the
user in order to prevent any uncertainty regarding spheres of competence in matters of
safety.
The user should check at specific intervals selected at his own discretion that the personnel
attend to their work in a safety--conscious manner, are fully aware of the risks involved during
operation and observe these operating instructions.
Do not allow personnel to be trained or instructed or personnel taking part in a general training
course to work on or with the robot system without being permanently supervised by an
experienced person.
Work on the electrical system or equipment of the robot system may only be carried out by
a skilled electrician himself or by specially instructed personnel under the control and
supervision of such an electrician and in accordance with the applicable electrical
engineering rules.
Work on the hydropneumatic counterbalancing system (if present) may only be carried out
by persons having special knowledge and experience of hydraulic and pneumatic systems.
The user must ensure, by means of appropriate instructions and checks, that the work station
and the environment of the robot system are kept in clean and orderly condition.

4.1.2 Operating personnel

The operating personnel are obliged to inform the user immediately of any changes
to the robot system which impair its safety or give reason to suspect that this might
be the case.
The user must ensure that the robot system is only ever operated in faultless
condition.

4.2 Danger zone


The danger zones of the robot system, i.e. areas in which the robot together with tools,
accessories and additional equipment moves, must in all cases be safeguarded, in
compliance with the standard concerning the safety of industrial robots, to prevent persons
or objects from entering these zones or to ensure that the robot system is safely brought to
a standstill and shut down by a Stop or EMERGENCY STOP command if a person or object
should nevertheless enter a danger zone. This safety facility is the responsibility of the user.
The maximum stopping distances of the robot must be taken into account when
determining the size of the danger zones.
The paint markings on the floor and signs indicating the danger zones must differ clearly in
form, color and style from other markings within the machine or plant in which the robot
system is integrated.

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General

If it is essential for personnel to enter the working range of the robot system for
conversion, adjustment, maintenance or repair work on the machine or plant in
which the robot system is integrated, the safety measures must always be designed
in such a way (e.g. enabling switches) that the robot system is switched off
immediately should an unintended situation arise.

When work is carried out in the danger zone of the robot, the latter may only be
moved, and then only if absolutely essential, in set--up mode (T1) with an enabling
switch and jog mode at jog velocity at the most, to allow the personnel enough time
either to avoid dangerous movements or to stop the robot.

All persons situated in the environment of the robot must be informed in good time that the
robot is about to move.
Wherever possible, only one person should work in the danger zone at any time.
If two or more persons are working in the danger zone at the same time, they must all use
an enabling switch. They must also all remain in constant visual contact and have an
unrestricted view of the robot system. Responsibilities for each type of work and for each
person must be clearly and comprehensibly defined.

In sensor--assisted operation, the robot is liable to perform unexpected movements


and path corrections if the main switch on the control cabinet has not been turned
to “OFF”.

If work is to be carried out within the working range of a switched--off robot, the
robot must first be moved into a position in which it is unable to move on its own,
whether the payload is mounted or not. If this is not possible, the robot must be
secured by appropriate means.

Components, tooling and other objects must not become jammed as a result of the robot
motion, nor must they lead to short--circuits or be liable to fall off.
Any motion of the robot that would cause indirect danger to persons or objects must be
avoided.
Due regard must be paid to hazards posed by the peripheral system components of the robot
such as grippers, conveyors, feed devices or other robots in a multi--robot system.

4.3 Safety equipment


Any method of working that impairs the functional and operating safety of the robot system
must be avoided.

No functional safety equipment may be dismantled or taken out of operation if this


would directly or indirectly affect the robot system and if exchange, adjustment,
maintenance or repair is carried out on the robot system. This would cause danger
to life and limb, such as contusions, eye injuries, fractures, serious internal and
external injuries, etc.
If it is necessary for such safety equipment nevertheless to be dismantled during the
above--mentioned work on the robot system, the machine or plant in which the robot system
is integrated must be shut down in the exact manner specified, with particular attention being
paid to the text passages of the operating instructions concerned marked with the symbol
, and measures must be taken to prevent unintentional or unauthorized start--up.
Immediately after completion of the exchange, adjustment, maintenance or repair work, the
safety equipment must be reinstalled and checked to ensure that it is functioning correctly.

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4 Safety measures (continued)

4.4 Installed equipment, attachments and conversion


Any unauthorized conversion or modification of the robot system is not allowed.
No customer--specific equipment may be installed without the approval of the sales
representative of KUKA Roboter GmbH responsible for your system.
The robot system including accessories and additional equipment may not be
equipped or operated with products of other manufacturers whose use is not
expressly permitted in these operating instructions or the parts catalog of the robot
system.
When using prescribed operating media which are specified as aggressive or toxic,
appropriate protective clothing must be worn. Warning remarks must be observed.
The maintenance cycles prescribed in these operating instructions must be adhered to.
These operating instructions must always be kept ready to hand at the place of use of the
robot system (e.g. in the tool compartment or in the receptacle provided for them) – whether
as a manual or CD--ROM.

4.5 Safety instruction


The personnel responsible for installation, exchange, adjustment, operation, maintenance
and repair must be instructed before any work is commenced in the type of work involved
and what exactly it entails as well as any hazards which may exist. Records are to be kept
of the content and extent of the instruction.
The above--mentioned personnel must be instructed orally every six months and in writing
every two years with regard to the observance of safety regulations and precautions. The
instruction may be carried out by safety officers of the user and/or within the framework of
a KUKA Roboter GmbH training program. Instruction is also required after particular
incidents or technical modifications.

4.6 Safety functions


The safety functions include:
-- Restricted envelope
-- EMERGENCY STOP
-- Enabling switches
-- Technical guard interlock
The circuits for EMERGENCY STOP, enabling switches and interlock conform to control
category 3 according to EN 954--1.

4.6.1 Restricted envelope – working space limitation


The robot is designed as standard to allow the attachment of adjustable mechanical stops
in the three main axes for the limitation of the working space. In addition, the range of motion
of all axes can be restricted using software limit switches.

4.6.2 EMERGENCY STOP


The EMERGENCY STOP button of the robot system is located on the KCP, which is also
used as the programming and operator control device.
When triggered in the test modes, the EMERGENCY STOP function causes a safety stop
with immediate disconnection of power to the drives, dynamic braking and application of the
holding brakes.
In the automatic modes, an EMERGENCY STOP causes a controlled stop, with power to
the drives being maintained in order to ensure this controlled stop. The power is only
disconnected once the robot has come to a standstill.

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General

4.6.2.1 External EMERGENCY STOP


If, due to the risk situation, it is necessary to install additional EMERGENCY STOP devices
or if several EMERGENCY STOP systems need to be linked together, this can be done via
a special interface provided for the purpose. See “Peripheral Interface” chapter.

4.6.3 Enabling switches


The KCP is equipped with three three--position enabling switches, which can be used to
switch on the drives in the operating modes Test 1 and Test 2. Each of these enabling
switches has three positions, of which only the middle position allows the robot to move. In
either of the other positions, hazardous motions are safely stopped and the drives are safely
disconnected.
4.6.3.1 External enabling switch
The “external enabling switch” function allows the connection of an additional enabling
device. If it is necessary for a second person to be in the safeguarded space, then this is only
permitted if this person also uses an enabling device.

4.6.4 Guard interlock (operator safety)


The robot controller features a two--channel safety input, to which the guard interlock can
be connected. In the automatic modes, the opening of the guard connected to this input
causes a controlled stop, with power to the drives being maintained in order to ensure this
controlled stop. The power is only disconnected once the robot has come to a standstill.
Motion in Automatic mode is prevented until the guard connected to this input is closed. This
input has no effect in Test mode.
The guard must be designed in such a way that it is only possible to acknowledge the stop
from outside the safeguarded space.

4.7 Emergency axis override device


The emergency axis override device can be used to move the robot mechanically after a
malfunction via the main axis drive motors and, depending on the type of robot, also via the
wrist axis drive motors in some instances. It is only for use in exceptional circumstances and
emergencies (e.g. for freeing people).

The emergency axis override device may only be used if the main switch on the
control cabinet has been turned to “OFF” and secured with a padlock to prevent
unauthorized persons from switching it on again.

If a robot axis has been moved using the emergency axis override device, all robot
axes must be remastered.

The robot may only be moved manually using the (optional) override device supplied by
KUKA Roboter GmbH. The override device is pushed onto the axle of the motor (remove
protective cap), which can then be turned. It is necessary to overcome the resistance of the
mechanical motor brake and any other loads acting on the axis. The protective cap must be
put back on after the operation.

The motors reach temperatures during operation which can cause burns to the
skin. Appropriate safety precautions must be taken.

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5 Safety labeling

5 Safety labeling
5.1 General
Identification plates, warning labels and safety symbols are attached to the robot and to the
inside and outside of the control cabinet. The connecting cables between the robot and the
control cabinet as well as electric cables and other lines both in and on the robot and control
cabinet are provided with designation labels, many also with position marks.
All of these plates, labels, symbols and marks constitute safety--relevant parts of the robot
system. They must remain attached to the robot or control cabinet concerned for the whole
of their service lives in their specified, clearly visible positions.

It is forbidden to remove, cover, obliterate, paint over or alter in any other way
detracting from their clear visibility
-- identification plates,
-- warning labels,
-- safety symbols,
-- designation labels and
-- cable marks.

5.2 Robot
See robot Doc. Module “Technical Data”.

5.3 Control cabinet


See control cabinet Doc. Module “Maintenance”.

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General

6 Planning and construction


The following measures must be implemented during the planning and construction of a
robotic installation.

6.1 Foundations and substructures


It must be ensured that the dimensions and qualities specified by KUKA Roboter GmbH for
the foundations, substructure or the ceiling construction have been adhered to. Deviations
from these dimensions or quality requirements are not permitted.

6.2 Load ratings of the robot


It must be checked that the torques, acceleration, weights and other mechanical and
environmental conditions to be expected in operation of the robot system lie within the
permissible range for the robot.

6.3 Safety (exclusion) zones and working zones


Working zones are to be restricted to the necessary minimum size. In addition to software
limitation, they can also be safeguarded with adjustable mechanical stops (“working range
limitation” accessory). The working zones must meet the safety requirements, i.e. on no
account may persons or equipment be exposed to any danger.
Danger zones, i.e. areas in which robots move, must be safeguarded by means of protective
barriers. These can take the form of safety fences, light barriers, light curtains or zone
scanners, for example.
Fixed safety devices (safety fencing) must be designed to withstand all forces that are likely
to occur in the course of operation, whether from inside or outside the enclosure.
Safety fences must be designed in accordance with DIN EN 294, DIN EN 349 and DIN EN
811. They must be high enough to prevent anybody from reaching over them. The size of
the fence sections must be selected in accordance with the strength of the fencing; design
measures must be taken to prevent them from bending. The number of entrances (gates)
in the fencing must be kept to a minimum. There should preferably be only one gate. All
entrances must be connected to the “technical guard interlock” incorporated in the robot and
to the overall EMERGENCY STOP system.
Shown below is an example illustrating the connection of gate position switches in
combination with a pushbutton for enabling operation when the safety gate is closed.

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6 Planning and construction (continued)

L+ A1 (+) Safety gate monitor


Ue e.g. PST3, manuf.: Pilz

L --- A2 ( ---)

= safety gate open


S11
= safety gate closed

= actuated element
S12

Gate position switches S23

S24

X1

Pushbutton for enable


with safety gate closed X2
13 14 23 24
This pushbutton must be
located outside the space
limited by the safeguards.

7 8 25 26
Peripheral connector X11

Safeguard channel B
Safeguard channel A

Test output B
Test output A

KR C2

3 9 22 28
Peripheral connector X11
Operator safety, channel A

Test output B

Operator safety, channel B


Test output A

KR C3

Irrespective of these safeguarding measures, the danger zone is to be indicated by means


of paint markings on the floor. These markings must differ distinctly in form, color and style
from other markings within the machine or plant in which the robot system is integrated.

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General

6.4 Collision protection


The robot can be equipped with a collision protection device (additional equipment). This
must in all cases be connected to the EMERGENCY STOP circuit of the robot system and
higher--level controller.
In the case of conveyor operation, additional precautions are required to ensure that the
conveyor cannot collide with the robot when the EMERGENCY STOP function is triggered.
Appropriate measures must be taken to prevent the conveyor from continuing to move in
areas where a collision is possible after an EMERGENCY STOP, e.g. by means of short
systems with transfer stations.

6.5 Counterbalancing system


Some robot types are equipped with a hydropneumatic or mechanical counterbalancing
system.

If work is to be carried out on the counterbalancing systems, the parts of the


robot assisted by these systems must be secured so that they are unable
to move in either the (+) or (--) direction.

The hydropneumatic counterbalancing systems are manufactured in


accordance with the Pressure Equipment Directive 97/23/EC. It is the
responsibility of the user to ensure that the relevant laws and directives of
the country in which the system is being installed are observed; in Germany,
the relevant legislation is the Plant Safety Regulation (BetrSichV), section
15 and annex 5.2 (category III, fluid group 2).

6.6 Tool change


Removal and installation stations must be provided to allow tools to be changed. These
stations must be accessible to the operator outside the danger zone and the robot must be
able to move to them by means of a special program step.

6.7 Safety mats


If the presence of operating personnel in the work envelope of the robot is unavoidable (e.g.
for loading components), the danger zone is to be isolated by means of a safety mat or light
curtain. This can be accomplished by connecting the safety mat or light curtain to range limit
switches (“working range monitoring” accessory) or a limit switch for the robot’s home
position and to the EMERGENCY STOP circuit.

6.8 Interface characteristics


The voltage and output load capacity values of all signals corresponding with the robot
controller must lie within the permissible limits for the controller.

6.9 EMERGENCY STOP system


A thorough risk assessment must be carried out in order to establish the required number
of command devices for stopping the robot system in the event of an emergency.
The effectiveness of the EMERGENCY STOP system must be checked at regular intervals.
If several robots, machines or machine parts are designed to work together, the
EMERGENCY STOP systems of the subsystems must be wired in such a way that the
EMERGENCY STOP command device can stop not only a single robot, but also all other
robots or devices, either upstream or downstream, insofar as their continued operation could
constitute a danger.

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6 Planning and construction (continued)

6.10 Presetting of outputs


Outputs are to be preset in accordance with the main project file, i.e. signals for hold functions
must not be reset when the robot controller is switched off if personnel or equipment would
be endangered as a result.

6.11 Tooling and additional equipment


If they have not been supplied by KUKA, tooling and additional equipment for the robot must
be designed to the same standard of safety as the robot system. The specifications valid for
the machine or plant into which the robot system is integrated must be applied analogously
to the tooling and equipment (e.g. fuses for the primary circuit of welding transformers).

6.12 Laser systems


If the robot system is operated in conjunction with a laser system, EN 60825--1 must be
observed. The responsibility for this lies with the person integrating the laser system.

Lasers can cause serious damage to health.

6.13 Regulations
The machine or plant into which the robot system is integrated must be checked before the
robot system is installed to ensure that the user’s safety regulations, general accident
prevention rules and trade association regulations have been observed. Please observe
Section 4.5.

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General

7 Installation, operation and other work

Personal protection:
All persons working within the danger zone of the robot system must wear
protective clothing. Of particular importance are safety footwear and closely fitting
clothing. In addition, the safety regulations of the relevant trade associations are
to be observed.

The motor units, the hydropneumatic counterbalancing system and the robot wrist
are liable to reach operating temperatures which may result in burns. Work on such
parts may be undertaken only when they have cooled down sufficiently.

7.1 Mains connection conditions


The mains connection conditions specified by KUKA Roboter GmbH in respect of conductor
cross--sections, fuses, voltage and frequency must be adhered to. The pertinent regulations
of the power utilities concerned must be observed.

7.2 Transportation
The prescribed transport positions for the robot must be observed. All angle specifications
are referred to the mechanical zero of the robot axis concerned.

If fork slots are installed on the robot’s base frame, the forks of the fork lift truck
must be placed in these slots. In this case, it is forbidden to pick up the robot in any
other way using a fork lift truck!

When being exchanged, individual parts and larger assemblies are to be fastened with care
to the lifting gear and secured so that they do not constitute a hazard. Only suitable and
technically faultless lifting gear and load--bearing equipment with an adequate carrying
capacity may be used.

Never work or stand under suspended loads!

The fastening of loads and the instructing of crane operators should be entrusted to
experienced persons only. The marshaller giving the instructions must be within sight or
sound of the operator.

7.3 Protection from dirt and UV radiation

No welding may be carried out in the immediate vicinity of the open control cabinet
due to, amongst other factors, the risk of EPROMs being erased by UV radiation.

Foreign matter (e.g. swarf, water, dust) must be prevented from entering the control
cabinet. If a particularly large amount of dirt or dust is created during the
installation phase, the control cabinet and robot must be covered.

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7 Installation, operation and other work (continued)

7.4 Start--up
It must be ensured that all safety devices, limit switches and other protective measures are
installed completely and functioning correctly before the robot system is started up. The
system elements of the robot and the control cabinet must be checked for foreign bodies.
No persons or objects may be in the danger zone (work envelope of the robot) during the
start--up procedure. It must be ensured that the correct machine data have been loaded
before the system is put into operation for the first time.

In order to comply with protection classification IP54 (KR C2) and IP20 (KR C3), the control
cabinet must only be operated with all of the provided cover plates for devices and options
which are not present (e.g. connectors, drive modules, disk drives).

7.5 Software

Special software has been developed for the control computer. The software
detects most incorrect entries and operator errors. For further information refer to
the relevant parts of these operating instructions.

The hardware and software supplied have been checked for viruses. It is the user’s
responsibility to make sure that the latest virus scanner is always used.

7.6 Operation
All safety regulations must be adhered to while the robot system is in operation. No changes
may be made to safety measures or equipment. In the event of a malfunction, the robot must
be switched off immediately. Until the fault has been eliminated, measures must be taken
to prevent unauthorized start--up and to preclude any danger to persons or objects.
Appropriate records are to be kept of malfunctions, their causes and the remedial action
taken.
Check the robot system at least once per working shift for obvious damage and defects.
Report any changes, including changes in the robot system’s working behavior to the
competent department or person immediately. If necessary, stop the robot immediately and
lock it!

7.7 Shut--down
Before any exchange, adjustment, maintenance or repair work is carried out, the robot
system must be shut down as specified in these operating instructions and precautions must
be taken to prevent unauthorized start--up (e.g. padlock, keyswitch). If it is absolutely
essential for the robot to be moved during certain activities, special attention must be paid
to the relevant remarks in Section 4.3.
It is important to be prepared for possible movements of the robot even after the controller
has been switched off and locked.

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General

7.8 Additional remarks


Always tighten any screwed connections that have been loosened during maintenance and
repair as specified.
When carrying out overhead work always use safety--oriented ladders and working
platforms. Never use the robot or the control cabinet as a climbing aid.
Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact!

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8 ESD directives

8 ESD directives
8.1 General
The ESD regulations (ESD: electrostatic sensitive devices) must be observed at all times
when handling modules. These modules are fitted with high--quality components and are
very sensitive to electrostatic discharges (e.s.d.).
As well as causing complete failure of components, e.s.d. can also be responsible for partial
damage to an IC or component, which in turn reduces service life or leads to sporadic faults
of parts which are still, for the time being, able to function.

For these reasons, not only new modules, but also defective modules
awaiting repair, must be handled very carefully in a way suitable for ESDs.

8.2 Handling ESD modules


G Components should only be unpacked and touched if
-- you are wearing ESD shoes or ESD shoe grounding strips, or
-- you are constantly earthed by means of an ESD armband with a safety resistance of
1 ΜΩ
G Before touching an electronic module you should discharge the voltage from your own
body (by touching a grounded, electroconductive object)
G Surroundings: antistatic table surfaces, conductive floor coverings, high relative air
humidity, grounded tables and chairs (through 1 MΩ protective resistor)
G Electronic modules must not be brought near VDUs, monitors or television sets
G Modules may only be measured if
-- the measuring instrument is grounded (e.g. by means of a protective conductor) or
-- before measuring with a potential--free measuring instrument, the measuring head is
briefly discharged (e.g. touched against an uncoated metallic section of the controller
casing).
G Only unpack and touch electronic components if it is absolutely necessary.
The best protection against the effects of electrostatic discharges is not letting these charges
build up in the first place. For this reason, the grounding of all possible electric potential
carriers is absolutely vital for the optimal handling of ESDs (see diagram).

Work surface Module Instruments,


Module Person
(conductive) packaging tools

R: protective resistor 1 MOhm

Fig. 1 Handling ESD modules

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General

8.3 Packaging suitable for ESDs


When packaging ESD modules and components, care should always be taken to use only
conductive and antistatic packaging materials, e.g. metallized or graphite--containing
packaging, antistatic plastic bags, etc.

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9 Applied directives and standards

9 Applied directives and standards


Standards Title
97/23/EC Directive 97/23/EC of the European Parliament and of the
Council of 29 May 1997 on the approximation of the laws of the
Member States concerning pressure equipment (Pressure
Equipment Directive )
98/37/EC Directive 98/37/EC of the European Parliament and of the
Council of 22 June 1998 on the approximation of the laws of the
Member States relating to machinery; version 22 June 1998
EN 292--1 DIN EN 292--1, Publication date: 1991--11
Safety of machinery – Basic concepts, general principles for design
– Part 1: Basic terminology, methodology; German version
EN 292--1: 1991
EN 292--2 DIN EN 292--2, Publication date: 1995--06
Safety of machinery – Basic concepts, general principles for design
– Part 2: Technical principles ; German version EN 292--2: 1991 +
A1: 1995
EN 294 DIN EN 294, Publication date: 1992--08
Safety of machinery – Safety distances to prevent danger zones
from being reached by the upper limbs; German version EN 294:
1992
EN 349 DIN EN 349, Publication date: 1993--06
Safety of machinery – Minimum gaps to avoid crushing of parts of
the human body; German version EN 349: 1993
EN 418: 1992 DIN EN 418, Publication date: 1993--01
Safety of machinery – EMERGENCY STOP equipment; German
version EN 418: 1992
EN 563 DIN EN 563, Publication date: 2000--01
Safety of machinery – Temperatures of touchable surfaces –
Ergonomics data to establish temperature limit values for hot
surfaces (includes Corrigendum AC: 1994 and Amendment A1:
1999); German version EN 563: 1994 + A1: 1999
EN 614--1: 1995 DIN EN 614--1, Publication date: 1995--04
Safety of machinery – Ergonomic design principles – Part 1:
Terminology and general principles; German version EN 614--1:
1995
EN 775: 1992 DIN EN 775, Publication date: 1993--08
Manipulating industrial robots – Safety (ISO 10218: 1992,
modified); German version EN 775: 1992 + AC: 1993
EN 811 DIN EN 811, Publication date: 1996--12
Safety of machinery – Safety distances to prevent danger zones
from being reached by the lower limbs; German version EN 811:
1996
EN 954--1: 1996 DIN EN 954--1, Publication date: 1997--03
Safety of machinery – Safety--related parts of control systems –
Part 1: General principles for design; German version EN 954--1:
1996

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General

EN 60204--1: 1997 DIN EN 60204--1, Publication date: 1998--11


Safety of machinery – Electrical equipment of machines – Part 1:
General requirements (IEC 60204--1:1997 + Corrigendum 1998);
German version EN 60204--1: 1997
EN 60825--1: 1994 DIN EN 60825--1, Publication date: 2003--10
Safety of laser products – Part 1: Equipment classification,
requirements and user’s guide (IEC 60825--1: 1993 + A1: 1997 +
A2: 2001); German version EN 60825--1: 1994 + A1: 2002 + A2:
2001
EN 50265--2--1 DIN EN 50265--2--1, Publication date: 1999--04
Common test methods for cables under fire conditions – Test for
resistance to vertical flame propagation for a single insulated
conductor or cable – Part 2--1: Procedures; 1 kW pre--mixed flame;
German version EN 50265--2--1: 1998
EN 55011 DIN EN 55011, Publication date: 2003--08
Industrial, scientific and medical (ISM) radio--frequency equipment
– Radio disturbance characteristics – Limits and methods of
measurement (IEC/CISPR 11:1997, modified + A1: 1999 + A2:
2002); German version EN 55011: 1998 + A1: 1999 + A2: 2002
EN 61000--4--4 DIN EN 61000--4--4, Publication date: 2002--07
Electromagnetic compatibility (EMC) – Part 4--4: Testing and
measurement techniques; Electrical fast transient/burst immunity
test (IEC 61000--4--4: 1995 + A1: 2000 + A2: 2001); German
version EN 61000--4--4: 1995 + A1: 2001 + A2: 2001
EN 61000--4--5 DIN EN 61000--4--5, Publication date: 2001--12
Electromagnetic compatibility (EMC) – Part 4--5: Testing and
measurement techniques; Surge immunity test (IEC 61000--4--5:
1995 + A1: 2000); German version EN 61000--4--5: 1995 + A1: 2001
EN 61000--6--2 DIN EN 61000--6--2, Publication date: 2002--08
Electromagnetic compatibility (EMC) – Part 6--2: Generic
standards: Immunity for industrial environments (IEC 61000--6--2:
1999, modified); German version EN 61000--6--2: 2001
EN 61000--6--4 DIN EN 61000--6--4, Publication date: 2002--08
Electromagnetic compatibility (EMC) – Part 6--4: Generic
standards; Emission standard for industrial environments
(IEC 61000--6--4: 1997, modified); German version EN 61000--6--4:
2001
EN 61800--3 DIN EN 61800--3, Publication date: 2001--02
Adjustable speed electrical power drive systems – Part 3: EMC
product standard including specific test methods (IEC 61800--3:
1996); German version EN 61800: 1996 + A11: 2000

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Index

A Exchange work, 19
Accelerations, 14 External EMERGENCY STOP, 11
Accessories, 11 External enabling switch, 12
Accident, 7
Accident prevention, 17 F
Adaptation, 8
Feed devices, 10
Additional equipment, 11
Fixed safety devices, 14
Adjustment, 8
Foreign bodies, 19
Adjustment work, 19
Foundations, 14
Auxiliary substances, 20
Frequency, 18
Fusing, 18
C
Cable cross--section, 18
G
Carrying capacity, 18
Climbing aid, 20 Gate position switches, 14
Clothing, 18 Gripper, 10
Collision protection, 16 Guard interlock (operator safety), 12
Connecting cables, 5, 13
Construction, 14 I
Consumables, 11, 20
Identification plate, 13
Control cabinet, 5
Improper use, 5
Conversion, 11
Industrial robot, 5
Conveyor, 10, 16
Injury, 7
Counterbalancing system, 9, 18
Installation, 8, 18
Interface characteristics, 16
D
Damage to the robot system, 7
J
Danger, 8
Danger zones, 9 Jog velocity, 10
Defects, 19
Designated use, 6 L
Designation labels, 13
Liability, 5
Dirt entering the control cabinet, 18
Lifting gear, 18
Light barriers, 14
E Light curtain, 14, 16
EC low voltage directive, 5 Load ratings, 14
EC machinery directives, 5
Electromagnetic compatibility, 5
M
Emergency axis override device, 12
EMERGENCY STOP, 11, 14, 16 Main switch, 8
EMERGENCY STOP system, 16 Mains connection conditions, 18
Employment for a purpose other than the inten- Maintenance, 8
ded one, 5 Maintenance cycles, 11
Enabling switches, 12 Maintenance specifications, 6
EPROMs, 18 Maintenance work, 19
ESD directives, 21 Manufacturer’s declaration, 5, 6
Exchange, 8 Modification, 11

Index -- i
Index

N Safety measures, 8, 19
Note, 7 Safety regulations, 19
Safety symbols, 7, 13
Screwed connections, 20
O
Sensor--assisted operation, 10
Operating instructions, 5
Serial number, 6
Operation, 18, 19
Shut--down, 19
Operator control, 8
Signs, 9
Skilled electrician, 9
P Software, 19
Padlock, 8 Standard concerning the safety of industrial
Paint markings, 9 robots, 8
Parts catalog, 11 Start--up, 19
Payload, 10 Substructures, 14
Personal protection, 18 Suspended loads, 18
Planning, 14
Plates, 13
Position marks, 13 T
Presetting of outputs, 17
Technical data, 6
Protection from dirt, 18
Tool change, 16
Protection from dirt and UV radiation, 18
Torques, 14
Protective barriers, 14
Trade association, 17, 18
Protective clothing, 11, 18
Put into operation, 6 Transport position, 18
Transportation, 18

R
Range limit switches, 16 U
Regulations, 17
Unauthorized start--up, 19
Repair, 8
Repair work, 19
Restricted envelope – working space limitation, V
11
Risk to life and limb, 5 Viruses, 19
Robot, 5 Voltage, 18
Robot system, 5

W
S
Warning labels, 13
Safety (exclusion) zones, 14
Warning remarks, 11
Safety equipment, 10, 19
Weights, 14
Safety fences, 14
Safety footwear, 18 Working platforms, 20
Safety functions, 11 Working range limitation, 14
Safety instruction, 11 Working zones, 14
Safety instructions, 8
Safety labeling, 13
Safety mat, 16
Z
Safety mats, 16 Zone scanners, 14

Index -- ii
SOFTWARE

KR C...

Operator Control

KUKA System Software (KSS)


Release 4.1

Issued: 09 Jan 2004 Version: 06


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e Copyright 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.

PD Interleaf

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Contents

1 Running up / shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . 9


1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Operator control elements on the control cabinet “KR C1” . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Operator control elements on the control cabinet “KR C2” . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Operator control elements on the control cabinet “KR C3” . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Running up the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Controller response when switched back on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7.1 Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7.2 Warmstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7.2.1 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7.2.2 Power failure with the system running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7.2.3 Power failure during a cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.2.4 Power failure during a restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.3 Setting external power supply and user outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Battery charge monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8.1 KR C1 response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8.2 KR C2 response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.9 Virus protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 The KUKA Control Panel KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29


2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Operator control elements of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 The rear of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Graphical user interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.1 Settings for brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.2 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.3 Input/output windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4.4 System status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.5 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.4.6 Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.7 Toggling to the Windows interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.7.1 Alt--Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.7.2 Alt--Escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.4.7.3 CTRL--Escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.4.8 Windows mouse emulation using keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3 Coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2 Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3 WORLD coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4 BASE coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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Operator Control

3.5 TOOL coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4 Jogging the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2 Selecting the jog mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3 Selecting the kinematic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.4 Selecting the coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.5 Jog override (jog velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.6 Moving the robot with the Space Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.6.2 Mouse position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.6.3 Degrees of freedom of the Space Mouse (Mouse configuration) . . . . . . . . . . . . . . . . . . . . . . 66
4.6.3.1 Motion of the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.6.3.2 Motion of the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.6.3.3 Unlimited functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6.4 Dominant axis of the Space Mouse (Mouse configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.6.4.1 Dominant axis activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.6.4.2 Dominant axis not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.7 Moving the robot with the jog keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7.1 Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7.2 Coordinate systems TOOL, BASE, WORLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.7.3 Incremental jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5 Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2 Graphical user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2.2 Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.2.3 Directory structure, attributes display, selection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.2.3.1 Directory structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.2.3.2 Attributes display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.3.3 Selection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.4 Directory and file list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2.4.1 Pop--up menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2.4.2 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.4.3 Windows 95 and kernel system attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2.5 Status line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2.6 Error display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2.6.1 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2.6.2 Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2.6.3 Data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2.6.4 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.3 “File” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.3.1 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.1.1 Create folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.1.2 Create module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.3.2 Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3.2.1 Open a subdirectory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3.2.2 Load file into the editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3.2.3 Edit a data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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5.3.2.4 Open an error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.3.3 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.3.1 Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.3.2 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.3.4 Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.3.4.1 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3.4.2 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3.4.3 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3.4.4 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3.4.5 Log Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3.4.6 Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3.5 Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.3.5.1 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3.5.2 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3.5.3 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3.5.4 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3.5.5 Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3.6 Rename . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.3.7 Format floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.3.8 Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.3.9 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.4 “Edit” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.4.1 Mark all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4.2 Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4.3 Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4.4 Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.4.5 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.4.6 Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4.7 Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.4.7.1 Without parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.4.7.2 With parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4.8 Cancel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4.9 Reset program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.5 “Monitor” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.6.1 Keyboard assignment of the Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.6.2 Default settings at User and Expert levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6 Executing, stopping and resetting a program . . . . . . . . . . . . . . . . . . . . . . 125


6.1 Selecting and opening a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.1.1 Symbols in the program window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.1.2 Program status line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.2 Setting work velocity (program override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.3 Stop reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.1 Ramp--down braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.2 Path--maintaining Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.3 Maximum braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.4 Short--circuit braking (dynamic braking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.3.5 Warning and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.4 Manual program execution (jog mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.4.1 Program run mode “Go”, “Single Step” or “I--Step” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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6.4.2 BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133


6.4.3 Executing individual program lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.4.4 Program start backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.4.5 Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.4.6 Resetting a program (Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.4.7 Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.5 Automatic program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.5.1 BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.5.2 Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.5.3 Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.6 Deselecting a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

7 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.1 Inputs/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.1.1 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.1.2 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.1.3 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.1.4 Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1.5 Automatic External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.1.5.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.1.5.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.2 Rob. Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.2.1 Cartesian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.2.2 Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2.3 Incremental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.2.4 Master/slave display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.3 Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.3.1 Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.3.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.3.2.1 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.3.2.2 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.3.2.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.3.3 Cyclic Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.3.4 Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.3.5 Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.3.6 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.4 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.4.1 Oscilloscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.4.2 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.4.2.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.4.2.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.4.3 CROSS Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.4.4 Caller Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.4.5 Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.4.6 Safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.4.7 Web Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.5 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.6 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.6.1 Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.6.1.1 Message window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.6.1.2 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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7.6.1.3 Inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.6.1.4 Error display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.6.2 Online Help -- Contents/Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.6.3 Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

8 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193


8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.2 File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.3 Program... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.3.1 “Program” in the navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.3.2 “Program” at programming level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
8.3.3 “Program” in the editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.4 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.5 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.6 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.7 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8.8 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.9 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

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1 Running up / shutting down the controller

1.1 General
The KR C... control cabinet contains the power and control electronics for the robot. Apart
from the main switch, all the operator control elements of the controller are located on the
KCP (KUKA Control Panel) hand programming unit.

Running up the controller presupposes that the initial start--up procedure has been carried
out correctly and that the system is set up ready for production.

The meaning of the symbols, icons and particular font conventions is explained in the
chapter [About this Documentation].

The KR C1 or KR C2 control cabinet door may only be opened by a skilled and appropriately
trained electrician for the purpose of service work. On completion of the work, the control
cabinet door must be carefully closed again to avoid dirt deposits and to prevent
unauthorized access!

The cabinet door of the KR C1 or KR C2 must be closed again immediately after service
work, otherwise the cooling effect of the internal airflow is lost. Failure to do so can cause
the controller to overheat and fail.

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1.2 Operator control elements on the control cabinet “KR C1”

Main switch

The robot system and controller are switched


on and off with the main switch.
A padlock fitted to the main switch can be
used to prevent it reliably from being switched
on accidentally (e.g. during maintenance
work on the robot system).
1
0

Computer drives and ports


A flap gives access to a floppy disk drive and
a CD--ROM drive, the ports COM1 and LPT1
and the status LED (Control ON).

Floppy disk drive COM1

Control
ON

CD--ROM drive LPT1

Cabinet lock
The cabinet lock is protected by a cover,
which also serves as the door handle.

It is also possible to connect a standard serial mouse to the computer system’s COM1 port.
This can even be connected and disconnected during operation without having to reboot the
system. For this reason, COM1 is automatically used by the mouse driver.

Applications and functions that access the COM1 port must be reconfigured to a different
COM port.

The temporary connection of a keyboard to the corresponding DIN or PS/2 port is also
possible.

The drives flap on the control cabinet door may only be opened for the purpose of using
the drives in order to prevent dust and moisture from entering the drives. Please make sure
that this flap remains closed and latched tight at all other times.

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1.3 Operator control elements on the control cabinet “KR C2”

Main switch

The robot system and controller are switched


on and off with the main switch.
A padlock fitted to the main switch can be
used to prevent it reliably from being switched
on accidentally (e.g. during maintenance
work on the robot system).

Options
If the control cabinet is equipped with extra
options, their functional status is indicated by
the LEDs.

Cabinet lock
The cabinet lock is protected by a cover,
which also serves as the door handle.

Computer drives
With the cabinet door open,
a CD--ROM drive and a
floppy disk drive are
accessible.

CD--ROM drive

Floppy disk drive

It is also possible to connect a standard serial mouse to the computer system’s COM1 port.
This can even be connected and disconnected during operation without having to reboot the
system. For this reason, COM1 is automatically used by the mouse driver.

Applications and functions that access the COM1 port must be reconfigured to a different
COM port.

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The temporary connection of a keyboard to the corresponding DIN or PS/2 port is also
possible.

In order to prevent dust and moisture from entering the control cabinet, the door may only
be opened for short periods of time. Make sure that this door is properly closed at all other
times.

1.4 Operator control elements on the control cabinet “KR C3”

KCP connection Status indication

The cable of the KCP (KUKA Control The first LED shows whether or not the
Panel) is connected to this socket. system is switched on. The second
indicates that the computer unit hard drive
is being accessed.

CD--ROM drive
Floppy disk drive
IUPS

On/off switch Reset

The entire robot system is switched on This button is used to reset the computer
and off with this switch. (warm start) without having to switch the
system off and back on again.

Both doors on the control module must be kept shut in order to keep dirt out.

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1.5 Running up the controller


On After the robot system has been switched on using the main switch on the control cabinet,
the computer begins to run up (load) the operating system and the control software. This
1

Off loading process lasts several minutes. Progress is displayed on the KCP display by means
0

of a progress indicator bar.


o

The display then shows the main menu for program creation, selection and execution:

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If the machine data loaded do not match the robot type, a corresponding error
message is generated when the controller is booted. The robot must not be moved
in this case.

The robot can be moved manually and programs started only if there is no EMERGENCY
STOP situation and -- in the “Automatic” mode -- the drives are switched on.

Information on the operator control elements “EMERGENCY STOP button” and “Drives
ON” may be found in the chapter [The KUKA Control Panel KCP], in the section
[Operator control elements of the KCP].

1.6 Shutting down the controller

On After the robot system has been switched off using the main switch on the control cabinet,
the controller shuts down its own software and the operating system. Certain data are auto-
1

Off matically saved in this procedure (Power OFF function). This only happens, however, if the
0

controller was correctly and completely run up beforehand.


o

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1.7 Controller response when switched back on


The controller offers two system boot variants:
G Cold start
G Warm restart

1.7.1 Cold start


The cold start behaves in the same way as the earlier control software versions. No program
is selected when the system has booted and the user outputs are set to “FALSE”.

In “Automatic External” mode, the program “CELL” is automatically selected and executed.

1.7.2 Warmstart
A warm start is intended to keep production downtimes to a minimum in the event of a power
failure. Once the system has booted, the position reached in the program immediately before
the power failure is restored. The field buses are reset (even in the event of a fault). Outputs
that were set at the time the system was switched off are set again when the system reboots.
The processing of the program can then be resumed from the point that had been reached
in the program. In most cases it is no longer necessary to move the cell free.
This variant is activated by default.

Before restarting the system, you must decide whether it is still sensible to resume
program execution given that the outputs will be reset or restored. It would not be
sensible to continue the program, for example, if the robot had lost the component.

From the point of view of the operator, the following things happen in the event of a power
failure:
-- Short--circuit braking (dynamic braking);
-- The text “Undervoltage” appears in the message window;
-- System variable “$STOPMESS” is set to 1 (True);
-- System variable “$POWER_FAIL” is set to 1 (True);
-- Backup routine starts, all modified files saved;
-- Machine switches off automatically.

The next time the system is booted, the initial state of the user interface is restored. If, for
example, forms were open or a program was loaded into the editor before the power failure,
they will not be displayed after the restart.
The state of the kernel system, including programs, block pointer, variable contents, outputs,
status messages and acknowledgement messages, is completely restored.

In the case of a restart after software problems, program resumption is only possible in
isolated cases.
All outstanding changes that have not yet been saved are lost after a shutdown.

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If there was an error present in the kernel system at the time of the power failure, or if the
system is shut down during a cold start, the system generates the file “vxworks.debug”.
KUKA can use this file to analyze the error.
The system restart then occurs as a cold start.

If a cold start is actively desired the next time the system is booted, the option “Configure”
--> “On/Off options” --> “Force cold Startup” is available for this purpose.

The menu command “Force cold startup” does not remain selected, i.e. it must be activated
each time a cold start is required.

Further information on the setup and configuration of the warm restart can be found in the
Programming Handbook in the documentation [Configuration], chapter [Configuring
the system].

1.7.2.1 Hardware requirements


Only power modules from version “E” onwards support the backup routine. This can last up
to 200 seconds, while older modules automatically switch off after 70 seconds.
In the event of a warm restart, the system configuration at the time of the power failure is
restored. The interpreter is returned to the point at which the program was interrupted, for
example, and the output image is restored. The restoration of the output image places
particular requirements on the system design.
In manual mode, the output periphery is linked to the system outputs “$PERI_RDY” and
“$STOPMESS”. In this way, changes to the status of the cell can only be made if the drives
are switched (enabling switch pressed and Emergency Stop acknowledged).

All peripheral devices which can trigger potentially dangerous movements in the
cell must be designed using pulse valve technology. This prevents unintentional
movements from occurring when the power supply is switched off or back on.

1.7.2.2 Power failure with the system running


In the event of a power failure during normal operation, the robot is stopped by short--circuit
braking (dynamic braking). A corresponding message is generated in the message window.

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The system variables “$STOPMESS” and “$POWERFAIL” are then set to “TRUE”.

An active application should react to the power failure with the KRL command “SYNC( )”.
If this message does not appear, a corresponding error message is generated.
It makes no difference whether the power failure was caused by failure of the mains supply
or by pressing the main switch during program execution.

All kernel system files with the archive bit are saved on the hard disk. Once the files are sa-
ved, the system waits until the PowerOff wait time has elapsed. This is then followed by one
of two eventualities:

When the wait time elapses the power has returned


The robot system is not switched off and the system variable “$POWER_FAIL” is set to
“FALSE” again. The message in the message window must then be acknowledged before
work can be resumed.

When the wait time elapses the power is still absent


The entire kernel system state is backed up on the hard disk in the file “vxworks.freeze” and
the controller is shut down, in a controlled manner, by the battery back--up (see Section 1.8).
All system files are saved in the usual way.
The control system is then switched off.

If the battery back--up is not sufficient, in exceptional circumstances files could be


destroyed. In such cases the system attempts a cold start.
Loss of mastering may occur if the battery voltage fails before the mastering data
are saved.

When power is restored the controller is automatically run up and selects the program that
was previously running. Program execution can be resumed from the point at which the
program was interrupted. There are two ways of doing this:
G If the robot is located on its programmed path (e.g. ramp--down braking), the program
can be started using the “start continue” function.
G If the robot has left its programmed path (e.g. short--circuit braking), a BCO run may
be necessary at the point where the path was left (RET position).

1.7.2.3 Power failure during a cold start


The variable “$POWER_FAIL” is set to the value “TRUE” and the system booting procedure
is aborted. In some cases a processor reset may be triggered and a cold start carried out
once the power has returned.

1.7.2.4 Power failure during a restart


The control software is completely restarted. The subsequent sequence of events then
corresponds to that described in Section 1.7.2.2.

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1.7.3 Setting external power supply and user outputs


External power supply
The computer unit in the robot controller can be supplied separately by an external power
supply (option). A 24--volt power source is required here, which works independently of the
normal power supply. In the event of a mains power failure, the computer unit is not shut
down.

Deactivating the user outputs


In the event of a power failure with a functioning external power supply, the user outputs are
not normally deactivated. Should this be desired, however, the variable
“IO_SYS_DOWN_ON_24V” must be set to “TRUE”.
When power returns, the user outputs are restored.

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1.8 Battery charge monitoring


Normally, when the system is shut down, or in the event of a power failure, the robot system
data are automatically backed up. The batteries used for backing up the computer system
are accommodated in the control cabinet.

1.8.1 KR C1 response
If the battery voltage drops too far during the backup procedure (below 22 V), an error
message is generated in the message window.

If this message is generated during normal operation, a short--circuit has occurred


in the battery.

No error message is generated as a result of disconnecting the batteries during normal


operation.

The error message can have the following causes:


G The batteries are not fully charged.
Cause: System switched on/off many times in quick succession.
Remedy: Leave the robot controller running for at least 10 hours, so that the
batteries can be completely recharged. If this does not help, the battery
is defective.
G One or both batteries are defective.
Remedy: Replace both batteries immediately, WITHOUT switching off the robot
controller (could result in faulty files or damage to the operating system).

Use only batteries that have been specially released by KUKA. No guarantee can
otherwise be provided for the correct functioning of the system.

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1.8.2 KR C2 response
If the battery voltage drops too far during the backup procedure (below 22 V), an error
message is generated in the message window.

If this message is generated during normal operation, a short--circuit has occurred


in the battery.

No error message is generated as a result of disconnecting the batteries during normal


operation.

The current state of the batteries is saved at the end of the backup procedure. Next time the
system is booted, a corresponding message is generated:
Voltage below 22 volts

This message indicates that enough voltage remains to back up the system data.
Voltage below 19 volts

If this message appears, operating system or robot system data may be damaged as the
computer was switched off before completion of the backup procedure. The system is
switched off in order to protect against an exhaustive discharge (and thus destruction) of the
batteries.

These messages can have two causes:


G The batteries are not fully charged.
Cause: System switched on/off many times in quick succession.
Remedy: Leave the robot controller running for at least 10 hours, so that the
batteries can be completely recharged. If this does not help, the battery
is presumably defective.
G One or both batteries are defective.
Remedy: Replace both batteries immediately, WITHOUT switching off the robot
controller (could result in faulty files or damage to the operating system).

Use only batteries that have been specially released by KUKA. No guarantee can
otherwise be provided for the correct functioning of the system.

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The message in the message window can be neither deleted nor acknowledged. This
message is deleted automatically, but not until the next battery backup procedure has been
successfully completed without the battery voltage falling too far.

Signal output “$LAST_BUFFERING_NOTOK”


If the battery voltage falls below 22 or 19 volts during the backup procedure, in addition to
the generation of error messages, the output “$LAST_BUFFERING_NOTOK” is set to
“TRUE”. This makes it possible to react to the situation accordingly with the peripheral
equipment connected.

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1.9 Virus protection


The control software package delivered with the controller includes a virus protection
program to protect it from computer viruses.

When the robot system is switched on, the Ikarus Software “Virus Utilities” program is
started. At the start of the program, an information window is briefly activated and the main
memory is searched.

It is not possible to remove a virus until the controller has booted completely.

The program “Ikarus--Guard”, which runs in the background, is then started; this is indicated
by an icon in the Windows taskbar.

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This program continually monitors the system’s main memory and drives.

In order to search for or remove viruses manually, it is necessary first to switch to the
Windows interface. Depending on the configuration, the user group “Expert” must be
accessed.

Further information about switching to the Windows interface can be found in the chapter
[The KUKA Control Panel KCP].

If a virus is discovered during operation, e.g. while accessing a floppy disk or network drive,
a corresponding virus warning is generated.

If this happens, please start the Virus--Utilities program via the Windows Start menu. Open
the Start menu using the keyboard shortcut “CTRL” + “ESC” and select the relevant program
using the arrow keys. Then press the Enter key.

The following window is then opened:

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The virus scanner does not, by default, intervene in the execution of the KRC software. This
default setting must be changed in order to be able to search for or delete a virus. To do this,
open the “Options” menu and select the entry “Configure”.

Activate the following option in the window which now opens and accept the settings by
pressing “OK”:

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Activate the option


“Remove virus”

Now select the directories which are to be searched.

Start the virus scanner by selecting the “Scan” function in the menu of the same name and
pressing the Enter key.

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The virus scanner then searches the specified drives and directories. Every virus detected
by the scanner is indicated in a dialog window and can be deleted by confirming the message.

If files in the operating system or robot control software are infected by viruses, the
software in question should be reinstalled as a precautionary measure once the
viruses have been deleted.

Finally, a summary is displayed of the drives searched and the viruses found.

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1 Running up / shutting down the controller (continued)

Further information about the virus scanner can be found in the instructions delivered with
the scanner.

It is in your own interest to make sure that you always use the latest version of the virus
scanner.

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2 The KUKA Control Panel KCP

2 The KUKA Control Panel KCP

2.1 General
The KUKA Control Panel, referred to hereafter as “KCP”, forms the interface between man
and machine and is used for easy operation of the “KR C...” robot controllers. All elements
required for programming and operator control of the robot system, with the exception of the
main switch, are located directly on the KCP. Due to its ergonomic design and its lightness,
the KCP can be used not only as a console unit but also as a handheld unit. The holding
domes and enabling switches on the back of the KCP are arranged in such a way that the
KCP can be easily used by both left--handed and right--handed people.
The VGA color--graphic LCD display helps to visualize operator and programming actions.
If you have already worked with the operating system “Windows”, you will find many familiar
features and elements on the user interface.
The following description gives you an overview of the KCP’s operator control elements and
graphical user interface.

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2.2 Operator control elements of the KCP

EMERGENCY STOP button

The EMERGENCY STOP button is the most


important safety element. This red slam push-
button is pressed in dangerous situations and
causes the drives of the robot to be switched
off immediately.
Before the drives can be switched on again,
the EMERGENCY STOP button must be
released. To do so, turn the top of the button
clockwise until it audibly disengages. The
associated EMERGENCY STOP message in
the message window must then be acknow-
ledged by pressing the softkey “Ack”.
Pressing the EMERGENCY STOP button
activates path--oriented braking.

Before the EMERGENCY STOP button is released, the situation that caused the stop
to be triggered, and if necessary its consequences, must first be rectified.

Drives ON
Pressing this pushbutton switches the drives
of the robot on.
These can only be switched on under normal
operating conditions (e.g. no EMERGENCY
STOP button pressed, safety gate closed,
etc.).
If the “Manual” mode is set, this pushbutton
has no function (see also “Mode selection”).

Drives OFF
Pressing this pushbutton switches the drives
of the robot off. The brakes of the motors are
also engaged after a slight delay and keep
the axes in their positions.
If the “Manual” mode is set, this pushbutton
has no function (see also “Mode selection”).
Drives OFF activates dynamic braking.

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2 The KUKA Control Panel KCP (continued)

Mode selection
Using this keyswitch you can switch between
the following operating modes:

Test 1
The robot moves only as long as one of
the enabling switches (on the rear of the
KCP) is held down.
Movements are executed at a reduced
velocity.

Test 2
The robot moves only as long as one of
the enabling switches (on the rear of the
KCP) is held down.
Movements are executed at the pro-
grammed velocity.

Automatic
The robot executes the selected pro-
gram automatically and is monitored
using the KCP.
Movements are executed at the pro-
grammed velocity.

External
The robot executes the selected pro-
gram automatically and is controlled
using a host computer or a PLC.
Movements are executed at the pro-
grammed velocity.

If the operating mode changes while the program is running, dynamic braking is activated.

Automatic operation is only possible with the safety circuit closed.

Further information can be found in the chapter [Executing, stopping and resetting
programs].

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Escape key (ESC)


An action that has been started can be
aborted at any time using the Escape key.
This includes, for example, open inline forms
ESC and status windows.
Menus opened by mistake can also be
closed again, one by one, by pressing this
key.

Window selection key

With this key, you can switch between the


program, status and message windows if
they are available.
The background of the selected (activated)
window is highlighted in color.
This activation is also called the “focus” in
this handbook.

Program STOP

Pressing this key stops a program that is


STOP running.
Path--maintaining braking is carried out and
this can be acknowledged in automatic mode.
To resume a program that has been stopped,
press the “Program start forwards” key.

Program start forwards

This key is used to start a selected program.


A program is only be started if the drives are
switched on and there is no EMERGENCY
STOP situation.
Releasing the “Program start forwards” key
in jog mode (T1 or T2) triggers path--
maintaining braking.

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2 The KUKA Control Panel KCP (continued)

To start the robot in the jog mode -- T1 and T2 -- one of the enabling switches must be held
down and then the “Program start forwards” key must be pressed. This start key must be
held down during program execution.

Program start backwards


By pressing this key, the motion blocks of the
selected program are executed step by step
towards the beginning of the program.
The robot is thus moved in reverse direction
along the path originally programmed.
This movement is used, for example, for
subsequently teaching intermediate points in
circular motions.
Releasing the “Program start backwards” key
triggers path--maintaining braking.

This function is only available


in the operating modes T1
(Test1) and T2 (Test2).

Enter key

This operator control element corresponds


to the “Enter” or “Return” key that you know
from a PC keyboard.
It is used to conclude commands, confirm
entries in forms, etc.

Arrow keys z " # !


The arrow keys are used to
-- change the position of the edit cursor, and
-- move between boxes in inline forms and
parameter lists.
To do so, press the corresponding arrow key.
The functions, including the repetition
function and the repetition rate, are similar to
those of a PC keyboard.

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Space Mouse

This operator control element is used for the


manually controlled motion of all 6 axes
(degrees of freedom) of the robot. The
magnitude of the deflection affects the
velocity of the robot.
Alternatively, the --/+ status keys on the right-
hand side of the display can also be used.
See also chapter [Jogging the robot].

Menu keys
These keys are used to open a menu in the
menu bar (at the top of the display).
You can select from the menu that is opened
as follows:
-- by using the (# ") arrow keys, which
highlights the selected menu item in
color, and then pressing the Enter key
or
-- by using the numeric keypad to enter
the numbers preceding the desired
menu item.
A menu can be closed one step at a time by
pressing the Escape key as often as required.

Status keys
The status keys (on the left and right of the
display) are used for selecting operating
options, switching individual functions and
setting values.
-- + The respective functions are graphically
indicated by icons in the status key bar. See
also Section 2.4 (Status key bar).

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2 The KUKA Control Panel KCP (continued)

Softkeys

These operator control elements are used to


select the functions indicated in the softkey
bar (at the bottom of the display).
The functions available are dynamically
adapted, i.e. the assignment of the softkey
bar is altered.
Further information can be found in Section
2.4 (Softkey bar).

Numeric keypad
The numeric keypad is used for entering
numbers. On a second level, the numeric
keypad is assigned cursor control
functions.
The “NUM” key on the keyboard is
pressed briefly to switch between these
levels.

The “NUM” box in the status line of the


display indicates the currently active function
of the numeric keypad:

Numeric input activated

Cursor control functions activated

HOME LDEL PGUP


Jumps to the beginning Deletes the line in Moves one screen
of the line in which the which the edit cursor towards the beginning
edit cursor is positioned. is positioned. of the file.

TAB
UNDO
Tab jump
Cancels the last entry
(not yet implemented).
PGDN
Moves one screen
towards the end of
END the file.
Jumps to the end of
the line in which the
edit cursor is positioned. CTRL
Control key; e.g. for
program--specific
INS commands.
Switches between insert
and overwrite modes.
DEL Arrow z
The set mode is indicated Deletes the character Backspace key;
in the status line as follows: to the right of the edit cur- deletes the character to
sor. the left of the edit cursor.

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Keyboard
You can switch between lower--case and
upper--case letters by means of the
“SHIFT” key.

If the shift key is pressed once, the next


character will be typed in upper case. To
type upper--case characters, the shift key
must be held down while the characters
are entered. It is also possible to switch to
continuous upper--case characters (Caps
Lock) using the keyboard shortcut
“SYM”+“SHIFT”. For control purposes,
”Caps” in the status line will be changed
from gray to highlighted.

Caps Lock inactive

Caps Lock active

Punctuation marks and special characters are available on a


second keyboard level. You can switch to this level by pressing
the “SYM” key.
If the “SYM” key is pressed once, the corresponding punctua-
tion mark or special character will be typed next. To obtain a
locking function, this key must be held down while characters
are entered.

In certain applications, e.g. auxiliary programs, it is possible


to control functions by means of key combinations
(e.g. “ALT”+“TAB”). On the KCP, the “ALT” key is located
in the position shown on the left.

The “CTRL” key is located on the numeric keypad.


Before the “CTRL” key can be used, the numeric keypad must
be switched to the cursor control functions (see the description
“Numeric keypad”).

The “SHIFT”, “ALT”, “CTRL” and “SYM” keys remain activated for one keystroke, i.e. if the
“SHIFT” key is pressed, for example, and then released, it is active for the next keystroke.

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2 The KUKA Control Panel KCP (continued)

2.3 The rear of the KCP

Enabling switch
Enabling switch

Connections

Space Mouse

Enabling switch

Program start
forwards
Rating plate

Enabling switch

Reserved for
subsequent ap-
plications.
Ethernet port

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2.4 Graphical user interface (GUI)


The display of the KUKA Control Panel is subdivided into several areas with various
functions. These are dynamically adapted to the different requirements during operation.
The elements of the graphical user interface include the menu bar, the status key bars and
the softkey bar, the program window, the inline forms, the status and message windows and
a status line.

These are illustrated below on the basis of examples. The assignment of the menu, status
and softkey bars depends on the applications installed.

2.4.1 Settings for brightness and contrast


For the sake of greater clarity of the graphical user interface, both the brightness and contrast
of the LCD display can be adjusted.
The jog function must be switched off first before the brightness and contrast can be
changed. The status key “Jog mode” is located at the top left of the display.

The two status keys on the right--hand side of the display are used for setting the brightness
and contrast. The respective values can be changed from 0...15 by pressing the correspond-
ing +/-- status key.

2.4.2 Function keys

Menu bar

Robot controller functions are grouped


together in the menu bar.
These groups (menu items) must be opened
using the menu keys (above the display) to
access the next function level.
Further information on the menu keys can be
found in Section 2.2.

Status key bars


The status key bars show the changeable
functions of the status keys to the left and
right of the display.
The appearance of, or the functions assigned
to, the status keys change during execution
of the program.

Further information on the status keys can


be found in Section 2.2.

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2 The KUKA Control Panel KCP (continued)

Softkey bar
The softkey bar, which adapts itself dynami-
cally, offers functions that can be selected
using the softkeys (at the bottom of the
display).

Further information on the softkey bar can


be found in Section 2.4.6.

2.4.3 Input/output windows


Program window
The program window shows the contents of
the selected program. If there is no program
selected, a list of the available programs is
displayed in the program window.
Located between the line number and the text
of the instruction, or statement, is a yellow
arrow pointing right, the “block pointer”. This
indicates the program line that is currently
being executed.
Block pointer (program pointer) Another marker is the “edit cursor”, a vertical
red line. The edit cursor is located at the
beginning of the line that is currently being
edited.
Further information on the use of the block
pointer is provided in Section 6.4.3.

Edit cursor

Status window
The status window is opened as required for
display purposes (e.g. assignment of outputs)
or for entry of data (e.g. during tool calibration).

You can move between the input boxes using


the “¯” and “­” arrow keys.

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Message window
The controller communicates with the operator
via the message window. Notification, status,
acknowledgement, wait and dialog messages
are displayed here.

Each type of message has a specific symbol


assigned to it. Further information can be
found in Section 2.4.5.

If the message text does not fit in one line, the remainder of the text is automatically cut.

Do you want to teach point “PointOfNoReturn” (TOOL_DATA[1], $WO

In order to view the entire message text, select the relevant line using the arrow keys. Then
press the Enter key. The complete message text is then displayed.

Do you want to teach point “PointOfNoReturn” (TOOL_DATA[1],


$WORLD, #BASE)

The “ESC” key takes you back to the normal display.

Inline form
Some of the program functions require values
to be entered.
These values are entered in an input mask
(inline form) or selected from inline sub-
menus.
In this way, you ensure that the programmed
instructions always have the correct format.

You can move between the input boxes using the “¯” and “­” arrow keys.

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2 The KUKA Control Panel KCP (continued)

2.4.4 System status

Status line (status bar)

The status line provides a collection of infor-


mation on important operating statuses.
This includes information on the status of the
PLC or a program.
More detailed information on the indications
of the status line can be found in Section
2.4.6.

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2.4.5 Messages
The symbols displayed in the message window have the following meaning.
Notification messages contain information or indicate operator actions, programming
errors and operator errors. They are purely for information purposes and do not interrupt
program execution.

Start key required

This message appears after a program has been selected.

Status messages indicate the status of the system. They are also informational in character
and can interrupt the application program to a certain extent. Status messages are automati-
cally deleted when the status that triggered them is no longer applicable.

EMERGENCY STOP

This message is generated if, for example, the EMERGENCY STOP button has been
pressed or a safety gate opened.

Acknowledgement messages frequently appear following a status message (e.g. EMER-


GENCY STOP) and must be explicitly confirmed. They indicate disruption to program execu-
tion.

Confirm EMERGENCY STOP

Acknowledgement messages stop robot operation until the cause of the error has been elimi-
nated and the message confirmed.

Wait messages are generated if a program is running and a wait condition is being executed.

WAIT FOR $IN[1]==TRUE

The robot controller is stopped until the condition is fulfilled or the program reset. In this
example the system is waiting for a signal at input 1.

The operator must respond to dialog messages. The result is stored in the relevant variable.
The program is stopped until the message is acknowledged, and subsequently resumed.

Do you want to touch point “P1”?

The “yes” and “no” softkeys are now offered in the softkey bar. When one of the two softkeys
is pressed, the message is deleted from the message window.

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2 The KUKA Control Panel KCP (continued)

2.4.6 Status bar


The status bar gives you information about important operating states.

Numbers are entered using the numeric keypad.

The numeric keypad’s cursor control functions are activated.

Upper--case characters are switched on (all characters will be written


in upper case)
Upper case characters are deactivated (both lower and upper--case
characters can be entered)

Gray: The “Submit” interpreter has been deselected.

Green: The “Submit” interpreter is running.

Red: The “Submit” interpreter has been stopped.

Green: The drives are ready.

Red: The drives are not ready.

Gray: No program has been selected.

Yellow: The block pointer is located in the first line of the


selected program.
Green: A program has been selected and is currently being
executed.
Red: The selected and started program has been stopped.

Black: The block pointer is located in the last line of the


selected program.

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This box indicates the name of the selected program.

This box indicates the block number of the program line currently being
executed.

Operating mode T1 (manual mode/jog mode).

Operating mode T2 (manual mode/jog mode).

Operating mode in which a host computer or PLC assumes control of


the robot system (Automatic External).

Operating mode (Automatic).

The Program override (the traversing velocity) in this example is set at


100% of the process velocity.

The Jog override (for jogging); in this example the jog velocity is set
to 50%.

The name of the robot is shown here.

The current system time.

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2 The KUKA Control Panel KCP (continued)

2.4.7 Toggling to the Windows interface


It is possible to toggle to the Windows interface (only at Expert level) using various keyboard
shortcuts. To do this, make sure that the “NUM” display in the status line is deactivated, so
that you can use the numeric keypad’s control functions.

Cursor control functions


activated

2.4.7.1 Alt--Tab
This combination makes it possible to toggle to another active program. These could include,
for example, the programs “KR C...” and “Kuka--Cross 3”. Hold the “ALT” key down and
repeatedly press the “TAB” key in the numeric keypad until the desired program is indicated.
Then release both keys.

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2.4.7.2 Alt--Escape
This returns you to the previous active application. Hold the “ALT” key down and repeatedly
press the “ESC” key. Then release both keys.

+ ESC

2.4.7.3 CTRL--Escape
The key combination “CTRL”+“ESC” allows you to open the Windows Start menu in order
to call a different application using the arrow keys.

+ ESC

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2 The KUKA Control Panel KCP (continued)

2.4.8 Windows mouse emulation using keys


This function enables you to move the mouse cursor using keyboard shortcuts and emulate
the left and right mouse buttons. This option is deactivated by default.
Activate mouse operation by pressing the “SYM” key and then the “Enter” key. The function
can be disabled again in the same way.

+ Standard mouse Mouse emulation


operation activated

The mouse cursor can be moved in the desired direction using the arrow keys. If a key is held
down, the mouse cursor moves with increasing speed in the desired direction.

The Enter key replaces the left mouse button.

The space--bar functions as the right mouse button.

The middle mouse button and “Drag and Drop” functions cannot be emulated.

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3 Coordinate systems

3 Coordinate systems
3.1 General
To jog the robot, using the Space Mouse or the jog keys, you must select a coordinate system
on which the robot movements are to be based.
For this purpose, you can choose from the following four systems, the use of which is
explained in greater detail further on in this chapter.

Joint coordinate system


Each robot axis can be individually moved in positive or negative direction;

WORLD coordinate system


Fixed, rectangular coordinate system whose origin is located at the base of the robot;

BASE coordinate system


Rectangular coordinate system which has its origin on the workpiece that is to be
processed;

TOOL coordinate system


Rectangular coordinate system, whose origin is located in the tool.

The robot moves in accordance with the reference coordinate system selected. This has
the effect that the robot movements are different in, say, the TOOL coordinate system from
those in the BASE coordinate system. More detailed information on this can be found in
the following descriptions of the individual coordinate systems.

The reference coordinate system can only be changed in jogging mode. The status key “Jog
mode” at the top left of the display must show either the “Space Mouse” or “Jog keys” symbol.
To select the desired coordinate system, repeatedly press the status key on the KCP
illustrated below until the symbol for the desired coordinate system appears in the status key
bar.

-- +

Further information can be found...


G ...in the chapter [Jogging the robot] for information on moving the robot with the Space
Mouse or the jog keys.
G ...in the documentation [Start--up], chapter [Calibration -- Tools and workpieces] for
information on calibrating tools and workpieces.

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3.2 Joint coordinate system


In the joint coordinate system, each robot axis can be individually moved in positive or
negative axis direction. This can be done using the jog keys or the Space Mouse, the Space
Mouse allowing 3 or 6 axes to be moved simultaneously.

The following jog keys/movements of the Space Mouse enable each axis to be moved
individually:

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

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3 Coordinate systems (continued)

3.3 WORLD coordinate system


The WORLD reference coordinate system is an absolute (fixed), rectangular, cartesian
coordinate system, the origin of which is generally located inside the work cell. The origin of
the reference system remains in the same position when the robot moves, i.e. it does not
move with it.
On delivery, the origin of the WORLD coordinate system is located in the base of the robot.

Position of
operator

Information regarding the Space Mouse:


The World coordinate system corresponds with that of the Space Mouse if the operator
(KCP) is standing directly in front of the robot in the position illustrated above. It is also
possible to communicate a different operator (KCP) position to the system in order that the
coordinate systems correspond with one another, thus ensuring that handling is kept as
simple and safe as possible.

The following jog keys/movements of the Space Mouse enable each axis to be moved
individually:

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

Further information on the Space Mouse may be found in the chapter [Jogging the robot],
in the section [Moving the robot with the Space Mouse].

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3.4 BASE coordinate system


The BASE coordinate system is a rectangular, cartesian coordinate system, the origin of
which is located in an external tool. This could be a welding gun, for example. If you have
selected this system as reference coordinate system, the robot moves parallel to the axes
of the workpiece. The BASE coordinate system only moves in the case of a workpiece that
is fixed to a mathematically coupled external kinematic system.

The following jog keys/movements of the Space Mouse enable each axis to be moved
individually:

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

On delivery, the origin of the BASE coordinate system is located in the base of the robot.

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3 Coordinate systems (continued)

3.5 TOOL coordinate system


The TOOL coordinate system is a rectangular, cartesian coordinate system, the origin of
which is located in the tool. This coordinate system is generally orientated in such a way that
its X axis is identical to the working direction of the tool. The TOOL coordinate system
constantly follows the movement of the tool.

The following jog keys/movements of the Space Mouse enable each axis to be moved
individually:

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

On delivery, the origin of the TOOL coordinate system is located at the center of the robot
flange.

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4 Jogging the robot

4 Jogging the robot


4.1 General
Jogging is used for manually controlled movement of the robot to teach end points, for
example, or to move the robot free after one of its axes has violated one of its software limit
switches.
The robot has a total of six axes as standard, which are defined as follows:

Overview:
Position and direction of rotation
of the robot axes

To jog the robot, the mode selector switch must be set to “Jog mode” -- T1 or T2. Jogging
is not possible with the switch in the positions “Automatic” and “Automatic External”.
The current setting of the mode selector switch is displayed in the status line:

Further information on the operator control element “Mode selector switch” can be found
in the chapter [The KUKA Control Panel KCP].

The robot can be jogged only if there is no EMERGENCY STOP situation.

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If a robot axis runs against one of its software limit switches, it is immediately switched off.
The robot can then be moved out of this position manually in the joint coordinate system.
All the other axes remain unaffected.

Please note:
If one or more of the robot axes hits its end stop without being braked and at more
than 20 cm/s (jog velocity set by the manufacturer), the buffer concerned must be
replaced immediately.
If this happens to axis 1 of a wall--mounted robot, its rotating column must be
replaced.

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4 Jogging the robot (continued)

4.2 Selecting the jog mode


The following modes are available for jogging the robot:

G Jogging switched off


Intended solely for program execution or operation in “Automatic” mode;

G Moving the robot with the “Space Mouse”


For simultaneous movement of 3 or 6 axes, depending on the setting of the degrees
of freedom;
G Moving the robot with the jog keys
In order to move each axis individually.

To make your selection, repeatedly press the status key “Jog mode” until the symbol for the
desired jog mode appears in the status key bar.

For the purposes of enhancing your overview of the robot movement, the positions of the
axes can be shown in a status window. To do this, the menu key “Monitor” is pressed and
one of the options in the submenu “Rob. Position” is selected.

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4.3 Selecting the kinematic system


The jog keys can be used to move both the standard robot axes and external axes, as well
as any external kinematic systems which have been configured. To select the desired axis
or kinematic system, repeatedly press the status key shown below.

-- +

The type and number of options available depend on your system configuration.

First ensure that jogging with the jog keys or Space Mouse is activated. Otherwise, moving
the external axes will not be possible. Details can be found in Section 4.2.

G Robot
Only the 6 robot axes A1...A6 (joint coordinate system) or X,Y,Z,A,B,C (reference
coordinate system) can be moved

G External axes
Here you can move only the external axes (E1...E6)

G Robot and external axes


The main axes of the robot (A1...A3 or X,Y,Z) and the first 3 external axes (E1...E3) can
be moved

Here the main axes (A1...A3 or X,Y,Z) and the external axes (E4...E6) can be moved

If you move the robot using the Space Mouse (axes A1...A6 or X,Y,Z,A,B,C), you can
move the external axes (E1...E6) using the status keys. To do so, keep the enabling
switch held down.

Further information about external axes can be found in the separate documentation
[External Axes].

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4.4 Selecting the coordinate system


After you have selected the Space Mouse or the jog keys, you can now choose the reference
coordinate system on which the robot movements are to be based. The individual axes then
move in relation to the system selected.
The following reference coordinate systems can be selected:

G Joint coordinate system


Each robot axis can be individually moved in positive or negative direction.

G WORLD coordinate system


A fixed, rectangular coordinate system which has its origin at the base of the robot.

G BASE coordinate system


Rectangular coordinate system, whose origin is located in the workpiece.

G TOOL coordinate system


Rectangular coordinate system, whose origin is located in the tool.

The robot moves in accordance with the reference coordinate system selected. This has
the effect that the robot movements are different in, say, the TOOL coordinate system from
those in the BASE coordinate system.

If the wrist axes A4 and A6 are in alignment (e.g. in the mastering position), axis A5 must
first be moved in the joint coordinate system in order to avoid the error message “Command
acceleration exceeded A4”.

In the extended wrist axis position (A4 and A6 in alignment), there is the danger that
an external energy supply system (if present) may be wound around the wrist axis.

Further information on the extended wrist axis position can be found in the documentation
[User Programming], in the chapter [Motion], section “Infinitely rotating axes”.

If the robot is moved through the extended position (axes A2 and A3 in a straight
line), axis A3 may abruptly drop 15--20 cm before the command velocity is exceeded
and the axis switched off.

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To select the desired coordinate system, repeatedly press the status key on the KCP
illustrated below until the symbol for the coordinate system illustrated above appears in the
status key bar.

-- +

For further information on the subject “reference coordinate systems” please refer to the
documentation [Operator Control], chapter [Coordinate systems].

As standard, when the robot is delivered, the BASE and TOOL coordinate systems are not
calibrated.
If the BASE coordinate system ($BASE) is not calibrated, it corresponds to the WORLD
coordinate system which is usually situated in the base of the robot.
If the TOOL coordinate system ($TOOL) is not calibrated, it is situated at the center of the
robot flange.

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4.5 Jog override (jog velocity)


In some cases (e.g. moving to end points during teaching) it is of vital importance to reduce
the jog velocity. Only in this way can points be addressed precisely and collisions with
tools/workpieces be avoided.

The “Jog override” function, which is only available in jog mode, can be used for this purpose.
The status key “Jog mode” (at the top left of the display) must show the symbol “Space
Mouse” or “Jog keys”.

You can now alter the jog override setting by means of the “+/--” status key to the right of the
symbol “Override” (at the bottom right of the display). The current setting is displayed both
in the symbol and in the status line.
With the Space Mouse, the velocity can be further decreased by reducing the deflection of
the mouse (velocity proportional to the deflection).

In modes “T1” and “T2”, the Jog override can also be altered during program execution.

The Jog override increment can be increased. To do this you must activate the option
“Jog--OV Steps” in the “Configure -- Jogging” menu. The value is then no longer altered in
increments of 1% but changes between 1, 3, 10, 30, 50, 75 and 100 per cent of the value
specified in the machine data.

If you have selected the joint coordinate system as the reference coordinate system, the
jog override refers to the specific axis.
If a rectangular coordinate system is set (e.g. WORLD coordinate system) the jog override
refers to the axis with the longest trajectory (leading axis). The motions of all other axes
are synchronized with the leading axis.

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4.6 Moving the robot with the Space Mouse


4.6.1 General
If you have selected the Space Mouse as the operator control element using the status key
“Jog mode”, you can now move the robot in 3 or 6 axes (degrees of freedom) at the same
time. The Space Mouse is assigned a coordinate system that stays the same in all reference
coordinate systems.

Please refer to the section [Selecting the jog mode] for information on selecting this jog
mode.

If you pull the Space Mouse towards you in the positive X direction, for example, the robot
axes will likewise move in the positive direction in the reference coordinate system. This also
applies to the Y and Z axes.
Turning the Space Mouse about its X axis, for example, likewise causes the tool center point
to rotate about the X axis of the set reference coordinate system. This again applies equally
to the Y and Z axes.

Please refer to the section [Selecting the coordinate system] for more information on
coordinate systems.

It is only possible to jog the robot if you first hold down one of the enabling switches (located
on the back of the KCP) and then operate the Space Mouse. If either the enabling switch
or the Space Mouse is released while the robot is moving, it is stopped immediately.
For robot motions in the world coordinate system, the function “Mouse position” is also
available.
For certain applications, e.g. fine positioning or tool calibration, it is useful not to move the
robot in 6 axes simultaneously. For this reason, the aids “Degrees of freedom” and “Dominant
axis” are available to reduce the number.

4.6.2 Mouse position


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In order to ensure intuitive operator control when jogging the robot using the Space Mouse,
the operator can inform the controller of his position.
This function is reached by pressing the menu key “Configure” and executing the option
“Jogging” --> “Mouse position”.

The default setting for the mouse position is 0 degrees (in the positive X direction the robot
will move towards the operator). To ensure that the deflection of the Space Mouse
corresponds to the motion direction, the operator should stand in front of the robot.

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If the operator now moves to the left of the robot and wishes to again move the robot towards
himself, he no longer has to rethink what he is doing. The mouse position is simply set to 90
degrees. This causes the world coordinate system to be rotated by 90 degrees in the robot
controller.

The same Space Mouse motion as before will once again move the robot towards the
operator.

You can change the position of the 6D mouse by pressing the corresponding softkeys. Each
time the softkey “+” is pressed, the world coordinate system is rotated an additional 45
degrees in a clockwise direction. The softkey “--” rotates the coordinate system in a counter-
clockwise direction.
The KCP symbol in the status window also moves each time the softkey is pressed, and thus
always indicates the current position.
The softkey “Close” accepts the current mouse position and closes the status window.

When switching to “AUT” (Automatic) or “EXT” (Automatic External) mode, the mouse
position is automatically reset to 0 degrees.

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Pressing the softkey “+” twice shifts the mouse position 90 degrees clockwise. The
operator is standing to the left of the robot in this case.

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4.6.3 Degrees of freedom of the Space Mouse (Mouse configuration)


The number of axes which can be moved simultaneously using the Space Mouse can be
limited. This is done using the function “Degrees of freedom”.
This function is reached by pressing the menu key “Configure” and executing the option
“Jogging” --> “Mouse configuration”.

A status window opens in which you can set the degrees of freedom.

Axis selection

all Axis (6D)

Degrees of freedom of the


Space Mouse

Dominant mode

A total of three options are available:

Motion of the Motion of the Unlimited


main axes wrist axes functionality

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4.6.3.1 Motion of the main axes


The functionality of the Space Mouse is here restricted to motion of the main axes A1, A2
and A3. Only pulling or pushing the Space Mouse, as shown in the figure below, moves
the robot. How the robot moves depends on the reference coordinate system of the robot
that has been set. Turning the Space Mouse has no effect on the robot.
Turning the Space Mouse about its coordinate axes therefore has no effect on the robot.
If you have selected a Cartesian (rectangular) coordinate system, you can only move the
robot translationally in the X, Y and Z coordinate axes. Several axes usually move
synchronously in this case. If, on the other hand, you have selected the joint (axis--specific)
coordinate system, you can only move the robot axes A1, A2 and A3 directly.
Joint reference coordinate system:

4.6.3.2 Motion of the main axes


The functionality of the Space Mouse is here restricted to motion of the wrist axes. Only
rotating the Space Mouse, as shown in the figure below, moves the robot. Here too, the type
of movement depends on the reference coordinate system of the robot that has been set.
Pulling and pushing the Space Mouse has no effect on the robot.
In a Cartesian coordinate system, you can only move the robot rotationally about the X, Y
and Z coordinate axes. Several axes can also move simultaneously in this case too. If, on
the other hand, you have selected the joint (axis--specific) coordinate system, you can only
move the robot axes A4, A5 and A6 directly.
Joint reference coordinate system:

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4.6.3.3 Unlimited functionality


With this setting, all 6 axes of the robot can be moved. If a Cartesian coordinate system is
selected, pushing or pulling the Space Mouse along its X, Y or Z axis causes the robot to
be correspondingly moved along the X, Y or Z axis of the set reference coordinate system.
Rotating the Space Mouse about its X, Y or Z axis similarly causes the tool center point to
be correspondingly rotated about the X, Y or Z axis.
If you select the joint coordinate system, you can specifically move the robot axes A1 to A6:
Pushing or pulling (translational motions) along the X, Y and Z coordinate axes of the
Space Mouse moves the robot axes A1, A2 and A3. If, on the other hand, you turn the Space
Mouse about its X, Y and Z coordinate axes, you can move the wrist (robot axes A4, A5 and
A6).
Joint reference coordinate system:

You can use the settings described above to reduce the number of degrees of freedom from
6 to 3, but it is not possible to move just one single axis with the Space Mouse.
It is, however, possible to define a so--called “dominant” axis in order to permit operation with
only one axis if required.

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4.6.4 Dominant axis of the Space Mouse (Mouse configuration)


For various applications, it is useful to limit the function of the Space Mouse to one robot axis,
the so--called “dominant” axis. When this function is switched on, only the coordinate axis
with the greatest deflection of the Space--Mouse is moved.
This function is reached by pressing the menu key “Configure” and executing the option
“Jogging” --> “Mouse configuration”.

A status window opens in which you can specify whether only the dominant axis is moved.

Axis selection

all Axis (6D)

Dominant mode
Dominant axis

The command “Dominant axis” can also be switched on and off using the corresponding
status key. This status key is only available in the jog mode “Space Mouse”.

Dominant axis Dominant axis


activated not activated

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4.6.4.1 Dominant axis activated


For moving the robot, the coordinate axis of the Space Mouse that is currently given the
greatest deflection is relevant.

In this diagram, the relative deflections of


the Space Mouse for axes A1--, A2+ and
A3-- are represented by different arrow
lengths.

As can be seen, the deflection for A2+ is


greatest in this example.
Axis 2 is thus the dominant axis, and only
axis 2 is jogged.

As soon as another axis registers a


greater deflection, this in turn becomes
Deflection the dominant axis.
of the Space Mouse

4.6.4.2 Dominant axis not activated


Either 3 or all 6 axes can be moved depending on the setting of the degrees of freedom. This
is known as a so--called superposed motion. Jogging of 3 or 6 axes simultaneously should
primarily be left to experienced users.

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4.7 Moving the robot with the jog keys


If, using the status key “Jog mode”, you have selected the jog keys as the input medium, you
can move the robot in accordance with the set reference coordinate system by pressing the
“+/--” status key.

Please refer to the section [Selecting the jog mode] for further information on selecting
the jog mode.

-- +

With some robot models, the user interface may vary slightly from the standard interface.
With a palletizing robot in axis--specific jog mode, for example, axes A4 and A5 are not
available, and in Cartesian jog mode, angles B and C are not available.

4.7.1 Joint coordinate system


If you have selected the joint (axis--specific) coordinate system, the main and wrist axes A1
to A6 will be displayed in the right--hand status key bar as soon as you press one of the
enabling switches on the rear of the KCP.
In the joint coordinate system, the jog keys are assigned the axis designations depicted
below. The arrows shown on the robot axes (A1 to A6) show the direction the axes will move
when the “+” status key is pressed.
The axes are moved in the opposite direction (--) by pressing the side of the status keys
marked “--”.

-- +

-- +

-- +

-- +

-- +

-- +

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4.7.2 Coordinate systems TOOL, BASE, WORLD


If you have selected the “TOOL”, “BASE” or “WORLD” coordinate system, the main axes
X, Y and Z, and the wrist axes A, B and C are displayed. Several axes are usually moved
synchronously.
In the world coordinate system, the jog keys are assigned the axis designations depicted
below. Here, too, the arrows indicate the positive axis directions.

-- +

-- +

-- +

-- +

-- +

-- +

Please refer to the chapter [Coordinate systems] for detailed information on the
reference coordinate systems.

It is only possible to jog the robot if you first hold down one of the enabling switches (located
on the back of the KCP) and then press the desired jog key. If either the enabling switch
or the jog key is released, the robot is stopped immediately.

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4.7.3 Incremental jogging


A motion command can be executed step by step using incremental jogging. In the event
of an error it enables the user to move the robot a defined distance or orientation away from
the component. The robot can then be moved step by step back to the previous position.

The positioning of equidistant points is significantly accelerated using this function.


This option can also be used when mastering with the dial gauge.

The following increments can be set as standard:

Incremental jogging switched off

Increment set to 100 mm linear (X, Y, Z) or 10 degrees orientation (A, B, C)

Increment set to 10 mm linear (X, Y, Z) or 3 degrees orientation (A, B, C)

Increment set to 1 mm linear (X, Y, Z) or 1 degree orientation (A, B, C)

Increment set to 0.1 mm linear (X, Y, Z) or 0.005 degrees orientation (A, B, C)

To toggle the increment, press the corresponding status key on the right--hand side of the
display. The “--” key toggles to the next value down while the “+” key toggles to the next value
up.

Incremental jogging is only available if jogging with the jog keys has been activated.

To jog the robot, you must hold down an enabling switch and then press the jog key of the
desired axis. Once the set increment has been reached, the status key must be released and
pressed again.
The robot keeps moving as long as the jog key remains pressed, and stops by itself after the
preset distance or number of degrees has been reached.
In the case of an interruption, e.g. Emergency Stop, change of operating mode, releasing
the jog key or enabling switch, the robot stops. This terminates the incremental motion that
has been started.

The increments are executed relative to the coordinate system selected.

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5 Navigator

5 Navigator
5.1 General
The Navigator is a so--called file manager which the operator can use to “navigate” through
the drives and directory structures. The Navigator can be used to create, select, copy, save,
delete and open files.
After the controller has run up, the KCP displays the following screenshot:

The meaning of the symbols, icons and particular font conventions is explained in the
documentation [Introduction] in the chapter [About this documentation].

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5.2 Graphical user interface


5.2.1 Fundamentals
The Navigator consists of the following four areas:

Header

Directory structure, Directory or file list


attributes display or
selection list
(templates and filters)

Status line

The following icons and symbols are used in the Navigator:

Drives

Symbol Type Default path


Robot KRC:\
Floppy disk A:\
Hard disk *1 e.g. “Kukadisk (C:\)” or “Kukadata (D:\)”
CD--ROM *1 E:\
Mapped network drive *1 F:\ , G:\ , ...

Backup drive Archive:\


*1: In the default setting, these symbols are not shown below the user group “Expert”
*2: If a network connection fails during operation, the Navigator is blocked by the operating
system until the network error is detected. Operator actions (e.g. select/open program)
are not possible during this time

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Directories and files

Symbol Type Meaning


Directory Normal directory
Directory open Open subdirectory
Archive ZIP file (compressed directory)
Read directory The contents of the subdirectory are being read
Module Program at user level (*.src, *.dat, *.sub)
Module containing Program at user level which must be corrected
errors before being run in the editor
Src file *1 Program file at expert level
Src file *1 Subprogram at expert level
Src file containing Program file at expert level which must be
errors *1 corrected before being run in the editor
Dat file *1 Data list at expert level
Dat file containing Data list containing errors
errors *1
ASCII file *1 File that can be read using any editor
Other files *1 Binary files which cannot be read in the text editor
*1: These symbols are not shown below the user group “Expert”

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5.2.2 Header
The left side of the header shows the filter or the templates that are available for selection.
The right side shows the directory and/or file path.

Filter

The current filter setting is The current drive or directory is


displayed above the directory displayed in the directory or file
structure. list.
In expert mode, the filter can
be set to default to “Modules”
or “Detail view”.

The filter setting cannot be changed below the user group “Expert”.

Further information about the “filter” can be found in Section 5.2.3.3.


Information on the “Expert level” can be found in the Programming Handbook in the
documentation [Configuration], chapter [Configuring the system], section “User
group”.

Template

The template selection is dis- The current drive or directory is


played above the directory displayed in the directory or file
structure. list.
This selection is only avail-
able at Expert level.

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5 Navigator (continued)

5.2.3 Directory structure, attributes display, selection list


5.2.3.1 Directory structure
By default, the Navigator displays the directory structure of the current drives or directories.

The current directory structure is normally shown on


the left--hand side of the Navigator. This display varies
according to the filter that has been set. (More detailed
information on this can be found in Section 5.2.3.3.)
Focus The contents of the drive or directory highlighted in
color are then displayed as a file list on the right--hand
side of the Navigator.

To select a drive or directory, move the focus to the


desired symbol using the “­” or “¯” arrow key.
To open or close a directory level, press the Enter key.

Further drives and directories are available at expert


level.
Here too you can use the “­”, “¯” arrow keys or the
Enter key.

To switch between the directory structure and the file list, use the “¬” or “®” arrow key.

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5.2.3.2 Attributes display


The attributes display is opened by first selecting a file or folder.

Then select the menu key “File” and the option “Attributes”.

This shows further information regarding the file or directory. Several of these options can
be changed.
The arrow keys “¯” and “­” can be used to move the focus to an input box. You can then enter
text or, using the space--bar, select an option.

To move the cursor within an input box, use the “!” or “z” arrow keys. On the “User data”
page, you can access the parameter values directly by pressing one of these keys.

The softkey “Tab+” or the Tab key on the numeric keypad can be used to switch between the
“General”, “Module info” and “User data” tabs. If you want to use the numeric keypad, the
“NUM” display in the status line must be switched off. If this is not already the case, press
the NUM key next to the numeric keypad.

Using the softkeys “OK” or “Cancel”, you can confirm the changes made or cancel the action.

Alternatively, you can use the Enter or ESC keys.


ESC

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General

The name of the selected file (in this case a module


comprising one “src” and one “dat” file)
Information about the file type (“Dir”, “Archive”,
“Bin”, “Text”, “Module”, “VirtualDir” und “Unknown”),
its path and the total amount of memory occupied

Date and time of file creation, change and most


recent access
Display of the Windows file attributes which can be
changed. More detailed information about this can
be found in Section 5.2.4.
The current edit mode (“Free”, “FullEdit”, “ProKor”
or “ReadOnly”)

Module info

Information about the release, the “src” and “dat” files


and the file type (“RobotSRC”, “SubmitSub” or
“None”)

Status of the file in the Submit interpreter “State 0”


and in the robot interpreter “State 1” (possibilities:
“Unknown”, “Free”, “Selected” or “Active”)
Switching the kernel system attribute “Visibility”.
More detailed information about this can be found in
Section 5.2.4.
User name, max. 30 characters
Additional comment which can be scrolled using the
“¯” and “­” arrow keys if required

User data

Any desired additional information can be anchored


in KRL modules. This could be information about the
version or the template name, for example.

Parameter “Template” and associated information

Name of the parameter


Associated parameter values

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5.2.3.3 Selection list


At present, “Filter” and “Templates” are available in selection lists.

Filter
The menu command “Filter”, which is only available at expert level, opens a window and
offers a choice of the following filter types:

This setting affects the output in the file window

The appearance of the file list changes depending on the filter that is set.

Filter “Module” Filter “Detail”

The arrow keys “¯” and “­” can be used to move the focus to the desired filter.
You can use the softkey bar to switch on the selected filter or cancel the action.

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Template
At expert level, the softkey instruction “New” opens a window and offers one of the following
templates depending on the directory selected:

Which of the templates shown here will be offered


depends on which directory the program is to be created
in. For example, a CELL program can only by created
in the directories “R1” and “Program”.

Here again you have the option of accepting the relevant setting or cancelling the action.

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5.2.4 Directory and file list


The contents of the current drive or directory are displayed as a file list on the right--hand side
of the Navigator.

To select a directory or file,


move the focus to the desired
symbol using the “­” or “¯”
arrow key.

To open or close a directory


level, press the Enter key.

At the expert level, the display of the file list can be influenced through the use of the filter
function. Details can be found in Section 5.2.3.3.

To switch between the directory structure and the file list, use the “¬” or “®” arrow key.

The space--bar can be used to select several files permanently or to cancel selections.

To do so, move the focus to the


desired file using the “¯” or “­”
arrow key and press the space--
bar. The file in question is now
selected.
Press the space--bar again and
the selection is cancelled.
Alternatively, more than one file
can be selected using the key
combination “Shift” + “¯” or
“Shift” + “­”.
The ESC key cancels the
selection of all the files high-
lighted.

Using the filter option “Detail” at expert level, the same file list has the following appearance:

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The contents of the file window can be moved left or right using the keys “Alt” + “¬” or “Alt”
+ “®” in order to enable the desired information to be seen. Alternatively, instead of the “Alt”
key you can use the “Shift” key.

5.2.4.1 Pop--up menu


For each selected object (e.g. program list or data list, etc.) a pop--up menu can be opened
as an alternative to the pull--down menus and softkeys. Only those commands which can
actually be executed at a given moment are available for selection.
There are three different ways of opening the menu:
G Pressing the “!” arrow key;
G Pressing the right mouse button (if a computer mouse is connected);
G Pressing the application key (if a corresponding keyboard is connected to the system).

The pop--up menu, which may look like the example below, is then opened:

Move the focus to the previous/next menu item using the “"” and “#” arrow keys. You can
open a submenu using “!” or the Enter key and close it again using “z” or the ESC key.
Alternatively, you can select a command by pressing the corresponding number on the
numeric keypad. The “NUM” display must be activated in order to do this. The numbers
preceding the individual commands are fixed, i.e. the commands are not dynamically
renumbered. Thus the experienced user need only remember the numbers relevant to him.

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In some circumstances, the pop--up menu cannot be opened. This is the case, for example,
when the attributes display is open.

The pop--up menu can also be used in conjunction with multiple directories or files selected
at the same time.

All the menu items that may appear in the pop--up menu are listed below:
0 Select 0 Without parameters

1 With parameters

1 Edit 0 File

1 Data list

2 Error list

2 Archive

3 Cut

4 Copy

5 Delete

6 Rename

7 Duplicate

8 Attributes

5.2.4.2 Additional information


The following additional information is available to the operator:

The title bar gives details about the type of information displayed. This information can also
be accessed and, to a certain extent, changed using the menu command “File” -->
“Properties”.

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5 Navigator (continued)

Directory or file name

File extension, e.g. “SRC”, “SUB”, “UPG” etc.

The first 10...15 characters of the comment

The existing Windows 95 and kernel system attributes


File size in kilobytes

Number of changes made to the file

Date and time of the last change

Creation date including time

5.2.4.3 Windows 95 and kernel system attributes


The “Windows 95” operating system uses the following file attributes:

Attribute Description Meaning


r Read only File can only be read, not deleted
An attribute used, for example, by backup programs to
a Archive
decide whether or not a file should be saved
h Hidden The file is, by default, not displayed
This system file is necessary for the correct functioning of
s System Windows 95
A number of important KRL files also have this attribute

The kernel system uses the following attributes:

Attribute Description Meaning


R Read File can only be read, not deleted
V Visible This file is visible and is displayed in the sequence window
$ Predefined System file
The program has been selected since the controller was last
P Parent
run up
This file had already been selected once before the controller
O Old father
was last run up
File contains errors; it must be corrected in the editor before
E Error
it can be selected

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5.2.5 Status line


Information about the number of files, their size, path, progress and other status messages
are displayed in the status line of the Navigator. The appearance of the status line depends
on the function called.

Here are several examples showing the possible appearance of the status line:

Contents display (turquoise)

Selection information (turquoise)

Action information (turquoise)

Process cancelled

User dialog (yellow)

User entries (green)

These are confirmed with the Enter key or cancelled by pressing the ESC key.

Request for confirmation (gray)

When a request for confirmation is made, a corresponding line is generated,


which must be answered via the softkey bar.

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5.2.6 Error display


This option is used for error diagnosis and elimination. When the contents of a directory are
read, the program or module, etc., is checked for syntax errors. If any are found, the files
containing errors are displayed accordingly.

Module containing errors

If the focus is moved to a file marked as containing errors, the appearance of the softkey bar
changes as follows:

5.2.6.1 Error list


This softkey opens the error display.

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Additional information concerning the errors that have occurred is listed in the error list.
Title bar with the name of the file

Short description
Error number
Line and column in which the error occurs

Source text line in which the error occurs


Error description

The arrow keys “­” and “¯” can be used to select the desired error.

The following commands are available in the softkey bar:

jump to
This command opens the editor on the left--hand side.

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So that the line numbers in the error list correspond to those in the editor, the options “All
FOLDs op” and “Detail view” must be activated. These functions are available by default
only at the “Expert” user level.

If you wish to open the folds, activate the option “Program” --> “FOLD” --> “All FOLDs opn”.
Then select the command “Configure” --> “Miscellaneous” --> “Detail view on/off”.

The line/column numbers in the error list now correspond to those in the editor, which makes
fault location significantly easier.

If the fault is located within a closed fold, the edit cursor will be positioned on the closed
fold.

When the file is closed, a request for confirmation is generated asking if the file should really
be saved to the hard disk.

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Once the file has been successfully saved, you can verify in the message window whether
the error has been successfully corrected.

Refresh
The error display window is updated, showing the number of errors that have occurred and
the source text.

Close
The error list is closed.

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5.2.6.2 Edit
This command opens the file selected in the file list. This can be either a “SRC” file or a “DAT”
file.

Further information about the “Edit” command can be found in Section 5.3.2.

5.2.6.3 Data list


The “DAT” file belonging to the program is loaded for editing. The data list can then be
modified.

5.2.6.4 Delete

The description of this command can be found in Section 5.4.5.

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5.3 “File” menu


File *1: Not available below the user group ”Expert”
New

Edit File/Directory

*.DAT *1

Error list

Print Current selection

Log book

Archive All

Applications

Machine data
*1
Configure I/O Drivers

I/O Longtexts

KUKA TechPack

Log Data

Current selection

Restore All

Applications

Machine data
*1
Configure I/O Drivers

I/O Longtexts

KUKA TechPack

Current selection UserTech

Rename

Format floppy disk

Attributes

Filter

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Open the menu “File” by pressing the corresponding menu key. The following menu is then
displayed:
*1 The menu command “Filter” is only offered at
expert level.

*1

The following menu commands are available for be selection:

5.3.1 New
To be able to create a folder or module at all, the program window must first be active, i.e.
highlighted in color. If it is not, press the “Window selection” key until the program window
is activated.
The folder or module name can be entered in the input line. This name can have a maximum
of 24 characters. In the case of programs, a comment may optionally be entered.

The symbol next to the input line indicates whether a folder or a file is being created.

Folder Module

Numbers for folder and program names are entered using the numeric keypad on the KCP.
To do this, the “NUM” display in the status line must be deactivated. If this is not the case,
please toggle this function.

The menu command “New” is also available in the softkey bar.

If a program has already been selected or there is a program in the editor, you must first
toggle to the Navigator. No new program can be created until this is done.

5.3.1.1 Create folder

To do this, the focus must be located in the directory structure.

Focus

Then select the command “New” under the menu “File”, or press the corresponding softkey.
Enter the desired name of the folder in the input line.

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Create folder
Folder name

To create the folder, press the softkey “OK” or the Enter key.
The desired file is automatically saved on the hard disk and displayed shortly afterwards in
the file window.

5.3.1.2 Create module


To do this, the focus must be located in the file list.

Focus

Then select the command “New” under the menu “File”, or press the corresponding softkey.
Enter the desired name of the module in the input line.

Create module
Module name
Comment

A comment can be entered along with the program name for the purpose of easier
identification. The relevant input box in the form is accessed using the “®” arrow key. The
first 15 characters of the comment, at most, are displayed in the file list.

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The comment can also be altered later in the attributes display. More detailed information
about this can be found in Section 5.2.3.2.

To accept the program “Prog_10” with the note “Comment”, press the softkey “OK” or the
Enter key.
The desired file is automatically saved on the hard disk and displayed shortly afterwards in
the file window.

By following this procedure, a so--called “skeleton program” will be created, the program
name being shown in the file list.

If a module with this name already exists, a corresponding message is generated in the
message window.

The softkey “Yes” overwrites the existing file

“No” or “Cancel” rejects the current program creation and closes the input
line

At expert level, in addition to modules other program files can be created. For this purpose,
when the command “New” is selected, instead of an input line a window is opened offering
a selection of the various templates available. Further information about filters and templates
can be found in Section 5.2.3.3.

Where possible, create user programs in the directory “R1\Program” in order to ensure that
they are automatically saved via the menu item “File” --> “Archive” --> “Applications”.

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5.3.2 Edit
The selected program or Folge is loaded for editing in the editor.

Once the submenu “Edit” has been selected, the following options are available:

5.3.2.1 Open a subdirectory


To do this, the focus must be located in the folder list.

5.3.2.2 Load file into the editor


While a program is being edited, the robot can at the same time be executing another
program in the background.

Example of an “SRC” file

The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars changes at the same time, in order to make functions available
which are necessary for programming the robot.
If you have opened a program which has so far only been initially created, the so--called
“skeleton program” is displayed in the programming window as the necessary basis for every
program. The following screenshot shows such a skeleton program.

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5.3.2.3 Edit a data list

Example of a “DAT” file

5.3.2.4 Open an error list

Example of an error list

A detailed description of the error list can be found in Section 5.2.6.1.


Further information about programs can be found in the documentation [User Programming],
chapters [Program editing], [Program commands].

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5.3.3 Print
You can use this command to create printouts of the current selection and the logbook. This
can take some time, depending on the amount of data to be printed.

5.3.3.1 Current selection


The selected files are sent to the printer.

File name KRC:\R1\PROG_02.SRC


INI
BAS INI
A20 INI
A10 INI
GRIPPER INI
SPOT INI
TOUCHSENSE INI
USER INI
PTP HOME Vel= 100 % DEFAULT
$BWDSTART = TRUE
$H_POS=XHOME
PDAT_ACT=PDEFAULT
BAS (#PTP_DAT )
FDAT_ACT=FHOME
BAS (#FRAMES )
BAS (#VEL_PTP,100 )
PTP XHOME

PTP P1 Vel= 100 % PDAT1 TOOL:1 BASE:0


$BWDSTART = FALSE
PDAT_ACT=PPDAT1
BAS (#PTP_DAT)
.
.
.

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File name KRC:\R1\PROG_02.DAT


EXTERNAL DECLARATIONS
BAS EXT
EXT BAS (BAS_COMMAND :IN,REAL :IN )
DECL INT SUCCESS
A10 EXT
A20 EXT
GRIPPER EXT
.
.
.

5.3.3.2 Log book


This command sends the logbook, which can be viewed via the menu “Monitor” -->
“Diagnosis” --> “Log book”, to the printer.

.
.
.
#9
----------------------------------------------------------------
08:21:15’254 11.02.2000 No.:5001: File modified /R1/$CONFIG.DAT
SOURCE: System

#10
----------------------------------------------------------------
08:21:15’081 11.02.2000 No.:306: Selection active
Source: System

#11
----------------------------------------------------------------
08:21:14’956 11.02.2000 No.:0: Program KRC:\R1\Prog_02 selected
.
.
.

Detailed information on the logbook can be found in the Operating Handbook, chapter
[Monitor Functions], section [Diagnosis], under “Log book”.

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5.3.4 Archive
This function allows you to save important data to floppy disk.

A request for confirmation is generated which must be answered before the saving process
is carried out.

The selected files are archived

The selected files are not archived

If you try to insert an existing file in an archive, the robot name is checked. The robot name
in the archive is compared with the name that is set in the controller. If the two names are
different, a request for confirmation is generated asking if you really wish to overwrite the
existing archive.

The progress of the operation is displayed in the message window:

Completion of the operation is also indicated:

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5.3.4.1 All
The following files are saved to floppy disk:

All
“KRC:\”
“C:\KRC\Data\”
“C:\KRC\Roboter\Init\”
“C:\KRC\Roboter\IR_Spec\”
“C:\KRC\Roboter\Log\”
“C:\KRC\Roboter\Template\”

The menu command “File” --> “Archive” –> “All” is also offered in the softkey bar.

5.3.4.2 Applications
All programs in the listed folders are saved:

Applications
“KRC:\R1\Program\”
“KRC:\R1\System\”
“KRC:\Steu\$Config.dat”

5.3.4.3 Machine data


The following files and folders can be selected:

Machine data
“KRC:\R1\MaDa\”
“KRC:\Steu\MaDa\”
“KRC:\Steu\$Config.dat”
“C:\KRC\Roboter\Ir_Spec\”

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5.3.4.4 Configure
The configurations of the following technologies are available:

I/O Drivers
“C:\KRC\Roboter\Init\”
I/O Longtexts
“C:\KRC\Roboter\Init\”
KUKA TechPack
The corresponding registry entries are saved here.

5.3.4.5 Log Data


The log book data, which can be viewed using the diagnostic logbook function, are written
to the hard disk.

Log Data
“C:\KRC\Roboter\Log\”

Detailed information on the logbook function can be found in the chapter [Monitor
Functions], in the section [Diagnosis].
For information on printing the logbook data, see Section 5.3.3.

5.3.4.6 Current selection


The selected files are saved on the floppy disk in drive A:\.

The menu command “File” --> “Archive” –> “Current selection” is also available in the
softkey bar.

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5.3.5 Restore
This command enables previously saved ZIP files to be written from floppy back on to the
hard disk.

This function is particularly useful, for example, if programs on the hard disk have become
damaged or if you wish to return a program to its original state after substantial changes have
been made to it. The files on the hard disk are hereby overwritten.
A request for confirmation is thus generated which must be answered before the saving
process is carried out.

The action will then be displayed in the message window:

After a short wait time the end of the operation is shown:

Restoring succeeded

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5.3.5.1 All
All data, with the exception of log files, are loaded from the floppy disk back onto the hard
disk. The I/O drivers are also reconfigured. The user interface is then reinitialized in order
to update any changes, e.g. to the menu structure (MenueKeyUser.ini).
Acknowledge the motion enable following restoration.

All
“KRC:\”
“C:\KRC\Data\”
“C:\KRC\Roboter\Init\”
“C:\KRC\Roboter\IR_Spec\”
“C:\KRC\Roboter\Template\”

The menu command “File” --> “Restore” --> “Restr. All” in the softkey bar has the same
function.

Following reinitialization, the user interface must be reloaded using the command
“Configure” --> “Miscellaneous” --> “BOF Reinitialization” in order to ensure that changes
to the menu structure (MenuKeyUser.ini) are displayed correctly.

5.3.5.2 Applications
The following directories and files are written back on to the hard disk:

Applications
“KRC:\R1\Program\”
“KRC:\R1\System\”
“KRC:\Steu\$Config.dat”

5.3.5.3 Machine data


Only machine data are loaded from the floppy disk.

Machine data
“KRC:\R1\MaDa\”
“KRC:\Steu\MaDa\”
“KRC:\Steu\$Config.dat”
“C:\KRC\Roboter\Ir_Spec\”

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To restore individual files from the floppy disk, move the focus to the “Archive:\” symbol and
open the directory “Disk” (corresponds to drive A:\). Then switch to the data list, locate the
desired files and paste them using the edit functions (“Program” menu). See also Section
5.4.

5.3.5.4 Configure
Only the selected data are loaded back onto the hard disk:
I/O Drivers
“C:\KRC\Roboter\Init\”
I/O Longtexts
“C:\KRC\Data\Kuka_Con.mdb\”
KUKA TechPack
The corresponding registry entries are restored here.
UserTech
“C:\KRC\Roboter\Init\MenueKeyUser.ini”
“C:\KRC\Roboter\Init\SoftKeyUser.ini”
“C:\KRC\Roboter\Template\”

Once the long text database (Kuka_Con.mdb) has been written back onto the hard drive,
the restored version is immediately available.

5.3.5.5 Current selection


Only the selected files or directories in the drive “Archive:\Disk\” are written back to the hard
disk.

The menu command “File” --> “Restore” –> “Current selection” has the same function as
the corresponding softkey.

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The floppy disk drive A:\ can be accessed directly at expert level:

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5.3.6 Rename
The command “Rename” allows you to change the name or the comment line of a program.

In the right--hand Navigator window, select the file or folder that you would like to rename.
Then activate the command “File” --> “Rename” and carry out the desired changes.

You can move to the next input box in the form using the “®” arrow key.

Then confirm the action using the softkey “OK” or the Enter key, or cancel the action by
ESC pressing the softkey “Cancel” or the Escape key.

At expert level the file extension (“SRC”, “DAT” or “SUB”) is shown.

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The renamed file is automatically saved on the hard disk. If a name is entered which already
exists, a corresponding error message is displayed in the message window and the action
is cancelled.

Certain folders cannot be renamed, depending on the particular configuration. In this case,
the menu command and the corresponding softkey cannot be selected.

5.3.7 Format floppy disk


The contents of a 1.44 MB floppy disk in drive A:\ are deleted using Quickformat.

After the menu item “File” --> “Format floppy disk” is selected, a request for confirmation is
generated in the message window, which must be answered.

If the formatting has been completed, a corresponding output is generated in the message
window.

The floppy disk must not be removed from the disk drive until this message has
appeared in the message window and the LED on the disk drive is no longer lit.
Otherwise the disk drive and/or the floppy disk could suffer irreparable damage.

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5.3.8 Attributes

Further information about the attributes display can be found in Section 5.2.3.2.

5.3.9 Filter

More detailed information about the “Filter” can be found in Section 5.2.3.3.

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5.4 “Edit” menu

Edit (*1): Partially unavailable in the user group “User”


Mark all *1: Not available as standard below Expert level
Copy

Paste

Cut

Delete (*1)

Duplicate

Select Without parameters

With parameters *1

Cancel program

Reset program

To open the “Program” menu, press the corresponding menu key. The following menu is then
displayed:

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5.4.1 Mark all


All directories and files in the file list are selected for editing.

The selection of directories or files can only be cancelled if


G another directory is selected in the directory tree,
G the space--bar is pressed when the focus is located on the desired symbol in the file list,
or
G the “ESC” key is pressed.

5.4.2 Copy
Selected directories and files are copied to the clipboard. The copied folders and files can
then be pasted in a different position.

5.4.3 Paste
After a request for confirmation, folders and files from the clipboard are inserted at the current
position (“Copy”), or moved there (“Cut”).

This command is only available if there are data in the clipboard.

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5.4.4 Cut
Selected folders are first copied to the clipboard. When this is done, the icons of the selected
folders will appear dimmed.

The file selection can be canceled using the Escape key.

The copied directories and files can then be pasted in a different position. A request for
confirmation is generated here also.

After being inserted, the folders and files are deleted from their original locations.

5.4.5 Delete
The selected files and directories are irrevocably deleted from the hard disk following a
request for confirmation. If you want to delete a program, it must not be currently selected
or being edited. You might first have to deselect the program or close the editor.
Use the arrow keys to select the program you want to delete, then press the menu command
“Program” --> “Delete”. A request for confirmation appears in the message window.

Several files can be selected for deletion at the same time. To do this, hold down the “Shift”
key while you select the desired files using one of the arrow keys. Files and directories
cannot by default be deleted in the user group “User”. The corresponding softkeys and
menu items cannot be selected.

If you press the softkey “Yes”, the program is deleted. It is then no longer displayed in
the list of programs available.
If you press the softkey “No”, the program remains unchanged.

Pressing the softkey “Cancel” immediately terminates the function.

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The menu command “Delete” is also available in the softkey bar.

Files and directories cannot by default be deleted in the user group “User”.

5.4.6 Duplicate
The option “Duplicate” creates a copy of a program. In order to be able to create a copy, you
must select a file in the program window using the arrow keys “¯” or “­” and then press the
softkey “Duplicate”. A form is then opened in which the name of the selected file is offered
as a suggestion.

Program name
Comment

On the lefthand side of this inline form is the input box “Name”. Here you can enter a name
for your program, up to 24 characters long. This name must begin with a letter.
You can additionally enter a text for this program. To do so, press the “®” arrow key to
position the edit cursor in the box “Comment” and enter the desired comment.
The entries are saved and the form is closed by pressing the Enter key. The desired program
is then created and displayed on the screen.
If you have entered a program name that already exists, an error message is displayed in
the message window:

The menu command “Duplicate” is also available in the softkey bar.

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5.4.7 Select
If you want to execute a program, you can use the menu command “File” --> “Select”. Here
you can test the program thoroughly.

*1: Not available below the user group “Expert”

*1

A selected program can continue to run in the background while at the same time another
program is being processed in the editor.

5.4.7.1 Without parameters


The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars changes at the same time, in order to make functions available
which are necessary for programming the robot.

If you have opened a program which has so far only been initially created, the so--called
“skeleton program” is displayed in the programming window as the necessary basis for every
program. The following screenshot shows such a skeleton program.

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The menu command “Select -- Without parameters” is also available in the softkey bar.

5.4.7.2 With parameters


At expert level, the entry of parameters is also possible. For this purpose the following form
is opened in which the relevant data can be entered:

Additional parameters are necessary if a program requires further entries to be able to run.
If, for example, the program “Test.SRC” contains the header
DEF TEST(INT :IN, BOOL :OUT)
an integer value and a boolean value are transferred when the program is called.

Further information about the program window can be found in the documentation [User
Programming], in the chapter [Program editing].

5.4.8 Cancel program

A program that has previously been selected, i.e. one that is ready for execution, can be
cancelled via the Navigator. A different program can then be loaded for editing.

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5.4.9 Reset program

A program selected in the background can be reset via the Navigator. In this way the program
can be brought back to the initial state it had immediately after it was loaded.

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5.5 “Monitor” menu


You can use the submenu “Windows” to toggle between the Navigator, a selected program,
and the editor. The function is accessed by pressing the menu key “Monitor” and selecting
the submenu “Windows”.

It is then possible to switch between the two windows.

It is also possible to switch between the program, the Navigator and the editor using the
corresponding softkey.

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5.6 Appendix

5.6.1 Keyboard assignment of the Navigator

The keys of the KCP for controlling the Navigator are assigned in such a way that selection
of files and folders can be carried out using one hand.

Function Keys

General

Change window to/from Folder list and


File list

Toggle numeric keypad to enter either


numbers or control characters
Used for entering special characters on
the KCP keyboard
Key for special functions in conjunction with
the Windows operating system

Directory structure

Select drive / folder

Open / close drive or folder

File list

Select folder / file

Open folder
Select / edit / display module
Edit text file

Select a number of adjacent folders or files +

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Select individual folders / files


Cancel a selection

Cancel all selections ESC

Open pop--up menu

Keyboard shortcuts

Copy +

Cut +

Paste +

The keys “SHIFT” and “SYM” remain activated for one keystroke. If more than one special
or control character is required, the corresponding key can also be held down.
For example, if the “Shift” key is pressed once, the next character will automatically be
typed in upper case.

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5.6.2 Default settings at User and Expert levels

Visibility of drives and folders User Expert


KRC:\

R1

MaDa

Program

System

TP

Steu

MaDa

Floppy disk (A:\)

Hard disk (C:\)

CD--ROM drive

Network drives

Archive:\

User privileges when creating folders User Expert


KRC:\

R1

MaDa

Program

System

TP

Steu

MaDa

Filter User Expert

Detail

Module

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Templates User Expert

Cell

Module

Submit

Expert Module

Expert Submit

Function

Default directories Available templates


R1 Cell, Expert, Expert Submit, Function, Module,
Submit
MaDa No

Program Cell, Expert, Expert Submit, Function, Module,


Submit
System Exp., Exp. Submit, Function, Module, Submit

TP Exp., Exp. Submit, Function, Module, Submit

Steu No

MaDa No

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6 Executing, stopping and resetting a program

6 Executing, stopping and resetting a program


A precondition for program execution is that the controller is switched on and the graphical
user interface (GUI) is active. Information on this can be found in the documentation
[Operator Control], in the chapter [Running up / shutting down the controller] and in
[The KUKA Control Panel KCP].

6.1 Selecting and opening a program


When the controller is run up, all programs are loaded from the hard disk into the robot’s main
memory.
In order to make entries when the message window, for example, is active (highlighted in
color), the program window must first be activated using the window selection key.

Use the “¯” or “­” arrow key to select the desired program and then press the softkey “Select”
(at the bottom left of the display). The selected program is then displayed in the program
window.

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6.1.1 Symbols in the program window


Various symbols are used in the program window. Their meanings will be explained in this
section.

Block pointer (program pointer)


The block pointer indicates which line of the program is currently being executed. It is shown
as either a yellow or a red arrow.

Current program line


Block pointer (program pointer)

If you want to place the block pointer on a particular line, first move the edit cursor to the
desired position using the arrow keys “"” or “#”. Then press the softkey “Line Sel”. The block
pointer is then placed on the selected line.

The block pointer is only available when a program has been selected, not in the editor.

The appearance of the block pointer changes to reflect whether or not the program line has
already been executed.
L--shaped arrow (yellow):
The motion instruction is being executed in the forward direction, but has not yet been
completed.

L--shaped arrow (yellow) with plus sign:


Here the block pointer is positioned on a closed fold. The motion instruction is being executed
in the forward direction and has not yet been completed. This display is not available below
the user group “Expert”.

Normal arrow (yellow):


The robot has completed the specified motion instruction in the forwards direction.

Normal arrow (yellow) with plus sign:


Here, too the block pointer is positioned on a closed fold. The motion instruction has been
completed. This display is also not available below the user group “Expert”.

L--shaped arrow (red):


The motion instruction is being executed backwards, but has not yet been completed.

L--shaped arrow (red) with plus sign:


Here the block pointer is positioned on a closed fold. The motion instruction is being executed
backwards and has not yet been completed. This display is not available below the user
group “Expert”.

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Normal arrow (red):


The robot has completed the specified motion instruction in the backwards direction.

Normal arrow (red) with plus sign:


Here, too the block pointer is positioned on a closed fold. The motion instruction has been
completed. This display is also not available below the user group “Expert”.

Edit cursor (Input mark)


The blinking edit cursor indicates the position in the program where changes are being made.

Edit cursor

Characters will, if possible, be inserted or deleted at this position. New commands, on the
other hand, will be inserted below the edit cursor.

Direction indicator
This symbol is displayed if the block pointer is not visible in the program window.

Direction indicator

The symbol indicates the required direction for scrolling to get back to the program pointer.
Double arrow (black) pointing up:
The block pointer is located higher up. Use the arrow key “"” or “PGUP” to scroll up.
Double arrow (black) pointing down:
The block pointer is located lower down. Use the arrow key “#” or “PGDN” to scroll down.

Line breaks
If the command line does not fit in the program window, a line break will be made automati-
cally. This will be marked by a small black L--shaped arrow.

Line break

You can prevent the line break at expert level by activating the option “Configure” -->
“Miscellaneous” --> “Editor” --> “Linebreak ON/OFF”.

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6.1.2 Program status line


The status line of a program which has been selected or which is in the editor shows the oper-
ator additional information about the program.

Program path and name Line, column Icon

Program name
The path and the program name of the program which has been selected or is in the editor.
Line/column
The current line and column position at which the edit cursor is located. Characters entered
will, if possible, be inserted at this position.
Icon
Here the operator can obtain additional information about the loaded program or about
program editing.
Padlock:
The file has been opened in write--protected mode. This means that no changes will be
saved. A selected program, for example, cannot at the same time be processed in the editor.
Likewise, no changes can be made if the opened file has been given the attribute
“ReadOnly”. If you nevertheless want to make corrections to the file, first remove the attribute
“ReadOnly”. To do this, use the option “File” --> “Attributes”. Details can be found in the
section “Navigator”.

Chain:
The file indicated is selected or integrated into the selected program.

Clipboard:
Data have been copied to the clipboard; they can be inserted at another location. Copy
functions are available only at the “Expert” user level and above.

ABC with check mark:


The option “Configure” --> “Miscellaneous” --> “Detail view” is activated. This function too is
available only at the “Expert” user level and above.

PTP:
An existing inline form has been opened by pressing the softkey “Change”.

PTP with star:


A new inline form has been opened.

Crossed--out (green) Start key:


The start interlock is active, i.e. the selected program cannot be started. This is the case for
example when a motion command is being inserted or modified.

Question mark:
A query dialog in the message window must be responded to. For example, deletion of a
block must first be confirmed by the operator.

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6.2 Setting work velocity (program override)

In some cases, e.g. when testing programs, it is of vital importance to reduce the velocity
of the robot. The “Program override” function, for which a status key can be found at the top
right of the display, can be used for this purpose.
The value can be changed using the +/-- key. The current setting is displayed both in the POV
icon in the status key bar and in the status line.

Depending on the configuration, the program override is automatically set to a default value
when the mode selector switch is switched to “T2”.

If you want to change the POV in larger steps, it is advisable to activate the option
“Program--OV Steps on/off” in the menu “Configure” --> “Override”. The value is then no
longer altered in increments of 1% but changes between 1, 3, 10, 30, 50, 75 and 100 per
cent.

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6.3 Stop reactions


If a running program is stopped, the EMERGENCY STOP button pressed or a safety gate
opened, the robot is stopped. The controller distinguishes here between the following states:

6.3.1 Ramp--down braking


The robot is stopped with a normal braking ramp and remains on its programmed path. This
occurs if...
G the “Program start forwards” or “Program start backwards” key has been released in
jog mode, or
G the “Stop” key has been pressed in “Automatic” or “Automatic External” mode (passive
stop);
G the driving condition is no longer present.

6.3.2 Path--maintaining Emergency Stop


The controller attempts to brake the robot on the path with a steeper braking ramp. This
occurs if...
G the Emergency Stop button has been pressed in Automatic mode;
if the Emergency Stop ramp cannot be completed, short--circuit braking occurs.
G the enabling switch has been released;
if the path can no longer be held, the controller switches automatically to the “maximum
braking” state.
G the safety gate to the work cell or the operator safety has been opened in automatic
mode;
if the path can no longer be held, the controller switches automatically to the “maximum
braking” state.
G the drives have been switched off during program execution;
if the path can no longer be held, the controller switches automatically to the “maximum
braking” state.
G the operating mode has been changed during program execution;
if the path can no longer be held, the controller switches automatically to the “maximum
braking” state.

6.3.3 Maximum braking

The robot is no longer on its path. This occurs if...


G an axis exceeds its command velocity or acceleration (the command velocity is lower
in jog mode T1 than in T2 or automatic mode);
G a software limit switch has been reached or a command value has been exceeded.

In order to protect the brakes against overheating, the braking energy is calculated along
with an associated cooling time.
If the braking energy exceeds a certain value, the drives are locked and a status message
is generated in the message window. The message cannot be acknowledged until the
motor brakes have cooled, and only then can the robot motion can be resumed.

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6.3.4 Short--circuit braking (dynamic braking)


The robot is no longer on its programmed path and may have left its positioning window. This
occurs if...
G the Emergency Stop button has been pressed in jog mode (T1 or T2);
G there is an encoder error;
G the controller is switched off or there is a power failure;
G the line between DSE and RDC has been interrupted.

In the event of short--circuit braking or dynamic braking, the holding brakes of the individual
axes are applied while the motion is still in progress. If this happens frequently while the
robot is still moving it leads to significantly increased wear on the holding brakes.

In order to protect the brakes against overheating, the braking energy is calculated along
with an associated cooling time.
If the braking energy exceeds a certain value, the drives are locked and a status message
is generated in the message window. The message cannot be acknowledged until the
motor brakes have cooled, and only then can the robot motion can be resumed.

The system variable “$ON_PATH” provides information about whether the robot is on its
programmed path (“TRUE”) or not (“FALSE”).
The positioning window is an area in space which can be likened to a tube around the
programmed path. Its radius is defined in the system variable “$NEARPATHTOL”.

Further information can be found in the documentation [Configuration], chapter


[Automatic External] in the section [Signal diagrams].

6.3.5 Warning and safety instructions

When safety devices are being used with “path--maintaining braking”, it must be
ensured that no--one enters the working range of the robot while the drives are on.
The optional function “path--maintaining braking in event of operator safety
violation” cannot be used in systems where there is a risk of people being situated
in the working range of the robot during the deceleration time (these include, for
example, light curtains in loading stations).

Before using the function “path--maintaining braking in event of operator safety


violation”, the user must carry out a danger analysis and a risk assessment for
every eventuality.

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6.4 Manual program execution (jog mode)


The descriptions in this section presuppose that a program has been selected. If this is not
the case, please follow the procedure described in Section 6.1.
Set the mode selector switch to mode T1 or T2.

If the option “AutoAck” has been activated, all the acknowledgeable messages displayed
are acknowledged when the Start key is pressed. These include all the actions which
trigger the message “Active commands inhibited” (e.g. moving the robot with the jog keys
or the Space Mouse).

Further information about “AutoAck” can be found in the Administrator handbook.

6.4.1 Program run mode “Go”, “Single Step” or “I--Step”

If you want to execute a program fully, select the setting “Go”. Then hold down one of the
enabling switches (on the back of the KCP) and press the “Program start forwards” key. The
program is executed until either the Start key or the enabling switch is released.

If you want to execute a program step by step, choose the setting “Single Step”. Hold down
one of the enabling switches (on the back of the KCP) and press the “Program start forwards”
key. If the motion block has been completely executed, the “Start” key must be released and
pressed again. The next motion block is then executed.

In expert mode, the option “Incremental Step” is also available. In this mode a program is
executed one line at a time (this also applies for a closed fold, although at first glance nothing
appears to be happening in such a case). In order to advance through the program the
“Program start forwards” key must be released and pressed again at each step.

This symbol indicates reverse traversing using the “Program start backwards” key. This
function cannot be switched manually but appears automatically when the “Program start
backwards” key is pressed. Here again the “Program start backwards” key must be pressed
after every motion command.

The “Program start forwards” key must be held down while the robot is moving, otherwise
the program will be interrupted.

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6.4.2 BCO run


For the purpose of ensuring that the robot position corresponds to the coordinates of the
current program point, a so--called BCO run (block coincidence) is executed. This is carried
out at reduced velocity (10%). The robot is moved to the coordinates of the motion block in
which the block pointer is situated.

This is done...
G after a program reset by means of a BCO run to the home position;
G after block selection to the coordinates of the point at which the block pointer is situated;
G after selection of the “CELL” program before the Automatic External mode can be started;
G after a new program has been selected;
G after modifying a command;
G after jogging in programming mode.

A BCO run is also necessary if the tool center point is located outside the positioning window.
The following examples are intended to illustrate this:

The tool center point is still located on the programmed path after the robot has stopped.
A BCO run is not therefore required.

Tool center point

P5 PTool P6

Positioning window
Programmed path

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The tool center point is situated within the positioning window. A BCO run is not required
here either.

Tool center point

PTool

P5 P6

Positioning window
Programmed path

The robot has left the positioning window. A BCO run must be carried out.

Tool center point Tool center point

PTool BCO run to P6


PTool

P5 P6 P5 P6

Positioning window
Programmed path

If a CIRC motion is left (e.g. through dynamic braking) the necessary BCO run is carried
out directly to the next point.

Tool center point

PTool PTool
BCO run
P5 P5

P6 P6

A BCO run always takes place by the direct route from the current position to the
destination position. It is therefore important to make sure that there are no
obstacles on this path in order to avoid damage to components, tools or the robot!

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6.4.3 Executing individual program lines

First of all ensure that the mode selector switch is in the jog mode position (T1 or T2).
The program starts at the line indicated by the block pointer (yellow arrow) on the left.

Edit cursor
Block pointer (program pointer)

Program execution starts at the line indicated by the block pointer (yellow arrow) on the left.
For the purpose of selecting a particular block in the program, move the edit cursor (vertical
red line) to the desired program line with the aid of the arrow keys.
This causes the block pointer to jump to the selected line. The block pointer jumps to the
selected line.

Now start the program from the selected line. To do this, press one of the enabling switches
(under the KCP) and the “Program start forwards” key.
During program execution, the program pointer (yellow arrow) always moves to the line that
is currently being executed.

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The first program step usually consists of a “BCO run” and must be triggered by pressing
an enabling switch and the Start key. When block coincidence is reached a corresponding
message is generated. At the start of the actual program, release the Start key briefly and
press it again.

The “Program start forwards” key must be held down while the robot is moving, otherwise
the program will be interrupted.

6.4.4 Program start backwards


Using the “Program start backwards” key, a program can be executed in the reverse
sequence.

For reverse traversing, only the operating modes “Test (T1/T2)” are available.

When the “Program start backwards” key is pressed, all outputs, flags and cycflags are
handled according to the configuration in the Backward.ini file.

If a program is executed using the “Program start


forwards” key, the yellow block pointer indicates
the last motion block addressed.

When the “Program start backwards” key is


pressed, the “Program run mode” status key
switches to reverse traversing.
The block pointer, which is now red, then indicates
the last motion block addressed backwards.

Once the corresponding motion block has been reached, the “Program start backwards” key
must be released and pressed again. The next motion block is then addressed.

Forwards and reverse traversing are only possible if BCO (block coincidence) exists.
In the case of reverse traversing, all programmed points are addressed with exact position-
ing. Approximate positioning is not possible here.

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If the robot is moved backwards inside an approximate positioning range, the exact
positioning point of the approximate positioning range is addressed.

P2 (Exact positioning point)

Approximate positioning range

Robot position at change


of direction P3

Forward direction
P1

Overlapping motions, e.g. weaving or sensor corrections, are not supported during reverse
traversing.

If the direction is changed from backwards to forwards between two points, the
outputs of the preceding block are not restored.

6.4.5 Stopping program execution


To stop the program in the jog mode, release the Start key. The program will be stopped
immediately.

6.4.6 Resetting a program (Reset)

With the menu function “Program” --> “Reset program”, a program that has been stopped
or interrupted can be returned to the initial state it had when loaded.

The yellow block pointer then jumps to the first instruction that can be executed in the
indicated program. The selected program can subsequently be restarted.

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After the program has been reset, a BCO run is carried out. This always takes place
by the direct route from the current position to the home position or to the next
point. It is therefore important to make sure that there are no obstacles on this path
in order to avoid damage to components, tools or the robot!

6.4.7 Continuing a program

A program that has been stopped or interrupted can be continued by holding down an
enabling switch and pressing the Start key.

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6.5 Automatic program execution


In normal robot operation, a program is executed cyclically, i.e. when the end of the
program is reached, program execution automatically continues from the beginning of the
program.
The following descriptions presuppose that a program has been selected. If this is not the
case, please follow the procedure described in Section 6.1.

Switch the drives of the robot on.

When a program is running, the menu commands “Configure” --> “I/O Driver” --> “Driver
Reset” and “I/O Reconfigure” are deactivated and cannot be used.

6.5.1 BCO run

Further information can be found in the section [Manual program execution].

Set the mode selector switch to “Automatic” or “Automatic External” mode.

The status line then changes for automatic mode as follows:

In Automatic External mode, the status line has the following appearance:

6.5.2 Stopping program execution


A program can be stopped by pressing the “Program stop” key. The program and the robot
are then stopped.
STOP

If the drives of the robot have been switched off by means of the “Drives OFF” key, the robot
stops and the brakes of the axes are engaged.

6.5.3 Continuing a program


If the drives of the robot have been switched off by means of the “Drives OFF” key, the drives
must first be switched on again before the program can be restarted. This is done by pressing
the “Drives ON” key.

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If the acknowledgement message for a passive stop is displayed in the message window it
must be acknowledged.

The mode must then be set back to “Automatic” or “Automatic External”.

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6.6 Deselecting a program


If you want to deselect a program, press the menu key “Program”. Select the option “Cancel
program” from the menu that is opened.

To check that the program has been deselected, please ensure that the name of the
previously selected program no longer appears in the status bar.

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7 Monitor

7 Monitor
A wide range of functions are grouped together under the menu item “Monitor” giving you
an overview of operating states and settings of the robot system.

After selecting the menu key, this menu is opened:

The individual menu options are described in more detail in the following sections.

More detailed information about the handling of menus, inline forms and status windows
can be found in the chapter [The KUKA Control Panel KCP].

7.1 Inputs/outputs
All of the available inputs and outputs can be viewed and some of them also altered by
choosing the menu item “I/O”.

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7.1.1 Digital inputs


Once this option has been selected a status window is opened, displaying the signal states
of the robot controller’s inputs and the configured long texts.

The name of an input can be changed by pressing the softkey “New Name”. This information
is saved in the long text database and is thus available again next time the status window
is opened.

You can open the status window for displaying the 1024 outputs with the aid of the softkey
“Outputs”. When you have pressed the softkey, its label and function change. You can return
to the status window for displaying inputs by pressing it again.

You can access the desired input directly via the numeric keypad by entering the
corresponding number (e.g. 524) and waiting.

Inputs can be simulated, i.e. set to fixed values, for the purposes of commissioning or in the
event of errors arising. This makes it possible to test robot programs even if the connected
peripheral equipment is not (yet) operational. This function can only be configured at Expert
level.

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7 Monitor (continued)

The designation “SIM” identifies simulated


inputs which may be either set or not set.

The designation “SYS” identifies inputs


whose value are saved in a system
variable.

Further information...
...on simulation of inputs and outputs can be found in the Programming Handbook in the
documentation [Configuration], chapter [Configuring the system, expert], section
[Simulated inputs/outputs].
...on the subject of system variables can be found in the Programming Handbook in the
documentation [Expert Programming], chapter [Variables and declarations], section
[System variables and declarations].

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7.1.2 Digital outputs


After this option has been selected a status window is opened, displaying the signal states
of the robot controller’s outputs.

The red LED symbol indicates that these


outputs are set.

The name of an input can be changed by pressing the softkey “New Name”. This information
is saved in the long text database and is thus available again next time the status window
is opened.

You can switch the output on which the color marker bar is located by pressing the softkey
“Change”. This softkey can only be used as long as one of the enabling switches on the rear
of the KCP is held down. Furthermore, it is not displayed in the operating mode “Automatic”.
You can open the status window for displaying the 1024 inputs with the aid of the softkey
“Inputs”. When you have pressed the softkey, its label and function change. You can return
to the status window for displaying outputs by pressing it again.

You can access the desired output directly via the numeric keypad by entering the
corresponding number (e.g. 524) and waiting. To do this, the function “NUM” must be
activated in the status line.

Outputs can be simulated, i.e. set to fixed values, for the purposes of commissioning or in
the event of errors arising. This makes it possible to test robot programs even if the
connected peripheral equipment is not (yet) operational. This function can only be configured
at Expert level.

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7 Monitor (continued)

The designation “SIM” identifies simulated


outputs which may be either set or not set.

The designation “SYS” identifies outputs


whose value are saved in a system
variable.

Further information...
...on simulation of inputs and outputs can be found in the Programming Handbook in the
documentation [Configuration], chapter [Configuring the system, expert], section
[Simulated inputs/outputs].
...on the subject of system variables can be found in the Programming Handbook in the
documentation [Expert Programming], chapter [Variables and declarations], section
[System variables and declarations].

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7.1.3 Analog Outputs

After this option has been selected a status window is opened, displaying the values of the
32 analog outputs.

The output values (ranging from --10 V to +10 V) are displayed in the boxes.

You can open the status window for displaying the 32 analog inputs with the aid of the softkey
“Tab +”. The values of these inputs cannot be changed.

You can return to the status window for displaying the 32 outputs by pressing the softkey
“Tab +” again.

When the softkey “Change” is pressed, the input box selected using the arrow keys is
opened. Enter the new value by means of the numeric keypad.

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7 Monitor (continued)

Press the softkey “OK” in order to let the new settings take effect. The input box closes again.

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7.1.4 Gripper
After this option has been selected a status window is opened, displaying the signal states
of configured grippers.

The red LED symbol indicates


that this output is set.

The softkeys and status keys described below are only displayed if they have been
activated via the menu item Configure/Status keys/GRIPPERTech.

Using the status key “Manual


The number and type of gripper operation”, you can
gripper that have been se- switch between the configured
lected with the status key functions of the selected
“Gripper” are displayed in the gripper. To do this, one of the
top line of the status window. enabling switches on the back
of the KCP must be held down.

A configured gripper can only be operated in the mode T1 (reduced velocity) or T2


(programmed velocity), with the enabling switch located on the back of the KCP held down.

You can use the two softkeys “Continue” and “Previous” or the status key “Gripper” to page
through the available gripper forms. The indication of the gripper number on the status key
“Gripper” does not change in this case.

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7.1.5 Automatic External


After this option has been selected a status window is opened, in which the signal states of
the “Automatic External” interface can be displayed.

7.1.5.1 Inputs

Status gray: No signal present at this input (FALSE)


Status red: Signal present at this input (TRUE)
Term: Description of the input currently being used

The softkey “Details” changes to a different status window displaying more information: the
type, the name of the variable and the channel number or value.

The type can be a variable (yellow) or an input (green).

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The variable or system variable (“$”) or the name of the input

The value of the input or the channel number

“Normal” switches back to the short version of the display.

The softkey “Outputs” takes you to the corresponding page.

The status window is closed by means of the softkey “Close”.

7.1.5.2 Outputs

Start conditions
This page contains all the status information relevant to the start.

Status gray: No signal present at this output (FALSE)


Status red: Signal present at this output (TRUE)
Term: Description of the output currently being used

You can page through the various pages of the “Outputs” display with the aid of the softkeys
“Tab+” and “Tab--”.

The softkey “Details” changes to a different status window displaying more information: the
type, the name of the variable and the relevant output.

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7 Monitor (continued)

The type can only be an output (green).

The variable or system variable (“$”)

The value of the output being used

“Normal” switches back to the short version of the display.

The softkey “Inputs” takes you to the corresponding page.

The status window is closed by means of the softkey “Close”.

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Program state
This page contains all the variables that are relevant to the program state.

Robot position
Here you will find a list of robot positions including, for example, the various HOME positions.

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Operation mode
The operating mode currently active is displayed on the last page.

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7.2 Rob. Position


You can display the position of the robot by using the menu item “Rob. Position”.
The following position displays can be selected:

7.2.1 Cartesian
This status window displays the current position of the robot in Cartesian mode. If the status
window remains open, you can constantly follow the position and orientation while the robot
is in motion.
Cartesian display
With this display mode, the position of the tool center
point (TCP) is displayed in relation to the WORLD
coordinate system in the base of the robot and the
rotational offset between the two coordinate systems.
The entries for “Status” and “Turn” are also displayed.

You can switch between the various windows at any time by pressing the softkeys
“Cartesian”, “Axis spec.” and “Increment”.
You can exit and close the status window by pressing the softkey “Close”.

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7.2.2 Joint
This status window displays the current position of the robot in joint (axis--specific) mode.
If the status window remains open, you can constantly follow the values of the axis angles
while the robot is in motion.

Axis--specific (joint) display


The rotational offset of each robot axis is displayed
here in relation to its zero position determined during
mastering.

You can switch between the various windows at any time by pressing the softkeys
“Cartesian”, “Axis spec.” and “Increment”.

You can exit and close the status window by pressing the softkey “Close”.

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7.2.3 Incremental
This status window displays the current position of the robot in increments. If the window
remains open, you can read the current display while the robot is in motion.

Incremental display
Values for the increments supplied by the axis drives
are displayed here.

You can switch between the various windows at any time by pressing the softkeys
“Cartesian”, “Axis spec.” and “Increment”.
You can exit and close the status window by pressing the softkey “Close”.

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7.2.4 Master/slave display

The angular momentum of the master/slave drives


is shown in this status window.

You can switch between the display modes at any time by pressing the softkeys
“Mas./Slave”, “Cartesian”, “Axis spec.” and “Increment”.
You can exit and close the status window by pressing the softkey “Close”.

The softkey “Mas./Slave” and the associated status window are only displayed if the
corresponding options are installed.

If the status window remains open, you can constantly follow the position and orientation
while the robot is in motion.

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7.3 Variable

7.3.1 Single

After this option has been selected a status window is opened, in which the values of the
variables are displayed and can be altered.

List boxes are opened


by means of the key
combination ALT + ¯.

To change the value of a variable, position the cursor in the input box “Name”, using the
softkey “Name” and enter the name of the variable you wish to change. Then press the Enter
key to confirm this.

The value the variable had when you pressed the Enter key is now displayed in the box
“Current value”. If this is not the case, please check the messages in the message window.
As long as the cursor remains in the box “Current value”, the arrow keys “¯” and “­” can be
used to scroll through the list of variables being edited and/or displayed.

Now press the softkey “New Value” to position the cursor in the input box “New Value”. Enter
the new value for the variable and confirm this by pressing the Enter key again.

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After your entry has been accepted by the controller, the new value is displayed in the box
“Current value”. If this is not the case, please check the messages in the message window.
In the basic setting, the search for the specified variable begins in the program currently
selected. If it is not found here, all global data lists are searched.

If you wish to search for the variable in a program other than the one currently selected, you
need to press the softkey “Module”. The input box of the same name is opened. Enter the
file path here for the program you wish to search.

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7.3.2 Overview
7.3.2.1 Monitor
After this option has been selected a status window is opened. The groups of variables
entered in the file ConfigMon.ini are displayed here.

The box “Status” indicates whether or not the line is updated automatically. This symbol is
displayed if the display is updated automatically.
The name of the input or output is displayed in the box “Name”.
If the box “Variable” exists, the name of the corresponding system variable is displayed.
Value gray: No signal present at the input or output (FALSE)
Value red: Signal present at the input or output (TRUE)

The arrow keys can be used to select a specific element in the group and make certain
modifications. This is done by pressing the softkey “Change”.

It is possible to see from the tabs at the bottom of the status window whether or not further
display groups are available.

If there is at least one other group available, you can toggle to this page using the softkey
“Tab+”. Otherwise, this softkey is deactivated.

The softkey “Config.” is available in the user group “Expert” or higher and enables the
configuration of individual groups.

The softkey “Refresh all” is used to update the display.

The softkey “start info” activates the automatic updating of the selected element. “Cancel
Info” can be used to deactivate the continuous automatic updating function.

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Elements selected using the arrow keys can be modified by pressing the softkey “Change”.
This applies to the names of inputs/outputs and the setting of outputs to “TRUE” or “FALSE”.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

Pressing “Save” saves the current changes in the file “ConfigMon.ini” and closes the status
window. The changes that have been saved are displayed again next time the window is
opened.

The variable display is closed using the softkey “Cancel”.

The values of write--protected variables cannot be changed.


If the current user group is lower than the entry in the “ConfigMon.ini” file, under “ Editable”,
the softkey “Change” cannot be pressed.

Information on configuring the display via the “ConfigMon.ini” file can be found in the
Programming Handbook in the documentation [Configuration], chapter [Configuring
the system, Expert].

7.3.2.2 Configure
This menu item is not available below the user group “Expert”.

Information on this command can be found in the Programming Handbook in the


documentation [Configuration], chapter [Configuring the system, Expert].

7.3.2.3 Display
This menu item is also not available below the user group “Expert”.

Information on this command can be found in the Programming Handbook in the


documentation [Configuration], chapter [Configuring the system, Expert].

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7.3.3 Cyclic Flags


After this option has been selected a status window is opened, displaying the signal states
of the 32 cyclical flags, also called “Notices”.

Gray: The cyclical flag is not set


Red: The cyclical flag is set
The number of the cyclical flag in question is displayed in the box “No”.
A description of the cyclical flag is displayed in the box “Name”.
The text stored for this cyclical flag is displayed in the lower section of the window.

The name of the cyclical flag selected using the arrow keys can be modified by pressing the
softkey “Change”; up to 40 characters are permitted here.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

More detailed information on the use and programming of cyclical flags can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [System variables and system files] and in the
chapter [Interrupt handling], section [Use of cyclical flags].

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7.3.4 Flags
After this option has been selected a status window is opened, displaying the states of all
999 flags.

Gray: The flag is not set


Red: The flag is set
The number of the flag in question is displayed in the box “No”.
The name of the flag is displayed in the box “Name”.

You can switch the flag on which the color marker bar is located by pressing the softkey
“Change”.
The name of the flag selected using the arrow keys can be modified by pressing the softkey
“Name”; up to 40 characters are permitted here.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

More detailed information on the use and programming of flags can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [System variables and system files].

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7.3.5 Counter
After this option has been selected a status window is opened, displaying the values of the
counters already configured.

After pressing the softkey “Value”, you can enter a new value for the selected counter using
the numeric keypad.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

The name of the counter can be modified using the softkey “Name”. The name may consist
of a maximum of 40 characters.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

If you close the status window without having pressed the softkey “OK” beforehand, the
changes will not be saved.

More detailed information on the use and programming of counters can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [Boxes].

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7.3.6 Timer
After this option has been selected a status window is opened, displaying the values and
operating states of all 10 timers.

Red: This timer is deactivated and set to a value ± 0


Red with check: This timer is deactivated and set to a value > 0
Green: This timer is activated and running in the range ± 0
Green with check: This timer is activated and running in the range > 0

The softkey “Change” starts the selected timer or stops one that is running.

After pressing the softkey “Value”, you can enter a new value for the selected timer using the
numeric keypad.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

The name of the timer can be modified using the softkey “Name”. The name may consist of
a maximum of 40 characters.

The softkey “OK” is used to accept the changes that have been made.

The softkey “Cancel” is used to reject the changes.

If you close the status window without having pressed the softkey “OK” beforehand, the
changes will not be saved.

More detailed information on the use and programming of timers can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [Timer].

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7.4 Diagnosis
The following functions are grouped together under the menu item “Monitor” --> “Diagnosis”:

Menu Function
Oscilloscope Recording and displaying motion data or the signal states of
inputs and outputs.
Log book Displaying logged operator actions on the KCP.
CROSS Log book Displaying log files of the trace program “KUKA Cross” that
(only in “Expert” mode) runs in the background and (depending on the configuration)
records a number of actions.
Caller Stack Menu--assisted monitoring of the advance run and main run
(only in “Expert” mode) pointers, and also “Arrived at point” and “Move to point”.
Interrupts List of all declared robot and submit interrupts.
(only in “Expert” mode)
Securitycircuit Starting the ESC diagnostic program which can be used to
(safety circuit) check the safety circuit of the robot.
Web Diagnosis Web--based diagnosis

The diagnostic functions are accessed by pressing the menu key “Monitor” and then
selecting the submenu “Diagnosis”.

Select the desired diagnosis function from the open submenu.

The menu items “CROSS Logbook”, “Caller Stack” and “Interrupts” can only be seen in the
user group “Expert”.

More detailed information about the handling of menus, inline forms and status windows
can be found in the chapter [The KUKA Control Panel KCP].

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7.4.1 Oscilloscope
The function “Oscilloscope” is used to record motion data or the status of the controller’s
inputs and outputs. These data are required for setup, optimization and troubleshooting, for
instance.
Up to twenty channels, which can then be viewed and analyzed later, can be traced at the
same time. An additional function allows two traces to be “superposed” on each other.

A detailed description of this function may be found in the Electrical Servicing handbook,
in the main chapter Diagnostic Functions, chapter [Oscilloscope].

7.4.2 Log book


The submenu “Logbook” displays on the KCP certain logged operator actions carried out by
the user. You can access this function by pressing the menu key “Monitor” and then selecting
the submenu “Diagnosis” and activating the “Logbook” option contained within it.

7.4.2.1 Display
Once this option has been selected, a status window is opened, in which information about
the configuration, logbook list and filter types can be viewed and modified.

Info
The user can view the current configuration in the Info display.

Configuration

Controller version

Robot name

Log book manager version

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The user can switch between the logbook, the filter and the information display by pressing
the softkey “Tab +”. The “TAB” key on the numeric keypad can be used for the same purpose.
To do this, however, the “NUM” display in the status line must be deactivated.
The logbook display can be terminated at any time using the softkey “Cancel”.

Log
Selecting this option opens a status window displaying, on the KCP, the operator actions that
have been carried out by the user and logged in a file.
The status window consists essentially of two main areas. The first area displays the type
and number of the log event along with a brief description, while the second area contains
more detailed information.

Area displaying type, number and


description of the log event.

Area with detailed description of the


log event

Area in which the selected filters are


displayed.

The log book can be evaluated online or offline. Software module debug information,
process data and robot characteristic data such as motor currents, command values, etc.
are not recorded.

If the text in the lower part of the status window is too big to fit in the display, you can scroll
through the display line by line using the status key “Detail” or the keyboard shortcut “ALT”
+ “Cursor” ¯ or ­.

The symbols in the log book display have the following meaning:

Icon Shape/color Content Type of log entry


round/yellow Warning during user operation

octagonal/ Error during user operation


Arm with hand
red
square/blue Information during user operation
round/yellow Robot kernel system warning
octagonal/ Robot kernel system error
red Robot
square/blue Robot kernel system information

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round/yellow Warning during boot procedure

octagon/red Arrow Error during boot procedure


square/blue Information during boot procedure
round/yellow Warning during installation
octagon/red Wrench Error during installation
square/blue Information during installation
round/yellow Program--generated warning

octagon/red Hammer Program--generated error

square/blue Program--generated information

The user can switch between the logbook, the filter and the information display by pressing
the softkey “Tab +”. The “TAB” key on the numeric keypad can be used for the same purpose.
To do this, however, the “NUM” display in the status line must be deactivated.
The information in the logbook is saved in a text file. The path and name of this file can be
set via “Log book” --> “Configure”. The default setting here is “C:\KRC\Roboter\Log\Log-
buch.txt”.
The softkey “Page +” displays the next page up. Alternatively, the “PGDN” key on the numeric
keypad can also be used.
The softkey “Page --” displays the next page down. The “PGUP” key on the numeric keypad
can also be used here.

Refresh The softkey “Refresh” updates the status window with the current data. This option is very
useful if other actions have been carried out in the meantime.
The log book display can be terminated at any time using the softkey “Cancel”.

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Filter
Using this status window, the user can select the filter types and classes to be listed in the
logbook.

The user can switch between the logbook, the filter and the information display by pressing
the softkey “Tab +”. The “TAB” key on the numeric keypad can be used for the same purpose.
To do this, however, the “NUM” display in the status line must be deactivated.
The softkey “Mark” can be used to confirm the filter type or class selected using the arrow
keys. This causes a check mark to appear or disappear in the corresponding box.
After completing your selection, press the softkey “Apply”.

The log book display can be terminated at any time using the softkey “Cancel”.

At least one filter type and one filter class must be selected, otherwise a corresponding
error message will appear when “Apply” is pressed.

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7.4.2.2 Configuration
After this option has been selected a status window is opened for configuring the logbook.

Number of logbook entries

Output as per filter


Path and name of the file

The maximum number of logbook entries is defined in the upper box of the window. You can
move to the lower box “Print / Output to file” by using the arrow keys. You can now use the
space--bar to select or deselect “Apply filter”. The path and the name of the desired logbook
file can be specified in the box “Filename”.
The softkey “OK” saves all changes and closes the configuration window.

The status window can be closed at any time by means of the softkey “Cancel”.

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7.4.3 CROSS Log book


This function displays the trace program “KUKA--Cross” that runs in the background.

A detailed description of this function may be found in the Electrical Servicing handbook,
in the main chapter [Diagnostic Functions].

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7.4.4 Caller Stack

This menu item is not available below the user group “Expert”.

How to change user group is described in the Programming Handbook, in the


documentation [Configuring the system], chapter [The “Configure” menu], section
“User group”.

This function evaluates the data for the process pointer ($PRO_IP) and displays them as
text. After this option has been selected, a status window is opened.
The following items are listed individually:

Call number

If the call is caused by an interrupt

Module name

Line number of the jump

Line contents

A summary of the information from above is displayed in the lower line.

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The softkey “jump to” can be used to open the selected call and display the corresponding
line with a gray background.

“Refresh” updates the caller stack.

The softkey “Close” terminates the function and closes the status window.

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7.4.5 Interrupts

This menu item is not available below the user group “Expert”.

How to change user group is described in the Programming Handbook, in the


documentation [Configuring the system], chapter [The “Configure” menu], section
“User group”.
When the menu item “Interrupts” is selected, a status window opens showing a list of
declared “robot” interrupts. Information is provided about priority (from 1 to 128), scope
(global, local), type (standard, stop, measure, error stop and trigger), module name with path
specification and the line number of the individual interrupt.

Interrupt type
Local or global interrupt
Priority
Interrupt category

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The interrupts are shown as symbols, which are explained in the table below:

Icon Shape/color/contents Nature of interrupt


Square / gray / -- Inactive interrupt
Square / red / D Active, disabled interrupt
Square / green / E Active, ON interrupt

You can obtain information about the Submit interrupts with the aid of the softkey “Submit”.
They are listed in the same way as the “Robot” interrupts. This softkey changes back and
forth between Submit and Robot.
Pressing this softkey updates the display.

To exit this menu, press the softkey “Close”.

Further information on the topic “Interrupts” may be found in the Programming Hand-
book, in the documentation [Expert Programming], chapter [Interrupt handling].

7.4.6 Safety circuit


This external program allows diagnosis of the safety circuit of the robot in question.

A description of the “Securitycircuit” function may be found in the Electrical Servicing


handbook, in the main chapter [Diagnostic Functions] chapter [Safety circuit].

7.4.7 Web Diagnosis


This function is used for remote diagnosis.

Further information about the Web Diagnosis function can be found in the Administrator
handbook.

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7.5 Windows

When Navigator, Program or Editor is selected, the corresponding window will be brought
to the foreground. If no program is selected, or nothing is present in the editor, these items
will be shown as inactive in the upper menu.

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7.6 Help
The “Help” menu offers the options “Online help”, “Online Help -- Contents/Index” and “Info”.

The window selection key will not work as long as the online help function is displayed.

If an external keyboard is connected, you can also call the online help function by pressing
function key “F1”.

7.6.1 Online help


The online help function gives additional information about messages selected in the
message window, the logbook display, the error display and inline forms. The element about
which you require information must be selected.
If the message window in which the element is located is inactive, first you must switch to
it using the window selection key. You can then highlight the desired message using the arrow
keys.

7.6.1.1 Message window


Select the desired message using the arrow keys.

Then activate the online help function.

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If the contents of the help window cannot all be displayed at one time, use the arrow keys
to page through the contents.

Use the softkey “Close” to exit the online help function and return to normal operation.

7.6.1.2 Log book


Select the desired message in the logbook using the arrow keys.

Then activate the online help function.

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If the contents of the help window cannot all be displayed at one time, use the arrow keys
to page through the contents.

Use the softkey “Close” to exit the online help function and return to normal operation.

7.6.1.3 Inline forms

Open an inline form for which you require a more detailed description. This may be a new
or existing motion command, for example.

Then activate the online help function.

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If the contents of the help window cannot all be displayed at one time, use the arrow keys
to page through the contents.
Use the softkey “Close” to exit the online help function and return to normal operation.

7.6.1.4 Error display


Use the arrow keys to select the line containing the error in question.

Then activate the online help function.

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If the contents of the help window cannot all be displayed at one time, use the arrow keys
to page through the contents.
Use the softkey “Close” to exit the online help function and return to normal operation.

7.6.2 Online Help -- Contents/Index


Here you can make targeted searches for information in the table of contents or index of the
online help function.

After this option has been selected the corresponding window appears on the user interface.

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The left--hand side of the window shows a list of contents or the index, while the right--hand
side displays the corresponding help messages. The following navigation options are
available:

The arrow keys “"” and “#” can be used to select a subject, or to page through the help
messages.

The arrow keys “!” and “z” or the Enter key can be used to open or close a subdirectory.

Once you have selected a subject, press the Enter key to display the corresponding help
page.

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Use this softkey to switch between Contents/Index and the corresponding help page. You
can then use the arrow keys to page through the subjects and/or help messages. If the focus
is on the left--hand side of the page, the Contents/Index is active; otherwise the help page
is active.

Contents/Index active Help page active

Pressing the softkey “Index” brings you to the overall index of the online help function. Typing
one or more letters in the input line will cause the list to be scrolled forward immediately to
the appropriate location.

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To avoid having to type in the entire term, you can use the arrow keys to scroll the focus up
or down a line at a time.

Once you have found the desired term, press the Enter key or the “Display” button. The help
page will then appear on the right--hand side of the display.

Pressing the softkey “Contents” takes you to the table of contents which is displayed by
default when the online help function is started.

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Press the softkey “Close” to end the online help function and return to normal operation.

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7.6.3 Info

This command displays the following version information:

Type of controller

General version number

GUI version

x... Kernel system version

User text

Manufacturer

The softkey “Tab+” takes you to the next page in which information about the robot is
displayed.

Robot name
Robot type and configuration

List of external axes (if


present) showing axis
number and name

Machine data version

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The next page contains information about the system.

Computer name

System version information

127MB 74,0%
Memory information
3097MB

Pressing the softkey again opens the next available page in which additionally installed
options, such as “MeasureTech” and “LaserCut” are listed.

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Additional comments can be found on the next page.

Space for additional comments

The next page contains information about the modules used.

Versions of the modules


present

The softkey “Save” allows you to send the module information to a text file. This, by default,
is the file “C:\KRC\Roboter\Log\ocxver.txt”.

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The last page contains information about the virus scanner running in the background.

The softkey “Export” allows you to send information about the virusscan-
ner to the file “C:\KRC\Roboter\Log\VirusInfo.xml”.

The version display is closed using the softkey “Close”.

Should you encounter any difficulties with your robot system, please quote the relevant
version numbers when making inquiries.

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8 Menu structure

8 Menu structure
8.1 General
The menus provided by the “KUKA System Software” can be opened by pressing the
corresponding menu key.

Menu bar Menu key

For further information about operator control please refer to the chapter [The KUKA
Control Panel KCP].

The following commands are available to you via the KUKA software menu bar:

Depending on whether the Navigator, Programming, or Editor level is being used, the menu
keys “Setup”, “Commands” and “Technology” will be activated or deactivated.

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You can open the menus shown below by pressing the corresponding menu key and select
the desired function from the submenu which then opens.

Menu key Options Section


File File operations and display 8.2

Program Commands relating to program creation and editing 8.3

Configure Inputs/outputs, drivers and other system settings 8.4

Monitor Monitor functions for inputs/outputs, position, counters, 8.5


variables and diagnosis
Setup 1) Mastering, calibration and service functions 8.6

Commands 2) Motion and logic commands, KRL Assistant 8.7

Technology Technology commands ARC Tech, SPOT Tech, GRIPPER 8.8


Tech, TOUCH Sense, USER
Help Version information and online help 8.9

1) No program may have been selected or loaded into the editor


2) This function is only available within a program

Whether or not specific submenus and commands can be accessed depends on the user
group that is being used.

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8 Menu structure (continued)

8.2 File
New
User group “Expert”

Open File/Folder
*.DAT
Errorlist

Print Current selection


Log book

Archive All
Applications
Machine data
Configure I/O Drivers
Log Data I/O Longtexts
Current selection KUKA TechPack

Restore All
Applications
Rename Machine data
Configure I/O Drivers
Format floppy disk Current selection I/O Longtexts
KUKA TechPack
Attributes User Tech

Filter

User group “User”


New

Open File/Folder
*.DAT
Errorlist

Print Current selection


Log book

Archive All
Applications
Machine data
Configure I/O Drivers
Log Data I/O Longtexts
Current selection KUKA TechPack

Restaure All
Applications
Rename Machine data
Configure I/O Drivers
Format floppy disk Current selection I/O Longtexts
KUKA TechPack
Attributes User Tech

Filter

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New

New
Creation of new files and subdirectories1) MC [Operator Control],
Ch. [Navigator]
1) Not available in the user group “User”.

Open File/Folder
*.DAT
Errorlist

Open
» File/Folder MC [Operator Control],
Opens the selected folder Ch. [Navigator]
Loads the source file of a selected module (*.SRC) into the
editor
» *.DAT
Opens the data list (*.DAT) of a selected file in the editor
» Errorlist
Opens a list of errors that have been detected in the selected
file

Print Current selection


Log book

Print
» Current selection MC [Operator Control],
The selected files are printed Ch. [Navigator]
[ g ]
» Log book
The logbook entries are printed

Archive All
Applications
Machine data
Configure I/O Drivers
Log Data I/O Longtexts
Current selection KUKA TechPack

Archive
» All MC [Operator Control],
All files are saved to floppy (Ini, MaDa, etc.) Ch. [Navigator]
[ g ]
» Applications
Saves the applications (*.SRC, *.DAT) to floppy
» Machine data
Only saves the machine data to floppy

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8 Menu structure (continued)

» Configure 1) MC [Operator Control],


» I/O Drivers Ch. [Navigator]
Saves the I/O drivers to floppy
» I/O Longtexts
Saves the long text database
» KUKA TechPack
Saves certain registry entries to floppy
» Log Data
Saves the logbook files to floppy disk
» Current selection
Saves selected files and directories to floppy
1) Not available in the user group “User”.

Restore All
Applications I/O Drivers
Machine data I/O Longtexts
Configure KUKA TechPack
Current selection User Tech

Restore
» All MC [Operator Control],
All data, with the exception of log files, are loaded from the Ch. [Navigator]
floppy disk (Ini, MaDa, etc.).
» Applications
The saved applications are loaded back from the floppy disk
onto the hard disk (*.SRC, *.DAT)
» Machine data
Only machine data are loaded from the floppy disk to the
controller
» Configure 1)
» I/O Drivers
Only the I/O drivers are loaded from the floppy disk
» I/O Longtexts
The I/O list is loaded from the floppy disk
» KUKA TechPack
Restores certain registry entries
» User Tech
UserTech--specific data are restored
» Current selection
Selected files are loaded back onto the hard disk
1) Not available in the user group “User”.

Rename

Rename
The name of the selected file can be altered MC [Operator Control],
Ch. [Navigator]

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Operator Control

Format floppy disk

Format floppy disk


The floppy disk in the disk drive is formatted MC [Operator Control],
Ch. [Navigator]

Attributes

Attributes 2)
Details about type, path, size, creation, attributes, edit mode and MC [Operator Control],
comment for the selected file Ch. [Navigator]
2) Not available for program editing

Filter

Filter 1) 2)

Display variants for file components MC [Operator Control],


Ch. [Navigator]
1) Not available in the user group “User”.
2) Not available for program editing

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8 Menu structure (continued)

8.3 Program...
The “Program” menu appears differently at the Navigator, Programming and Editor levels.
8.3.1 “Program” in the navigator
User group “Expert” User group “User”

Mark all Mark all

Copy Copy

Paste Paste

Cut Cut

Delete Delete

Duplicate Duplicate

Select Without parameters Select Without parameters


With parameters With parameters
Cancel program Cancel program

Reset program Reset program

Mark all

Mark all
All files in the selected folder are highlighted. MC [Operator Control],
Ch. [Navigator]

Copy

Copy 1)
Selected files are copied to the clipboard. MC [Operator Control],
Ch. [Navigator]
1) Not available in the user group “User”.

Paste

Paste 3)

Files from the clipboard are inserted at the current position MC [Operator Control],
Ch. [Navigator]
3) Only available if a file has first been copied or cut

Cut

Cut
The selected files are deleted from their original position and MC [Operator Control],
copied to the clipboard Ch. [Navigator]

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Operator Control

Delete

Delete
All selected files are permanently deleted after a request for MC [Operator Control],
confirmation Ch. [Navigator]

Duplicate

Duplicate
The selected file is copied into the current folder under a different MC [Operator Control],
name Ch. [Navigator]

Select Without parameters


With parameters

Select
» Without parameters MC [Operator Control],
The program is selected without function parameters. Ch. [Navigator]
[ g ]
» With parameters
The function parameters are transferred when the program is
selected.

Cancel program

Cancel program 2)
The selected program is closed. MC [Operator Control],
Ch. [Navigator]
2) Only available if a program has been selected

Reset program

Reset program 2)
The initial state of the program after loading is restored. MC [Operator Control],
Ch. [Navigator]
2) Only available if a program has been selected

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8 Menu structure (continued)

8.3.2 “Program” at programming level

User group “Expert” User group “User”

FOLD Current FOLD opn/cls FOLD Current FOLD opn/cls


all FOLDs opn all FOLDs opn
Copy all FOLDs cls Copy all FOLDs cls

Paste Paste

Cut Cut

Delete Delete

Find Find

Replace Replace

Cancel program Cancel program

Reset program Reset program

Modify A10 Online Modify A10 Online


Points in TTS Points in TTS

FOLD Current FOLD opn/cls


all FOLDs opn
all FOLDs cls

FOLD 1)

» Current FOLD opn/cls HB Progr. Handbook


The fold in the current program line is opened or closed. MC [Expert
[ p Progr.]g ]
» all FOLDs opn Ch [General
Ch. [G l iinforma-
f
Opens all FOLDs in the selected program. tions on KRL pro-
grams]
» all FOLDs cls
Closes all FOLDs in the selected program.
1) Not available in the user group “User”.

Delete

Delete
After a request for confirmation, the line in which the edit cursor MC [User Progr.]
is situated is deleted. Ch. [Program editing]

Find

Find
It is possible to search the current program for a search string. MC [User Progr.]
Ch. [Program editing]

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Operator Control

Cancel program

Cancel program 3)
The selected program is closed. MC [User Progr.]
Ch. [Program editing]
3) Only available if a program has been selected

Prog. zurücksetzen

Reset program 3)
The initial state of the program after loading is restored. MC [User Progr.]
Ch. [Program editing]
3) Only available if a program has been selected

Modify A10 Online


Point in TTS

Modify 1)
» A10 Online 2) HB ArcTech10
Zusätzliche Option für die Technologie “ARC Tech 10”
» Points in TTS MC Expert Programming
Various online modification options for programs and motion Ch. [External editor]
commands.
1) Not available in the user group “User”.
2) Available if the technology package ArcTech10 has been loaded

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8 Menu structure (continued)

8.3.3 “Program” in the editor


User group “Expert” User group “User”

FOLD Current FOLD opn/cls FOLD Current FOLD opn/cls


all FOLDs opn all FOLDs opn
Copy all FOLDs cls Copy all FOLDs cls

Paste Paste

Cut Cut

Delete Delete

Find Find

Replace Replace

Close Close

FOLD Current FOLD opn/cls


all FOLDs opn
all FOLDs cls

FOLD 1)

» Current FOLD opn/cls HB Progr. Handbook


The fold in the current program line is opened or closed. MC [Expert
[ p Progr.]g ]
» all FOLDs opn Ch [General
Ch. [G l iinforma-
f
Opens all FOLDs of the program loaded in the editor. tions on KRL pro-
grams]
» all FOLDs cls
Closes all FOLDs in the program loaded in the editor.
1) Not available in the user group “User”.

Copy

Copy 1)
The program line selected via the edit cursor is copied to the HB Progr. Handbook
clipboard. MC [Expert Progr.]
Ch. [General informa-
tions on KRL pro-
grams]
1) Not available in the user group “User”.

Paste

Paste 1)
Data from the clipboard are inserted at the current position. HB Progr. Handbook
MC [Expert Progr.]
Ch. [General informa-
tions on KRL pro-
grams]
1) Not available in the user group “User”.

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Operator Control

Cut

Cut 1)
The program lines selected by means of the edit cursor are HB Progr. Handbook
deleted from their original position and copied to the clipboard. MC [Expert Progr.]
Ch. [General informa-
tions on KRL pro-
grams]
1) Not available in the user group “User”.

Delete

Delete
After a request for confirmation, the line in which the edit cursor MC [User Progr.]
is situated is deleted. Ch. [Program editing]

Find

Find
Search the current program for a specified search string MC [User Progr.]
Ch. [Program editing]

Replace

Replace 1)
Search and replace program sections in the editor. HB Progr. Handbook
MC [Expert Progr.]
Ch. [General informa-
tions on KRL pro-
grams]
1) Not available in the user group “User”.

Close

Close
The editor is closed. MC [User Progr.]
Ch. [Program editing]

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8 Menu structure (continued)

8.4 Configure

Gripper User goup “Expert”


I/O Automatic External

I/O Driver Edit Config.


Start/select Driver Reset
SUBMIT--Interpr. Stop I/O Reconfigure
Cancel
Statuskeys GRIPPER Tech
ARC Tech 10
Jogging Prog.--OV--Steps ARC Tech 20
Jog.--OV--Steps
User group Mouse position
Mouse configuration
Cur. tool/base
Tool type
Tool definition Base type
External Axis Force cold Startup
On/Off options PowerOff Delay
Language
Miscellaneous Change password Def--line
Editor Detail view on/off
Office--GUI Linebreak on/off
Mon. work.envelope Override
Technology sel. Configuration
Reinitialization USERTech reinit.
BOF Reinitialization

Gripper User group “User”


I/O Automatic External

Driver Edit Config.


Start/select Driver Reset
SUBMIT--Interpr. Stop I/O Reconfigure
Cancel
Statuskeys GRIPPER Tech
ARC Tech 10
Jogging Prog.--OV--Steps ARC Tech 20
Jog.--OV--Steps
User group Mouse position
Mouse configuration
Cur. tool/base
Tool type
Tool definition Base type
External Axis Force cold Startup
On/Off options PowerOff Delay
Language
Miscellaneous Change password Def--line
Editor Detail view on/off
Office--GUI Linebreak on/off
Mon. work. envelope Override
Technology sel. Configuration
Reinitialization USERTech reinit.
BOF Reinitialization

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Operator Control

I/O Gripper
Automatic External

I/O
» Gripper HB Progr. Handbook
Gripper settings. MC [Configuration]
» Automatical External Ch. [Configuring the
Settings for the Automatic External interface. system]

I/O Driver Edit Config.


Driver Reset
I/O Reconfigure

I/O Driver
» Edit Config. 1) HB Progr. Handbook
Opens the file “IOSYS.INI”. MC [Configuration]
[ g ]
» Driver--Reset Ch [C
Ch. [Configuring
fi i th
the
Resets the peripheral interfaces. system]

» I/O Reconfigure
The inputs/outputs are reconfigured.
1) Not available in the user group “User”.

SUBMIT--Interpr. Start/Select
Stop
Cancel

SUBMIT Interpreter
» Start/Select HB Progr. Handbook
Start/select Submit interpreter. MC [Configuration]
[ g ]
» Stop Ch [C
Ch. [Configuring
fi i th
the
Stop Submit interpreter. system]

» Cancel
Deselect Submit interpreter.

Statuskeys GRIPPER Tech


ARC Tech 10
ARC Tech 20

Statuskeys
» GRIPPER Tech HB Progr. Handbook
Status keys for optional technology package MC [Configuration]
» ARC Tech 10 Ch. [Configuring the
Status keys for optional technology package system]
» ARC Tech 20
Status keys for optional technology package

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8 Menu structure (continued)

Jogging Prog.--OV--Steps
Jog.--OV--Steps
Mouse position
Mouse configuration

Jogging
» Program--OV--Steps on/off HB Progr. Handbook
Switches program override on/off. MC [Configuration]
[ g ]
» Jog--OV--Steps on/off Ch [C
Ch. [Configuring
fi i th
the
Switches manual (jog) override on/off. system]

» Mouse position
Definition of the spatial relationship between the 6D mouse
and the robot.
» Mouse configuration
Axis selection and dominant mode.

User group

User group
Access to certain user levels. HB Progr. Handbook
MC [Configuration]
Ch. [Configuring the
system]

Cur. tool/base

Cur. tool/base
Selection of the desired tool, base system and/or kinematics. HB Progr. Handbook
MC [Configuration]
Ch. [Configuring the
system]

Tool type
Tool definition Base type
External Axis

Tool definition
» Tool type HB Progr. Handbook
Display saved calibration data for the tool type. MC [Configuration]
[ g ]
» Base type Ch [C
Ch. [Configuring
fi i th
the
Display saved calibration data for the base type. system]

» External Axis
Display saved calibration data for external axes.

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Operator Control

On/Off options Force cold Startup


PowerOff Delay

On/Off options
» Force cold Startup HB Progr. Handbook
The next time the controller is run--up, a complete restart MC [Configuration]
without selection of any programs will be forced. Ch. [Configuring the
system]
» Disable PowerOff Delay 1)
Delay before the system can be rebooted.
1) Not available in the user group “User”.

Language
Miscellaneous Change password Def--line
Editor Detail view on/off
Office GUI on/off Linebreak on/off
Mon. work. envelope Override
Technology sel. Configuration
Reinitialization USERTech reinit.
BOF Reinitialization

Miscellaneous
» Language HB Progr. Handbook
Changes the language used in the graphical user interface. MC [Configuration]
[ g ]
» Change password Ch [C
Ch. [Configuring
fi i th
the
Change the password for a user group. system]

» Editor 1)
» Def--line
Displays the DEF lines in a program.
» Detail view on/off
The program is displayed in KRL code.
» Linebreak on/off
Activates/deactivates line breaks in the program window.
» Office GUI on/off 1)
Additional operator control elements on the GUI for mouse
operation.
» Monitoring working envelope 1)
» Override
Overrides the monitoring of the work envelope.
» Configuration
Definition of the workspaces.
» Technology selection 2)
Selection of technologies (e.g. Kuka ARCTech, GRIPPER--
Tech, ServoGun, ...) to be loaded.

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8 Menu structure (continued)

» Reinitialization 1) HB Progr. Handbook


» USER Tech reinitialize MC [Configuration]
USER Tech files are reinitialized without rebooting the Ch. [Configuring the
system. system]
» BOF reinitialization
The GUI (Graphical User Interface) is reinitialized without
rebooting the system.
1) Not available in the user group “User”.
2) Only available if a corresponding technology package has been installed.

8.5 Monitor
User group “Expert”
I/O Digital Inputs
Digital Outputs
Rob. Position Cartesian Analog Outputs
Axis specific Gripper
Incremental Automatic external
Master/Slave

Variable Single Display


Overview Configure
Cyclic Flags Edit “ConfigMon.ini”
Flags
Counter
Timer
Display
Diagnosis Configure
Oscilloscope
Log book
Display
Windows Navigator CROSS--Log book
Configure
Program Caller Stack
Icon Edit Editor Interrupts
Security circuit
Web Diagnosis

User group “User”


I/O Digital Inputs
Digital Outputs
Rob. position Cartesian Analog Outputs
Axis specific Gripper
Incremental Automatic external
Master/Slave

Variable Single Display


Overview Configure
Cyclic Flags Edit “ConfigMon.ini”
Flags
counter
Timer
Display
Diagnosis Configure
Oscilloscope
Log book
Display
Windows Navigator CROSS--Log book
Configure
Program Caller Stack
Icon Edit Editor Interrupts
Security circuit
Web Diagnosis

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Operator Control

I/O Digital Inputs


Digital Outputs
Analog Outputs
Gripper
Automatic external

I/O
» Digital Inputs MC [Operator Control],
Assignment of the digital inputs. Ch. [Monitor]
[ ]
» Digital Outputs
Assignment of the digital outputs.
» Analog Outputs
State of the analog outputs.
» Gripper
Assignment of the grippers.
» Automatic external MC [Operator Control],
Assignment of the Automatic External interface. Ch. [Monitor]

Rob. position Cartesian


Axis specific
Incremental
Master/Slave

Rob. position
» Cartesian MC [Operator Control],
Current position of the TCP with respect to the world Ch. [Monitor]
coordinate system with the components “Position”,
“Orientation”, “Status” and “Turn” of the standard axes
and the configured external axes.
» Axis specific
Current, axis--specific position of the standard axes and the
configured external axes.
» Incremental
Current position of the robot axes in increments.
» Master/Slave
Current position of the master and slave axes in increments.

Variable Variable -- Single Display


Overview Configure
Cyclic Flags Edit “ConfigMon.ini”
Flags
Counter
Timer

Variable
» Single MC [Operator Control],
Display and modification of individual variable values. Ch. [Monitor]

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8 Menu structure (continued)

» Overview MC [Operator Control],


» Display Ch. [Monitor]
Displays the groups of variables in “ConfigMon.ini”.
» Configure 1) HB Progr. Handbook
Settings for the variable group “Monitor”. MC [Configuring the
» Edit “ConfigMon.ini” 1) system, Expert]
Editing of the file “ConfigMon.ini”.
» Cyclic Flags (Notice) MC [Operator Control],
Signal states for Notices (cyclical flags). Ch. [Monitor]
[ ]
» Flags
Signal states of the flags.
» Counter
Displays the values of the counters.
» Timer
Values and operating states of the timers.
1) Not available in the user group “User”.

Display
Diagnosis Configure
Oscilloscope
Log book
Display
CROSS--Log book
Configure
Caller Stack
Interrupts
Security circuit
Web Diagnosis

Diagnosis
» Oscilloscope HB Electrical Servicing
» Display
View and analyze saved traces.
» Configure
Setting of the oscilloscope functions.
» Log book MC [Operator Control],
» Display Ch. [Monitor]
Displays logged actions.
» Configure
Configuration of the logbook function.
» Cross--Log book 1) HB Electrical Servicing
Log program “Kuka--Cross”.
» Caller Stack 1) MC [Operator Control],
Shows the sequence of program and subprogram calls. Ch. [Monitor]
[ ]
» Interrupts1)
Listing of interrupts.
» Security circuit HB Electrical Servicing
Displays the safety circuit of the robot.
» Web Diagnosis
Starts the internal Web browser which can be used to display
predefined pages
1) Not available in the user group “User”.

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Operator Control

Windows Navigator
Program
Editor

Windows
» Navigator MC [Operator Control],
Displays the Navigator in the user interface. Ch. [Monitor]
» Program 2)
Switches the user interface to the selected program.
» Editor 3)
Displays the program that is loaded in the editor.
2) Only available if a program has been selected.
3) Only if there is a program in the editor.

Icon Edit

Icon Edit 4)
Additional module for icon--based programming. Optional
program package
4) Optionally available

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8 Menu structure (continued)

8.6 Setup
User group “Expert” XYZ--4--Point
XYZ--Reference
ABC--2--Point
ABC--World 3--Point
Numeric Input Indirect
Tool Payload data Numeric Input
Base
Fixed tool Workpiece
Suppl. load data Tool
Ext. kinematic Offset ext. Kinematic
Measur. Points Numeric Input
Measure Tolerances
Root point
Root point (numeric)
Offset
Offset (numeric)

Tool type
Base type
External Axis
Set mastering
Check mastering
Master Dial Standard
EMT With load corr.
First mastering
UnMaster
Teach offset
Master load
Software--Upd. automatic
With offset
Service DSE--RDW Without offset
Load data determ.
Robot name External Editor
Config. External Axis
Long text

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Operator Control

User group “User” XYZ--4--Point


XYZ--Reference
ABC--2--Point
ABC--World 3--Point
Numeric Input Indirect
Tool Payload data Numeric Input
Base
Fixed tool Workpiece
Suppl. load data Tool
Ext. kinematic Offset ext. Kinematic
Measur. Points Numeric Input
Measure Tolerances
Root point
Root point (numeric)
Offset
Offset (numeric)

Tool type
Base type
External Axis
Set mastering
Check mastering
Master Dial Standard
EMT With load corr.
First mastering
UnMaster
Teach offset
Master load
Software--Upd. automatic
With offset
Service DSE--RDW Without offset
Load data determ.
Robot name External Editor
Config. External Axis
Long text

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8 Menu structure (continued)

XYZ--4--Point
XYZ--Reference
ABC--2--Point
ABC--World 3--Point
Numeric Input Indirect
Tool Payload data Numeric Input
Base
Fixed tool Workpiece Direct measuring
Suppl. load data Tool Indirect measuring
Ext. kinematic Offset ext. kinematic
Measur. Points Numeric Input
Measure Tolerances Root point
Tool type Root point (numeric)
Base type Offset
External Axis Offset (numeric)

Measure
» Tool MC [Start--up],
Calibration programs for position, orientation and structural Ch. [Calibration]
calculations for a tool mounted on the robot wrist.
» XYZ--4--Point
Moving the robot to a fixed reference point.
» XYZ--Reference
Moving the robot with a known reference tool to a reference
point.
» ABC--2--Point
Moving the robot to 2 points with orientation data.
» ABC--World
Positioning perpendicular to the world coordinate system.
» Numeric Input
Entering the tool data.
» Payload data
Entering the mass, center of mass and mass moment of
inertia.
» Base
Calibration programs to determine workpiece position and
orientation.
» 3--Point
Moving to the reference point of a workpiece.
» Indirect
Entering the inaccessible reference point of a workpiece.
» Numeric Input
Entering a reference point manually.
» Fixed tool
Calibration programs to define an external fixed tool.
» Workpiece
Moving with a workpiece mounted on the robot flange.
» Tool
Moving the robot to a fixed tool.

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Operator Control

» Offset external kinematic MC [Start--up],


Moving the robot to a fixed tool on an external kinematic Ch. [Calibration]
system.
» Numeric Input
Entering a fixed tool manually.
» Supplementary load data
Entry of data for a supplementary load on the robot.
» External kinematic MC [Start--up],
» Root point Ch. [Calibration --
Moving the distance from the world coordinate system to the External kinematics]
external kinematic system.
» Root point (numeric)
Entering the distance from the world coordinate system to
the external kinematic system manually.
» Offset
Moving the distance from the external kinematic system to
the workpiece.
» Offset (numeric)
Entering the distance from the external kinematic system to
the workpiece manually.
» Measurement Points MC [Start--up],
» Tool type Ch. [Calibration]
Display saved calibration data for the tool type.
» Base type
Display saved calibration data for the base type.
» External Axis
Display saved calibration data for the external axes.
» Tolerances 1)
Entry of tolerance limits for tool calibration.
1) Not available in the user group “User”.

Set mastering
Check mastering
Master Dial Standard
EMT With load corr.
First mastering
Teach offset
Master load

With offset
Without offset

Master
» Dial MC [Start--up],
Mastering with a mechanical dial gauge. Ch. [Robot mastering
/ unmastering]

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8 Menu structure (continued)

» EMT MC [Start--up],
Mastering with the electronic measuring tool. Ch. [Robot mastering
» Standard / unmastering]
» Set mastering
The robot is mastered in the mechanical zero position with
or without a payload.
» Check mastering
Checks the mastering.
» With load corr.
» First mastering
The robot is mastered in the mechanical zero position
without a payload.
» Teach offset
The robot is mastered with a payload and the encoder
offset relative to the first mastering is calculated for this
payload.
» Master load
» With offset
This function is used to check the mastering of a payload
mounted on the robot, that has previously been
mastered with “Teach offset”.
» Without offset
Mastering of the robot with any load; the difference from
the first mastering is calculated.

UnMaster

Unmaster
Unmastering of selected axes. MC [Start--up],
Ch. [Robot mastering /
unmastering]

Software Upd. automatic

Software Update
» Automatic MC [Start--up],
Load new version of program from CD--ROM. Ch. [Software Update]

Service DSE--RDW
Load data determ.
External Editor
Config.External Axis
Long text

Service
» DSE -- RDW 1) HB Electrical Servicing
Displays for the “Digital Servo Electronics” and “Resolver--
Digital Converter”

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Operator Control

» Load data determination see additional package


Determination of the load data [Load data Determination]
» External Editor 1) HB Progr. Handbook
External program for editing application programs at GUI and MC [Expert Progr.]
KRL levels. Ch. [External Editor]

» Config. External Axis 1) Separate documentation


Setting up of external axes. [External Axes]
» Long text 1) HB Progr. Handbook
Names of inputs/outputs. MC [Configuration]
Ch. [Configuring the
system]
1) Not available in the user group “User”.

Robot name

Robot name
Changes the robot name. MC [Start--up]
Ch. [Robot name]

8.7 Commands
User group “Expert” and “User”

Last command PTP


LIN
Motion CIRC

Moveparams Torquemon.

Logic WAIT OUT


WAITFOR PULSE
OUT SYN OUT
IBUS--Seg. on/off SYN PULSE

Analog output Static


Dynamic

Comment Normal
Stamp

KRL--assistant PTP
PTP_REL
LIN
LIN_REL
CIRC
CIRC_REL

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8 Menu structure (continued)

Last command

Last command
Repeats the last command executed. MC [User programming]
Ch.
[Program commands]

Motion PTP
LIN
CIRC

Motion
» PTP MC [User programming]
Motion command “Point--to--Point”. Ch.
» LIN [Program commands]
Motion command “Linear”.
» CIRC
Motion command “Circular”.

Moveparams Torquemon.

Moveparams
» Torquemon. MC [User programming]
Collision monitoring call. Ch.
[Program commands]

Logic WAIT OUT


WAITFOR PULSE
OUT SYN OUT
IBUS--Seg. on/off SYN PULSE

Logic
» WAIT MC [User programming]
Time--dependent wait function. Ch.
» WAITFOR [P
[Program commands]
d ]
Signal--dependent wait function.
» OUT
» OUT
Simple switching function.
» PULSE
Simple pulse function.
» SYN OUT
Path--dependent switching function.
» SYN PULSE
Path--dependent pulse function.
» IBUS--Seg. on/off
Coupling and decoupling an Interbus segment.

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Operator Control

Analog output Static


Dynamic

Analog output
» Static MC [User programming]
Setting of analog outputs under program control to a fixed Ch.
value. [Program commands]
» Dynamic
Setting of analog outputs under program control to a fixed
value that is dependent on the velocity or the specific
technology package

Comment Normal
Stamp

Comment
» Normal MC [User programming]
Inserts a comment line into a program. Ch.
» Stamp [P
[Program commands]
d ]
Comment line with the date and time in a program.

KRL assistant PTP


PTP_REL
LIN
LIN_REL
CIRC
CIRC_REL

KRL assistant
» PTP MC [User programming]
Absolute “point--to--point” motion. Ch.
» PTP_REL [Program commands]
Relative “point--to--point” motion.
» LIN
Absolute linear motion.
» LIN_REL
Relative linear motion.
» CIRC
Absolute circular motion.
» CIRC_REL
Relative circular motion.

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8 Menu structure (continued)

8.8 Technology
User group “Expert” PTP
LIN
CIRC
ARC Tech 10 ARC ON
ARC SWITCH LIN
ARC OFF CIRC

PTP
LIN
CIRC
ARC Tech 20 ARC ON
ARC SWITCH LIN
ARC OFF CIRC

SPOT Tech SPOT PTP


RETRACT LIN
CIRC

GRIPPER Tech Gripper


Check Gripper
LIN
PTP
TOUCHSENSE SEARCH
CORR
Turn off
USER Tech 1--dimensional
2--dimensional
3--dimensional
Free programmable

PTP
LIN
CIRC
ARC Tech 10 ARC ON
ARC SWITCH LIN
ARC OFF CIRC

ARC Tech 10
» ARC ON Additional documenta-
Start welding, including motion, start and ignition parameters. tion
» PTP Arc Welding
Point--to--point motion. [ArcTech 10]
» LIN
Linear motion.
» CIRC
Circular motion.

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Operator Control

» ARC SWITCH Additional documenta-


Welding of several seam sections, including parameters for the tion
seam section, and also for mechanical and thermal weaving. Arc Welding
» LIN [ArcTech 10]
Linear motion.
» CIRC
Circular motion.
» ARC OFF
Welding and ending a seam, including end parameters, crater
filling, the gas postflow time and burnback.
» LIN
Linear motion.
» CIRC
Circular motion.

PTP
LIN
CIRC
ARC Tech 20 ARC ON
ARC SWITCH LIN
ARC OFF CIRC

ARC Tech 20
» ARC ON Additional documenta-
Start welding, including motion parameters, program number for tion
the power source and start delay. Arc Welding
» PTP [ArcTech 10]
Point--to--point motion.
» LIN
Linear motion.
» CIRC
Circular motion.
» ARC SWITCH
Welding of several seam sections, including parameters for the
seam section, mechanical weaving.
» LIN
Linear motion.
» CIRC
Circular motion.
» ARC OFF
Welding and ending a seam, including motion parameters,
program number for the power source, velocity and weave
pattern, as well as crater filling.
» LIN
Linear motion.
» CIRC
Circular motion.

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8 Menu structure (continued)

SPOT Tech SPOT PTP


RETRACT LIN
CIRC

SPOT Tech
» SPOT Additional documenta-
Moves the robot to a weld spot, opens and closes the welding tion
gun. Spot Welding
» PTP [SPOT Tech 10]
Point--to--point motion.
» LIN
Linear motion.
» CIRC
Circular motion.
» RETRACT
Moves the robot to a weld spot, opens and closes the welding
gun.
» PTP
Point--to--point motion.
» LIN
Linear motion.
» CIRC
Circular motion.

GRIPPER Tech Gripper


Check Gripper

GRIPPER Tech
» Gripper Additional documenta-
Programming gripper functions. tion
» Check Gripper [G i
[Gripper T
Tech]
h]
Interrogations of any sensors fitted on the gripper.

LIN
PTP
TOUCHSENSE SEARCH
CORR
Turn off
1--dimensional
2--dimensional
3--dimensional
Free programmable

TOUCHSENSE
» SEARCH Additional documenta-
Programming a search motion. tion
» LIN [Touch--Sensor]
Linear motion
» PTP
Point--to--point motion

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Operator Control

» CORR Additional documenta-


Programming a correction instruction. tion
» Turn off [Touch--Sensor]
» 1--dimensional
» 2--dimensional
» 3--dimensional
» Free programmable

USER Tech

USER Tech
Programmable inline forms, status keys and scripts. MC [Additional Func-
tions]
Ch. [UserTech]

8.9 Help
User groups “Expert” and “User”

Online help

Contents/Index

Info

Online help

Online help
Starts context--specific online help for the topic currently MC [Operator Control],
selected. Ch. [Monitor]

Contents/Index

Online help -- Contents/Index


Overall index of the online help function. MC [Operator Control],
Ch. [Monitor]

Info

Version
Provides version information MC [Operator Control],
(GUI / kernel system / system data) Ch. [Monitor]

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Index

Symbols C
$LAST_BUFFERING_NOTOK, 21 Cabinet lock, 10, 11
$PERI_RDY, 16 Caller Stack, 175, 211
$POWER_FAIL, 15 Cancel program, 200, 202
$PRO_IP, 175 Caps Lock, 36
Cartesian, 156, 210
$STOPMESS, 15, 16
CD--ROM drive, 10, 11
*.DAT, 196
Change, 148, 165
Change password, 208
Numbers Check Gripper, 223
Check mastering, 217
3--Point, 215
CIRC, 219
Close, 204
A COM1, 10
Commands, 194, 218
ABC--2--Point, 215
Comment, 96, 115, 220
ABC--World, 215
Computer drives, 10, 11
ALT key, 36 Config. External Axis, 218
Alt--Escape, 46 ConfigMon.ini, 162
Alt--Tab, 45 Configure, 194, 205
Analog output, 220 Continue, 150
Analog Outputs, 148, 210 Continuing a program, 139
Archive, 102, 196 Contrast, 38
Arrow keys, 33 Control cabinet, 9
Attributes, 87, 111, 198 Control ON, 10
Attributes display, 76, 80 Control--Escape, 46
Aut, 44 Controller switched back on, 15
Automatic, 55, 146 Coordinate system, 49, 59
Coordinate systems TOOL, BASE, WORLD,
Automatic External, 55, 151
72
Automatic external, 210
Copy, 113, 199, 203
Automatic program execution, 139 Counter, 211
Automatical External, 206 Counters, 194
Axis specific, 210 CROSS Log book, 168, 174
Cross--Log book, 211
CTRL key, 35, 36
B
CTRL--Escape, 46
Backspace key, 35 Cur. tool/base, 207
Backwards key, 33 Current selection, 196
BASE, 49, 52 Current value, 160, 161
Base, 215 Cut, 114, 199, 204
Base type, 207, 216 Cyclic Flags, 211
BCO run, 133, 139
Block coincidence, 133 D
Block pointer, 39, 43, 126 Data list, 93
BOF reinitialization, 209 Def--line, 208
Braking ramp, 130 Degrees of freedom of the Space Mouse, 66
Brightness, 38 DEL key, 35

Index -- i
Index

Delete, 93, 114, 200, 201, 204 Ext, 44


Deselecting a program, 141 External axes, 58
Detail view, 78 External Axis, 207, 216
Detail view on/off, 208 External kinematic, 52, 216
Diagnosis, 104, 211 External kinematic systems, 58
Dial, 216 Externer Editor, 218
Digital Inputs, 210
Digital Outputs, 210 F
Direction indicator, 127
File, 94, 194, 195, 196
Directory list, 76, 84
File attributes, 87
Directory structure, 76, 79 File list, 76, 84
Disable PowerOff Delay, 208 File manager, 75
Display, 194 ”File” menu, 94
Dominant axis, 69 File name, 87
Dominant axis activated, 70 File operations, 194
Dominant axis not activated, 70 Filter, 78, 82, 111, 198
Driver Reset, 206 Find, 201, 204
Drives, 76 First mastering, 217
Drives off, 30, 139 Fixed tool, 215
Drives on, 30 Flags, 211
DSE -- RDW, 217 Floppy disk drive, 10, 11
Duplicate, 115, 200 Fold, 201, 203
Dynamic, 220 Folder, 196
Dynamic braking, 131 Force cold Startup, 208
Format floppy disk, 110, 198
E
Edit, 93, 98, 112 G
Edit Config., 206 Go, 132
Edit cursor, 127 Graphical user interface, 76
“Edit” menu, 112 Gripper, 150, 206, 210, 223
Edit mode, 198 GUI, 38
Editor, 208
EMERGENCY STOP button, 30 H
EMT, 217
Header, 76, 78
Enabling switch, 33, 37, 150
Help, 180, 194, 224
Enabling switches, 62
HOME key, 35
END key, 35
HOV, 44
Enter key, 33, 115
Error diagnosis, 89
Error display, 89 I
Error list, 89 I--Step, 132
Errorlist, 196 I/O Driver, 206
Escape key, 32 I/O Reconfigure, 206
Executing program lines, 135 IBUS--Seg., 219
Executing, stopping and resetting a program, Icon, 128
125 Icons, 76
Expert level, 79 In/Outputs, 206
Expert user group, 168 Incremental, 158, 210

Index -- ii
Index

Incremental jogging, 73 Log Data, 104


Incremental Step, 132 Logic, 219
Increments, 158 Logic commands, 194
Indirect, 215 Long text, 218
Info, 189 LPT1, 10
Inline form, 40
Input mark, 127 M
Inputs, 146 Main axes, 67
Inputs/Outputs, 210 Main switch, 10, 11
Inputs/outputs, 143 Manual gripper operation, 150
INS key, 35 Manual mode, 44
Interrupts, 211 Manual program execution, 132
Mark all, 199
J Master, 216
Master load, 217
Jog keys, 49, 57, 71
Master/Slave, 210
Jog mode, 38, 44, 49, 55, 57, 132
Master/slave display, 159
Jog OV steps, 61
Maximum braking, 130
Jog override, 44, 61, 207
Measure, 215
Jog--OV--Steps on/off, 207
Measurement Points, 216
Jogging, 49, 57, 207
Menu, 193
Jogging the robot, 55
Menu bar, 38, 193
Joint, 49, 157
Menu key, 193
Joint coordinate system, 71 Menu keys, 34
jump to, 90 Message window, 40
Messages in the status bar, 43
K Miscellaneous, 208
Mode selector switch, 31, 55
KCP, 29
Modify, 202
KCP connection, 12
Modul info, 81
KCP front, 29
Module, 161
KCP rear, 37
Modules, 78
Keyboard, 36
Monitor, 119, 143, 194, 209
KRL Assistant, 194
”Monitor” menu, 119
KRL assistant, 220
Monitoring working envelope, 208
KUKA--Cross, 174
Motion, 219
Motion commands, 194
L Mouse configuration, 66, 69, 207
Language, 208 Mouse position, 62, 207
Last command, 219 Moveparams, 219
LDEL key, 35
LIN, 219 N
Line breaks, 127 Name, 115, 160, 165
Line/column, 128 Navigator, 75
Linebreak on/off, 208 New, 83, 95, 196
Load corr., 217 New Value, 160
Load data determination, 218 Notices, 164, 211
Log book, 168, 169, 196, 211 NUM, 43, 80

Index -- iii
Index

NUM key, 35 Program start forwards key, 32, 37


Numeric Input, 215, 216 Program stop key, 32
Numeric keypad, 35 Program window, 39, 126
Program--OV--Steps on/off, 207
PTP, 219, 220
O
PULSE, 219
Office GUI on/off, 208
Offset, 216
R
Offset external kinematic, 216
On/Off options, 208 Ramp--down braking, 130
On/off switch, 12 Reduced velocity, 150
Online help, 180, 184, 224 Reference coordinate system, 59
Refresh, 171
Open, 196
Reinitialization, 209
Operating mode, 44
Releasing EMERGENCY STOP, 30
Operator control elements, 10, 30
Rename, 109, 197
Oscilloscope, 168, 211
Replace, 204
OUT, 219
Reset, 12, 137
Outputs, 144
Reset program, 200, 202
Resetting a program, 137
P Restore, 105, 197
Page +, 171 Return key, 33
Page --, 171 Reverse traversing, 132
Parameter, 200 Rob. Position, 156
Parameters, 116 Rob. position, 210
Paste, 113, 199, 203 Robot name, 218
Path--maintaining braking in event of operator Root point, 216
safety violation, 131 Running up the controller, 9, 13
Path--maintaining Emergency Stop, 130
Payload data, 215 S
PGDN key, 35
Safety circuit, 168
PGUP key, 35 Safety instructions, 131
Points in TTS, 202 Security circuit, 211
Position, 194 Securitycircuit, 168
POV, 44 Select, 116, 125, 200
Power failure, 15 Selecting the kinematic system, 58
Power OFF function, 14 Selection list, 76, 82
Previous, 150 Service, 217
Print, 100, 196 Set mastering, 217
Process pointer, 175 Setup, 194, 213
Program, 194, 199 Shift key, 36
Program creation, 194 Short--circuit braking, 131
Program name, 128 Shutting down the controller, 9, 14
Program OV steps, 129 Signal states, 144, 146
Program override, 44, 129, 207 Simultaneous motion, 50
Program pointer, 126 Single Step, 132
Program run mode, 132 Skeleton program, 97, 98, 116
Program start backwards, 132, 136 Softkey bar, 39
Program start backwards key, 33 Softkeys, 35, 150

Index -- iv
Index

Software limit switches, 56 User group, 175, 177, 207


Software Update, 217
USER Tech reinitialize, 209
Space Mouse, 34, 49, 57, 62
Stamp, 220
START key, 32
Static, 220
Status bar, 41, 43 V
Status key bar, 38
Status keys, 34, 150 Variable, 161, 210
Status LED, 10
Variables, 194
Status line, 41, 55, 76, 88, 128
Status window, 39, 57, 150 Version, 224
Statuskeys, 206 Version information, 194
STOP key, 32
Virus protection, 22
Stopping program execution, 137, 139
SUBMIT Interpreter, 206
Superposed motion, 70
Supplementary load data, 216
SYM key, 36 W
Symbols, 76
Symbols in the program window, 126 WAIT, 219
SYN OUT, 219
WAITFOR, 219
SYN PULSE, 219
System time, 44 Warning and safety instructions, 131
Web Diagnosis, 211
T Web Diagnosis, 178
T1, 44, 55
Window selection key, 32, 95
T2, 44, 55
TAB key, 35 Windows, 212
Teach offset, 217 Windows interface, 45
Technology, 194, 221
Windows mouse, 47
Technology commands, 194
Technology selection, 208 With offset, 217
Templates, 83 Without offset, 217
Timer, 211
Work cell, 51
Toggling to the Windows interface, 45
Tolerances, 216 Workpiece, 215
TOOL, 49 WORLD, 49
Tool, 53, 215
Tool definition, 207
Tool type, 207, 216
Torquemon, 219
X
U
X axis, 53
UNDO key, 35
Unmaster, 217 XYZ--4 Point, 215
User data, 81 XYZ--Reference, 215

Index -- v
SOFTWARE

KR C...

Start--up

KUKA System Software (KSS)


Release 4.1

Issued: 09 Jan 2004 Version: 06


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e Copyright 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.

PD Interleaf

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Contents

1 Robot mastering / unmastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Mastering with the dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Mastering with the EMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 Brief description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Preparation for EMT mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4.1 Set mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4.2 Check mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.5 With load correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.5.1 First mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.5.2 Teach offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.5.3 Master load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Mastering the KR 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.1 Reset Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.2 Commutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4.3 Set Robot Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.5 Mastering of master/slave drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.6 Reference point mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.7 Unmastering an axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.2 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Tool calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.2 X Y Z -- 4 Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.3 X Y Z -- Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.4 A B C -- 2 Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2.5 A B C -- World . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2.5.1 The “A B C -- World (5D)” method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2.5.2 The “A B C -- World (6D)” method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2.6 Numeric Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2.7 Tool load data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3.2 3--Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3.3 Indirect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.3.4 Numeric Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Fixed tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.4.2 Workpiece (TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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Start--up

2.4.3 Tool (BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88


2.4.4 Offset external kinematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.4.5 Numeric Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.5 Supplementary load data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.6 External kinematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.7 Measurement Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.8 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.9 Error treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3 Calibration -- External kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113


3.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1.2 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 External kinematic calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2.2 Root point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.3 Root point (numeric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.4 Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.5 Offset (numeric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.6 Offset external kinematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4 Robot name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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1 Robot mastering / unmastering


1.1 General
When mastering the robot, the axes are moved into a defined mechanical position, the so--
called mechanical zero position. This mechanical zero position represents an assignment
to the axis drive angle and is defined by a reference notch or mark.
If the robot is in this mechanical zero position, the increment counter for each axis is set to
the value corresponding to the axis angle (generally 0 increments for 0 degrees). In order
to move the robot exactly to the mechanical zero position, a dial gauge or electronic
measuring tool (EMT) is used.

The robot must always be mastered under the same temperature conditions in order to
avoid inaccuracies arising through thermal expansion.
This means that mastering must be carried out with the robot always cold or always at
operating temperature.

Vernier on axis 5 Gauge cartridge on axis 2


Depending on the size of the robot, the axes feature either a vernier or a gauge cartridge for
receiving a dial gauge or an electronic measuring tool (EMT).

1 Reference notch
2 Electronic
measuring tool or
4 dial gauge
3 Measuring pin
4 Gauge cartridge

1
3
Cross--section of a gauge cartridge

To locate the mechanical zero position of a robot axis precisely, it must first be aligned to its
pre--mastering position. The protective cap of the gauge cartridge is then removed and a dial

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gauge, or the supplied EMT, is fitted to it. The EMT is now plugged into the robot junction
box (connection X32) and thus connected to the robot controller.
When, on passing over the reference notch, the gauge pin reaches its lowest point, the
mechanical zero position is reached. The electronic measuring tool sends an electronic
signal to the controller.
If using a dial gauge, the zero position can be recognized by the abrupt reversal of the pointer.
The pre--mastering position makes it easier to move to the mechanical zero position. The
pre--mastering position is indicated externally by a scratch mark or “frontsight/rearsight”
markers and is located just before the zero position. The robot must be brought into this
position before the actual mastering procedure.
Axis traversing direction Axis traversing direction

EMT or EMT or
dial dial
gauge gauge

Scratch mark or
“frontsight/rear-
sight” marker

Pre--mastering position Mechanical zero position

An axis may only be moved to its mechanical zero position from “+” to “--”. If the
axis has to be moved from “--” to “+”, it must first be moved past the pre--mastering position
mark in order to move it subsequently back to the mark in the right direction. This is of vital
importance, in order to eliminate the effect of gear backlash.

The robot may have to be remastered for a number of different reasons:

The robot has to be mastered... Mastering is cancelled...


...after repairs ...automatically on booting the
(e.g. replacement of a drive motor or RDC) system1)
...when the robot has been moved without the ...automatically on booting the
controller (e.g. with hand crank) system1)
...after an impact with a mechanical end stop at
...manually by the operator
more than manual velocity (20cm/s)
...after a collision between the tool or robot and a
...manually by the operator
workpiece
1)If discrepancies are detected between the resolver data saved when shutting down the
controller and the current position, all mastering data are deleted for safety reasons.

The robot can be unmastered... Mastering is cancelled...


...if the mastering values saved for the individual
...manually by the operator
axes are to be specifically deleted

You can only master the axes if there is no EMERGENCY STOP situation and the drives are
switched on. The EMERGENCY STOP circuits of the periphery must be wired up, if applicable.
Information on the EMERGENCY STOP button can be found in the documentation
[Operator Control], chapter [The KUKA Control Panel KCP], while the wiring of the
EMERGENCY STOP circuits and the connection X32 for the EMT are described in the
documentation [Operating Handbook, Control Cabinet].

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When mastering the wrist axes, consideration needs to be given to the position of any
external energy supply system as axes 4 and 6 are defined as infinitely rotating before the
mastering process is carried out.

1.2 Mastering with the dial gauge

Information on manual traversing of the robot can be found in the documentation


[Operator Control], in the chapter [Manual traversing of the robot].

Bring all axes to the pre--mastering position.

The pre--mastering position depends on the robot type.

!
n
Pre--mastering position of axis 3

An axis may only be moved to its mechanical zero position from “+” to “--”. If the
axis has to be moved from “--” to “+”, it must first be moved past the pre--mastering position
mark in order to move it subsequently back to the mark in the right direction. This is of vital
importance, in order to eliminate the effect of gear backlash.

Remove the protective cap of the gauge cartridge and fit the dial gauge.

This function is only available in the operating mode Test (T1/T2). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

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Press the “Setup” key. A menu opens. Select here the option “Master”. In the submenu which
opens, confirm the offered selection “Dial”.

A status window opens, in which the axes to be mastered are displayed.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. More detailed information about this can be found in Section 1.7.
If axis 1 has been mastered, it may be moved for the purposes of mastering the
remaining axes. Axes 2...6, on the other hand, may not be moved until all axes have
been mastered.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

Before carrying out mastering, please use jog override to reduce the traversing velocity to
1%. Move the robot axis that is to be mastered across the pre--mastering position marker,
in the negative axis direction, while watching the pointer of the dial gauge. At the lowest
position of the reference notch, recognizable by the abrupt change in direction of the pointer,
set the dial gauge to 0.
Then move the axis back to the pre--mastering position. Move the axis that is to be mastered
in the negative axis direction again. Stop when the pointer of the dial gauge is about 5--10
scale divisions before the zero position. In order to increase the accuracy of mastering, move
the robot forward more carefully now, in predefined increments. To do this, you need to switch
to the (incremental manual traversing).

The procedure for activating incremental manual traversing is described in the documenta-
tion [Operator Control], chapter [Manual traversing of the robot].

Each time the traversing keys are pressed, the axes now only advance in small steps. In this
way, move the axis in the negative axis direction until the zero position of the dial gauge is
reached.

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If you overshoot this point, you must go back and move to the reference notch from the
pre--mastering position again.

The current axis position, highlighted by the colored selection bar, is saved as the mechanical
zero position by pressing the softkey “Master”. The axis that has been mastered is removed
from the window.
Before mastering the next axis or ending the complete mastering procedure, switch back to
the normal traversing mode.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1.3 Mastering with the EMT


A number of different functions are available for mastering with the EMT. These are grouped
together under two main points: “Standard” and “With load correction”. The difference here
is that using the option “With load correction” it is possible to master the robot as if the tool
had been removed, but actually leave the tool mounted on the robot. This is done by correct-
ing the weight of the tool “arithmetically”. “Standard” mastering is used if the robot is always
mastered with the same tool or always mastered with no tool.

1.3.1 Brief description of the functions

Standard:

G Set mastering
The robot is mastered in the mechanical zero position with or without a payload.

G Check mastering
Here it is possible to check the mastering, i.e. if you are not sure whether or not the
currently valid mastering is correct, the difference from the “Set mastering” values can
be calculated. Bear in mind that the robot must be fitted with the same load as when
“Set mastering” was carried out.

With load correction:

G First mastering
The robot is mastered in the mechanical zero position without a payload. The increment
counter value for each axis is saved. First mastering serves as the basis for the other
functions listed below.

G Teach offset
Using this function, the robot is mastered with a load (tool). The encoder value for the
offset from the first mastering is determined for this load and saved.

G Master load with offset


This function is used to check the mastering of a tool mounted on the robot, for which
an “offset” has been learnt. The saved “offset” is used to recalculate the mastering value
“without load” and calculate and display the difference between this value and the
current mastering (up to this point no values have yet been saved).
Following this check function, the operator is asked whether the existing mastering
state is to be retained or whether the newly calculated mastering values are valid and
should be saved. This menu item thus allows the first mastering to be restored even
after a collision or following the replacement of a motor.

G Master load without offset


The robot can be mastered with any load (including a tool whose weight has not been
learnt), i.e. no allowance is made for an offset. Instead, only the absolute encoder value
determined in first mastering is used to recalculate the first mastering. A precondition
for this function is that nothing has been mechanically displaced (e.g. collision, replace-
ment of motor, parts, etc.) since the first mastering.

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Mastering with EMT


Set--up

Set mastering First mastering

Teach offset
Loss / Check

Master load with-


Mastering

Check mastering Master load with


offset out offset *)1

*)1 Only possible if the first mastering is still valid (i.e. no change to the drive train
e.g. replacement of a motor or parts, or following a collision, etc.)

For reasons of accuracy, the wrist axes should remain, if possible, in their mechanical zero
position during the EMT mastering function.

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1.3.2 Application examples

Example 1 Mastering without consideration of the load


You have carried out “Set mastering” and then taught a program on which you have been
working for some time. Now you are not sure if this mastering is correct. You can now check
this using the “Check mastering” function. A precondition for this is that the robot is fitted
with the same load as when “Set mastering” was carried out. Once the check has been
carried out, the difference from the currently valid mastering is displayed and you have the
option of overwriting the old mastering with the one just carried out or retaining the existing
mastering values as valid. If you decide to opt for the new mastering, you must be aware
that, in the event of a significant mastering difference, the program you have taught is no
longer correct.

Example 2 Mastering with consideration of the load


Despite having a load mounted on the robot flange, you wish to master the robot, as if no
load were present. In this way you can always precisely master a robot which works, for
example, with different loads (gripper, tool changer, etc.), irrespective of the current load
and without having to remove the load. There are two ways of doing this:
1. Taking the tool load into account by learning the weight difference:
In this case, the mastering difference caused by a load is explicitly measured and saved
in advance for the load in question. Using this value, the computer can take this difference
into consideration in the event of subsequent mastering with a load. When using this
method, the following must be carried out:
First mastering must be carried out once without a load. The weight of each tool must then
be learnt using the function “Teach offset”. Provided that this has been done, you can
subsequently carry out a “Master load with offset” run to restore the old first mastering.
2. Taking the tool load into account by saving the encoder value:
When mastering without a load (first mastering), the path calibration system value
(absolute encoder value) is read and saved for each axis. In the event of subsequent
mastering with a load, the difference is determined and corrected by comparing the current
encoder value with the saved value. The precondition for this method is that the robot has
not undergone any mechanical changes since the first mastering. When using this method,
the following must be carried out:
First mastering must be carried out once without a load. Provided that this has been done,
you can subsequently restore the old first mastering by means of the function “Master load
without offset”.

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1.3.3 Preparation for EMT mastering


When mastering with the EMT, the axis that is to be mastered is moved at a preset velocity
from + to -- under program control. When the EMT detects the bottom of the reference notch,
the controller automatically stops the robot motion and saves this point.

If during the mastering operation a specified distance is overshot, the program is aborted
and an error message is displayed. The most common reason for this happening is that
the axis was positioned to the pre--mastering position with inadequate accuracy.

Bring the axis to be mastered to the pre--mastering position.

!
n
Pre--mastering position of axis 3

Information on how to move the robot manually can be found in the documentation
[Operator Control], in the chapter [Manual traversing of the robot].

When mastering with the EMT, an axis is always moved to the mechanical zero
position from “+” to “--”. If the axis has to be moved from “--” to “+”, it must first be moved
past the pre--mastering position mark so that it can then be moved back to the mark again.
This is done in order to eliminate the effect of gear backlash.

Remove the protective cap of the gauge cartridge and fit the measuring tool.

Connect the measuring tool to the robot controller using the cable supplied with the EMT set.

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Junction box on the rota-


ting column of the robot

Connection X32
The connecting cable for
the EMT is connected
here.

If you wish to remove the connecting cable from the EMT or X32, the connector on
the cable must be released. Otherwise the cable could be torn out or the EMT
damaged.

Press the “Setup” key. Select the submenus “Master” --> “EMT” and then the desired
function.

The options available here are described in more detail in the following sections.
First of all, a distinction is made between standard mastering and mastering with load
correction.

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1.3.4 Standard

In the “Standard” menu, mastering with/without a load can be set and checked. This
mastering function is recommended if the robot is always mastered with the same tool (load)
or always mastered with no tool (load).

1.3.4.1 Set mastering

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Standard” from the submenu “Set mastering”.

A status window opens, in which the axes to be mastered are displayed.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background. If all axes have been mastered, the text
“No axes to master” appears in the window.

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The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. More detailed information about this can be found in Section 1.7.
Furthermore, it is also possible to initiate a new mastering procedure via the menu item
“Check mastering” (“Standard” menu).

The axis that is to be mastered is selected by pressing the softkey “Master”. The text “Start
key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

1.3.4.2 Check mastering


This function allows the old robot mastering values to be checked. The robot is mastered in
the same way as for “Set mastering”.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Standard” from the submenu “Check mastering”.

A status window is opened, in which the axes to be checked are listed.

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If, for example, axis 2 has not been mastered, or has been unmastered, it is not possible
to check the mastering of an axis with a higher number. Axis 2 must first be mastered using
“Set mastering” or “Check mastering” in order to be able to check, for example, axis 3.

The axis for which the mastering is to be checked is selected by pressing the softkey “Check”.
The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The values are calculated and the status
window illustrated below is opened, in which the difference from the old mastering is
displayed in increments and degrees.

Pressing the softkey “Save” saves the mastering values and enables the selection of the next
axis.

You must be aware, when accepting the new mastering, that difficulties may arise
during execution of the program, depending on the difference in increments. For
this reason, it is necessary to reteach all programs.
Acceptance of the new mastering also offsets the mastering of all subsequent
mechanically coupled axes (the wrist axes are generally mechanically coupled). In
this case, it is absolutely necessary to check the mastering of these axes and, if the
deviation is too great, set the mastering as well.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1.3.5 With load correction

The menu “With load corr.” allows you to carry out first mastering or load mastering and teach
an offset (load) for different tools and loads. A precondition for “Master load” and “Teach
offset” is first mastering.

1.3.5.1 First mastering

Please note:
The first mastering of the robot must always be carried out without a payload or a
supplementary load.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item “With
load corr.” from the submenu “First mastering”.

A status window opens, in which all the axes (both mastered and unmastered) for which an
offset has been taught are available for selection. Select here the axis to be mastered.

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The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background. If all axes have been mastered, the text
“No axes to master” appears in the window.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. Please refer to Section 1.7 for more information. It is also possible to
initiate a new mastering procedure via the menu item “Check mastering” in the “Standard”
menu. Refer to the section Standard in this chapter.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

The axis (highlighted in color) that is to be mastered is selected by pressing the softkey
“Master”. The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

1.3.5.2 Teach offset


If, after first mastering, the robot is fitted with a heavy tool or workpiece, the increased load
gives rise to deviations (offset) from the first mastering. Should it be necessary to repeat
mastering (e.g. due to a collision or the replacement of a motor), this offset can be used to
recalculate the first mastering (further information is given in this section under “Load
mastering with offset”). Where different tools or payloads are used, in order to be able to
recalculate the mastering without having to change the tool, the offset must be taught for all
tools and payloads.
For this purpose, the robot is fitted, after first mastering, with the corresponding tool or
workpiece and, if necessary, a supplementary load. In the subsequent mastering procedure,
the robot “learns” the mastering difference caused by the load (offset).

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item “With
load corr.” from the submenu “Teach offset”.

The input window for selecting a tool is opened.

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Use the status key (at the bottom right of the display) to select the tool number.

...
Press the softkey “Tool OK” (at the bottom of the display) in order to enter data for this tool.
A status window opens, in which all axes are available for selection for which the load of the
selected tool has not yet been taught. Select here the axis to be mastered.

The axis (highlighted in color) that is to be mastered is selected by pressing the softkey
“Learn”. The text “Start key required” appears in the message window.

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Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.
When the data for the tool or workpiece fitted to the robot flange have been successfully
determined, the status window depicted below is opened, displaying in increments and
degrees the offset from the mastering without load.

Pressing the softkey “OK” saves the mastering values and enables the selection of the next
axis. The axis whose weight has just been learnt is removed from the status window. If the
offsets have been taught for all axes, the message “No offset to teach” appears in the
window.
If you wish to delete an offset, press the softkey “Delete”. A window opens, in which the axes
to be deleted are displayed. The tool number previously selected is confirmed.
Use the arrow keys to select the axis for which the offset is to be deleted and press the softkey
“Delete”. If there are no more offsets to be deleted, the message “No offset to delete” appears
in the window.

The values for learnt tools remain valid even after the replacement of a motor or a collision,
as they contain only the difference from the first mastering.

If, at the beginning of the learning process, no first mastering has yet been carried out, this
must be done first. For this reason the program automatically opens the necessary dialog
window. Please pay particular attention to the contents of the text in the status window!

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1.3.5.3 Master load


With the load mastering function, mastering is carried out with a load. A distinction is made
here between “With offset” and “Without offset”.

In order to carry out Load mastering, it must be ensured that robot axes A 4 and A 6
have not been rotated from the positions they occupied during initial mastering.

With offset
This function makes it possible to check and, if necessary, restore the robot’s old mastering
values without having to remove the tool. The robot is mastered with the tool (known offset).
The mastering data for the state “Without load” (first mastering) are recalculated using the
offset and overwritten after confirmation by the operator. This can be necessary, for example,
if a motor has been replaced or a collision has occurred.

A check is also possible in the event of loss of mastering; in this case the data are marked
as invalid, but these old values are nonetheless still available.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Master load” from the submenu “With offset”.

The input window for selecting a tool is opened.

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Use the status key (at the bottom right of the display) to select the tool number.

...
Press the softkey “Tool OK” (at the bottom of the display) in order to enter data for this tool.

If no offset has yet been taught for the tool, an error message is now generated.

A status window opens, in which all the axes (both mastered and unmastered) for which an
offset has been taught are available for selection. Select here the axis to be mastered.

If, for example, axis 2 has not been mastered, or has been unmastered, it is not possible
to check the mastering of an axis with a higher number. Axis 2 must first be mastered using
“Set mastering” or “Check mastering” in order to be able to check, for example, axis 3.
A status window opens, in which all the axes (both mastered and unmastered) for which an
offset has been taught are available for selection. Select here the axis to be mastered.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

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When the mastering data for the tool or workpiece fitted to the robot flange have been
successfully determined, a status window is opened, displaying the difference from the old
mastering in increments and degrees.

No new mastering values have yet been set, however. This is done once the data have
been saved.

Pressing “Save” saves the new mastering values and enables the selection of the next axis.
If you do not save the new data, the old mastering state is retained.

You must be aware, when accepting the new mastering, that difficulties may arise
during execution of the program, depending on the difference in increments. For
this reason, it is necessary to reteach all programs.
Acceptance of the new mastering also offsets the mastering of all subsequent
mechanically coupled axes (the wrist axes are generally mechanically coupled). In
this case, it is absolutely necessary to check the mastering of these axes and, if the
deviation is too great, set the mastering as well.

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1 Robot mastering / unmastering (continued)

Without offset
This function makes it possible to restore mastering data that have been lost. The robot can
be mastered with any tool, for which the offset does not need to have been “taught” before-
hand. Using the data determined in first mastering and the current values, the difference is
calculated and the mastering corrected accordingly.

The robot must not have been changed mechanically, since first mastering, in the
drive train between the drive motor with resolver and the gear system of the axis
concerned (e.g. following replacement of a motor or a collision). Otherwise first
mastering must be carried out again.

Unlike the menu item “Teach offset” (which only measures the difference from first
mastering) “Restore mastering” uses exclusively the absolute encoder value determined
during first mastering to recalculate the first mastering.

First mastering must have been carried out before mastering can be restored in this way.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Master laod” from the submenu “Without offset”.

A status window opens, displaying a message.

Please read the message and confirm it by pressing the softkey “OK” in order to continue.
A status window opens, in which the axes to be mastered are displayed.

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The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. Please refer to Section 1.7 for more information.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

The axis to be mastered, highlighted by the colored selection bar, is selected by pressing the
softkey “OK”. The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1 Robot mastering / unmastering (continued)

1.4 Mastering the KR 3


On the robot type “KR 3”, mastering is carried out using the verniers only; these are installed
on each axis.

Vernier on the KR 3

The mastering procedure and mastering menu are completely different from those of the
KR C1 and KR C2 versions. There is a total of three different commands available:

Command Function
Reset Encoder Normal mastering
Commutation Motor -- encoder synchronization
Set Robot Position First mastering

First of all, make sure that the operating mode “T1” and the option “Manual traversing” are
set.

Information on manual traversing of the robot can be found in the documentation


[Operator Control], in the chapter [Manual traversing of the robot].

Then press the menu key “Setup”. Select the option “Master” from the menu that is opened,
then select the desired command.

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This menu items “Commutation” and “Set Robot Position” are not available below the user
group “Expert”.

1.4.1 Reset Encoder


This command can be used to master the robot, provided that first mastering (“Set Robot
Position”) has already been carried out. To do this, select the command “Reset Encoder”.

This causes the corresponding status window to be opened, in which the axes still to be
mastered are displayed.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. More detailed information about this can be found in Section 1.7.

Then move the desired axis into the mastering position by bringing the respective vernier
marks into alignment.
After that, press the softkey “Master”. The entry for the corresponding axis is then removed
from the status window.

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1 Robot mastering / unmastering (continued)

1.4.2 Commutation
Commutation is used to synchronize the motor and the encoder. This function is required in
the event of an encoder or motor exchange.

This function may only be carried out by our Service department or by personnel
trained at KUKA Roboter GmbH.

Select the command “Commutation”.

This causes the corresponding status window to be opened, in which the axes to be
commutated are displayed.

Then move the desired axes to a position which is as gravity--neutral as possible, and
press the Start key.

A position which is as gravity--neutral as possible is necessary because the brake of the


axis in question will be released briefly. An unfavorable position may lead to unintended
axis motion during this procedure.

Then press the softkey “Master”. The brake of the axis in question is released briefly, the
synchronization is carried out and then the brake is applied again.
The entry for the corresponding axis is not removed from the list; the procedure can be
repeated at any time.

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1.4.3 Set Robot Position


This command is used for first mastering of the KR 3. Since as a rule all robots are shipped
with the first mastering already performed by the manufacturer, this step is normally not
necessary. It must be carried out, however, if an encoder or motor is exchanged.

In order to carry out first mastering, the axis in question must first be unmastered and then
commutated.

Move the axis to be mastered into the mastering position by bringing the vernier into
alignment. Use a spirit level to check the exact position. Then press the softkey “Master”.
The entry for the corresponding axis is then removed from the status window.

Further information on setting the robot position or initial mastering can obtained from our
Service department.

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1 Robot mastering / unmastering (continued)

1.5 Mastering of master/slave drives


If the robot system contains additional position--controlled master/slave drives, they must be
mastered prior to use.

This function is only available if the appropriate master/slave drives are present and the
necessary entries have been made in the machine data.
Torque--controlled slave drives do not require mastering, and are not shown in the status
window.

To open this menu, press the menu key “Setup”. Select here the option “Master” --> “Dial”.

EMT mastering of the master/slave drives is not possible.

The status window for mastering is then opened.

The status line of the status window shows


the robot axis currently active and the drive
which is selected.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered is indicated by a color background.
The status keys “Drive +” and “Drive --” can be used to select a drive, which can then be
traversed using the jog key of the corresponding axis. The possibilities here are:
G All: The selected axis and the master and slave drives are traversed
together
G Master: Only the master drive is traversed
G Drive 1 ... 5: Only the corresponding slave drive is traversed

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-- + Here the status line in the status window indicates that


when the “+/--” jog key of axis 1 is pressed, only slave drive
no. 2 will be traversed.

If all axes and drives have been mastered, the text “No axes to master” appears in the
window.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. More detailed information about this can be found in Section 1.7.
Furthermore, it is also possible to initiate a new mastering procedure via the menu item
“Check mastering” (“Standard” menu).

The selected axis and the corresponding master and slave drives are mastered by pressing
the softkey “Master”.

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1 Robot mastering / unmastering (continued)

1.6 Reference point mastering


If a robot axis has an absolute encoder, reference point mastering is possible for this axis.
The following mastering types are permissible here:
Mastering

Dial

EMT Standard Set mastering

Check mastering

With load corr. First mastering

Teach offset With offset

Master load Without offset

If at least one axis with an absolute encoder is unmastered, an additional status window for
reference point mastering is displayed.

Availability

Displays the last value


saved

The following options are offered in the softkey bar:

The two softkeys “Drive +” and “Drive --” are used to select the required master/slave drive.

The data saved on the DSE are used for mastering.

The mastering file most recently saved to the hard drive is used.

The robot is remastered using the dial gauge or EMT. The relevant procedures are described
in the corresponding sections in this chapter.
Reference point mastering is terminated using the softkey “Close”.

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1.7 Unmastering an axis


With the aid of this function, individual axes can be specifically unmastered.
Press the “Setup” key. A menu opens. Select the option “UnMaster” from the menu that is
opened.

A status window is then opened, in which the mastered axes are displayed. If all axes have
already been unmastered, the text “No axes to unmaster” appears in the window.

The mastering data for the axis highlighted in color are deleted by pressing the softkey
“UnMaster”.

On account of the mechanical coupling of the robot wrist axes, the data for axes 5 and 6
will also be deleted when axis 4 is unmastered, and similarly the data for axis 6 when axis
5 is unmastered.

The robot axes do not move during unmastering.

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2 Calibration

2 Calibration
2.1 Fundamentals
2.1.1 General
With the aid of the predefined calibration programs, you have a means of easily defining the
dimensions of an
G unknown tool or
G unknown workpiece
using several different procedures.

Tool center point Workpiece reference point


(TCP)
Robot guides the XYZ -- 4 Point
Position 3--Point
tool XYZ -- Reference Position and
orientation
i t ti
ABC -- World
indirect
Orientation
ABC -- 2 Point
Robot guides the
Position and Tool Position and workpiece
workpiece orientation orientation

The data for up to 16 tools or workpieces can be stored. These data are then called by num-
ber in the application program and enable a tool change to be easily programmed.

For reasons of safety, the calibration programs can only be executed in the operat-
ing mode “T1” or “T2”.

2.1.2 Preconditions
Using the calibration functions requires adequate knowledge of operating the robot system.

Relevant information can be found in the documentation


· The KUKA Control Panel KCP,
· Manual traversing of the robot and
· Robot mastering/unmastering

In addition to this, the following preconditions must be met on the part of the robot:
G the correct machine data are loaded;
G all axes must be correctly mastered;
G no program may be selected;
G mode “T1” or “T2” is selected.

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2.1.3 Introduction

Axis 5
45°

Axis 3
75° Axis 4
45°

Axis 6 0° Axis 1 0°
X

Axis 2
Z 75°

X Y

Installed on each axis of the robot are so--called “resolvers”, which constantly measure the
axis angle. Together with the known distances between the robot axes, the controller can
calculate the position and orientation of the flange centerpoint.
The position of the flange center point is defined by its distance from the origin of the world
coordinate system1) (dotted line). This distance is specified in its X, Y and Z components
(dashed lines).

X
The origin of the robot
flange coordinate sys- Y
tem is situated here.
Z
Z

X
Y
The origin of the WORLD coordinate
system is situated here 1).

1) In the basic setting, the world and robot coordinate systems coincide.

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2 Calibration (continued)

The orientation of the robot flange coordinate system, whose origin lies at the flange
centerpoint, is defined by its rotational offset (Z--Y--X Euler angles) from the world coordinate
system1).

X
Y

Z
X

1. Rotation about die Z--Achse --


Rotation about the Z--axis
Angle magnitude A Y --

X
Y

If a coordinate Z +
system is rotated,
a consistent se-
quence must be
+
followed in order
to achieve repro- 2. Rotation about the Y--axis
X
ducible results. Angle magnitude B
Y

Z
--
Z

X 3. Rotation about the X--axis


X
Angle magnitude C
Y --
Y
The information representing a point in space by specification of the coordinates X, Y, Z and
the rotation angles A, B, C is called a FRAME.

1) In the basic setting, the world and robot coordinate systems coincide.

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To enable the position of the reference point of a tool or workpiece mounted on the robot
flange to be calculated, its location and orientation in relation to the robot flange coordinate
system must be known to the robot controller.

The origin of the robot flange


coordinate system is situated
here. Its position and orienta-
tion are known to the robot
controller.

This is the TCP X


(Tool Center Point).

These data can be determined with the aid of an external measuring device. Having been
recorded on a form, the data can be entered into the robot controller at any time. After a
collision, however, these data are no longer valid and must be re--determined.

200

Z
Y

X X
200

TCP (Tool Center Point)


Another possible method of determining the tool data consists in measuring the tool by
means of the calibration systems and calculation functions of the robot.
For this purpose, the TCP of the tool or workpiece mounted on the robot flange is moved to
a reference point from various directions. This reference point can be located at any point
within the work envelope of the robot.

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2 Calibration (continued)

The position of the TCP is then calculated on the basis of these various positions and orienta-
tions of the robot flange.
To enable the tool or workpiece to be moved as quickly as possible without overloading the
drive systems of the robot, the load data of the tool or workpiece must also be taken into
account.

10 kg
Load

100
kg

Maximum acceleration / velocity


For this purpose, the weight, center of gravity and mass moment of inertia of the tool or
workpiece must be entered into the controller.
Any supplementary loads mounted on the robot must not be forgotten.

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2.2 Tool calibration


2.2.1 Overview
The submenu “Tool” contains the following subprograms:

Program Calibration by...


X Y Z -- 4 Point moving the robot to a fixed reference point
X Y Z -- Reference moving the robot with a known reference tool to a reference
point
A B C -- 2 Point moving the robot to 2 points with orientation data
A B C -- WORLD positioning perpendicular to the world coordinate system
Numeric Input entering the tool data
Tool load data entering the mass, center of mass, mass moment of inertia

Each of these calibration programs is assigned forms that guide you interactively through the
program.

Methods for determining the position


These methods are used to determine the position of the TCP (tool center point) in relation
to the origin of the robot flange coordinate system.
These methods include the calibration programs “X Y Z -- 4 Point” (see Section 2.2.2), and
“X Y Z -- Reference” (see Section 2.2.3).

Methods for determining the orientation


These methods are used to determine the rotational offset (A, B and C according to the
Z--Y--X Euler angles) of the tool coordinate system from the robot flange coordinate system.
These methods include “A B C -- 2 Point” (see Section 2.2.4) and “A B C -- WORLD” (see
Section 2.2.5).

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2 Calibration (continued)

Axis 5

Y0

Z0

Z
45°
Y
X X0

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

A B C -- 2 Point
This method is used if an exact orientation of the three tool axes is required for
positioning and manipulation. It requires marked points to be available on the positive
side of the XY plane and on the negative side of the X axis of the tool.
A B C -- World (5D)
This method is used if only the working direction of the tool is required for its positioning
and manipulation (MIG/MAG welding, laser or waterjet cutting).
A B C -- World (6D)
This method is used if the orientation of all three tool axes is required for positioning
and manipulation (for example: welding guns, grippers, adhesive nozzles, etc.).
Method for TOOL orientation
If a tool is known, its dimensions and angular positions are entered. This is done via the menu
item “Numeric Input” (see Section 2.2.6).

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2.2.2 X Y Z -- 4 Point
In the “4--Point” method, the TCP of the tool is moved to a reference point from four different
directions (hence “4--Point” method).

The position of the TCP (TOOL Center Point) is then calculated on the basis of the various
positions and orientations of the robot flange.
Procedure
Mount the tool to be calibrated onto the robot flange and establish a suitable reference point.
This can be the tip of the reference spike installed in the work envelope or also a distinctive
corner of a workpiece or a fixture.
Using the menu key “Setup” (at the top of the display) open the menu “Measure” (“Calibrate”)
and “Tool” and there select the submenu “X Y Z -- 4--Point”.

The dialog window for 4--point calibration is opened:

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2 Calibration (continued)

Use the status key (at the bottom right of the display) and the +/-- key to select the desired
tool number. Calibration data for a total of 16 different tools can be stored. The current dimen-
sions or angles of the tool in question are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.
Press the softkey “Tool OK” (at the bottom of the display) in order to calibrate the selected
tool. The next status window is then automatically opened.

You are now prompted to align the tool to a reference point from different directions. Either
the axis traversing keys or the Space Mouse can be used to do this. Now carry out the
following steps in the order given:
G Set the desired tool orientation.
G Move the TCP to the reference point.
G When the TCP is located exactly on the reference point, save its position by pressing
the softkey “Point OK”.
If the selected points are too close together, an error message is generated. You can now
press the softkey “Repeat” to repeat the last calibration, or the softkey “Repeat All” to repeat
all calibrations.
After the point has been accepted by the controller, you are prompted to align the TCP to
the reference point from another direction. Repeat these steps until the reference point has
been addressed from four directions and the point coordinates transferred.

P4
P1

P3

YT
XT
P2
ZW
fixed point
in space ZW

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Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

For this purpose you can use increase or decrease the traversing velocity using the +/-- key
of the “Jog--OV” status key. Reducing the deflection of the Space Mouse also reduces the
velocity.

At the end of the calibration procedure, you will be offered the softkey “Save” (at the bottom
of the display). Save the tool data by pressing this softkey. The function is terminated.

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2 Calibration (continued)

2.2.3 X Y Z -- Reference
In this method, the data of a tool to be calibrated are determined by means of comparison
with a known tool by moving the TCP to a reference point.

To achieve this, a tool of known


dimensions is moved, from any
direction, to a reference point.
known tool

fixed point in space

The tool to be calibrated is then


mounted on the robot flange.
This tool is also moved to the
unknown tool reference point, again from any
direction.

fixed point in space

On the basis of the various positions and orientations of the robot flange and the known
dimensions of the tool previously used, the robot controller can now calculate the dimensions
of the tool that is to be calibrated.

Procedure
Mount a tool whose dimensions are known to the controller onto the robot flange and
establish a suitable reference point.
This can be the tip of the reference spike installed in the work envelope or also a distinctive
corner of a workpiece or a fixture.
Using the menu key “Setup” open the menu “Measure” (“Calibrate”) and “Tool” and there
select the menu item “X Y Z -- Reference”.

The following dialog window is opened after this menu has been selected:

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Use the status key (at the bottom right of the display) and the +/-- key to select the desired
tool number. Calibration data for a total of 16 different tools can be stored. The current dimen-
sions or angles of the tool in question are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.
Press the softkey “Tool OK” in order to edit the data for this tool. The dialog window for data
entry is then opened.

Use the numeric keypad to enter the dimensions of the reference tool, i.e. the known tool,
in the input boxes X, Y and Z.
You can move between the input boxes using the “¯” or “­” arrow keys.

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2 Calibration (continued)

Example:
X, Y, Z Distance between the origin of the robot flange coordinate system (located
at the center of the flange) and the TCP (tool center point) of the reference
tool in relation to the robot flange coordinate system.

Y
Z

X= + 50 X Flange adap-
tor plate as
reference
tool

In the example:

If the entries have been made correctly, confirm this by pressing the softkey “Data Ok”. The
window prompting you to move to the reference point is opened.

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The robot can be moved using either the traversing keys or the Space Mouse. Now carry out
the following steps in the order given:
G Set the desired tool orientation.
G Move the TCP to the reference point.
G When the TCP is located exactly on the reference point, save its position by pressing
the softkey “Point OK”.

Reduce the traversing velocity in the vicinity of the reference point in order to avoid
a collision.

To do so, repeatedly press the status key on the right of the display.

After the point has been accepted by the controller, you are prompted to align the tool that
is to be calibrated to the reference point.

First move the tool away from the reference point. Then replace the known tool with the un-
known tool and move to the reference point again.

known tool
unknown tool
fixed point
in space

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

To do so, repeatedly press the status key “Jog override”, on the right of the display.

Now confirm the position with the softkey “Point Ok”. The X, Y and Z dimensions of the
defined tool are displayed in the form that is then opened.

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2 Calibration (continued)

The data are saved and the calibration program is ended by pressing the softkey “Save”.

You are currently able to open the corresponding subprograms by means of the softkeys
“A B C -- 2 Point”, “A B C -- World” or “Load data”. It is also possible to view the calibrated
points by pressing the softkey “Meas. Pt.”. Further information on this can be found in the
following sections.

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2.2.4 A B C -- 2 Point
In this method, the orientation of the tool coordinate system is defined in two steps.

The first step is to show the robot control


system the working direction of the tool.
Y To achieve this, the TCP is first moved
to any reference point.
Z

X Reference
point

A point on the tool opposite the TCP (in


the reverse working direction) must
now be moved to the same reference
Z point.
Y This serves to define the working direc-
tion of the tool is determined in this way.

Reference
point X

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2 Calibration (continued)

The YZ plane can still rotate freely about


the X axis (working direction) of the tool
and is defined in the second step.
Z To achieve this, the tool is positioned in
such a way that the reference point lies
Y in the future XY plane with a positive Y
value.
Reference
point
X

Procedure
Mount the tool to be calibrated onto the robot flange and establish a suitable reference point.
This can be the tip of the reference spike installed in the work envelope or a distinctive corner
of a workpiece or a fixture.
Using the menu key “Setup” open the menu “Measure” (“Calibrate”), the submenu “Tool” and
the option “A B C -- 2 Point”.

The following dialog window is opened after this menu has been selected:

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Use the status key (at the bottom right of the display) and the +/-- key to select the desired
tool number. Calibration data for a total of 16 different tools can be stored. The current dimen-
sions or angles of the tool in question are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

If this definition procedure is called by means of the softkey “X Y Z -- Reference” (see


Section 2.2.3), the form for entering the tool number will not be opened.

Press the softkey “Tool OK” in order to edit the data for this tool. The dialog window for enter-
ing the TCP value is then opened.

Position the TCP (tool center point) to a reference point.

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

For this purpose you can raise or lower the traversing velocity using the +/-- key of the
“Jog--OV” status key. Reducing the deflection of the Space Mouse also reduces the velocity.

When the TCP (tool center point) is located exactly on the reference point, save this position
by pressing the softkey “Point OK”. The status window then changes.

First move the tool away from the reference point.

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2 Calibration (continued)

Here also, reduce the traversing velocity in the vicinity of the reference object in or-
der to avoid a collision.

To do so, press the status key “Jog--OV” again.


Position a point located opposite the TCP in the reverse working direction to the reference
point.

Z
Y

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

To do so, repeatedly press the status key shown here (on the right of the display).

When the TCP (tool center point) is located exactly on the reference point, save this position
by pressing the softkey “Point OK”. The status window then changes again.

Move the tool so that the reference point is located with a positive Y value on the future XY
plane of the tool.

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

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To do so, repeatedly press the status key shown here (on the right of the display).

When the TCP (tool center point) is located exactly on the reference point, save this position
by pressing the softkey “Point OK”.

If the error message Point too near to reference point is displayed, the distance to the
previous point is too small. The form cannot be closed by pressing “Point Ok” until the
distance has been increased.

You are currently able to open the corresponding subprogram by means of the softkey
“Load data”. More detailed information about this can be found in Section 2.2.7.It is also
possible to view the three different measuring points (coordinates) by pressing the softkey
“Meas. Pt.”

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is then terminated.

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2 Calibration (continued)

2.2.5 A B C -- World
The desired function is selected by pressing the menu key “Setup”, and then calling
“Measure” (“Calibrate”) and the submenu “Tool”.

The approach is different depending on whether you are using the 5D method (see Section
2.2.5.1) or 6D method (see Section 2.2.5.2).
2.2.5.1 The “A B C -- World (5D)” method
In this method, the tool must be oriented parallel to the Z axis of the world coordinate system
in the working direction. The Y and Z axes are oriented by the robot controller. The orientation
of these axes is not readily foreseeable in this instance, but it is exactly the same in each
calibration procedure.

Condition:
X parallel to Z0
Z0
Z Y
X
X0
Y0

Procedure

Mount the tool to be calibrated onto the robot flange.


Select the menu item “A B C -- World”. The dialog window for selecting the tool number is
then opened:

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Select the tool number (1...16) which can be altered by means of the +/-- keys of the
corresponding status key (at the bottom right). The current values for the selected tool are
displayed in the lower part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Press the softkey “Tool OK” (at the bottom of the display), in order to enter data for this tool.

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If the “6D” option is activated (i.e. is highlighted in color), you must select the “5D” method
using the status key.Then press the softkey “Data OK” in order to be able to edit the tool
data. You will now be prompted to align the tool.

Z Y
X
Z0
Condition:
X parallel to Z0
or
Z parallel to Z0
X0
Y0

When all entries have been made, confirm them by pressing the softkey “Point OK” (at the
bottom of the display).

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At this point you can open the corresponding subprogram by means of the softkey “Load
data”.
Further information on this can be found in Sections 2.2.7. and 2.7.

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is terminated.

In the event of 5D calibration, the angle “C” (corresponding to a rotation about the X--axis
of the tool direction) is set by default to “0”.

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2 Calibration (continued)

2.2.5.2 The “A B C -- World (6D)” method


In this method, the tool must be oriented in alignment with the world coordinate system. The
axes of the tool coordinate system must be parallel to the axes of the world coordinate
system.

Conditions:
X parallel to Z0
Z
Y parallel to Y0
X Y
Z parallel to X0 Z0

X0
Y0
Procedure
Mount the tool to be calibrated onto the robot flange.
Select the menu item “A B C -- World”. The dialog window for selecting the tool number is
then opened:

Select the tool number (1...16) which can be altered by means of the +/-- keys of the
corresponding status keys (on the bottom, righthand side). The current values for the
selected tool are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Press the softkey “Tool OK” (at the bottom of the display) in order to enter data for this tool.

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Next select the “6--D” method by means of the status key (at the bottom right of the display).
Then press the softkey “Data OK” in order to be able to edit the tool data. You will now be
prompted to align the tool.

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2 Calibration (continued)

Conditions:
X parallel to Z0
Y parallel to Y0
Z parallel to X0

Z
Y Z0
X

X0
Y0

When all entries have been made, confirm them by pressing the softkey “Point OK” (at the
bottom of the display).

Once again you are able to open the corresponding subprogram by means of the softkey
“Load data”.
Further information on this can be found in Sections 2.2.7. and 2.7

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is terminated.

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2.2.6 Numeric Input

This menu item enables you to enter the numeric values of a fixed tool. Open the menu item
using the softkey “Setup”, the menu “Measure” (“Calibrate”) and the menu option “Numeric
Input”.

The corresponding dialog window is then opened:

Select the tool number from 1...16 using the status key at the bottom right of the display.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.
Press the softkey “Tool OK” in order to edit the data for this tool. The dialog window for data
entry is opened.

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2 Calibration (continued)

You can move between the input boxes and make the desired entries using the “¯” or “­”
arrow keys.

The abbreviations in the dialog window have the following meaning:

X, Y, Z Distance between the origin of the robot flange coordinate system


(located at the center of the flange) and the TCP (tool center point) in
relation to the robot flange coordinate system.

Please note !
Z= + 200
The illustrated position for the
X flange coordinate system is
only valid if axes 4, 5 and 6 are
in the zero position.

In the example:

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A, B, C Rotational offset of the tool coordinate system (Z--Y--X Euler angles)


from the robot flange coordinate system.

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

Y0

Z0

Please note !
Z
45° The illustrated position for the
Y flange coordinate system is
only valid if axes 4, 5 and 6 are
X X0 in the zero position.

In the example:

When all entries have been made, confirm them by pressing the softkey “Data OK” and save
the entries that have just been made.

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The tool number and tool data are displayed in the form. These data are saved and the form
is closed by pressing the softkey “Save”.

You are currently able to open the corresponding subprogram by means of the softkey
“Load data”. More detailed information about this can be found in the following section.

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2.2.7 Tool load data


In order to optimize use of the available maximum moments of acceleration of the robot axes,
it is possible to enter the load data of the tool that is being used.

If loads lower than those actually existing are programmed, the robot system is
liable to be mechanically or electrically overloaded.

If the tool load is greater than the permissible rated load given in the payload
diagram of the robot specification, mechanical or electrical overloads of the robot
system are liable to occur in the case of LIN and CIRC motions. This is dependent
on the programmed path velocity and the position of the robot.

No liability will be accepted for any resultant damage!


The menu item “Payload data” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “Tool”.

It is possible to branch directly to the tool load data from the calibration programs
“X Y Z -- Reference”, “A B C -- 2 Point”, “A B C -- World” and “Numeric Input”. It is not
possible, in this case, to enter a tool number.

The relevant dialog window is then opened in which you can enter the number of the tool to
be changed:

Here also a total of 16 different tools can be entered.

...
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Press the softkey “Tool OK” in order to be able to edit the data for the selected tool. The status
window for data entry is then opened.

You can move between the input boxes with the aid of the “¯” and “­” arrow keys and enter
the desired values using the number keys in the numeric keypad.
or
Press the softkey “Default” in the bottom part of the display to accept the standard load data
defined in the basic settings of the system.

The default setting in the box “M [kg]” is --1 (load specified in the machine datum). If 0 is
entered here, there is no tool load on the robot arm.

Check beforehand by referring to the payload diagram in the robot specification


whether the tool lies within the permissible range for standard loads!

The abbreviations in the dialog window have the following meaning:


M Weight of the tool.
X, Y, Z Distance between the center of gravity of the tool and the origin of the
robot flange coordinate system (located at the center of the flange) in
relation to the robot flange coordinate system.

Y
Z

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A, B, C Rotational offset of the principal inertia axes of the tool (Z--Y--X Euler
angles) from the robot flange coordinate system.

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

JX, JY, JZ Mass moments of inertia about the principal inertia axes of the tool.
When all entries have been made, confirm them by pressing the softkey “Data OK”. The tool
load data are displayed for control purposes.

The softkey “Save” is then used to save the data and close the dialog window.

Further information on the calculation of tool load data can be found in the additional
documentation Load Data Determination.

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2.3 Base
2.3.1 Overview

The menu “Base” is opened by first pressing the menu key “Setup”, and then selecting the
menu “Measure” (“Calibrate”).

The submenu “Base” contains the following subprograms:

Program Calibration by...


3--Point moving to the reference point of a workpiece
Indirect entering the inaccessible reference point of a workpiece
Numeric Input entering a reference point manually

Each of these calibration programs is assigned forms that guide you interactively through the
program.

2.3.2 3--Point
This method is used to determine the reference point of a workpiece (BASE).
This is done by positioning a tool whose dimensions are known to the controller to three
specific points, which are then programmed. These three points determine both the position
of the origin and the orientation of the base coordinate system.

Z
Origin Point on the X Point in the Result
axis XY plane with
a positive Y
value
Procedure
Mount a tool whose dimensions are known to the controller onto the robot flange.
Open the menu using the menu key “Setup”, then the submenu “Base” and finally select the
command “3--Point”.

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The input window for the base system is opened:

Use the +/-- status key (at the bottom right of the display) to select the number of the base
coordinate system.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.
Press the softkey “Base OK” (at the bottom of the display) in order to open the next input
window.

The input window for selecting the reference tool is then opened:

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Use the +/-- status key (at the bottom right of the display) to select the tool number.

...
Press the softkey “Tool OK” (at the bottom of the display) in order to perform the calibration
with this tool.
A window is opened.

You are prompted to position the TCP (tool center point) to the future origin of the base
coordinate system (BASE).

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key shown here (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired origin of the base
coordinate system (BASE), save this position by pressing the softkey “Point OK”.

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The next window is opened:

You are prompted to show the controller the orientation of the X axis by positioning the TCP
to a specific point.
First move the tool away from the workpiece:

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key shown here (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired point, save this position
by pressing the softkey “Point OK”.

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The following dialog window is opened:

You are prompted to show the controller the orientation of the XY plane by moving the tool
to a point with a positive Y value.

First move the tool away from the workpiece:

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key (at the top right of the display).

When the TCP (tool center point) is located exactly at the point with a positive Y value on
the XY plane, save this position by pressing the softkey “Point OK”.

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When the softkey “Meas. Pt.” is pressed, a window appears in which the values of the
individual measurements are listed once again.
Save the workpiece data by pressing the softkey “Save” (at the bottom of the display).
The function is terminated.

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2.3.3 Indirect
This method is used if the reference point of the workpiece (BASE) is not located inside the
work envelope of the robot (in the case of very large workpieces) or cannot be reached by
the robot (workpieces of complex shape).
In this method, the robot is moved to four points whose positions are known (manufacturing
drawing, CAD data, etc.). The tool dimensions must be known to the controller.

Procedure
Mount a tool whose dimensions are known to the controller onto the robot flange.
The menu “Indirect” is accessed via the menu key “Setup”, the menu “Measure” and the sub-
menu “Base”.

The input window for selecting the base coordinate system is opened:

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Use the status key (at the bottom right of the display) to select the workpiece (base) number.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.
Press the softkey “Base OK” (at the bottom of the display) in order to enter data for this
workpiece.

The input window for selecting a tool is opened.

Use the +/-- status key, at the bottom right of the display, to select the tool number.

...
Press the softkey “Tool OK” in order to perform the calibration with this tool.

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The following window is opened:

You are prompted to enter the coordinates of points known to you and then to position the
TCP to these points. To do so, carry out the following procedure:

Step 1 -- Enter the values by means of the numeric keypad.


You can move between the input boxes using the “¯” arrow key.
X, Y, Z Distance between the calibration point and the workpiece reference point
(BASE).

Point 2

Point 1
Point 3

Point 4
Workpiece Z
reference
point (BASE)

X
Y
Step 2 -- Move the TCP to the specified point.

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key shown here (at the top right of the display).

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Step 3 -- Save the point


When the TCP (tool center point) is located exactly at the point you specified beforehand,
save this position by pressing the softkey “Point OK”.

After the point has been accepted by the controller, you are prompted to move the TCP to
the next three points. Repeat steps 1 to 3 until all four points have been addressed.
At the end of the calibration procedure, you will be offered the softkey ”Save” (at the bottom
of the display). Save the workpiece data by pressing this softkey. The function is then
terminated.

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2.3.4 Numeric Input


Open the menu the menu “Measure” using the softkey “Setup”, then select “Base” and finally
“Numeric Input”.

The input window for the base coordinate system is opened:

Use the +/-- status key to select the desired coordinate system.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.
Press the softkey “Base OK” in order to enter the corresponding data.
The following window is then opened:

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Enter the values by means of the numeric keypad.

You can move between the input boxes using the “¯” arrow key.
X, Y, Z Distance between the origin of the world coordinate system and the workpiece
reference point (BASE) in relation to the world coordinate system.

Workpiece Z
reference
point

X
Y
A, B, C Rotational offset of the base coordinate system (Z--Y--X Euler angles)
from the world coordinate system.
Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

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When all entries have been made, confirm them by pressing the softkey “Data OK” (at the
bottom of the display).

Save the workpiece data by pressing the softkey “Save” (at the bottom of the display).
The function is terminated.

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2.4 Fixed tool


2.4.1 Overview
The menu “Fixed tool” is opened by first pressing the menu key “Setup”, and then selecting
the menu “Measure”.

The submenu “Fixed tool” contains the following subprograms:

Programs Calibration by...


Workpiece (TOOL) moving with the workpiece mounted on the robot flange
Tool (BASE) moving the robot to a fixed tool
Offset external kinematic moving the robot to a fixed tool on an external kinematic
system
Numeric Input entering a fixed tool manually

Each of these calibration programs is assigned forms that guide you interactively through the
program.

2.4.2 Workpiece (TOOL)


This method is used to determine the reference point (BASE) of a workpiece mounted on
the robot flange.
This is done by positioning and saving three specific points on the workpiece to a fixed tool
whose dimensions are known to the controller. These three points determine both the
position of the origin and the orientation of the base coordinate system.

Y
X

Origin Point on the X Point in the Result


axis XY plane

Procedure
Install a fixed tool whose dimensions are known to the controller.
Using the menu key “Setup” open the menu “Measure” (“Calibrate”), then the submenu
“Fixed tool” and there select the menu item “Workpiece”.

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The following input window is opened:

Use the +/-- status key to select the workpiece coordinate system.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.
Press the softkey “Tool OK” in order to switch to the next input window.
This opens the following window:

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Use the +/-- status key to select the tool number.

...
Press the softkey “Base OK” in order to perform the calibration with this tool.

The next window is opened:

You are prompted to position the future origin of the base coordinate system (BASE) to the
TCP (center point) of the fixed tool.

Reduce the path velocity in the vicinity of the fixed tool in order to avoid a collision.

To do so, repeatedly press the status key (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired origin (BASE), save this
position by pressing the softkey “Point OK”.

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The next window:

You are prompted to show the controller the orientation of the X axis by positioning a specific
point to the TCP.
First move the workpiece away from the TCP.

Reduce the path velocity in the vicinity of the fixed tool in order to avoid a collision.

To do so, repeatedly press the status key (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired point, save this position
by pressing the softkey “Point OK”.

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Another window is opened:

You are prompted to show the controller the orientation of the XY plane by positioning a
specific point to the TCP.

First move the workpiece away from the TCP.

Reduce the path velocity in the vicinity of the fixed tool in order to avoid a collision.

To do so, repeatedly press the status key “Jog override”.

When the TCP (tool center point) is located exactly at the point with a positive Y value in the
XY plane, save this position by pressing the softkey “Point OK”.

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X
Y

At this point you can open the corresponding subprograms by means of the softkeys “Load
data” or “Meas. Pt.”.
Further information on this can be found in Sections 2.2.7. and 2.7.
Save the workpiece data by pressing the softkey “Save”. The function is then
terminated.

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2.4.3 Tool (BASE)


This method is used to determine the TCP (center point) of a tool that is stationary rather than
handled by the robot.

First of all, a tool of known


dimensions is moved to the
TCP of the fixed tool.

In a second step, the robot


flange is positioned perpendi-
cularly to the working direction
of the tool.

Procedure
Mount a tool whose dimensions are known to you onto the robot flange.
The corresponding menu is opened by pressing the menu key “Setup”, followed by the menu
“Measure” (“Calibrate”) and “Fixed tool”.

The following dialog window is opened:

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2 Calibration (continued)

Use the +/-- status key (at the bottom right of the display) to select the tool number (1...16)
of the tool to be calibrated.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.
Press the softkey “Tool OK” to open the next dialog window.

Use the status key to select the number of the reference tool mounted on the robot.

...
When you have selected both tools by pressing the softkey “Tool OK” you can choose
between the measurement methods 5--D and 6--D.

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It is possible to switch between the 5--D and 6--D measurement methods by pressing the soft-
key at the bottom, right edge of the display.

5--D method
This method is used if only the working direction of the tool is required for its positioning
and manipulation (MIG/MAG welding, laser or waterjet cutting).

The working direction of the


fixed tool is determined by the
position of the robot flange
alone. It is perpendicular to the
X flange. The orientation of the X
and Y axes of the tool coordi-
Z Y nate system is now determined
by the robot control system.
The orientation of these axes is
thus not readily predictable, but
is identical with every calibra-
tion.

In the event of 5D calibration, the angle “C” (corresponding to a rotation about the X--axis
of the tool direction) is set by default to “0”.

6--D method
This method is used if the orientation of all three tool axes is required for positioning
and manipulation (for example with welding guns, grippers, adhesive nozzles).

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The orientation of the tool coor-


dinate system is parallel to the
robot flange coordinate system.

Use the softkey “Data Ok” to confirm your selection and open the form for defining the TCP.

Define the working direction of the tool for the controller.

You are now prompted to move the reference tool on the robot to the fixed tool. This can be
done using the axis traversing keys or the Space Mouse.

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Reduce the traversing velocity in the vicinity of the reference point in order to avoid
a collision.

To do so, repeatedly press the status key on the right of the display.

Now carry out the following steps in the order given:


G Set the desired tool orientation.
G Move the TCP (tool center point) of the reference tool until it coincides with the point
on the fixed tool.
G The data are saved by pressing the softkey “Point OK”.

After the point has been accepted by the controller, the status window for orientating the wrist
flange is then opened:

First move the tool away from the reference point.

Reduce the traversing velocity in the vicinity of the reference point in order to avoid
a collision.

To do so, repeatedly press the status key on the right of the display.

Now move the axes in such a way as to align the wrist flange perpendicular to the fixed tool
with the axis traversing keys or with the Space Mouse.
The data are adopted and the form for saving the data is opened by pressing the softkey
“Point Ok”.

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2 Calibration (continued)

When the softkey “Meas. Pt.” is pressed, a window appears in which the values of the
individual measurements are listed once again.

Save the tool data by pressing the softkey “Save”. The function is then terminated.

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2.4.4 Offset external kinematic


With this definition procedure, you can define a tool on an external kinematic system.

IV

III
Here a tool has been mounted on
the external kinematic system.
The distance between coordinate
system III and coordinate system
IV must be manually entered or ca-
librated.

Press the menu key “Setup”, then select the menu “Measure” (“Calibrate”) and the submenu
“Fixed tool” and finally the menu item “Offset external kinematic”.

The following form is then opened

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Use the +/-- status key (at the bottom right of the display) to select the tool number (1...6)
of the tool to be calibrated on the external kinematic system.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the external axis.
Press the softkey “ExtBase OK” (at the bottom of the display) in order to calibrate the external
tool.
The window for selecting the reference tool is opened:

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Now select the number of the desired reference tool (1...16).

...
Press the softkey “Tool OK” in order to specify the calibration method for this tool.
The following window is opened:

Here you can select the measurement method that is to be used. The selected method
affects the orientation of the tool coordinate system.
The 5D method is used if only the working direction of the tool is required for its positioning
and manipulation (MIG/MAG welding, laser or waterjet cutting).
The 6D method is used if the orientation of all three tool axes is required for positioning and
manipulation (for welding guns, grippers, adhesive nozzles, etc.).

5D method
In this method, the Z axis of the robot flange coordinate system tool must be oriented
parallel to the future working direction of the tool. The Y and Z axes are oriented by
the robot controller. The orientation of these axes is not readily foreseeable in this
instance, but it is exactly the same in each calibration procedure.

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In the event of 5D calibration, the angle “C” (corresponding to a rotation about the X--axis
of the tool direction) is set by default to “0”.

X
Condition:
Z parallel to X0

Y
Z
X0 Robot flange
Y0 coordinate system

Z0

Resulting tool coordi-


nate system, orienta-
tion of Y and Z not
readily foreseeable.

6D method
In this method, the robot flange must be oriented in alignment with the tool. The axes
of the robot flange coordinate system must be parallel to the future axes of the tool
coordinate system.

X
Conditions:
X parallel to Z0
Y parallel to Y0
Z parallel to X0
Y
Z
Robot flange
X0 coordinate system
Z0

Y0
Resulting tool
coordinate system

Use the status key (at the bottom right of the display) to select the method meeting your
requirements and confirm your choice by pressing the softkey “Data OK” (at the bottom of
the display).

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Use the softkey “Data Ok” to confirm your selection and open the form for defining the TCP.

You are prompted to move the TCP (tool center point) of the selected reference tool to the
future TCP (tool center point) of the tool attached to the external kinematic system.

Reduce the traversing velocity in the vicinity of the tool in order to avoid a collision.

To do so, repeatedly press the +/-- key of the status key “HOV” (on the right of the display).

When the two TCPs (tool center points) coincide exactly, save this position by pressing the
softkey “Point Ok”.

TCP of the reference tool

TCP of the external tool

The next status window asks for a change in the orientation of the wrist flange:

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2 Calibration (continued)

Now align the robot flange perpendicular to the future working direction of the tool attached
to the external kinematic system using the axis traversing keys or the Space Mouse.

Reduce the traversing velocity in the vicinity of the tool in order to avoid a collision.

To do so, repeatedly press the status key “HOV” again.

When the robot flange is exactly perpendicular to the working direction of the tool, save this
position by pressing the softkey “Point OK”. The next dialog window shows the number and
the data of the calibrated tool:

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When the softkey “Meas. Pt.” is pressed, a status window appears in which the values of the
measuring points are listed once again.
The data are saved and the calibration program is ended by pressing the softkey “Save”.

Further information on this can be found in the documentation [Start--up], chapter


[Calibration -- External kinematics].

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2 Calibration (continued)

2.4.5 Numeric Input


The menu “Numeric Input” is opened by first pressing the menu key “Setup”, and then
selecting the menu “Measure” (“Calibrate”) and the submenu “Fixed tool”.

After selecting this menu item, the first dialog window for entering the tool number is opened.

It is possible to activate the relevant tool number (1...16) using the +/-- status key at the
bottom right of the display.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.
Press the softkey “Tool OK” (at the bottom of the display) in order to be able to enter data
for this tool. The status window then changes:

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Move to the desired input box with the aid of the “¯” or “­” arrow keys and enter the tool data
using the numeric keypad.

The abbreviations in the dialog window have the following meaning:


X, Y, Z Distance between the TCP (Tool Center Point) and the origin of the world
coordinate system in relation to the world coordinate system.

TCP
(Tool
Center Z
Point)

X
Y
A, B, C Rotational offset of the tool coordinate system (Z--Y--X Euler angles)
from the world coordinate system.

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2 Calibration (continued)

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
When all entries have been made, confirm them by pressing the softkey “Data OK” (at the
bottom of the display).

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is terminated and the dialog window closed.

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2.5 Supplementary load data

After selecting the menu item “Supplementary load data”, the relevant dialog window is
opened:

For entry of the supplementary load, axis 3 is displayed as standard. The desired axis (1...3)
for entry of the supplementary load can be selected using the +/-- status key at the bottom
right of the display.

Confirm your choice of axis by pressing the softkey “Axis Ok”.


It is now possible to enter the supplementary load data for your chosen axis.

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2 Calibration (continued)

You can move between the individual input boxes with the “¯” or “­” arrow keys and enter
the necessary data by means of the alphanumeric keypad.
or
Press the softkey “Default” in the bottom part of the display to accept the standard load data
defined in the basic settings of the system.

The default setting in the box “M [kg]” is --1 (load specified in the machine datum). If 0 is
entered here, there is no supplementary load on the robot arm.

Load center

Z
--

Flange

Z
+ Y
X

The abbreviations in the dialog window have the following meaning:


M Weight of the tool.
X, Y, Z Distance between the center of gravity of the supplementary load and the
origin of the robot flange coordinate system (located at the center of the
flange) in relation to the robot flange coordinate system.
A, B, C Rotational offset of the principal inertia axes of the supplementary load
(Z--Y--X Euler angles) from the robot flange coordinate system.

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Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
JX, JY, JZ Mass moments of inertia about the principal inertia axes of the
supplementary load.

Check beforehand by referring to the payload diagram in the robot specification


whether the supplementary load lies within the permissible range for standard
loads!

When all entries have been made, confirm them by pressing the softkey “Data OK”. This
closes the form and opens the form for saving the data.

The softkey “Save” is used to save the data and close the dialog window.

Further information on the calculation of load data can be found in the documentation
[Load Data Determination].

2.6 External kinematic

Information on this can be found in the chapter [Calibration -- External kinematics].

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2 Calibration (continued)

2.7 Measurement Points


With this menu item, you can view the saved calibration data.

After this selection has been made, a status window is opened displaying the respective
calibration methods used and listing the coordinates of all calibration points (measurement
points).

You can switch between the various tools or workpieces by means of the status key (at the
bottom right of the display).

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2.8 Tolerances
Here, you can use the numeric keypad to enter the tolerance limits for tool calibration.

Minimum Distance [TOOL]


The minimum distance for tool calibration.
Range of values 0...200 mm.
Minimum Distance [BASE]
The minimum distance for base calibra-
tion. Range of values 0...200 mm.
Minimum Angle
The minimum angle between the straight
lines through the three calibration points in
base calibration. Range of values
0...360˚.
Maximum Calibration Error
Maximum error in calculation. Range of
values 0...200 mm.

The data in the input boxes are saved by pressing the softkey “Data OK”.

The default settings are restored by pressing the softkey “Default”. They must be saved by
pressing the softkey “Data OK”.

Retain the preset values where possible and only modify them in exceptional cases!
Otherwise, increased error messages and inaccuracy may result.

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2 Calibration (continued)

2.9 Error treatment


If an error occurs during a calibration procedure, a status window is opened containing
detailed information about the error that has occurred.

In the event of the following errors:


G Point too near to reference point
G Point too near to origin point
G Point too near to other point
this status window is opened.

In the adjacent example, the fourth


point of the X Y Z -- 4 Point tool cal-
ibration was impermissibly close to
the first point.

Error message Remedy


Point too near to reference point Move to a point that is further away from the refer-
ence point.
Point too near to origin point Move to a point that is further away from the origin.
Point too near to other point Move to a point that is further away from other
points.

Pressing the softkey “Repeat” repeats the calibration that has been queried.

If you want to repeat the whole calibration procedure from the beginning, press the softkey
“Repeat All”.

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In the event of the following errors a corresponding status window is opened:


G Measurement error too big
G All points in one plane
G All points in a line

Measurement error too big

Error message Remedy


Measurement error too big Positioning was too inaccurate. Repeat with
greater precision.
Further possibilities:
-- the robot was not mastered or incorrectly
mastered
-- the machine data are incorrect/no longer correct
-- mechanical defect of the robot
All points in a line Make sure that the calibration points are not all in
a straight line.
All points in one plane The robot flange must have a greater change in
orientation.

Pressing the softkey “Repeat” repeats the last calibration point.

If you want to view the coordinates of the calibration points, press the softkey “Calib. Pt”.

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2 Calibration (continued)

If you want to repeat the whole calibration procedure from the beginning, press the softkey
“Repeat All”.

Special feature of 4--point calibration


With 4--point calibration it is possible to refer back to previously measured points, thus simpli-
fying the calibration process. The following additional softkeys are available for this purpose:

Drive to p. Automatically moves to the previously measured point, as defined in the table, when the start
key is pressed.
The calibration program saves the coordinates of the current robot position.

To move to a previously measured point by means of the softkey “Drive to p.” the operating
mode “T1” must be set.

The robot moves to previously measured points with a PTP motion when the softkey “Drive
to p.” is pressed. No check is made to see whether it is possible to move to this point from
the current robot position.

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3 Calibration -- External kinematics

3 Calibration -- External kinematics


3.1 Fundamentals
3.1.1 General
If the robot is mathematically coupled to an external kinematic system, such as a turntable
or a two--axis positioner, the robot controller must know the exact position of this kinematic
system to ensure correct operation.
The fixed, invariable data of this kinematic system are entered in the machine data of the
robot system.
Data that depend on the installation and setup are individually determined by calibrating the
external kinematic system with the robot.
The data for up to 6 external kinematic systems can be stored. These data are called up in
the user program by means of their number.

For reasons of safety, the calibration programs can only be executed in the
“Manual” operating mode (Single Step (T1) or Single Step (T2)).

The meaning of the symbols, icons and particular font conventions is explained in the
documentation [Introduction], in the chapter [About this documentation].

3.1.2 Preconditions

Using the calibration functions requires adequate knowledge of operating the robot
system. Information on this can be found in the Operating Handbook in the chapters
· [The KUKA Control Panel KCP],
· [Manual traversing of the robot]
· [Robot mastering/unmastering] and
· [Calibration -- Tools and workpieces].

The following preconditions must be met on the part of the robot:


G the data of the external kinematic system must be correctly entered in the machine data;
G all axes must be correctly mastered;
G no program may be selected;
G mode Single Step (T1) or Single Step (T2) is selected.

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3.2 External kinematic calibration


3.2.1 Overview
The submenu “External kinematic” contains the following subprograms:

Program Calibration by...


Root point moving the distance between the robot and the external
kinematic system
Root point (numeric) manual entry of the distance between the robot and the
external kinematic system
Offset moving the distance between the external kinematic system
and the workpiece
Offset (numeric) manual entry of the distance between the external kine-
matic system and the workpiece

Each of these calibration programs is assigned forms that guide you interactively through the
program.

3.2.2 Root point

III Z

II

Y
Coordinate system I = World coordinate system, which is identical to the Robot
coordinate system.
Coordinate system II = External kinematic coordinate system
Coordinate system III = Workpiece coordinate system
The distance between coordinate system II and coordinate system III is entered in the
machine data.
The distance between coordinate system I and coordinate system II must be manually
entered or calibrated.

The menu item “Root point” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “External kinematic”.

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3 Calibration -- External kinematics (continued)

The input window for selecting the kinematic system is opened:

Select the desired kinematic number (1...6) using the +/-- status key at the bottom right of
the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.
Press the softkey “ExtBase Ok” (at the bottom left of the display) in order to enter data for
this kinematic system.

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The dialog window for entering the reference tool is then opened:

A reference tool is a tool which has already been calibrated and is used to calibrate the
external kinematic.

Use the +/-- status key to select the tool number (1...16).

...
Press the softkey “Tool Ok” in order to perform the calibration with this tool.

The next window is opened:

You are prompted to re--check the entry in the machine data for the distance between the
origin of the kinematic coordinate system III and the reference mark.

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3 Calibration -- External kinematics (continued)

If this distance is not correctly entered, the machine data must be corrected. Cancel the
calibration procedure, in this case, by pressing the “ESC” key. (The entries made up to this
point will not be saved.)

If the distance is correctly entered, confirm it by pressing the softkey “Point OK”.

You will then be prompted to move the axes of the external kinematic system and to position
the TCP (tool center point) of the reference tool to the reference mark in a number of different
positions. The following steps are necessary for this:

Step 1 -- Move the TCP to the reference mark


This can be done using either the traversing keys or the Space Mouse.

Reduce the traversing velocity in the vicinity of the reference mark in order to avoid
a collision.

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To do so, repeatedly press the status key “HOV”, which is depicted here, and can be found
on the right of the display.

Step 2 -- Save the point

When the TCP is located exactly on the reference mark, save its position by pressing the
softkey “Point Ok”.

Step 3 -- Move the axis/axes of the external kinematic system

After the point has been accepted by the controller, you are prompted to define the root point
of the kinematic system by carrying out further measurements.

The external kinematic system is moved for this purpose.

Repeat steps 1 to 3 until the reference mark has been addressed in a total of four different
positions of the external kinematic system.

After all necessary measurements have been successfully completed, the dialog window for
saving the root data is opened:

Save the root data

At the end of the calibration procedure, you will be offered the softkey “Save” (at the bottom
of the display). Save the data of the kinematic system by pressing this softkey. The function
is then terminated.

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3 Calibration -- External kinematics (continued)

3.3 Root point (numeric)

III Z

II

X
The distance between coordinate
system II and coordinate system III I
is entered in the machine data.
The distance between coordinate
system I and coordinate system II Y
must be manually entered or
calibrated.

Using the menu key “Setup” (at the top of the display) open the menu “Measure” (“Calibrate”)
and “External kinematic” and there select the submenu “Root point (numeric)”.

The input window for selecting the kinematic system is opened:

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Select the desired kinematic number (1...6) using the +/-- status key at the bottom right of
the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.

Press the softkey “ExtBase OK” (at the bottom left of the display) in order to enter data for
this kinematic system. A window is opened for entering the root point data:

Now enter the values by means of the numeric keypad. You can move between the input
boxes using the “¯” or “­” arrow keys.

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3 Calibration -- External kinematics (continued)

The abbreviations in the dialog box have the following meaning:


X, Y, Z Distance between the root point of the kinematic system and the world1)
coordinate system.
1) In the basic setting, the world and robot coordinate systems coincide.
A, B, C Rotational offset of the kinematic coordinate system from the world1)
coordinate system.
Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
1) In the basic setting, the world and robot coordinate systems coincide.

When all entries have been made, confirm them by pressing the softkey “Data Ok”.

By pressing the softkey “Offset” on the bottom lefthand side of the display, it is possible to
switch directly to the input form with the same name. Further information can be found in
Sections 3.4 and 3.5.

Save the data of the kinematic system by pressing the softkey “Save” (at the bottom right
of the display). The function is then terminated.

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3.4 Offset

IV

The distance between coordinate


III system III and coordinate system
IV must be manually entered or
calibrated.

The menu item “Offset” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “External kinematic”.

The input window for selecting the kinematic system is opened:

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3 Calibration -- External kinematics (continued)

Select the desired kinematic number (1...6) using the +/-- status key at the bottom right of
the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.
Press the softkey “ExtBase OK” (at the bottom left of the display) in order to enter data for
this kinematic system. A window is opened for entering the reference tool:

Use the +/-- status key to select the tool number (1...16).

...
Press the softkey “Tool OK” in order to perform the calibration with this tool.
The following window is then opened:

You are prompted to position the TCP (Tool Center Point) to the future origin of the base
coordinate system (BASE). This can be done using either the traversing keys or the Space
Mouse.

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Reduce the traversing velocity in the vicinity of the workpiece in order to avoid a
collision.

To do so, repeatedly press the +/-- status key “HOV” (on the right of the display).

When the TCP (tool center point) is located exactly at the desired origin of the base
coordinate system (BASE), save this position by pressing the softkey “Point Ok”.

The next dialog window is then opened:

You are prompted to show the controller the positive side of the X axis by positioning the TCP
to a specific point.
First move the tool away from the workpiece:

Reduce the traversing velocity in the vicinity of the workpiece in order to avoid a
collision.

To do so, repeatedly press the +/-- status key “HOV” again.

When the TCP (tool center point) is located exactly at the desired point, save this position
by pressing the softkey “Point OK”.

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3 Calibration -- External kinematics (continued)

The status window changes:

You are prompted to show the controller the orientation of the XY plane by moving the tool
to a point with a positive Y value.
Here also, move the tool away from the workpiece first.

Reduce the traversing velocity in the vicinity of the workpiece in order to avoid a
collision.

To do so, repeatedly press the status key “HOV”.

When the TCP (tool center point) is located exactly at the point with a positive Y value on
the XY plane, save this position by pressing the softkey “Point OK”.

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Save the offset data

At the end of the calibration procedure, you will again be offered the softkey “Save” situated
at the bottom of the display. Save the kinematic data by pressing this softkey. The function
is then terminated.

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3 Calibration -- External kinematics (continued)

3.5 Offset (numeric)

IV

III The distance between coordinate


system III and coordinate system
IV must be manually entered or
calibrated.

The menu item “Offset (numeric)” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “External kinematic”.

The input window for selecting the kinematic system is opened:

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Select the kinematic number (1...6) using the +/-- status key at the bottom right of the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.
Press the softkey “ExtBase OK” in order to enter data for selected kinematic system.

The following dialog window for entering the offset data is then opened:

Enter the desired values by means of the numeric keypad.

You can move between the input boxes using the “¯” or “­” arrow keys.
The abbreviations in the status window have the following meaning:

X, Y, Z Distance between the workpiece reference point (BASE), IV in the


illustration, and the kinematic coordinate system, III in the illustration.
A, B, C Rotational offset of the base coordinate system from the
kinematic coordinate system.
Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

When all entries have been made, confirm them by pressing the softkey “Data OK” situated
at the bottom of the display.

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3 Calibration -- External kinematics (continued)

Save the offset data by pressing the softkey “Save”. You will find this softkey at the bottom
right of the display. The function is thus completed.

3.6 Offset external kinematic

Further information can be found in the documentation [Start--up], chapter [Calibration],


section [Fixed tool].

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4 Robot name

4 Robot name
This option allows you to change the robot name, serial number and the validity of the
MADAs.
To do so, select the menu item “Setup” --> “Robot name”.

The following status window is opened:

To achieve an unambiguous assignment of a KCP to a robot, the name of each robot can
be changed. The name can have a maximum length of 8 characters.
For positionally accurate robots, the serial number is important. The program can use it to
establish whether the robot (RDC component) or the controller (DSE component) has been
changed (e.g. use of the controller with another robot).

Specification of the serial number is particularly important for mastering (with or without
load), as the mastering data are saved in a separate file, the name of which corresponds
to the serial number.
The option of saving the machine data is only displayed if the MADAs saved on the robot
(RDC) do not agree with those on the hard disk of the computer. In this case, the RDC data
are displayed under “Machine data until now” and those saved on the hard disk are displayed
under “Current machine data”. Selecting “Yes” replaces the robot MADAs (RDC) with the
current machine data.

The serial number of the robot and the validity of the machine data (MADAs) can only be
changed in the operating modes (T1) and (T2).

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The entries are saved by pressing the softkey “Change”. The robot name is then displayed
in the status line.

Pressing the softkey “Close” closes the status window.

If the serial number has not been configured and if the valid machine data have not been
confirmed, the error message text “Wrong machine data for this robot type” is displayed
in the message window.

Information about saving the robot serial number in the RDC (Resolver--Digital Converter)
and checking the serial number for the purposes of the correct assignment of robot and
controller can be found in the Electrical Servicing handbook, documentation [Diagnostic
Functions], chapter [DSE--RDW].

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4 Robot name (continued)

NOTES:

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Index

Numbers F
3--Point, 69 Fixed tool, 82
5D, 55, 90, 96 Flange center point, 36
6D, 59, 90, 97 Frame, 37
Frontsight/rearsight marker, 6

A
H
A B C -- 2 Point, 40, 41, 50
HOV, 124
A, B, C, 37, 64, 68, 102, 105, 121, 128
ABC--World, 40, 55
ABC--World (5D), 41 I
ABC--World (6D), 41 Indirect, 69, 75
Absolute encoder, 33 Introduction, 36
All points in a line, 110
All points in one plane, 110 J
Arrow keys, 46, 63, 120, 128
Jog--OV, 44
Axis traversing keys, 43
JX, JY, JZ, 68, 106

B K
Base, 69, 123 Kinematic number, 115
Base coordinate system, 123 KR 3, 27

C M
Commutation, 29 M, 67, 105
Coordinates, 107 MADA, 131
Coupling of the wrist axes, 34 Mastered, 6
Mastering, 13
Mastering the KR 3, 27
D
Mastering with consideration of load, 12
Data Ok, 121 Mastering with the dial gauge, 7
Default, 67, 105 Mastering with the EMT, 10
Detailed information, 109 Mastering without consideration of load, 12
Determining the orientation, 40 Measurement error too big, 110
Determining the position, 40 Measurement Points, 107
Dial gauge, 5 Mechanical zero position reached, 6
DSE, 131 Move the axis/axes of the external kinematic
system, 118
Move the TCP to the reference mark, 117
E
EMERGENCY STOP, 6
N
EMT, 6
Numeric Input, 40, 41, 62, 69, 79, 82, 101
Enabling switch, 16, 17, 19, 21, 23, 26
Error message, 54
Error treatment, 109 O
ExtBase Ok, 115 Offset, 114, 122
External kinematic, 106 Offset (numeric), 114, 127
External measuring device, 38 Offset external kinematic, 82, 94, 129

Index -- i
Index

Operating mode, 131 Tool (BASE), 82, 88


Orientation, 37 Tool Center Point, 38, 123
Overloaded, 66
Tool load data, 40, 66
Tool number, 43
P
Tool OK, 116
Point too near to origin point, 109
Point too near to other point, 109 Traversing velocity, 44
Point too near to reference point, 109
Position, 36
Pre--mastering position, 6, 13
Program start forwards, 16, 17, 19, 21, 23, U
26
Protective cap, 5 Unmastered, 6
Unmastering an axis, 34
R
RDC, 131
Reference point, 38
Reference point mastering, 33
V
Reference tool, 40, 116
Velocity, 44
Reset Encoder, 28
Vernier, 5
Resolver, 36
Robot coordinate systems, 36
Robot flange coordinate, 36
Robot mastering, 5
Robot name, 131 W
Root point, 114
Weight difference, 12
Root point (numeric), 114, 119
Rotation about the X--axis, 37 Working direction, 50
Rotation about the Y--axis, 37 Workpiece (TOOL), 82
Rotation about the Z--axis, 37 WORLD coordinate system, 36

S
Save, 24
Save the point, 118 X
Serial number, 131
X Y Z -- 4 Point, 40, 42
Set Robot Position, 30
Space Mouse, 43 X Y Z -- Reference, 40, 45
Start key, 16, 17, 19, 20, 26 X, Y, Z, 37, 47, 63, 67, 102, 105, 121, 128
Supplementary load data, 104
X32, 6

T
TCP, 38, 42, 123
Test (T1), 15, 16, 18, 19, 22, 25 Z
Test (T1/T2), 7
Tolerance limits, 108 Z--Y--X Euler angles, 37
Tolerances, 108 Zero position, 5

Index -- ii
SOFTWARE

KR C...

User Programming

KUKA System Software (KSS)


Release 4.1

Issued: 09 Jan 2004 Version: 06


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e Copyright 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.

PD Interleaf

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Contents

1 Program editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.3 Open (Edit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.4 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4.1 Current program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4.2 Logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Saving changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.6 Saving programs to floppy disk (Archive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.7 Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Editing a selected program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Cancel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Reset program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Working with the program editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.1 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.2 Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.3 Close editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Program commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Last command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.1 Point--to--point motions (PTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.2 Linear motions (LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.3 Circular motions (CIRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3 Motion parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.1 Wait functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.1.1 Time--dependent wait function (WAIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.1.2 Signal--dependent wait function (WAIT FOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4.2 Switching functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.2.1 Simple switching function (OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.2.2 Simple pulse function (PULSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.2.3 Path--dependent switching function (SYN OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.2.4 Path--dependent pulse function (SYN PULSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4.3 Coupling and decoupling the INTERBUS segment (IBUS--Seg on/off) . . . . . . . . . . . . . . . . . 51
2.5 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.1 Static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5.2 Dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.6 Comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.6.1 Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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2.6.2 Stamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6.3 ...changing comment lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.6.4 ...Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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1 Program editing

1 Program editing
1.1 General
Before creating a robot program for the first time, you should familiarize yourself with the
KUKA file manager “Navigator”.
If you wish to create a new program, you must first create a so--called “skeleton program”.
If, on the other hand, you wish to modify an existing program, you simply need to select it
or load it in the editor.

More detailed information on using the file manager may be found in the documentation
[Operator Control], chapter [Navigator].

1.2 Programs

More detailed information about programs can be found in the documentation [Operator
Control], chapter [Navigator], section [“File” menu].
Block functions (e.g. Copy) are also available at expert level. More detailed information can
be found in the Programming Handbook in the documentation [Expert Programming].

1.2.1 New
With the Navigator active, press the softkey “New”.

If a program has been selected or there is a program in the editor, you must first toggle to
the file selection window, otherwise no new program can be created.

Enter the desired program name (max. 24 characters) and the corresponding comment in
the input line.

Program name Comment

Where possible, create user programs in the directory “R1\Program” in order to ensure that
they are automatically saved via the menu item “File” --> “Archive” --> “Applications”.

1.2.2 Selecting
The softkey “Select” is available for the purposes of program execution.

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In this way the program can also to be tested at the same time as being created.
The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars changes at the same time, in order to make functions available
which are necessary for programming the robot.

1.2.3 Open (Edit)


If you wish to make modifications to an existing program, you can either select the program
or load it into the editor. While you are editing one program in the editor, another (selected)
program can simultaneously be executed.
The command “Open” is provided in the softkey bar for loading files into the editor.

The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars changes at the same time, in order to make functions available
which are necessary for programming the robot.

If a program has already been selected, the option “Open” is no longer available in the
softkey bar.

Instead, use the menu command “File” --> “Open” --> “File/Folder”.

The following options are available for processing two programs simultaneously:

Select program then edit another


Select the desired program, toggle back to the Navigator and load the next program into the
editor via the menu “File” --> “Open”.

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1 Program editing (continued)

A selected program cannot be edited at the same time.

Load program into the editor then select another program


Load the desired program into the editor, toggle to the Navigator and select the next program
for editing using the softkey “Select”.

A program in the editor cannot be selected.

1.2.4 Print
If you have connected a printer to your control computer or network, you can print out
program listings or the logbook. This is done using the command “File” --> “Print”.

The print function is only available if a printer has been configured in the operating system.
More detailed information on this can be found in the “Windows” online help file.

1.2.4.1 Current program


If you wish to print a selected program, you can, if you so desire, include the Folds. It is not
necessary to open the Folds first. The relevant request for confirmation is made in the
message window:

Do you want to print with opened Folds?

The printout contains opened Folds


The Folds are not printed

The action is cancelled; nothing is sent to the printer

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Here is an example of a file without Folds:

File name KRC:\R1\TEST02.SRC

1 INI
2 PTP HOME Vel= 100 % DEFAULT
3 PTP P1 Vel= 100 % PDAT1 Tool[1] Base[0]
4 WAIT FOR IN 1 ’Enable’ State= TRUE
5 PTP P2 Vel= 100 % PDAT2 Too[1] Base[0]
6 WAIT FOR IN 2 ’Periphery’ State= TRUE
7 PTP P3 Vel= 100 % PDAT3 Tool[1] Base[0]
8 PTP P4 Vel= 100 % PDAT4 Tool[1] Base[0]
9
10 PTP HOME Vel= 100 % DEFAULT

1.2.4.2 Logbook
This function sends the logbook file, which can be viewed via the menu “Display” -->
“Diagnosis” --> “Logbook” --> “Display”, to the printer.

#1
-------------------------------------------------------------------
10:36:08’056 28.03.2000 Nr.:0: New command: SN 63: WAIT FOR IN 2
’Periphery’ State= TRUE
Source: TP_KUKA

#2
-------------------------------------------------------------------
10:35:35’596 28.03.2000 Nr.:0: New command: SN 51: WAIT FOR IN 1
’Enable’ State= TRUE
Source: TP_KUKA

#3
-------------------------------------------------------------------
10:35:20’386 28.03.2000 Nr.:0: Change IO name: Input, 2, Input->
Enable
Source: ProjLangText
.
.

Detailed information on the logbook can be found in the Operating Handbook, in the
documentation [Monitor], chapter [Diagnosis], section [Log book].

1.2.5 Saving changes


You can deselect a selected program by using the menu command “Program” --> “Cancel
program”. A program in the editor can be closed using the command “Program” --> “Close”.
Alternatively, you can press the softkey “Close”. The changes are automatically saved, after
a request for confirmation where relevant.

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1 Program editing (continued)

The softkey “deselect” is only available in the softkey bar if no program window is open.

1.2.6 Saving programs to floppy disk (Archive)


This function allows you to save important data to floppy disk. All files are saved in
compressed form as Zip files.
Compressed data require much less storage space than the original data, but must be
decompressed before they can be read. This is carried out automatically in this case. With
Navigator, the user can see what is stored in the archives.

*1

*1 Not available below the user group “Expert”

A request for confirmation is generated which must be answered before the saving process
is carried out.

Completion of the operation is indicated in the message window:

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Information about saved files can be found in the documentation [Operator Control],
chapter [Navigator], section [“File” menu].

1.2.7 Duplicate
The option “Duplicate” creates a copy of a program.

Program name Comment

1.2.8 Delete
If you want to delete a program, it must not be currently selected or being edited. You might
first have to deselect the program or close the editor. The program is permanently deleted
after a request for confirmation.

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1 Program editing (continued)

1.3 Editing a selected program


1.3.1 Delete
Use the arrow keys to move the edit cursor to the line you want to delete.

Edit cursor

Press the menu key “Program” and select the command “Delete” from the menu that is
opened.

Read the message displayed in the message window.

Press the softkey “Yes” if you are sure that you want to delete the selected line. Pressing this
softkey removes the line from the program.

Pressing the softkey “No” or “Cancel” cancels the action.

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1.3.2 Find
Here you can search through the program for a character string of your choice.
Press the menu key “Program” and select the option “Find...” from the menu that is opened.

Alternatively, you can use the keyboard shortcut “CTRL” + “F”.


This function searches through the program for a character string entered by the user. Once
the command has been selected, the search form is displayed in the program window:

This function searches through the program for a character string entered by the user. The
search is started by pressing the softkey “Find” or the Enter key and commences at the
position where the edit cursor is located.
If the search program finds the character string entered, the corresponding line is selected.

The character string entered remains displayed in the search form as a suggestion. You can
now search further through the program by pressing the softkey “Find” or the Enter key, or
search for a new string.

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1 Program editing (continued)

If the term being searched for is not found, a corresponding text is displayed in the message
window:

Only the visible area of the program is searched.

The expert must switch the option “Detail view ” on if hidden Folds are also to be included
in the search.

Alternatively, you can terminate the search function by pressing the softkey “Cancel” or the
Escape key. The edit cursor is then located in the line in which the last character string was
found.

If the search function is called again, the last string to be entered is shown in the form as
a suggestion.

1.3.3 Cancel program


This command saves the changes made to the program and closes the program window.
Press the menu key “Program” and select the option “Cancel program” from the menu that
is opened.

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1.3.4 Reset program


With the menu function “Program” --> “Reset program”, a program that has been stopped
or interrupted can be returned to the initial state it had when selected.

The yellow block pointer then jumps to the first line of the indicated program. The selected
program can subsequently be restarted.

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1 Program editing (continued)

1.4 Working with the program editor


1.4.1 Delete
Use the arrow keys to move the edit cursor to the line you want to delete.

Edit cursor
Press the menu key “Program” and select the option “Delete” from the menu that is opened.

Read the message displayed in the message window.

Press the softkey “Yes” if you are sure that you want to delete the selected line. Pressing this
softkey removes the line from the program.

Pressing the softkey “No” or “Cancel” cancels the action.

1.4.2 Find
Here you can search through the program for a character string of your choice.
Press the menu key “Program” and select the option “Find...” from the menu that is opened.

Alternatively, you can use the keyboard shortcut “CTRL” + “F”.


This function searches through the program for a character string entered by the user. Once
the command has been selected, the search form is displayed in the program window:

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This function searches through the program for a character string entered by the user. The
search is started by pressing the softkey “Find” or the Enter key and commences at the
position where the edit cursor is located.
If the search program finds the character string entered, the corresponding line is selected.

The character string entered remains displayed in the search form as a suggestion. You can
now search further through the program by pressing the softkey “Find” or the Enter key, or
search for a new string.
If the term being searched for is not found, a corresponding text is displayed in the message
window:

Only the visible area of the program is searched.

The expert must switch the option “Detail view ” on if hidden Folds are also to be included
in the search.

Alternatively, you can terminate the search function by pressing the softkey “Cancel” or the
Escape key. The edit cursor is then located in the line in which the last character string was
found.

If the search function is called again, the last string to be entered is shown in the form as
a suggestion.

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1 Program editing (continued)

1.4.3 Close editor


This command saves on the hard drive the changes made in the editor and loads them into
the real--time system. The program window is then closed.
Press the menu key “Program” and select the option “Close” from the menu that is opened.

The menu command “Close” is also available in the softkey bar if the editor is displayed
in the program window.

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2 Program commands

2 Program commands
This chapter is intended to provide an overview of the fundamentals of the PLC instructions
available, as well as their functions and the procedure for programming.
Within a program, you can add so--called PLC instructions, for example, to a motion
command. These instructions are then executed depending on the PLC trigger.

Further information about the trigger can be found in the Programming Handbook.

The meaning of the symbols, icons and particular font conventions is explained in the
chapter [About this documentation].

This chapter describes the functions provided in the KCP menu “Commands”.

Overview

Last command Instruction for entering the last command executed


Motion Enables the programming of PTP, LIN and CIRC motions
Moveparams Programming of torque monitoring
Programming of logic commands and wait times,
Logic path--dependent switching and pulse functions, setting
or polling inputs and outputs
Analog output Setting of analog outputs under program control
Comment Used to insert comments in programs
KRL assistant Syntax--supported KRL programming of special functions

The “Commands” menu is only available if a program has been selected or loaded in the
editor.

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2.1 Last command

This instruction allows you to enter the last command executed, with suggested values
already entered in the input boxes.
Use the menu key “Commands” to open the menu and there select the menu item “Last
command”.

If the “GRIPPER Tech” option has been selected from the “Configure -- Status keys” menu,
the softkey “Last Cmd”, which has the same function, is available in the softkey bar.

This softkey is not available if “Configure -- Status keys -- ARC Tech 10” or “ARC Tech 20”
has been selected.

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2 Program commands (continued)

2.2 Motion

To move a robot tool to a point under program control, a corresponding motion instruction
must be programmed. This instruction contains the type of motion and the velocity, the defini-
tion of the end point -- for circular paths also a midpoint -- and other settings depending on
the type of motion.
All the motion instructions, their significance and their intended application are described in
the following sections.

Types of motion
The following types of motion are available for programming movements:

Standard motions

The tool is moved as quickly as possible along a curved path in


PTP (point--to--point)
space to a end point
LIN (linear) The tool is guided at a defined velocity along a straight line
CIRC (circular) Motion of the tool at a defined velocity along a circular path

In sequences of motion instructions, there are two alternatives for selecting how movements
between individual points are executed:

Motion between the individual points

Exact positioning The motion stops exactly at the programmed point.


Approximate A smooth transition can be made from one motion to the next
positioning (Cont) without exact positioning at the end point.

Please note:
If one or more of the robot axes hits its end stop without being braked and at more
than 20 cm/s (manual velocity set by the manufacturer), the buffer concerned must
be replaced immediately.
If this happens to axis 1 of a wall--mounted robot, its rotating column must be
replaced.

Programming

To program a motion command, you must select a program or load it in the editor. More
detailed information on creating and altering programs can be found in the chapter
[Program editing].

Please note the position of the edit


cursor. The next line you add to the
program will be inserted as a new line
after the cursor.

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Open the menu using the menu key “Commands”. From this menu select “Motion”. The
following submenu is displayed:

You can now make your selection from the motion instructions (PTP, LIN or CIRC) offered.

Infinitely rotating axes


All the robot axes (A1 ... A6) are defined by the manufacturer as finitely rotating axes
(i.e. with software limit switches). For certain applications, however, axes A4 and A6 can
be configured as infinitely rotating axes. The corresponding settings are made in the file
“$MACHINE.DAT”.

A4 and A6 also definable as infinitely


rotating axes [$MACHINE.DAT]

All other axes are


finitely rotating axes.

If the machine data have been altered to define the axes A4 and/or A6 as infinitely rotating
axes, please bear in mind that each rotation is executed along the shortest path.
This can cause problems if a tool with supply lines (for example, a welding gun) is
installed on the robot.

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2 Program commands (continued)

In the following example, two motion instructions (P1 -- P2 and P2 -- P3) are programmed
and the coordinates saved. Please refer to the following sketch.

The first motion instruction in this Tool P3 (220_)


example causes axis A6 to turn
120_ from P1 (0_) to P2. The sec-
ond motion command rotates A6 a P1 (0_) P1 (0_)
further 100_ from P2 (120_) to P3
(220_).
Robot flange P2 (120_)

With the third motion command is actual:


intended to move the tool 200_ in P3 (220_) 160_
P3 (220_)
the opposite direction from P2 to
P3, i.e. to the position 20_ from the
starting position P1. P1 (0_)
When the program is executed,
however, axis A6 will turn along the
P4 (380_)
shorter path from P3 (220_) to P4 P3 (120_)
(380_), covering just 160_. (desired: 200_)

This will inevitably result in any


supply lines from the robot to
the tool being “wound” round
the wrist.

It is therefore necessary for the


second (return) motion to be split
up into two motion instructions. P3 (220_)
In this example, two motions
(P3--P4 and P4--P5) have been
programmed, each with an angle 100_ P5 (20_)
of rotation of 100_. This ensures
that the tool moves to the end point
in the correct direction when the 100_
P4 (120_)
progam is executed.

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2.2.1 Point--to--point motions (PTP)


Here, the robot system is positioned using the quickest route between two points. Since the
motion starts and ends in all of the axes at the same time, the axes have to be synchronized.
The path taken by the robot cannot, therefore, be predicted exactly.

When this instruction is used, motion is executed on a path defined by the robot. In
order to take into account dynamic effects and avoid collisions, the path should
initially be executed at reduced program override (POV).

Point names may not begin with “POINT” as this is a keyword.

PTP motions with exact positioning

In the case of PTP motions with exact positioning, the robot stops exactly at each end point.

Possible Possible
PTP path PTP path
P2

Exact positioning
P3
P1
Exact positioning

PTP motions with approximate positioning

During approximate positioning, the controller monitors a so--called approximate positioning


range around the end point. This, in our example, is the point P2. When the TCP enters this
area, the robot motion immediately proceeds towards the end point of the next motion
command.

Approximate
positioning range P2

P3

P1

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2 Program commands (continued)

Programming a PTP motion


After the option “PTP” is selected from the menu “Motion”, the inline form for entering the
values required for executing this instruction is opened in the program window.

Box name Function Range of values


PTP Type of motion PTP, LIN, CIRC
P1 Point name Max. 23 characters
Tool Tool number Nullframe, Tool_Data[1]...[16]
Nullframe, Base_Data[1]...[16],
Base Workpiece number
EX_AX_DATA[1]...[6]
external
Robot guides tool/workpiece True, False
TCP
CONT Approximate positioning ON “ ”, Cont
1 to 100% of the maximum value
Vel=100% Velocity
(default: 100%)
PDAT1 Motion parameters
Acceleration Acceleration 0 ... 100
Approximation Approximate positioning
0 ... 100
Distance *1 range
*1 Only available if “CONT” has been switched on

The assignment of the softkey bar changes at the same time, as follows:

It is possible to abort programming of the PTP motion at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the left--hand input box. The status key (at the bottom right of the display)
changes its assignment.
Using this status key, you can choose between the different types of motion again.

The type of motion can also be set using the softkey “LIN/CIRC”.
Move the cursor to the next input box on the right, here “P1”.

A parameter list is opened for entering data relating to the workpiece and tool. Activate this
parameter list using the “Window selection” key.

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Tool
Select here from the 16 available tools.
Base
Select here one of the 16 saved workpiece coordinate sys-
tems (BASE).
external TCP
Tell the controller here whether the robot is guiding the tool
or the workpiece:
Robot guiding tool: external TCP = False
Robot guiding workpiece: external TCP = True

Now activate the program window again using the “Window selection” key.
If the softkey “Suggest” is pressed, the program finds the lowest standard point name
available in the local data list and enters this name in the open inline form, i.e. if points P1
and P3 are occupied, P2 will be suggested.
Then move the robot to the end point you wish to program. There press the softkey “Touch
Up”. Read the messages displayed in the message window.

The softkey “Touch Up” allows you, at any moment, to save the current robot coordinates
for the program line in which the edit cursor is positioned. You thus have the possibility, for
example, to program a sequence of motion instructions and then define the exact end point
coordinates later.
The coordinates of the programmed point are saved in the data list.

Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.
The approximate positioning function can be switched on or off using this status key.

Inline form Press the status key on Using the status key, Press the
“Exact the bottom right--hand side. choose between “Exact Enter key
positioning”. The menu is opened positioning” and “Approxi- and the menu
in the inline form. mate positioning” (CONT). is closed.

Move the cursor to the box “Vel=”.

Here you can specify what percentage of the maximum possible velocity the robot should
use later when executing the motion. You can either enter the value using the keyboard or
alter it using the status key to the right of the display.
Move the cursor to the next input box on the right, here “PDAT2”.

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2 Program commands (continued)

A parameter list is opened, in which data must be entered characterizing the motion in greater
detail. Activate this status window using the “Window selection” key. You can either enter the
values in the input boxes using the keyboard or alter them using the status key to the right
of the display.

Acceleration
Here you can reduce the acceleration to be used in the
motion.
Depending on the length of the path, the degree of
acceleration and the approximation distance, it is
possible that the programmed velocity will not be
reached.
This is liable to happen when the wrist axes would have
to turn at an infinitely high speed when passing through
the extended position and would thus exceed the
maximum permissible values.
Therefore please be sure to use practically feasible
values.

Approximation Distance
Here you can reduce the approximate positioning range
to be used in the motion.

Now press the softkey “Cmd Ok” or the Enter key. The motion function is now fully
programmed and saved.

If the position of the end point has not yet been taught (Touch Up), the current position of
the robot is automatically saved.

You can use the softkey “Comment” at any time to insert a comment line into your program,
irrespective of the input box that is currently in focus.

Detailed information on comments in robot programs can be found in the section


[Comment].

You can use the softkey “Logic” at any time to insert a so--called logic command into your
program, irrespective of the input box that is currently in focus.

Detailed information on logic commands can be found in the section [Logic].

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2.2.2 Linear motions (LIN)


With a linear motion, the robot axes are coordinated in such a way that the TCP or workpiece
reference point is moved along a straight line to the end point.
Linear motions are used if the robot has to follow an exact path to a point at a defined velocity.

Only the reference point follows the programmed path. The actual tool or workpiece is able
to change its orientation during the motion.
Point names may not begin with “POINT” as this is a keyword.

LIN motions with exact positioning

In the case of LIN motions with exact positioning, the robot stops exactly at each end point.

Exact positioning

P2
P3
P1
Exact positioning

LIN motions with approximate positioning

During approximate positioning, the controller monitors a so--called approximate positioning


range around the end point. This, in our example, is the point P2. When the TCP enters this
area, the robot motion immediately proceeds towards the end point of the next motion
command.

Approximate
positioning range P2

P3

P1

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2 Program commands (continued)

Programming a LIN motion


After the option “LIN” is selected from the menu “Motion”, the inline form for entering the
values required for executing this instruction is opened in the program window.

Box name Function Range of values


LIN Type of motion PTP, LIN, CIRC
P1 Point name Max. 23 characters
Tool Tool number Nullframe, Tool_Data[1]...[16]
Base Workpiece number Nullframe, Base_Data[1]...[16]
external
Robot guides tool/workpiece True, False
TCP
CONT Approximate positioning ON “ ”, Cont
Vel=2m/s Velocity 0.001 ... 2 m/s (Default 2 m/s)
CPDAT1 Motion parameters
Acceleration Acceleration 0 ... 100
Approximation Approximate positioning
0 ... 300
Distance *1 range
*1 Only available if “CONT” has been switched on

The assignment of the softkey bar changes at the same time, as follows:

It is possible to abort programming of the LIN motion at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the left--hand input box. The status key (at the bottom right of the display)
changes its assignment.
Using this status key, you can choose between the different types of motion again.

The type of motion can also be set using the softkey “CIRC/PTP”.
Move the cursor to the next input box on the right, here “P1”.

If the softkey “Suggest” is pressed, the program finds the lowest standard point name avail-
able in the local data list and enters this name in the open inline form, i.e. if points P1 and
P3 are occupied, P2 will be suggested.
A status window is opened for entering data relating to the workpiece and tool. Activate this
status window using the “Window selection” key.

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Tool
Select here from the 16 available tools.
Base
Select here one of the 16 saved workpiece coordinate sys-
tems (BASE).
external TCP
Tell the controller here whether the robot is guiding the tool
or the workpiece:
Robot guiding tool: external TCP = False
Robot guiding workpiece: external TCP = True

Now activate the program window again using the “Window selection” key.
Then move the robot to the end point you wish to program. There press the softkey “Touch
Up”. Read the messages displayed in the message window.

The softkey “Touch Up” allows you, at any moment, to save the current robot coordinates
for the program line in which the edit cursor is positioned. You thus have the possibility, for
example, to program a sequence of motion instructions and then define the exact end point
coordinates later.
The coordinates of the programmed point are saved in the data list.
Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.
The approximate positioning function can be switched on or off using this status key.

Inline form Press the status key on Using the status key, Press the
“Exact the bottom right--hand side. choose between “Exact Enter key
positioning”. The menu is opened positioning” and “Approxi- and the menu
in the inline form. mate positioning” (CONT). is closed.

Move the cursor to the box “Vel=”.

Here you can specify the velocity at which the robot should execute the motion. You can
either enter the value using the keyboard or alter it using the status key to the right of the
display.
Depending on the length of the path, the degree of acceleration and the approximation di-
stance, it is possible that the programmed velocity will not be reached.
Move the cursor to the next input box on the right, here “CPDAT1”.

A parameter list is opened, in which data must be entered characterizing the motion in greater
detail. Activate this parameter list using the “Window selection” key. You can either enter the
values in the input boxes using the keyboard or alter them using the status key to the right
of the display.

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2 Program commands (continued)

Acceleration
Here you can reduce the acceleration to be used in the
motion.
Depending on the length of the path, the degree of
acceleration and the approximation distance, it is
possible that the programmed velocity will not be
reached.
This is liable to happen when the wrist axes would have
to turn at an infinitely high speed when passing through
the extended position and would thus exceed the
maximum permissible values.
Therefore please be sure to use practically feasible
values.

Approximation Distance
Here you can reduce the approximate positioning range
to be used in the motion.

Now press the softkey “Cmd Ok” or the Enter key. The motion function is now fully
programmed and saved.

If the position of the end point has not yet been taught (Touch Up), the current position of
the robot is automatically saved.

You can use the softkey “Comment” at any time to insert a comment line into your program,
irrespective of the input box that is currently in focus.

Detailed information on comments in robot programs can be found in the section


[Comment].

You can use the softkey “Logic” at any time to insert a so--called logic command into your
program, irrespective of the input box that is currently in focus.

Detailed information on logic commands can be found in the section [Logic].

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2.2.3 Circular motions (CIRC)


Here, the TCP or workpiece reference point moves to the target point along an arc. The path
is defined using start, auxiliary and end points. The end point of a motion instruction executed
with exact positioning serves as the start point for the subsequent motion. The orientation
changes uniformly over the whole length of the path.
CIRC motions are used when processing operations are to be executed at a preset velocity
along a circular path.

The start, auxiliary and end points lie in a plane in space. In order for the controller to be
able to determine this plane as accurately as possible, these three points should be as far
apart as possible. Only the reference point follows the programmed path. The actual tool
is able to change its orientation during the motion.
Point names may not begin with “POINT” as this is a keyword.

CIRC motions with exact positioning

In the case of CIRC motions with exact positioning, the robot stops exactly at each end point.

Auxiliary point End point

Start
point
End point

Start
point
Auxiliary point
End point

CIRC motions with approximate positioning


During approximate positioning, the controller monitors a so--called approximate positioning
range around the end point. When the TCP enters this area, the robot motion immediately
proceeds towards the end point of the next motion command.

Approximate
positioning
range

End point
Start
point
End point

Auxiliary point
Start Auxiliary point
point

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Programming a CIRC motion


After the option “CIRC” is selected from the menu “Motion”, the inline form for entering the
values required for executing this instruction is opened in the program window.

Box name Function Range of values


CIRC Type of motion PTP, LIN, CIRC
P1 Auxiliary point name Max. 23 characters
P2 Point name Max. 23 characters
Tool Tool number Nullframe, Tool_Data[1]...[16]
Base Workpiece number Nullframe, Base_Data[1]...[16]
external
Robot guides tool/workpiece True, False
TCP
CONT Approximate positioning ON “ ”, Cont
Vel=2m/s Velocity 0.001 ... 2 m/s (Default 2 m/s)
PDAT1 Motion parameters
Acceleration Acceleration 0 ... 100
Approximation Approximate positioning
0 ... 300
Distance *1 range
*1 Only available if “CONT” has been switched on

The assignment of the softkey bar changes at the same time, as follows:

Teach Aux Teach End


It is possible to abort programming of the LIN motion at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the left--hand input box. The status key (at the bottom right of the display)
changes its assignment.
Using this status key, you can choose between the different types of motion again.

The type of motion can also be set using the softkey “PTP/LIN”.
Move the cursor to the next input box on the right, here “P1”.

If the softkey “Suggest” is pressed, the program finds the lowest standard point name
available in the local data list and enters this name in the open inline form, i.e. if points P1
and P3 are occupied, P2 will be suggested.

Teach Aux Now move the robot to the auxiliary point. There press the softkey “Teach Aux”. Read the
messages displayed in the message window.

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The coordinates of the auxiliary point must be saved manually before conclusion of the
motion command; they are not automatically saved. If you want to define the point
coordinates later, “Teach Aux” can be carried out first in any robot position.

Move the cursor to the next input box on the right, here “P2”.

A status window is opened for entering data relating to the workpiece and tool. Activate this
status window using the “Window selection” key.

Tool
Select here from the 16 available tools.
Base
Select here one of the 16 saved workpiece coordinate sys-
tems (BASE).
external TCP
Tell the controller here whether the robot is guiding the tool
or the workpiece:
Robot guiding tool: external TCP = False
Robot guiding workpiece: external TCP = True

Now activate the program window again using the “Window selection” key.

Then move the robot to the end point you wish to program. There press the softkey “Touch
Teach End
Up”. Read the messages displayed in the message window.

The softkey “Touch Up” allows you, at any moment, to save the current robot coordinates
for the program line in which the edit cursor is positioned. You thus have the possibility, for
example, to program a sequence of motion instructions and then define the exact end point
coordinates later.
The coordinates of the programmed point are saved in the data list.

Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.

The approximate positioning function can be switched on or off using this status key.

Inline form Press the status key on Using the status key, Press the
“Exact the bottom right--hand side. choose between “Exact Enter key
positioning”. The menu is opened positioning” and “Approxi- and the menu
in the inline form. mate positioning” (CONT). is closed.

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2 Program commands (continued)

Move the cursor to the box “Vel=”.

Here you can specify the velocity at which the robot should execute the motion. You can
either enter the value using the keyboard or alter it using the status key to the right of the
display.
Move the cursor to the next input box on the right, here “CPDAT1”.

A parameter list is opened, in which data must be entered characterizing the motion in greater
detail. Activate this parameter list using the “Window selection” key. You can either enter the
values in the input boxes using the keyboard or alter them using the status key to the right
of the display.

Acceleration
Here you can reduce the acceleration to be used in the
motion.
Depending on the length of the path, the degree of
acceleration and the approximation distance, it is
possible that the programmed velocity will not be
reached.
This is liable to happen when the wrist axes would have
to turn at an infinitely high speed when passing through
the extended position and would thus exceed the
maximum permissible values.
Therefore please be sure to use practically feasible
values.

Approximation Distance
Here you can reduce the approximate positioning range
to be used in the motion.

Now press the softkey “Cmd Ok” or the Enter key. The motion function is now fully
programmed and saved.

If the position of the end point has not yet been taught (Touch Up), the current position of
the robot is automatically saved.

You can use the softkey “Comment” at any time to insert a comment line into your program,
irrespective of the input box that is currently in focus.

Detailed information on comments in robot programs can be found in the section


[Comment].

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You can use the softkey “Logic” at any time to insert a so--called logic command into your
program, irrespective of the input box that is currently in focus.

Detailed information on logic commands can be found in the section [Logic].

Please note:
A full circle must be made up of at least two segments to prevent the circle from tilting in
the plane.

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2 Program commands (continued)

2.3 Motion parameters


This function allows the monitoring tunnel for collision monitoring to be changed. The sensiti-
vity of the collision monitoring can be defined in this way.

Detailed information on the subject “TorqMon” may be found in the Programming Hand-
book, in the documentation [Expert Programming], chapter [Motion programming].

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2.4 Logic
Inputs and outputs of the controller enable the robot system to communicate with its periph-
eral environment. Specific commands are provided for polling inputs and setting outputs.
It is also possible for wait times to be programmed in order to ensure that operations are
completed before the robot starts moving again.

Programming

To program a so--called logic command, you must select a program or load it in the editor.
More detailed information on creating and altering programs can be found in the chapter
[Program editing].

Pay attention to the position of the


edit cursor. The next program line
created by you will be inserted as a
new line after the cursor.

Open the menu using the menu key “Commands”. From this menu select “Logic”. The follow-
ing submenu is displayed:

You can now make your selection from the logic instructions offered.

2.4.1 Wait functions

2.4.1.1 Time--dependent wait function (WAIT)

You can use this function to program a defined wait time. After selecting the menu item
“WAIT”, the inline form for entering the wait time is opened in the programming window.

The assignment of the softkey bar changes at the same time, as follows:

It is possible to abort programming of the wait function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.

Pressing the softkey “Motion” switches immediately to motion instruction programming, can-
celing programming of the time--dependent wait function.

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2 Program commands (continued)

Pressing the softkey “W_F/IBUS” switches immediately to programming of the signal--


dependent wait function, canceling programming of the time--dependent wait function.
Pressing the softkey “Comment” switches immediately to the programming function for
comment lines, canceling programming of the time--dependent wait function.
You can alter the default wait time in increments of 0.05 seconds using this status key. You
can also enter the desired value using the numeric keypad.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

2.4.1.2 Signal--dependent wait function (WAIT FOR)


This function waits until the named input/output has assumed the defined state: True or
False.
After selecting the menu option “WAITFOR”, the inline form for entering the parameters that
are required for executing the signal--dependent wait function is opened in the programming
window.

Box name Function Range of values


WAIT FOR IN Type of wait function WAIT FOR IN, WAIT FOR OUT
1 Input/output 1 ... 1024
Demo Long text The long text assigned to the input or
output
State State TRUE, FALSE
CONT Approximate positioning “ ”, CONT

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the wait function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.

If the programming window is in focus, the various input boxes can be selected using the “¯”
and “­” arrow keys. The box that is currently selected is highlighted by a color background.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “Motion” switches immediately to motion instruction programming, can-
celing programming of the signal--dependent wait function.
Pressing the softkey “IBUS/WAIT” switches immediately to the function for coupling and
decoupling an INTERBUS segment under program control. Programming of the signal--
dependent wait function is thus canceled.
Pressing the softkey “Comment” switches immediately to the programming function for
comment lines, canceling programming of the signal--dependent wait function.

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The long text belonging to the corresponding input/output can be modified by pressing the
“Longtext” softkey. This option is not available in the user group “User”.
Move the cursor to the left--hand input box. The assignment of the status key at the bottom
right of the display changes accordingly. Here you can specify whether or not the system
should wait for an input or output signal.

Move the cursor to the next input box, here “1”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, specify the input or output
for which the system is to wait. It is also possible to change the value shown in the input box
using the status key (at the bottom right of the display).

The long text of the input or output can be modified in the next input box. To do so, the user
group “Expert” must be active. Press the “Longtext” softkey and enter the desired name.

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. Using this status key, you can specify the state at which the motion
program is to be resumed.

In the last input box you can activate the option “CONT” (Continue). This option causes the
condition to be checked as soon as the advance run pointer reaches the “WaitFor” line. If the
condition is fulfilled at this time, the advance run pointer jumps to the next line. Otherwise,
it stops at this point and waits until the condition is fulfilled.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.4.2 Switching functions

After selecting the menu item “OUT”, a submenu with further options is opened:

This menu offers you various switching functions, which are described in detail below.

2.4.2.1 Simple switching function (OUT)

Sets an output to True or False.


After selecting the menu option “OUT”, the inline form for entering the parameters that are
required for executing the simple switching function is opened in the programming window.

Box name Function Range of values


1 Output 1 ... 1024
Demo Long text Name of the input or output
State State TRUE, FALSE
CONT Approximate positioning “ ”, CONT

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the switching function at any time by pressing the
softkey “Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “PULSE” switches immediately to programming of the simple pulse
function, canceling programming of the simple switching function.
Pressing the softkey “SYNOUT” switches immediately to programming of the path--
dependent switching function, canceling programming of the simple switching function.
The long text belonging to the corresponding output can be modified by pressing the
“Longtext” softkey. This option is not available below the user group “Expert”.
Move the cursor to the input box “OUT”. The assignment of the status key at the bottom right
of the display changes. Using the numeric keypad, specify the output that is to be set. It is
also possible to change the value shown in the input box using the status key (at the bottom
right of the display).

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The long text of the output can be modified in the next input box. To do so, the user group
“Expert” must be active. Press the “Longtext” softkey and enter the desired name.

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the state to which the selected
output is to be set.

Move the cursor to the input box “CONT”. The assignment of the status key at the bottom
right of the display changes. If you set “CONT”, the output is set with the advance run pointer.
If “CONT” is not selected, the output is set with the main run pointer, i.e. as soon as the
advance run pointer reaches this function, it is stopped until the main run pointer has also
reached this function.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2 Program commands (continued)

2.4.2.2 Simple pulse function (PULSE)

This function sets a selected output to TRUE/FALSE for the duration of a defined pulse time.
After selecting the menu option “PULSE”, the inline form for entering the parameters that are
required for executing the simple switching function is opened in the programming window.

Box name Function Range of values


1 Output 1...1024
Demo Long text Name of the input or output
State State TRUE, FALSE
CONT Approximate positioning “ ”, CONT
Time Length of the pulse 0.1 ... 3 s

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the pulse function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.

If the programming window is in focus, the various input boxes can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “OUT” switches immediately to programming of the simple switching
function, canceling programming of the simple pulse function.
Pressing the softkey “SYNPULSE” switches immediately to programming of the path--
dependent pulse function, canceling programming of the simple pulse function.
The long text belonging to the corresponding output can be modified by pressing the
“Longtext” softkey. This option is not available below the user group “Expert”.
Move the cursor to the input box “PULSE”. The assignment of the status key at the bottom
right of the display changes. Using the numeric keypad, specify the output that is to be set.
It is also possible to change the value shown in the input box using the status key (at the
bottom right of the display).

The long text of the output can be modified in the next input box. To do so, the user group
“Expert” must be active. Press the “Longtext” softkey and enter the desired name.

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the state to which the selected
output is to be set.

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Move the cursor to the input box “CONT”. The assignment of the status key at the bottom
right of the display changes. If you set “CONT”, the function is executed when reached by
the advance run pointer. If “CONT” is not selected, the function is executed when the main
run pointer arrives, i.e. as soon as the advance run pointer reaches this function, it is stopped
until the main run pointer has also reached this function.

Move the cursor to the input box “Time”. The assignment of the status key at the bottom right
of the display changes. Using this status key, you can set the length of the pulse between
0.1 and 3 seconds in increments of 0.1 seconds.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2 Program commands (continued)

2.4.2.3 Path--dependent switching function (SYN OUT)

After selecting the menu option “SYN OUT”, the inline form for entering the parameters that
are required for executing the path--dependent switching function is opened in the
programming window.

Box name Function Range of values


SYN OUT Output 1...1024
Demo Long text Name of the input or output
State State TRUE, FALSE
at Time at which the switching START, END, PATH
function is executed
Distance from the end --2000 ... 2000 mm
point at which the output is
set *1)
Delay Delay of the switching --1000 ... 1000 ms
action
*1) Only available if “PATH” is selected as the start option

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the switching function at any time by pressing the
softkey “Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “SYNPULSE” switches immediately to programming of the path--
dependent pulse function. Programming of the path--dependent switching function is can-
celed first.
Pressing the softkey “OUT” switches immediately to programming of the simple switching
function. Programming of the path--dependent switching function is canceled first.
The long text belonging to the corresponding output can be modified by pressing the
“Longtext” softkey. This option is not available below the user group “Expert”.
Move the cursor to the input box “SYN OUT”. Using the numeric keypad, specify the output
that is to be set. It is also possible to change the value shown in the input box using the status
key (at the bottom right of the display).

The long text of the output can be modified in the next input box. To do so, the user group
“Expert” must be active. Press the “Longtext” softkey and enter the desired name.

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Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the state to which the selected
output is to be set.

Move the cursor to the input box “at”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the point of the path segment
at which the selected output is to be set.

Move the cursor to the input box “Delay”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can shift the time at which the selected out-
put is to be set, by any amount in increments of 1 ms between the start and end points of
the path segment. It is also possible to enter the value via the numeric keypad.

If, on the other hand, you want to set the output in relation to the path, you must select the
option “PATH” in the input box “at”.

An additional input box then appears in the inline form in which you can specify the distance
from the end point at which the output should be set. If, for example, you want the output to
be set between the start point and the end point, you must enter a value with a negative sign.
The current value of the variable $DIST_NEXT can be displayed and altered by means of
the menu function “Monitor” -- “Variable” -- “Single”

The motion commands (type: LIN) before and after the SYN OUT function are important for
determining locally the start and end points and the points along the path.

G Case 1: the start point and end point are exact positioning points

Program: Start
LIN P1 +
SYN OUT
LIN P2 P1 P2
--
END
PATH

G Case 2: the start point is approximated, the end point is an exact positioning point

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2 Program commands (continued)

Program: P2
P1
LIN P1
LIN P2 CONT
SYN OUT
LIN P3
Start

+ --

END
P3 PATH

G Case 3: the end point is approximated, the start point is an exact positioning point

Program: Start P1
LIN P1
SYN OUT
LIN P2 CONT +
LIN P3

END
-- PATH
P3
P2 +

G Case 4: the start point and end point are approximated

Program: P2
LIN P2 CONT
SYN OUT P1
LIN P3 CONT
LIN P4 Start

END
-- PATH
P4
P3 +

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Example:
Adhesive application:
An adhesive gun is to start applying adhesive at a certain point on the workpiece. For this
purpose the command SYN OUT is set. When output 1= TRUE, the adhesive gun is
activated. PATH=10 mm defines the point at which the adhesive application is to begin. The
adhesive gun itself, however, must be activated approximately 15 ms earlier, as a certain
advance time is required before the adhesive begins to flow. The delay time is thus set to
--15 ms.

Extract from the illustration


relating to “case 4”
P2

Output 1 is set to TRUE


at this point

PATH
--15 ms

P4
P3
+10 mm
Adhesive application

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.4.2.4 Path--dependent pulse function (SYN PULSE)

After selecting the menu option “SYN PULSE”, the inline form for entering the parameters
that are required for executing the path--dependent pulse function is opened in the program-
ming window.

Box name Function Range of values


SYN Output 1...1024
PULSE
Demo Long text Name of the input or output
State State TRUE, FALSE
Time Pulse duration 0.1 ... 3 s
at Time at which the pulse START, END, PATH
function is executed
Distance from the end --2000 ... 2000 mm
point at which the output is
set *1)
Delay Delay of the pulse function --1000 ... 1000 ms
*1) Only available if “PATH” is selected as the start option

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the pulse function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “SYNOUT” switches immediately to programming of the path--
dependent switching function, canceling programming of the path--dependent pulse
function.
Pressing the softkey “PULSE” switches immediately to programming of the simple pulse
function, canceling programming of the path--dependent pulse function.
The long text belonging to the corresponding output can be modified by pressing the
“Longtext” softkey. This option is not available below the user group “Expert”.
Move the cursor to the input box “SYN PULSE”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, specify the output that is to
be set. It is also possible to change the value shown in the input box using the status key (at
the bottom right of the display).

The long text of the output can be modified in the next input box. To do so, the user group
“Expert” must be active. Press the “Longtext” softkey and enter the desired name.

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Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can switch between the states to which the
selected output can be set.

Move the cursor to the input box “Time”. The assignment of the status key at the bottom right
of the display changes. You can set the length of the pulse in increments of 0.1 seconds within
the range of 0.1 to 3 seconds using this status key. It is also possible to enter the value via
the numeric keypad.

Move the cursor to the input box “at”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the point of the path segment
at which the selected output is to be set.

Move the cursor to the input box “Delay”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can shift the time at which the selected out-
put is to be set, by any amount in increments of 1 ms between the start and end points of
the path segment. It is also possible to enter the value via the numeric keypad.

If, on the other hand, you want to set the output in relation to the path, you must select the
option “PATH” in the input box “at”.

An additional input box then appears in the inline form in which you can specify the distance
from the end point at which the output should be set. If, for example, you want the output to
be set between the start point and the end point, you must enter a value with a negative sign.
The motion commands (type: LIN and CIRC) before and after the SYN PULSE function are
important for determining locally the start and end points and the points along the path.
Compare cases 1 to 4 for the previous function SYN OUT!
Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2 Program commands (continued)

2.4.3 Coupling and decoupling the INTERBUS segment (IBUS--Seg on/off)

After selecting the menu option “IBUS--Seg. on/off”, the inline form for programming the
coupling and decoupling of the INTERBUS segment is opened in the programming window.

Box name Function Range of values


IBUS Coupling and decoupling ON, OFF
an IBus segment

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of this function at any time by pressing the softkey “Cmd
Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “Motion” switches immediately to motion instruction programming, can-
celing programming of the function.
Pressing the softkey “WAIT/W_F” switches immediately to programming of motion instruc-
tions, canceling programming of the function.
Pressing the softkey “Comment” switches immediately to the programming function for
comment lines, canceling programming of the function.
By pressing the status key “CMD”, you can switch between coupling and decoupling of the
INTERBUS.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.5 Analog output

The eight analog outputs of the robot controller are set under program control using this
function.

Programming

To program the analog output, you must select a program or load it in the editor. More
detailed information on creating and altering programs can be found in the chapter
[Program creation].

Pay attention to the position of the edit


cursor. The next program line created
by you will be inserted as a new line
after the cursor.

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2 Program commands (continued)

2.5.1 Static

This option is used to set an analog output with a fixed value. After selecting the menu option,
the inline form for entering the necessary values is opened in the program window.

Box name Function Range of values


ANOUT Analog output 1 ... 32
0 Output voltage 0 ... 1

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the function at any time by pressing the softkey “Cmd
Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the left--hand input box. The assignment of the status key at the bottom
right of the display changes. Here you can specify which of the eight analog outputs you want
to set.

Move the cursor to the next input box, here “0”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter the value the analog
output should take. It is also possible to change the value shown in the input box using the
status key (at the bottom right of the display) in increments of 10 mV.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.5.2 Dynamic

This option is used to set an analog output depending on the velocity or technology. After
selecting the menu option, the inline form for entering the necessary values is opened in the
program window.

Box name Function Range of values


ANOUT Switching simulation mode ON, OFF
on and off
CHANNEL 1 Analog output 1 ... 32
1 Multiplier 0 ... 10
VEL ACT Velocity or technology pa- VEL ACT, TECHVAL1 ... TECHVAL6
rameters
Offset Offset voltage --1 ... 1
Delay Delay --0.2 ... 0.5 s

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the function at any time by pressing the softkey “Cmd
Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “¯”
and “­” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the left--hand input box. The assignment of the status key at the bottom
right of the display changes. Here you can specify whether you wish to switch the analog
output on or off.

Move the cursor to the next input box, here “Channel 1”. The assignment of the status key
at the bottom right of the display changes. Here you can specify which of the eight analog
outputs you want to set or reset.

Move the cursor to the next input box, here “1”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter the factor by which the

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2 Program commands (continued)

corresponding velocity/technology parameters are to be multiplied. It is also possible to


change the value shown in the input box using the status key (at the bottom right of the
display) in increments of 0.05.

Move the cursor to the next input box, here “VEL_ACT”. The assignment of the status key
at the bottom right of the display changes. Here you can specify the velocity/technology
parameters with which the selected analog output is to be combined.

Move the cursor to the next input box, here “Offset”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter the value of the offset
voltage for the selected analog output. It is also possible to change the value shown in the
input box using the status key (at the bottom right of the display) in increments of 100 mV.

Move the cursor to the next input box, here “Delay”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter a delay value. It is also
possible to change the value shown in the input box using the status key (at the bottom right
of the display) in increments of 1/100 second.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.6 Comment

For the purpose of giving your programs a clearer structure, comment lines should be
inserted containing texts explaining the program modules.
Place the edit cursor one line above the position where you want to insert the comment line.
Open the menu by means of the menu key “Commands” and from it select the submenu
“Comment”.

You can now select one of the comment types “Normal” or “Stamp”.

2.6.1 Normal

Using the command “Normal”, you can insert a comment line containing any text into your
program. A semicolon ( ; ) will automatically be inserted at the beginning of the comment line.

Any text

Press the softkey “Cmd Abort” to discard your entries and close the inline form without
inserting a comment line into the program listing.
You can switch to the inline form for the stamp directly by using the softkey “Stamp”.

If you would like to enter a different text, you can delete the entry by means of the softkey
“New text”.
Press the softkey “Cmd Ok” to discard your entries and close the inline form without entering
them into the program listing.

Any text

When the “Comment” command is selected again, the previously entered string will already
be offered as a default text in the inline form.

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2 Program commands (continued)

2.6.2 Stamp

You can also insert a stamp in your program, however. In this instance, it is a comment line
with the time and date added. A semicolon ( ; ) will automatically be inserted at the beginning
of the line in this case as well.

Any text

Use this type of comment to document changes to programs.

You can enter your name in the first input box after NAME. Enter an abbreviation for the
change that has been made in the second box after CHANGES.

Press the softkey “Cmd Abort” to discard your entries and close the inline form without
inserting a comment line into the program listing.
You can switch to the inline form for a normal comment directly by using the softkey “Normal”.

The new system time and the system date are entered into the inline form by pressing the
softkey “New time”.
If you would like to enter a different name, the previous entry can be deleted by pressing the
softkey “New name”.
If you want to enter something else after CHANGES, press the softkey “New text”. This
deletes the previous entry and a new text can now be entered.
Use the softkey “Cmd Ok” to save your entry, close the inline form and insert the comment
line.

Any text

When the “Comment” command is selected again, the previously entered string will already
be offered as a default text in the inline form.

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2.6.3 ...changing comment lines

Move the program cursor to the line that is to be altered and press the softkey “Change”. This
opens an inline form. The existing text is displayed as a suggestion in the input box.
Depending on the type of comment, ’Normal’ or ’Stamp’, the softkey bar has one of these
two assignments:

Now alter the text as desired.


Press the softkey “Cmd Abort” to discard your entries and close the inline form without
carrying out the change to the program.
You can switch to the inline form for the stamp directly by using the softkey “Stamp”.

You can switch to the inline form for a normal comment directly by using the softkey “Normal”.

The new system time and the system date are entered into the inline form by pressing the
softkey “New time”.
If you would like to enter a different name, the previous entry can be deleted by pressing the
softkey “New name”.
If you would like to enter a different text, you can delete the entry by means of the softkey
“New text”.
Use the softkey “Cmd Ok” to terminate your entry, close the inline form and alter the comment
line accordingly.

2.6.4 ...Delete

Use the “­” or “¯” arrow key to move the edit cursor to the line you want to delete.
Press the menu key “Program” and select the option “Delete” from the menu that is opened.

Read the message displayed in the message window.

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2 Program commands (continued)

Press the softkey “Yes” if you are sure that you want to delete the selected line. When you
press this softkey, the selected line will be removed from the program.
Pressing the softkey “No” cancels the action.

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NOTES:

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Index

A Linear motions, 28
Loading and saving programs, 9
Acceleration, 25, 27, 29, 31, 33, 35
Logic, 38
Analog output, 52
Long text, 40, 41, 43, 45, 49
Approximate positioning, 21, 28, 32
Approximation Distance, 25, 29, 33
at, 46, 50 M
Motion, 21, 39, 51
Motion commands, 21
C
Motion parameters, 37
Changing comment lines, 58
CIRC, 21, 32
N
Circular motions, 32
Close editor, 17 New, 5
CMD, 51 New name, 57
Comment, 39, 51, 56 New text, 57
CONT, 21, 25, 26, 29, 30, 33, 34, 40, 42, New time, 57
44 Normal, 56, 57, 58
CPDAT1, 29
O
D Offset voltage, 55
Delay, 46, 50 Open, 6
Orientation, 28, 32
Delay value, 55
OUT, 41, 43, 45
Delete, 15, 58
Deleting comment lines, 58
Deleting programs, 10 P
Depending on the technology, 54 PATH, 46, 50
Depending on the velocity, 54 PDAT1, 25, 33
Duplicate, 10 Point--to--point motions, 24
Program editing, 5
Program editor, 15
E
Programmed velocity, 27, 31, 35
Edit, 6 Programming, 38, 52
Edit cursor, 21, 38, 52 Programming a LIN motion, 29
Exact positioning, 21, 28, 32 Programming a PTP motion, 25
Programming movements, 21
F Programs, 5
PTP, 21, 24
Find, 12, 15
PTP motions with approximate positioning, 24
Full circle, 36
PTP motions with exact positioning, 24
PULSE, 41, 43, 49
I
IBUS--Seg on/off, 51 R
IBUS/WAIT, 39
Robot coordinates, 26, 30, 34
Infinitely rotating axes, 22

S
L
Save, 27, 31, 35
Last command, 20 Save the current robot coordinates, 26, 30,
LIN, 21, 28 34

Index -- i
Index

Select/open/save a program, 5
Stamp, 57
Standard motions, 21
State, 40, 42, 43, 46, 50
SYN OUT, 45
SYN PULSE, 49
SYNOUT, 41, 49
SYNPULSE, 43, 45

T
Technology parameters, 55
Time, 44, 50
Touch Up, 26, 30, 34
Types of motion, 21

V
Vel, 25, 29, 33
Velocity parameters, 55

W
W_F/IBUS, 39
WAIT, 38
WAIT FOR, 39
Wait functions, 38
WAIT/W_F, 51

Z
Zip file, 9

Index -- ii
SOFTWARE

KR C...

Installation

KUKA System Software (KSS)


Release 4.1

Issued: 07 Sep 2004 Version: 01


InstallationR4.1 02.02.01 en

1 of 46
 Copyright 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.

PD Interleaf

InstallationR4.1 02.02.01 en

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Contents

1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Installation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Preconditions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Installing the operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7


2.1 Creating a boot disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1 Formatting the floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.2 Copying system data to floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 BIOS settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 Defining hard drive parameters (Standard CMOS Feature) . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.2 Changing the boot sequence (Soyo Combo Feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.3 Saving the settings (Save & Exit Setup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Modifying the partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1 Deleting existing partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.2 Creating new partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.3 Setting the active partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Formatting partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Installing the operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.1 Copying operating system data to the hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.2 Installation of the operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Installing additional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3 Installing the KSS (KUKA System Software) . . . . . . . . . . . . . . . . . . . . . . . 37


3.1 Preventing an automatic start of the KSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Installing the KSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4 Automatic software update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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1 Fundamentals

1 Fundamentals
1.1 Installation types
An operational version of the KUKA System Software (KSS) is supplied with the control
cabinet. The KSS itself runs under a specially–modified version of the Windows operating
system.

Only use the operating system supplied with the control cabinet for operating the
robot controller! Only this version ensures that the KUKA software will function
correctly.

There are several different ways of installing the operating system or a more up–to–date
version of the KSS:

Procedure Action Situation

Operating system *1
Configuration of the entire hard Deletion of all data on the hard Defective operating
disk disk; system or hard drive
Installation and configuration
of the operating system
KSS *1
Installation of “KUKA System Installation and configuration Important components
Software” of the KSS alongside the oper- have changed (e.g.
ating system that has already new machine data
been installed required)
Automatic update
Updating of “KUKA System Installation and configuration KSS update
Software” of the KSS with the operating
system running
*1Basic knowledge of the “Windows” operating system is required for the installation of
the operating system and the KSS.

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1.2 Preconditions for installation


A number of preconditions must be met before you can install the current KUKA Roboter
GmbH programs.
 First of all, you need a CD–ROM with the relevant version of the KUKA robot controller.
This CD contains the complete Windows operating system and the KUKA software. An
external keyboard is required for manipulation of the BIOS settings.
 A 3 1/2” floppy disk with a capacity of 1.44 Mbytes is required for installation of the
operating system.
 An external keyboard is required for installation of the operating system and the KSS.
Use of a mouse is optional.

For KUKA control cabinets, the following minimum requirements apply:


 Cabinet type KR C1/ KR C2 / KR C3
 Motherboard Only KUKA–approved types
 Processor: 400 MHz Pentium or equivalent
 Main memory Minimum 128 Mbytes RAM
 Hard drive At least 1 GB

If your control cabinet does not meet the requirements listed, it may be possible to
exchange the control cabinet’s computer unit. More detailed information about this can be
obtained from Customer Support.

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2 Installing the operating system

2 Installing the operating system


The following steps must be carried out in order to install the operating system:
 Create a boot disk;
 Call up the BIOS settings and modify as required;
 Check the partitions, modify if required and define the active partition;
 Format the partitions;
 Install the operating system.

All data on the hard disk are irrevocably lost during this procedure. You should
therefore make backup copies of any relevant data. Only change settings that are
explicitly indicated.

If you are using an external monitor, this can only be used once the operating system has
been installed.

If you are using a hard drive supplied by KUKA, the partitions are already set up the right
size as standard. In this case, it may still be necessary to format the partitions.

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2.1 Creating a boot disk


A boot disk can be created on any Windows platform. Create the boot disk before deleting
data from the hard disk.

The function keys must not be disabled, otherwise it is not possible to create a boot disk.
Keys, such as “CTRL” can be accessed in the following ways:
 Windows is started without the KSS.
In this case you need an external keyboard, as the drivers required for the KCP are
only loaded when the KSS is called.
 Switch to expert level with the controller running.
You can access the Windows function keys from here. The “NUM” option must be
deactivated by pressing the corresponding key on the KCP.

The following keys are used for navigating in the operating system:

Key Designation Action

Arrow keys Selection of an entry

SHIFT +
+ down arrow key
Selection of multiple entries

Execution of a selected entry


Enter key
Opening a selected directory

Backspace key Moves back up a level in Explorer

Positions the cursor on the next input or selection


TAB key
box

Space bar Switches a selected option on or off

Ctrl + CTRL+Escape Opens the Start menu of the operating system

+ ... ALT+ ... Opens the corresponding menu in the Explorer

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2 Installing the operating system (continued)

2.1.1 Formatting the floppy disk


First open Windows Explorer. Use the keyboard shortcut “CTRL” + “ESC”. Then select the
Explorer, using the arrow keys, and press the Enter key.

Press the Backspace key on the


keyboard to access a higher
directory level.

Position the focus on the floppy disk


drive icon using the “” and “” arrow
keys.

If a mouse is connected, you can click on the floppy disk icon directly using the right–hand
mouse button and select the corresponding option from the pop–up menu.

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Then hold the “ALT” key down and press the “D” key.

Use the “ arrow key to select the option Format from the
submenu and confirm this by pressing the Enter key.

You can access the various settings


using the “TAB” key.

Use the arrow keys to select the


formatting type “Complete”.

For the purposes of easier


identification, you can assign a name
to the floppy disk.

You can activate and deactivate the


desired options using the space bar.

Finally, select the “Start” button using the “TAB” key and
press Enter. The progress of the operation is then
displayed by means of a progress indicator bar.

The floppy disk must not be removed from the drive while it is being accessed by the
computer. Otherwise the floppy disk and/or the disk drive could suffer irreparable
damage.

On completion, the results of the


formatting are summarized in a
window in which any errors that may
have occurred are also displayed. If
errors are listed here, replace the
floppy disk with a different one.

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2 Installing the operating system (continued)

2.1.2 Copying system data to floppy disk


Once the disk is successfully formatted, place the KUKA CD in the CD–ROM drive.
Switch to the CD–ROM drive in
Explorer. This is usually the drive with
the designation “E:”.
Then open the directory “Bootdisk” on
the CD.

In order to be able to copy all the files for the boot disk, the Explorer option
“View” –> “Options” –> “Show all files” must be activated.

Select all the files in this directory.


This can be done using the keyboard
shortcut “SHIFT” + “”.

Copy the files to the clipboard using the keyboard


shortcut “CTRL” + “C” or the menu command
“Edit” –> “Copy”.

Then switch to the floppy disk drive


in Explorer.

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Paste the copied files to the floppy disk using the


keyboard shortcut “CTRL” + “V” or the menu
command “Edit” –> “Paste”.

The boot disk is now finished.

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2 Installing the operating system (continued)

2.2 BIOS settings


After exchanging a hard drive, call up the computer’s BIOS settings in order to check the
parameters and alter them if necessary.

Only make changes in the areas shown!


No responsibility can be accepted for incorrect modifications to the BIOS settings.

The appearance and structure of the BIOS settings depend, among other things, on the
hardware used and may therefore differ from those illustrated in these examples.

The following keys are required for navigating in the BIOS settings:

Key Designation Action

Arrow keys For selecting the desired entry

Opens the selected entry or corresponding


Enter key
window

Closes the current window and opens the


ESC key
previous one

PgUp PgDn
Scroll keys Selection of a parameter

Calls up the BIOS settings when the system is


Del Del key
booted

Switch the robot controller on. During the boot sequence (just after the memory test) press
the “Delete” key on the keyboard. This takes you to the BIOS settings main menu.

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SOYO COMBO Feature PC Health Status

Standard CMOS Feature Load KUKA Defaults

Advanced BIOS Features Set Supervisor Password

Advanced Chipset Features Set User Password

Integrated Peripherals Save & Exit Setup

PnP/PCI Configurations Exit Without Saving

Esc : Quit mobd : Select Item


F10 : Save & Exit Setup

Change CPU’s Clock & Voltage

2.2.1 Defining hard drive parameters (Standard CMOS Feature)


If the size of the newly installed hard drive is different from that of the previous drive, this is
normally detected automatically by the system. If this is not the case, the corresponding
setting must be made in the BIOS.
Using the arrow keys, select the option “Standard CMOS Feature” and press Enter. Select the
relevant IDE connection (by default the hard drive is set as “Primary Master”) and press Enter
again.

Date (mm:dd:yy) Thu, Jul 1 2004 Item Help


Time (hh:mm:ss) 15 : 12 : 51

IDE Primary Master WDC AC14300R


IDE Primary Slave None
IDE Secondary Master _NEC CD–ROM CD–3
IDE Secondary Slave None

Drive A 1.44MB, 3.5 in.


Drive B None

Video EGA/VGA
Halt On All, But Disk/Key

Base Memory 640K


Extended Memory 261120K
Total Memory 262144K

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2 Installing the operating system (continued)

If necessary, set the entries “IDE ...” and “Access Mode” to “Auto”. Proceed in the same way
with the entries for the other IDE connections.

IDE HDD Auto–Detection Press Enter Item Help

IDE Primary Master Auto


Acess Mode Auto

Then press the “ESC” key twice to return to the main menu.

2.2.2 Changing the boot sequence (Soyo Combo Feature)


This option determines the sequence in which the different drives are searched for an
operating system. Usually, the floppy disk drive is deactivated here. In order to install a new
operating system, this setting may need to be changed.
Select the option “SOYO COMBO Feature” in the main menu and press the Enter key.
In the screen illustrated below, only the entries “... Boot Device” are of importance.

CPU Frequency Select Auto Item Help


x Frequency 1MHz Stepping 100
Auto Detect DIMM/PCI Clk Enabled
Spread Spectrum Disabled
Quick Power On Self Test Enabled
First Boot Device Floppy
Second Boot Device HDD–0

Select the entries using the arrow keys. Set the entries to “Floppy” and “HDD–0” using the
“PgUp” and “PgDn” keys.
Press “ESC” to return to the main menu.

2.2.3 Saving the settings (Save & Exit Setup)


In order for the changes to take effect the settings must be saved. Select the menu item
“Save & Exit Setup” and press the Enter key.
A request for confirmation is generated, which must be answered by pressing “Y”. The
system will then be restarted.

SAVE to CMOS and EXIT (Y/N) Y

The boot disk should already be in the floppy disk drive when the system is rebooted so
that you can continue with the system set–up.

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2.3 Modifying the partitions


A hard disk for use in the KUKA robot controller must have at least 2 partitions. The first is
the “Primary partition”, while the second is a so–called “Extended partition”.
When the system is booted, the files from the boot disk are loaded. Wait until the DOS
command prompt appears.
A:\>
Enter the command “FDISK” and press the Enter key.
A:\>fdisk
The program “FDisk.exe” is then started; this program can be used to modify the partitions
on the hard disk.

Be extremely careful when making changes! Some operations are carried out
without a request for confirmation.
No liability will be accepted for lost data.

2.3.1 Deleting existing partitions


To delete the partitions or logical drives, enter the number “3” in the FDISK options and
confirm the selection with the Enter key. Commands relating to the deletion of partitions are
all grouped together in the submenu “Delete DOS Partition or Logical DOS Drive”.

FDISK options

Current hard disk: 1

Select one of the following options:

1. Create DOS partition or logical DOS drive


2. Define active partition
3. Delete partition or logical DOS drive
4. Display Partition Information

Enter option number: [3]

Press Esc to exit FDISK

Delete any existing partitions in the following sequence:


 Remove the logical drives
 Delete the extended partitions
 Delete the primary partition(s)
Bear in mind that the extended partition can only be deleted if the logical drives have
already been deleted.

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2 Installing the operating system (continued)

Removing the logical drives


Select the option
3. Delete logical DOS drive in the extended DOS partition

In the example, a total of 3 logical drives have been set up, which share the available capacity
of the extended partition between them.

Delete logical DOS drive in the extended DOS partition

Drive Name MB System Assignment


D: DATA1 502 FAT16 28%
E: DATA2 502 FAT16 28%
F: DATA3 810 FAT16 44%

Total Extended DOS Partition size is 1814 Mbytes (1 Mbyte = 1048576


bytes)
WARNING! Data in the deleted logical DOS drive will be lost.
Delete which drive..........................? [D]
Enter drive name................................? [DATA1 ]
Are you sure (Y/N)..........................................? [Y]

Press ESC to continue.

Enter the drive letter and the name of the drive and confirm these entries. Repeat this
procedure with the remaining logical drives.
Pressing the “ESC” key twice returns you to the screen “FDISK Options”.

Deleting the extended partition


After deleting the logical drives, the extended partition can be deleted. Select the option
2. Delete extended DOS partition

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Delete Extended DOS Partition

Current hard disk: 1

Partition Status Type Volume label Mbytes System Usage


C: 1 PRI DOS SYSTEM 200 FAT16 10%
2 EXT DOS 1814 90%

Total disk space is 2014 Mbytes (1 Mbyte = 1048576 bytes).

WARNING!All data in the extended DOS partition will be lost.


Do you want to continue (Y/N)..................................? [N]

Press ESC to return to the FDISK options.

Confirm the request for confirmation by pressing “Y” and the Enter key.

Deleting the primary partition


Finally, delete the primary partition from the hard disk. First of all, select the following option
in the submenu:
1. Delete primary DOS partition

Delete primary partition

Current hard disk: 1

Partition Status Type Volume label Mbytes System Usage


C: 1 PRI DOS SYSTEM 200 FAT16 10%

Total disk space is 2014 Mbytes (1 Mbyte = 1048576 bytes).

WARNING! Data in the deleted primary DOS partition will be lost.


Which primary partition would you like to delete? [1]
Enter drive name................................? [SYSTEM ]
Are you sure (Y/N)..........................................? [Y]

Press ESC to continue.

Press “ESC” to return to the FDISK Options menu. New partitions can now be created.

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2 Installing the operating system (continued)

2.3.2 Creating new partitions


Once the existing partitions have been deleted, the hard drive must be partitioned by means
of option “1”.

FDISK options

Current hard disk: 1

Select one of the following options:

1. Create DOS partition or logical DOS drive


2. Define active partition
3. Delete partition or logical DOS drive
4. Display Partition Information

Enter option number: [1]

Press Esc to exit FDISK

Create new partitions in the following sequence:


 Create the primary partition
 Create the extended partition
 Create a logical drive in the extended partition.
Bear in mind that a logical drive can only be created if an extended partition has been
created first.

Creating the primary DOS partition


Select the first option and confirm the selection again by pressing the Enter key.
The program then asks if the entire capacity of the hard disk is to be assigned to the primary
partition. Answer this question with “N”. You can now enter the size of the primary partition
in Mbytes or as a percentage. Set the desired partition size and confirm the value with the
Enter key.

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Create Primary DOS Partition

Current hard disk: 1

Total disk space is 19093 Mbytes (1 Mbyte = 1048576 bytes).


Maximum available disk space for the partition: 19093 MB (100%)

Enter the partition size of the Primary DOS Partition in MB or as a


percentage of the available disk space................... : [ 5000 ]

No partitions defined

Press ESC to return to the FDISK options.

The size of the primary partition must be at least 500 MB. At least as much space should
be available in the second partition for user data.

Press “ESC” to return to the FDISK Options menu.

Creating the extended DOS partition


In order to create the drive for the user data, it is first necessary to create an extended
partition. Enter the remaining disk space as the size of this partition.

Create extended DOS partition

Current hard disk: 1

Partition Status Type Volume label Mbytes System Usage


C: 1 PRI DOS 5005 UNKNOWN 25%

Total disk space is 19093 Mbytes (1 Mbyte = 1048576 bytes).


Maximum available disk space for the partition: 14080 MB (75%)

Enter the partition size in MB or as a percentage of the available disk


space in order to create the Extended DOS Partition........ : [14080 ]

Press ESC to continue.

Press the Enter key to confirm the desired size. Pressing “ESC” returns you to the FDISK
options where you can define logical drives.

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2 Installing the operating system (continued)

Creating a DOS drive in the extended partition


If required, select the third option and confirm the selection by pressing the Enter key. The
program then asks how large the first logical drive should be. Enter the space remaining on
the hard disk.

Create Logical DOS Drives in the Extended Partition

No Logical Drives defined

Total Extended DOS Partition size is 14080 Mbytes (1 Mbyte = 1048576


bytes)
Maximum available disk space for logical drives: 14080 MB (100%)

Enter size of Logical Drive in MB or as % of available disk space:


[14080]

Press ESC to continue.

The program then displays all existing logical drives.


The “ESC” key takes you back to the main menu where you can set the active boot partition.

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2.3.3 Setting the active partition


The active partition determines the primary partition from which the operating system is
loaded.

If no active partition is set, the system cannot be booted from the hard disk.

Select “Define Active Partition” and enter the number “1”. Confirm this selection by pressing
the Enter key.

Define Active Partition

Current hard disk: 1

Partition Status Type Volume label Mbytes System Usage


1 PRI DOS 5005 UNKNOWN 25%
2 EXT DOS 14080 UNKNOWN 75%

Total disk space is 19093 Mbytes (1 Mbyte = 1048576 bytes).

Enter the number of the partition you want to make active:....[1]

Press ESC to return to the FDISK options.

The partition that is currently selected is indicated by the letter “A” under “Status”.
Partition Status Type Volume label Mbytes System Usage
1 A PRI DOS 5005 UNKNOWN 25%

The “FDISK” program is exited by pressing the “ESC” key twice.


The hard drive partitions must then be formatted. Only then can data be loaded onto the disk.

The system must be rebooted in order for the changes to take effect.

Remove the boot disk from the drive to prevent the disk from being damaged when the
system is shut down. The switch the system off. Wait a few seconds before rebooting the
system.

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2 Installing the operating system (continued)

2.4 Formatting partitions

All data present in a partition are lost when that partition is formatted.

Switch the robot system on and insert the boot disk into the drive. Wait until the DOS
command prompt appears:
A:\>

Enter the command to format drive “C:\” (primary partition) and press the Enter key.
A:\>format c:

Confirm the warning which then appears by pressing “Y” and the Enter key.
Warning, all data on non–removable disk
drive C: will be lost!
Proceed with format (Y/N)? Y

After a short wait time, drive C: is formatted. Enter the label


“KUKADISK”.
Volume label (11 characters, ENTER for none)?
KUKADISK

Then format drive “D:\” (logical drive) in the same way:


A:\>format d:

Enter the label “KUKADATA”.


Volume label (11 characters, ENTER for none)?
KUKADATA

In order to be able to boot from the hard disk, a number of system files must be copied onto
the hard disk. Enter “SYS C:”.
A:\>sys c:

Once the system files have been transferred, the installation of the operating system can
begin.

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2.5 Installing the operating system


2.5.1 Copying operating system data to the hard disk
Place the KUKA CD–ROM in the CD–ROM drive. Enter the following command at the DOS
command prompt:
A:\>xcopy32 E:\english\win95 D:\english\win95/v/s/e
Pay particular attention to the spaces and confirm the entry with the Enter key.

The program then asks whether a file (“F”) or a directory (“D”) is meant. Enter “D”:
Does WIN95 specify a file name or
directory name on the target drive
(F = file, D = directory)? D
The copying procedure lasts several minutes.

2.5.2 Installation of the operating system


The files required for the installation of the operating system are now located on drive “D:\”.
Switch to this drive by entering “d:” at the command prompt and pressing the Enter key:
C:\>d:

On drive “D:\”, change the current directory:


D:\>cd english\win95

You can now load the Setup program which will then execute the corresponding installation
routines.
D:\ENGLISH\WIN95>setup

Confirm the following request for confirmation by pressing the Enter key.
Please wait while Setup initializes
Setup is now going to perform a routine check on your system
To continue with Setup, press ENTER. To quit Setup, press
ESC.

“Scandisk” is then loaded; this program automatically checks drives C:\ and D:\. If the
program detects errors, the hard drive must be exchanged. On successful completion of
“Scandisk”, close the program.
The next step is to load the actual Setup program which installs the operating system.

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2 Installing the operating system (continued)

The final step of the actual installation procedure is the license agreement.
Accept the license agreements in order to start the Setup Wizard. Press the keys “ALT” +
“Y” or click with the mouse on the button “Yes”.

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Answer the system information question by selecting “Next”. This is done by pressing the
“TAB” key repeatedly until the correct button is selected. Then press the Enter key.

Press “Next” to accept the directory “C:\Windows” offered by default.

The installation program then scans the hard disk and checks the amount of disk space
available.

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2 Installing the operating system (continued)

Under Setup Options, leave the option “Typical” selected. Activate the “Next” button using
the “TAB” key and press Enter.

In the User Information dialog, enter “KR C” under Name and press “TAB” to toggle to the
next input box. Under Company, enter “KUKA Roboter GmbH”. Toggle to the “Next” button
using the “TAB” key and press Enter to confirm the entries.

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Under “Analyzing Your Computer” (hardware detection), leave the check boxes empty. To
toggle to the “Next” button, press the “TAB” key again.

The subsequent procedure lasts several minutes. The system is checked for connected
hardware and the drivers are installed accordingly. The progress of the operation is indicated
in a progress indicator bar.

Ensure that the communications settings check boxes are deactivated. The Enter key takes
you to the next window.

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2 Installing the operating system (continued)

Under Windows Components, select the option “Install the most common components”.

In the Startup Disk window, enter “No, I do not want a startup disk”. Use the “#” and “"” arrow
keys or TAB to change the option. Confirm the change by pressing the Enter key.

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Start the copying procedure by pressing the Enter key.

This procedure lasts several minutes and requires no intervention.

Remove the floppy disk from the drive. The operating system must be restarted in order to
continue the installation process. Press the Enter key again to do this.

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During the reboot, certain Windows components are configured accordingly.

Make sure that the check box for switching automatically between summer and winter time
is not activated! Close the “Date/Time” window by pressing the Enter key.

The Add Printer Wizard is now started.

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Select no printer by using the “TAB” key to activate the “Cancel” button and confirming this
with the Enter key.

Rebooting the system completes the configuration and terminates the installation of the
operating system.

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2.6 Installing additional components


Before installing the KSS, the following components must be installed from the KUKA
CD–ROM:
 Shared memory driver
 Network Client (optional)
 File sharing (optional)
 Network card driver (optional)

Installing shared memory driver


Open the Windows Start menu by holding down the “CTRL” key and pressing the “ESC” key.
Using the arrow keys, select the Start menu option “Run” and press Enter.

In the input box of the Run window,


enter “e:\internat\tools\smsetup\smsetup.exe ” and press Enter.

The shared memory driver is then installed.

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Installation

Installing Network Client and file sharing (optional)


In order for a user to log onto a network, a Network Client is required. If data are to be
exchanged via a network connection, file and printer sharing must be installed as well as an
additional network card.
To do so, open “Settings” –> “Control Panel” via the Start menu.

Select the option “Network” and press the Enter key.

The network settings contain the two entries “RTACC VxWorks” and the corresponding
“TCP/IP” protocol.

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2 Installing the operating system (continued)

Install a client for Microsoft Networks via “Add” –> “Client” –> “Add”.

Select the entry “Client for Microsoft Networks” and activate the properties. This opens the
window for the file and printer sharing settings. Select the required option boxes.

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Installation

Specifiy the name of the computer and the corresponding workgroup for identification
purposes.

Additional network card (optional)

If an additional network card is being used (it must be a type approved by KUKA Roboter
GmbH), the corresponding card driver and TCP/IP protocol must now be be installed.

System reboot
The system must be rebooted at this point.

Remember to restore the original boot sequence in the BIOS. This eliminates the possibility
of the system automatically booting from a floppy disk or CD–ROM.

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3 Installing the KSS (KUKA System Software)

3 Installing the KSS (KUKA System Software)


Place the “KUKA System Software” CD in the CD–ROM drive.

The operating system settings influence the appearance of the individual components.
They may therefore vary from the examples illustrated here.

The following keys are required for navigation during installation of the KSS:

Key Designation Action


Opens the Start menu of the operating
Ctrl + Control + Escape system
Not available in the user group “User”

Arrow keys For selecting the desired entry

In the Start menu, this key opens the


Enter key submenu corresponding to the selected
entry or starts the selected program

Closes the current window and opens the


ESC key
previous one

Toggles to a different area in the Explorer


TAB key
window where selections can then be made

Del Del key Deletes the element selected in the Explorer

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Installation

3.1 Preventing an automatic start of the KSS


If a version of the KSS is already installed, this is automatically started when the robot system
is booted. To prevent this automatic start, proceed as follows in the user group “Expert”:

Open the Start menu and start Explorer

Hold the “CTRL” key down and press the “ESC” key.
Using the arrow keys, select the entry
“Programs” –> “MS–DOS Prompt”
and press the Enter key

Prevent Startup
At the command prompt, enter the following text to delete the shortcut to the Startup
directory:
C:\WINDOWS>del c:\windows\startm~1\progra~1\autost~1\cross3.lnk

The tilde character “ ~ ” can be entered using the KCP by holding down the ALT key and
typing “126” on the numeric keypad. Then release the ALT key.

Confirm the command by pressing the Enter key.


Close the command prompt.
A:\>exit
Confirm this command also by pressing the Enter key.

Restart the system


Then restart the system. Once the operating system has booted, you can continue with
“Installing the KSS”.

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3 Installing the KSS (KUKA System Software) (continued)

3.2 Installing the KSS


Open the Start menu by holding down the “CTRL” key and
pressing the “ESC” key. Using the arrow keys, select the Start
menu option “Run” and press Enter.

Enter the command line


“E:\Setup.exe” in the input line in the
Run window. Confirm this command
also by pressing the Enter key. This
starts the Setup program.

Language selection
In the first step, you can choose the language in which texts are to be displayed during
installation.

Select the desired


language by pressing
the “” and “” arrow
keys and pressing
the space bar once to
highlight the option.
The selected lan–
guage is confirmed
by pressing the Enter
key.

If you wish to modify any of the settings, press the button “Back” to take you
step–by–step back through the previous dialog windows.
Press “Next” to accept the settings in the current window and proceed to the next
step.
Pressing “Cancel” terminates the installation.

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Installation

Welcome page
Please read the text in the welcome page.
The next window is
opened by pressing
“Next”.

Copying the CD–ROM

This dialog window only appears if the software is being installed from the CD–ROM and
there is a second hard disk partition available. If the CD was already copied onto the hard
disk during an earlier installation, that copy will now be overwritten.

Select the box


“Copying
CD–ROM” by
pressing the space
bar if you wish to
copy the contents
of the CD–ROM to
the hard disk.

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3 Installing the KSS (KUKA System Software) (continued)

Parameter input
Select the desired
customer version.

The settings are confirmed by pressing the Enter key.

Conversion
If there is an earlier version of the software already installed on the hard drive, data such as
machine data, Init files and programs can be converted.
Specify which data
are to be converted.

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Installation

Robot type
The robot type can only be selected if no machine data from an earlier installation are
converted.
Select the robot
type to be used.

If your robot does not correspond with the


type suggested, activate the “Browse”
button using the “TAB” key and press
Enter.
Using the arrow keys, search in the
“MaDa” directory for the control cabinet
you are using (e.g. “KR C2”) and there
select the robot.

If the machine data loaded do not match the robot type, a corresponding error
message is generated when the controller is booted. The robot must not be moved
in this case.

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3 Installing the KSS (KUKA System Software) (continued)

Options

Select the options


that are present in
your system. This
is also done using
the arrow keys and
the space bar.

Summary
Finally, a summary
of the setup settings
is displayed.
If all the settings are
correct, press the
Enter key. The
installation process
is now carried out.

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Installation

Restart
Windows must
be restarted on
completion of the
installation
process.

Once the operating system has rebooted, the KSS is started for the first time.

Remember to remove the installation CD–ROM from the drive.

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4 Automatic software update

4 Automatic software update


Place the CD with a new program version or service pack in the CD–ROM drive.

The update CD must remain in the CD–ROM drive throughout the whole process.
Failure to do this will result in loss of data and incorrect installation.

A request for confirmation is then generated in the message window.

The software update is not carried out.

The software update is carried out.

In the next stage the controller must be restarted.

Switch the controller off and wait until the computer unit has shut down completely. Only now
may the controller be switched back on again.

If errors occur during software update, you can view these in the display.

Once the update is complete the computer is run back down again. The controller is then
started automatically. Only now may the CD be removed from the drive.

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Installation

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Index

A L
Automatic update, 5
Language, 39
Language selection, 39
B
BIOS settings, 13
Boot disk, 8
Boot sequence, 15 N
Bootdisk, 11
Network Client, 34

C
Conversion, 41
Copying operating system data to the hard disk, O
24
Copying system data to floppy disk, 11 Operating system, 5
Copying the CD–ROM, 40 Options, 43
Creating partitions, 19

D
P
Deleting partitions, 16
Parameter input, 41
E Preconditions for installation, 6
Extended partition, 16 Prevent Startup, 38
Primary partition, 16
F
FDISK, 16
File sharing, 34
Formatting partitions, 23 R
Formatting the floppy disk, 9
Robot type, 42

H
Hard drive parameters, 14
Hardware detection, 28 S

Setting the active partition, 22


I
Setup Options, 27
Installation of the operating system, 24
Shared memory driver, 33
Installing the KSS, 39
Installing the KSS (KUKA System Software), Software update, 45
37
Installing the operating system, 7, 24

U
K
KSS, 5 Update, 5

Index – i
SOFTWARE

KR C

Appendix

KUKA System Software (KSS)


Release 4.1

Issued: 09 Jan 2004 Version: 06


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e Copyright 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.

PD Interleaf

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Contents

1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 A ............................................................................ 5
1.3 B ............................................................................ 6
1.4 C ............................................................................ 7
1.5 D ............................................................................ 8
1.6 E ............................................................................ 9
1.7 F ............................................................................ 11
1.8 G ............................................................................ 11
1.9 H ............................................................................ 12
1.10 I ............................................................................. 12
1.11 J............................................................................. 13
1.12 K ............................................................................ 13
1.13 L ............................................................................ 13
1.14 M ............................................................................ 14
1.15 N ............................................................................ 15
1.16 O ............................................................................ 15
1.17 P ............................................................................ 16
1.18 R ............................................................................ 17
1.19 S ............................................................................ 18
1.20 T ............................................................................ 20
1.21 U ............................................................................ 21
1.22 V ............................................................................ 21
1.23 W ............................................................................ 22
1.24 X ............................................................................ 23

2 Operating Handbook history from V4.1.5-- > V4.1.6 . . . . . . . . . . . . . . . . . . 25


2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Operator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Configuration --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 User Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Expert Programming --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.8 Additional Functions --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.9 Applications --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Appendix

2.10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Overall index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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1 Glossary

1 Glossary
KUKA--specific terms from the software documentation are briefly explained in this section.

1.1 Symbols
$...
More detailed information on this can be found in the chapter [Appendix] under
“System variables”
#...
Variables of the enumeration type “Enum”
*
Placeholder, e.g. *.src – valid for all files with the ending “.src”
-->Text
The term Text is explained elsewhere in the glossary

1.2 A
A B C -- 2 Point
Tool calibration program which first determines the working direction of the tool and
then a point in the XY plane.
A B C -- World
Tool calibration program in which the coordinate system of the tool is aligned parallel
to the world coordinate system.
ACC (Acceleration)
Specifies how quickly the corresponding axes reach their maximum set velocity.
Acknowledgment message
Information in the status window, e.g. EMERGENCY STOP, which must be
acknowledged.
Actual position
-->Cartesian, -->Joint or -->Incremental display.
Advance run
The computer can process ahead of the motion command currently being executed
in order to eliminate the computing time at the end of the motion command which
would otherwise be required for execution of the next motion command.
Advance run stop
Certain instructions stop the advance run until the arrival of the main run (e.g. setting
an output).
Air conditioner
Special -->Control cabinet with additional cooling for special applications.
Alt key
Used for entering certain control functions.
Analog input
Can be connected to a voltage between +10 V and –10 V.

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Appendix

Analog output
Output with variable output voltage (e.g. from 0...9999 mV).
Approximate positioning (VE)
The robot moves, for example, from P1 to P3 via P2 without -->Exact positioning at
P2; the robot takes a shortcut, so to speak, in that it only approaches the point in
question before moving on to the next point.
Archive
Saves data to floppy disk or network.
Array
Grouping of objects of the same data type to form a data object.
Attributes display
Window in the Navigator with additional information regarding a selected file.
Automatic External mode
Control of the robot is taken over by a PLC.
Automatic mode
In this operating mode, the robot executes its program automatically.
Axis acceleration
The acceleration of an axis given as a percentage of the maximum value defined in
the machine data.
Axis--specific (joint) coordinate system
Here, the linear offsets (for translational axes) or the rotational offsets (for rotational
axes) are specified for each robot axis.
Axis--specific (joint) display
Rotation of each individual axis in degrees relative to its mechanical zero position
determined during -->Mastering.
Axis velocity
The velocity at which an axis is moved given as a percentage of the maximum value
defined in the machine data.

1.3 B
Base coordinate system
This is used as the reference system to define the position of the workpiece. It has the
world coordinate system as its reference coordinate system.
Base--related interpolation
When interpolating the motion path, the robot controller calculates the current position
($POS_ACT) in relation to the $BASE coordinate system.
Battery monitoring
The serviceability of the batteries in the control cabinet is checked when the system
is shut down.
BCO (block coincidence)
Correspondence between the robot position and the coordinates of the motion block.
Binary output
Binary coded output.

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1 Glossary (continued)

Block functions
Editing operations to -->Cut, -->Copy, -->Paste, -->Find and -->Delete.
Block pointer
Colored marker in the program window indicating the block currently selected in the
program.
BS A/F
-->Time--distance function for setting outputs or -->Flags.
BS bin/ana
-->Time--distance function for the output of binary or analog signals.

1.4 C
Calibration
The dimensions of a tool or workpiece are entered into the robot controller.
Caller Stack
Display of the statuses of the advance run and main run pointers.
Cartesian coordinate system
Rectangular coordinate system with an X, Y and Z axis.
Cartesian display
Difference between the tool center point and the world coordinate system.
CD--ROM drive
Drive for reading data from compact disks.
CellProj
External program which allows easy modification of the file “Cell.src”.
Check
Checks the -->Mastering of a tool mounted on the robot.
CIRC (Circular)
Motion command for circular motions.
Clipboard
An area in the main memory of a computer which other programs may access under
certain conditions.
Cold start
The computer system is switched off and back on again. The state of the system prior
to the deactivation of the system is not restored. This state is restored in the event of
a -->Warm start.
COM1
Connection for an external serial computer mouse.
Comment
Additional information allowing easier recognition of program contents by the
operator.
Compiler
Translates the program code, legible to humans, into machine code and carries out
a syntax check.

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Appendix

Configuration
Miscellaneous system settings affecting inputs/outputs, I/O drivers, language, etc.
Continuous--path motions
The start point and end point are specified here. The TCP moves along a linear or
circular path between these points.
Control cabinet
Houses the components necessary for controlling the robot, such as -->Processor unit
and -->Power module.
Control ON
LED underneath the flap on the control cabinet displaying the status of the computer.
Coordinate system
The robot motions are always executed relative to the system currently set; e.g. joint,
world, etc.
Coordinate transformation
Axis--specific (joint) coordinates are transformed to Cartesian coordinates and vice
versa.
Copy
Data are copied to the -->Clipboard.
Counter
Incrementation function with a settable start value.
Crash
Collision between the robot and a tool, workpiece or device which makes -->Mastering
necessary.
Cross
The “Kuka--Cross” program which runs in the background.
Cross logbook
Displays the data from the Kuka--Cross program which runs in the background.
CTRL key
Control key for program--specific commands.
Cursor key
Operator control element allowing movement of the edit cursor or the focus in the
display.
Cut
A selected area of text is deleted from the current position and copied to the
-->Clipboard.

1.5 D
Data list
The “DAT” file (item list) belonging to a program.
DAT file
Data list which can be seen at expert level.

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1 Glossary (continued)

Degrees of freedom
Limitation of the number of axes which can be moved simultaneously using the Space
Mouse.
Delay
Delay of certain commands, e.g. for adhesive applications.
Delete
A selected area or file is permanently removed.
DEL key
Deletes the character to the right of the -->Edit cursor .
Diagnosis
Functions for checking the statuses of the system.
Dial gauge
Tool for robot -->Mastering.
Dialog message
Safety query generated by the system which must be answered.
Directory
A kind of “Drawer” for organizing files.
Directory list
Display of directories in the -->Navigator window.
Directory structure
Window for displaying -->Drives and -->Directories in the -->Navigator.
Display
The graphical user interface which is displayed on the LCD screen of the (V)KCP.
Dominant axis
Movement of just one axis using the Space Mouse.
Drive
Data storage medium for loading and saving data.
Driver
Program for the correct control of hardware components.
Drives ON / OFF
Buttons for activating or deactivating the drives.
DSEAT (Digital servo--electronics)
This module is responsible for digital control of the robot axes and the servo -->Power
module.
Duplicate
A copy is made of a selected area or file.

1.6 E
Edit cursor
The cursor located in the position at which characters can be entered or deleted and
which indicates the current position in the program.

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Appendix

Editor
Program section for editing text or program lines.
EMERGENCY STOP
Immediate stoppage of the robot if the red EMERGENCY STOP button is pressed or
a safety gate is opened during operation.
EMT
Electronic measuring tool necessary for -->Mastering the robot.
Enabling switch
Button on the back of the -->(V)KCP which must be pressed in order to carry out certain
actions, e.g. manual traversing or program start.
End key
This is situated in the numeric keypad and moves the -->Edit cursor to the last
character in the program line.
End stop
Buffer which reduces the impact of a robot axis.
Enter key
Operator control element for completing inputs or confirming queries, etc.
Error display
Display in a -->Status window of the errors that have occurred in a program.
Error list
-->Softkey which calls the error display.
ESC (Electronic Safety Circuit)
Safety system which provides permanent monitoring of certain safety modules (e.g.
Emergency Stop, operator safety, etc.).
Escape key
Operator control element used to cancel an action.
Exact positioning
The robot moves exactly to the point.
Expert level
-->User group.
Extension
-->File extension.
External axes
Additional axes, e.g. axis 7 for movement of the entire robot.
External kinematics
e.g. a turntable, which moves while the robot works on a part clamped on it.
External tool
A tool which is not mounted on the robot.

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1 Glossary (continued)

1.7 F
FALSE
Corresponds to the state “false” or bit “0” set.
File
A program or data created by a program.
File extension (e.g. Test.SRC)
Generally the last three characters of a file, which are used by a program in order to
identify its own data.
File list
Display of files in the -->Navigator window.
Filter
Limits the display to files of certain kinds; only available at expert level.
First Mastery
-->Mastering of the robot without load or additional load.
Flag
A status (comparable to a switch) which can be switched on or off via the “Monitor”
menu or during program execution; it is evaluated the moment it is assigned.
Focus
Colored marking which can be used for selecting -->Drives, -->Directories, -->Files,
-->Menu entries and input boxes -->Inline forms.
Folge
Program comprising a -->SRC file and a -->DAT file.
Format floppy
Completely delete the contents of a floppy disk.
Formatting
The storage medium (e.g. floppy disk, hard disk) is reorganized and all data on it are
deleted.
Forward transformation
Conversion from axis--specific to Cartesian coordinates.

1.8 G
Gauge cartridge
This is used to hold a -->Dial gauge or -->EMT for -->Mastering the robot.
Go
-->Program run mode.
Graphical user interface
Graphic display of the KUKA software on the LCD screen of the (V)KCP.
GUI (Graphical User Interface)
The (V)KCP display contains the menu and softkey bars, the status key bars, the
program window, the inline forms, the status and message windows and a status line.

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Appendix

1.9 H
Hand programming unit.
-->(V)KCP
Header
The bar at the top of the -->Navigator.
Hexadecimal system
Base 16 system: digits 0--9 and A--F.
Home key
This is situated in the numeric keypad and moves the -->Edit cursor to the first
character in the current program line.
Home run
The first motion instruction in a program.

1.10 I
I--Step
-->Program run mode.
Icon
Graphic representation of operational steps, hints, warnings, etc.
IconEditor
Optional extra module which can be used to create programs using pictograms.
Incremental display
Values for the angular momentum delivered by the axis drives are displayed.
Inline form
Input mask for program commands.
Input box
Area in the -->GUI in which data (e.g. numbers or letters) can be entered.
Insert mode
When characters are entered, the text at the edit cursor position is shifted to the right.
INS key
Switches to insert mode in which characters already present in a text are shifted to
the right.
Installation
The loading of a program onto the hard drive of a computer from which it can then be
run; its configuration is also changed in this procedure.
Interface
Connection between hardware and other hardware or software.
Interrupt
An asynchronous event which interrupts the current program execution and continues
with a program assigned to the event in question. Once this program has been
executed, execution of the previously interrupted program is resumed. The program
interrupt can be caused by the operator, error messages, safety devices, etc.

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1 Glossary (continued)

1.11 J
Jog mode
-->Operating mode.

1.12 K
KCIRC
Special motion command for circular motions in adhesive applications.
KCP (KUKA Control Panel)
Robot controller control panel equipped with operator control elements and a
-->Display for displaying the contents of the user interface (-->GUI).
Key CD
CD--ROM which must be situated in the CD--ROM drive in order to access expert level.
Keyboard
Entry of letters, control functions and special characters.
KLIN
Linear motion command for adhesive applications.
KR C (KUKA Robot Control)
Designation for the KUKA robot controller, consisting of the control panel and control
cabinet.
KRL (KUKA Robot Language)
Programming language developed especially for robot controllers.
KUKA VGA card
Standard VGA card with interface for (V)KCP color display.

1.13 L
LDEL key
Deletes the line in which the -->Edit cursor is positioned.
Learn Tool
-->Mastering of the robot with a tool or -->Additional load.
Left--arrow key
The character to the left of the -->Edit cursor is deleted.
LIN
Linear motion command for the shortest distance between two points at a defined
velocity.
Linear motion
Motion in a straight line from one point to another.
Linkage editor
Internal program which checks for modules containing errors.
Log book
Output of a chronological list of operator actions and error messages to a window on
the -->GUI or to the -->Printer.

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Appendix

Logic operators
These are used for logic operations (AND, OR, etc.) with boolean variables, constants
and simple logic expressions.
Long text
Additional comment for inputs and outputs making identification easier.
Loop
A program section which is continuously repeated.
LPT1
Interface for connecting an external printer.

1.14 M
Macro
Combination of frequently--used -->PLC commands.
Main axes
Axes A1, A2 and A3 of the robot.
Main switch
Operator control element on the front of the control cabinet for switching the robot
system on or off.
Manual override (HOV)
Manual traversing velocity can be reduced.
Manual/test mode
The operating modes T1 and T2 allow manual/test traversing of the robot with reduced
velocity or process velocity.
Mastering
The robot axes are moved to the mechanical zero position.
Mechanical zero position
This position represents an assignment to the axis drive angle and is defined by a ref-
erence notch or mark.
Menu
Collection of commands grouped together.
Menu bar
Row of keys at the top of the (V)KCP display for selecting menus.
Menu key
Individual keys at the top of the (V)KCP display which, together, form the -->Menu bar.
Merker (notices)
Links between -->PLC commands which are cyclically evaluated.
Message window
Display of notification, error and status messages, etc.
MFC (Multi--function card)
This is situated in the processor unit of the -->Control cabinet and contains an Ethernet
connection and a Device--Net/Can bus connection; it constitutes the interface
between the -->PC and the -->(V)KCP and can hold up to two -->DSEATs.

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1 Glossary (continued)

Mirror
Here, programmed points in the path are mirrored in the X--Z plane of the robot
coordinate system.
Module
Program at -->User level comprising a *.src file and a *.dat file.

1.15 N
Navigator
Directory/file manager for program management and creation which is active by
default after the controller has run up.
Notification message
Display of information in the message window, e.g. information regarding operator
actions or programming errors.
Numeric input
Tool calibration program in which tool data are entered manually via the (V)KCP or an
external keyboard.
Numeric keypad
Used for numeric input or -->Cursor control functions.
Num key
Used for switching the numeric keypad between numeric input and -->Cursor control
functions.

1.16 O
Office--GUI
Symbols in the (V)KCP display which can be switched on in order to be able to operate
control elements such as the enabling switch or start key using the mouse.
Offline
The system is not ready for operation.
Offset external kinematic
Calibration program for moving the distance between the origin of the external
kinematic system to the tool located on the external kinematic system.
Offset numeric
Manual entry of -->Offset external kinematic.
Online
The system is ready for operation.
Online help
Displays brief descriptions of certain topics and problems.
Operating mode
The robot is traversed in test/manual mode (T1 or T2), “Automatic” or “Automatic
External” mode.
Oscilloscope
Recording and display of motion data and signal states.

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Appendix

Overhead area
If the x--value of the wrist root point, expressed in the A1 coordinate system, is
negative, the robot is in the overhead area.
Override
See -->Manual override and -->Program override.
Overwrite mode
When text is entered at the edit cursor position, the existing text already there is
deleted.

1.17 P
Parameter
Additional information transferred to a program when it is started.
Parameter list
Configuration window in some inline form boxes.
Passive stop
The -->Stop key was pressed while a program was running in -->Automatic External
mode.
Paste
Data from the -->Clipboard are inserted at the current cursor position.
Path velocity (VB)
The velocity with which the robot, or the tool or workpiece, moves along the
programmed path.
Periphery
Additional hardware, e.g. Interbus module.
PGDN key
Scrolls a page further down the window, where possible.
PGUP key
Scrolls a page back up the window, where possible.
PLC instructions
Programmable Logic Controller instructions.
Power module
The actual power unit for robot operation, comprising the supply module, the servo
output stages and the logic module.
Power unit
-->Power module.
Pre--mastering position
Position indicated by markings to which the robot axes are moved before
-->Mastering.
Processor unit
Standard personal computer with KUKA--specific equipment, housed in the -->Control
cabinet.

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1 Glossary (continued)

ProgrammMaker
External utility program for the creation and modification of existing application
programs.
Program override (POV)
The process velocity can be reduced.
Program pointer
Colored pointer in the program window which indicates where the robot is or where
it should be moved to.
Program run mode
Specifies how a program should be executed in manual mode. The options “Single
Step” (step by step), “I--Step” (line by line), “Go” (continuous) and “Backwards” are
available for selection.
Program start backwards
Operator control element for starting a selected program in the reverse direction.
Program start forwards
Operator control element for starting a selected program in the normal direction.
Program window
Displays the program that is selected and can be modified.
PTP
Motion command for point--to--point motion by the quickest route.
Pulse outputs
Outputs can be set or reset for a specified period.

1.18 R
Rapid gauging
The KR C1 DSEAT inputs, channels 1 -- 4 (125 ms cycle), are used here.
Rating plate
Sticker with the serial number of the controller or robot.
RDW (Resolver Digital Converter -- RDC)
Located in the base of the robot and connected to the -->DSE ; it is responsible for
resolver power supply, R/D conversion and monitoring of the motor temperature.
Reference point
Known reference point for -->Calibration.
Relational operators
These operators (equal to, not equal to, greater than, ...) can be used to form logical
expressions. The result of a comparison is therefore always of the data type BOOL,
since a comparison can only ever be (TRUE) or (FALSE).
Rename
Change the name of a file.
Reset
-->Reset program.

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Appendix

Reset program
The selected program is reset ready for restarting, i.e. returned to the state it had
directly after it was selected.
Resolver
Reads the motor pulses and sends them to the -->RDW.
Restore
Data are written back onto the hard drive having previously been saved to floppy disk
or the network using the command -->Archive.
Restore
-->Mastering of the robot with any load.
Return key
-->Enter key.
Reverse transformation
Conversion from Cartesian to axis--specific coordinates.
Reverse traversing
Execution of the program towards the start of the program.
Robot coordinate system
This is located in the base of the robot and serves as the reference coordinate system
for the mechanical construction of the robot. It, in turn, is derived from the -->World
coordinate system.
Robot mastering
-->Mastering.
Robot name
Name given to the robot in a system.
Root point
Distance from the world coordinate system to the origin of an external kinematic
system.
Root point numeric
Manual entry of the -->Root point.

1.19 S
Select
A program is loaded into the main memory and displayed in the -->Editor ready for
editing. The program can subsequently be restarted using -->Program start forwards.
Selection list
-->Filter.
Selection window
Input line in which a preset value can be selected.
Serial number
Number used by manufacturers to identify their products.
Serial number
The -->Serial number of the -->Control cabinet or robot.

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1 Glossary (continued)

Setup
-->Installation.
Shift key
For switching between upper and lower case characters.
Simple data types
These types are Integer, Real, Bool and Character.
Single Step
-->Program run mode.
Softkey
One of the keys in the softkey bar which is pressed in order to trigger the function
assigned to it.
Softkey bar
The softkey bar is formed by the lower softkeys.
Software limit switch
When a certain axis angle is reached the axis affected is immediately deactivated.
Software--Update
Install current program version.
Space Mouse
Operator control element for moving up to 6 robot axes simultaneously.
SRC file
Program file which can be seen at expert level.
SStep(T1) and SStep(T2)
-->Operating mode.
Stand--by device
Spare device that can be quickly brought into operation if another device fails.
Start key
Operator control element used to execute the program currently selected. A
distinction is made between -->Operating modes “T1”, “T2” and “Automatic”.
Status LED
-->Control ON.
Status key
Keys on the left and right--hand sides of the (V)KCP display which, together, form the
-->Status key bar. System settings can be modified here, for example.
Status key bar
Rows of keys on the left and right--hand sides of the (V)KCP display.
Status line
Display of important system information such as operating mode, program status and
program name.
Status message
Information displayed in the -->Message window in the event of certain system states,
e.g. “EMERGENCY STOP”. The message is automatically deleted when the status
that triggered it is no longer applicable.

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Appendix

Status window
Certain states, e.g. coordinates and the assignment of inputs/outputs, are displayed
in this window.
Stop key
Operator control element for stopping a program in “Automatic” or “Automatic
External” mode.
Structures
Using the declaration statement STRUC, different data types which have been
previously defined or are predefined data types are combined to form a new composite
data type.
SUBMIT interpreter
A program running cyclically in the background which can take over robot operator and
control tasks. The SUBMIT interpreter can monitor the cooling water circuit or safety
devices, for example.
Subprogram
Part of a program which can be called more than once to save space.
Supplementary load
Additional weight on axis 3.
Sym key
For entering special characters via the keyboard of the -->(V)KCP.
System variables
Certain variables which cannot be modified by the user.

1.20 T
Tab key
Tabulation.
TCP (Tool Center Point)
The reference point of the tool that has been set (e.g. the tip of the tool).
Technologies
Combination of additional software and hardware, for example “ARC Tech 10”.
Test/manual mode
The robot can be moved manually or a program can be executed in -->Operating mode
T1 or T2. One of the -->Enabling switches on the back of the (V)KCP must be held
down. Program execution continues as long as the -->Start key is held down.
Three--dimensional array
Corresponds to several two--dimensional matrices situated one behind the other.
Time--distance functions
Functions for binary/analog outputs and for setting outputs and -->Flags.
Timer
This function can be compared with a stopwatch for which the start value can be
altered.
Tool
-->TOOL.

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1 Glossary (continued)

Tool center point


-->TCP.
Tool coordinate system
This has its origin at the tip of the tool (Tool Center Point: TCP). If the tool center point
is moved, the tool coordinate system is moved with it. It has the world coordinate
system as its reference coordinate system.
TOOL coordinate system
The robot moves in the -->Coordinate system of the mounted tool.
Tool load data
Manual entry of the mass, the center of mass, the orientation and the moments of
inertia of a tool.
Top--mounted cabinet
An additional -->Control cabinet which can be installed on top of another one.
Transport position
Configuration of the axes which allows the robot to be transported safely – varies
according to the robot type. The robot must be brought into the transport position
before the mounting base bolts are slackened.
Traversing keys
Operator control element for the manual traversing of each individual robot axis.
Traversing mode
Determines whether the robot can be moved using the -->Space Mouse or the
-->Traversing keys or whether -->Manual traversing is not possible at all.
Trigger
Activation of -->Time--distance functions at a determined distance or a given amount
of time before the target point is reached.
TRUE
Corresponds to the state “true” or bit “1” set.

1.21 U
Unmastering
The -->Mastering of the robot is deleted in order to be able to carry out a new mastering
procedure.
USER
-->KRL function call with parameter transfer.
User group
Depending on the operator (e.g. “User”, “Expert”), different funtions are available on
the KUKA program interface.
User level
-->User group.

1.22 V
VB
-->Path velocity.

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Appendix

VE
-->Approximate positioning.
Vernier
Scale on the axes of certain robot models enabling -->Mastering to be carried out
without a -->Dial gauge or -->EMT.
Version number
Number used by manufacturers to identify their programs; the higher the number, the
more up to date the program in question.
(V)KCP (VW KUKA Control Panel)
Hand--held unit and interface for operation and control of the robot.
VK--Editor
External utility program for loading, displaying and editing files.
(V)KR C1
Robot controller comprising the -->Control cabinet and the -->(V)KCP.

1.23 W
Waiting condition
The program waits until the corresponding states have been reached (e.g. input
present, output set, etc.).
Wait message
Output in the message window if a waiting condition is executed while a program is
running.
Warm start
When the system is switched back on and rebooted, the state prior to deactivation is
restored (e.g. program position, outputs, etc.).
Weave
Superpositioning of a path motion with one of the weave patterns available for
selection, e.g. triangle, trapezoid, etc.
Window selection key
Operator control element for toggling between different windows.
Workpiece
-->BASE.
World coordinate system
This is a fixed coordinate system, which serves as the underlying coordinate system
for a robot system (robot, component support or tool). It represents the reference
system for the robot system and the peripheral equipment of the cell.
Wrist axes
Axes A4, A5 and A6 of the robot.
Wrist root point
Intersection of the -->Wrist axes.

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1 Glossary (continued)

1.24 X
X Y Z -- 4 Point
Tool calibration program in which a reference point is addressed by a tool from four
different directions.
X Y Z -- Reference
Tool calibration program in which a known reference point is addressed first by a
calibrated tool and then by an uncalibrated tool.

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Appendix

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2 Operating Handbook history from V4.1.5--> V4.1.6

2 Operating Handbook history from V4.1.5-- > V4.1.6

2.1 Introduction
Standard chapter

2.2 Safety
Standard chapter

2.3 Operator Control


Running up / shutting down the controller

The KUKA Control Panel KCP

Coordinate systems

Jogging the robot

Navigator

Executing, stopping and resetting a program

Monitor

Menu structure

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Appendix

2.4 Start--up
Robot mastering/unmastering

Calibration -- Tools and Workpieces

Calibration -- External kinematics

Robot name

2.5 Configuration --> see Programming Handbook

2.6 User Programming


Program editing

Program commands
G Analog outputs expanded to “32”

2.7 Expert Programming --> see Programming Handbook

2.8 Additional Functions --> see Programming Handbook

2.9 Applications --> see Programming Handbook

2.10 Appendix
Glossary

History
G The file you are currently reading...

Overall index
G Updated version

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3 Overall index

3 Overall index

Symbols
$LAST_BUFFERING_NOTOK: Operator Control 21
$PERI_RDY: Operator Control 16
$POS_ACT: Appendix -- Operating Handbook 6
$POWER_FAIL: Operator Control 15
$PRO_IP: Operator Control 175
$STOPMESS: Operator Control 15, 16
*.DAT: Operator Control 196

Numbers
3--Point: Operator Control 215; Start--up 69
5D: Start--up 55, 90, 96
6D: Start--up 59, 90, 97

A
A B C -- 2 Point: Start--up 40, 41, 50
A, B, C: Start--up 37, 64, 68, 102, 105, 121, 128
ABC--2--Point: Operator Control 215
ABC--World: Operator Control 215; Start--up 40, 55
ABC--World (5D): Start--up 41
ABC--World (6D): Start--up 41
Absolute encoder: Start--up 33
Acceleration: User Programming 25, 27, 29, 31, 33, 35
Accelerations: Safety 14
Accessories: Safety 11
Accident: Safety 7
Accident prevention: Safety 17
Adaptation: Safety 8
Additional equipment: Safety 11
Adjustment: Safety 8
Adjustment work: Safety 19
All points in a line: Start--up 110
All points in one plane: Start--up 110
ALT key: Operator Control 36
Alt--Escape: Operator Control 46
Alt--Tab: Operator Control 45
Analog output: Operator Control 220; User Programming 52
Analog Outputs: Operator Control 148, 210
Application: Introduction 9
Approximate positioning: User Programming 21, 28, 32
Approximation Distance: User Programming 25, 29, 33
Archive: Operator Control 102, 196
Arrow keys: Operator Control 33; Start--up 46, 63, 120, 128
at: User Programming 46, 50

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Appendix

Attributes: Operator Control 87, 111, 198


Attributes display: Operator Control 76, 80
Aut: Operator Control 44
Automatic: Operator Control 55, 146
Automatic External: Operator Control 55, 151
Automatic external: Operator Control 210
Automatic program execution: Operator Control 139
Automatical External: Operator Control 206
Auxiliary substances: Safety 20
Axis specific: Operator Control 210
Axis traversing keys: Start--up 43

B
Backspace key: Operator Control 35
Backwards key: Operator Control 33
BASE: Operator Control 49, 52
Base: Operator Control 215; Start--up 69, 123
Base coordinate system: Start--up 123
Base type: Operator Control 207, 216
BCO run: Operator Control 133, 139
Block coincidence: Operator Control 133
Block pointer: Operator Control 39, 43, 126
BOF reinitialization: Operator Control 209
Bold: Introduction 8
Braking ramp: Operator Control 130
Brightness: Operator Control 38

C
Cabinet lock: Operator Control 10, 11
Cable cross--section: Safety 18
Caller Stack: Operator Control 175, 211
Cancel program: Operator Control 200, 202
Caps Lock: Operator Control 36
Carrying capacity: Safety 18
Cartesian: Operator Control 156, 210
Caution: Introduction 6
CD--ROM drive: Operator Control 10, 11
Ch.: Introduction 8
Change: Operator Control 148, 165
Change password: Operator Control 208
Changing comment lines: User Programming 58
Check Gripper: Operator Control 223
Check mastering: Operator Control 217
CIRC: Operator Control 219; User Programming 21, 32
Circular motions: User Programming 32
Climbing aid: Safety 20
Close: Operator Control 204

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3 Overall index (continued)

Close editor: User Programming 17


Clothing: Safety 18
CMD: User Programming 51
Collision protection: Safety 16
COM1: Operator Control 10
Commands: Operator Control 194, 218
Comment: Operator Control 96, 115, 220; User Programming 39, 51, 56
Commutation: Start--up 29
Computer drives: Operator Control 10, 11
Config. External Axis: Operator Control 218
ConfigMon.ini: Operator Control 162
Configure: Operator Control 194, 205
Connecting cables: Safety 5, 13
Construction: Safety 14
Consumables: Safety 11, 20
CONT: User Programming 21, 25, 26, 29, 30, 33, 34, 40, 42, 44
Continue: Operator Control 150
Continuing a program: Operator Control 139
Contrast: Operator Control 38
Control cabinet: Safety 5; Operator Control 9
Control ON: Operator Control 10
Control--Escape: Operator Control 46
Controller: Introduction 9
Controller serial number: Introduction 9
Controller switched back on: Operator Control 15
Conversion: Safety 11
Conveyor: Safety 10, 16
Coordinate system: Operator Control 49, 59
Coordinate systems TOOL, BASE, WORLD: Operator Control 72
Coordinates: Start--up 107
Copy: Operator Control 113, 199, 203
Counter: Operator Control 211
Counterbalancing system: Safety 9, 18
Counters: Operator Control 194
Coupling of the wrist axes: Start--up 34
CPDAT1: User Programming 29
CROSS Log book: Operator Control 168, 174
Cross reference
Ch.: Introduction 8
HB: Introduction 8
MC: Introduction 8
Section: Introduction 8
Cross references: Introduction 8
Cross--Log book: Operator Control 211
CTRL key: Operator Control 35, 36
CTRL--Escape: Operator Control 46
Cur. tool/base: Operator Control 207
Current selection: Operator Control 196

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Appendix

Current value: Operator Control 160, 161


Cut: Operator Control 114, 199, 204
Cyclic Flags: Operator Control 211

D
Damage to the robot system: Safety 7
Danger: Safety 8
Danger zones: Safety 9
Data list: Operator Control 93
Data Ok: Start--up 121
Def--line: Operator Control 208
Default: Start--up 67, 105
Defects: Safety 19
Degrees of freedom of the Space Mouse: Operator Control 66
DEL key: Operator Control 35
Delay: User Programming 46, 50
Delay value: User Programming 55
Delete: Operator Control 93, 114, 200, 201, 204; User Programming 15, 58
Deleting comment lines: User Programming 58
Deleting programs: User Programming 10
Depending on the technology: User Programming 54
Depending on the velocity: User Programming 54
Description of the problem: Introduction 9
Deselecting a program: Operator Control 141
Designated use: Safety 6
Designation labels: Safety 13
Detail view: Operator Control 78
Detail view on/off: Operator Control 208
Detailed information: Start--up 109
Determining the orientation: Start--up 40
Determining the position: Start--up 40
Device type: Introduction 10
Diagnosis: Operator Control 104, 211
Dial: Operator Control 216
Dial gauge: Start--up 5
Digital Inputs: Operator Control 210
Digital Outputs: Operator Control 210
Direction indicator: Operator Control 127
Directory list: Operator Control 76, 84
Directory structure: Operator Control 76, 79
Dirt entering the control cabinet: Safety 18
Disable PowerOff Delay: Operator Control 208
Display: Operator Control 194
Dominant axis: Operator Control 69
Dominant axis activated: Operator Control 70
Dominant axis not activated: Operator Control 70
Driver Reset: Operator Control 206

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3 Overall index (continued)

Drives: Operator Control 76


Drives off: Operator Control 30, 139
Drives on: Operator Control 30
DSE: Start--up 131
DSE -- RDW: Operator Control 217
Duplicate: Operator Control 115, 200; User Programming 10
Dynamic: Operator Control 220
Dynamic braking: Operator Control 131

E
EC low voltage directive: Safety 5
EC machinery directives: Safety 5
Edit: Operator Control 93, 98, 112; User Programming 6
Edit Config.: Operator Control 206
Edit cursor: Operator Control 127; User Programming 21, 38, 52
”Edit” menu: Operator Control 112
Edit mode: Operator Control 198
Editor: Operator Control 208
Electromagnetic compatibility: Safety 5
Emergency axis override device: Safety 12
EMERGENCY STOP: Safety 11, 14, 16; Start--up 6
EMERGENCY STOP button: Operator Control 30
EMERGENCY STOP system: Safety 16
Employment for a purpose other than the intended one: Safety 5
EMT: Operator Control 217; Start--up 6
Enabling switch: Operator Control 33, 37, 150; Start--up 16, 17, 19, 21, 23, 26
Enabling switches: Safety 12; Operator Control 62
END key: Operator Control 35
Enter key: Operator Control 33, 115
EPROMs: Safety 18
Error diagnosis: Operator Control 89
Error display: Operator Control 89
Error list: Operator Control 89
Error message: Start--up 54
Error treatment: Start--up 109
Errorlist: Operator Control 196
Escape key: Operator Control 32
ESD directives: Safety 21
Exact positioning: User Programming 21, 28, 32
Example: Introduction 7
Exchange: Safety 8
Exchange work: Safety 19
Executing program lines: Operator Control 135
Executing, stopping and resetting a program: Operator Control 125
Expert level: Operator Control 79
Expert user group: Operator Control 168
Ext: Operator Control 44

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Appendix

ExtBase Ok: Start--up 115


External axes: Introduction 9; Operator Control 58
External Axis: Operator Control 207, 216
External EMERGENCY STOP: Safety 12
External enabling switch: Safety 12
External kinematic: Operator Control 52, 216; Start--up 106
External kinematic systems: Operator Control 58
External measuring device: Start--up 38
Externer Editor: Operator Control 218

F
Feed devices: Safety 10
File: Operator Control 94, 194, 195, 196
File attributes: Operator Control 87
File list: Operator Control 76, 84
File manager: Operator Control 75
”File” menu: Operator Control 94
File name: Operator Control 87
File operations: Operator Control 194
Filter: Operator Control 78, 82, 111, 198
Find: Operator Control 201, 204; User Programming 12, 15
First mastering: Operator Control 217
Fixed safety devices: Safety 14
Fixed tool: Operator Control 215; Start--up 82
Flags: Operator Control 211
Flange center point: Start--up 36
Floppy disk drive: Operator Control 10, 11
Fold: Operator Control 201, 203
Folder: Operator Control 196
Force cold Startup: Operator Control 208
Foreign bodies: Safety 19
Foreword: Introduction 5
Format floppy disk: Operator Control 110, 198
Foundations: Safety 14
Frame: Start--up 37
Frequency: Safety 18
Frequency of the fault: Introduction 9
Frontsight/rearsight marker: Start--up 6
Full circle: User Programming 36
Fusing: Safety 18

G
Gate position switches: Safety 14
Glossary: Appendix -- Operating Handbook 5
Go: Operator Control 132
Graphical user interface: Operator Control 76
Gripper: Safety 10; Operator Control 150, 206, 210, 223

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3 Overall index (continued)

Guard interlock (operator safety): Safety 12


GUI: Operator Control 38

H
HB: Introduction 8
Header: Operator Control 76, 78
Help: Operator Control 180, 194, 224
Help with service requests: Introduction 5
History, Operating Handbook: Appendix -- Operating Handbook 25
HOME key: Operator Control 35
HOV: Operator Control 44; Start--up 124
How to use this documentation: Introduction 6

I
I--Step: Operator Control 132
I/O Driver: Operator Control 206
I/O Reconfigure: Operator Control 206
IBUS--Seg on/off: User Programming 51
IBUS--Seg.: Operator Control 219
IBUS/WAIT: User Programming 39
Icon: Operator Control 128
Icons: Introduction 6, 7; Operator Control 76
Example: Introduction 7
Info: Introduction 7
Modifications or entries not permissible: Introduction 7
Modifications or entries required: Introduction 7
Note: Introduction 7
See also: Introduction 7
Tip: Introduction 7
Identification plate: Safety 13
KR C3: Introduction 11
Linear unit: Introduction 10
Robot: Introduction 10
Identification plates: Introduction 10
Improper use: Safety 5
In/Outputs: Operator Control 206
Incremental: Operator Control 158, 210
Incremental jogging: Operator Control 73
Incremental Step: Operator Control 132
Increments: Operator Control 158
Indirect: Operator Control 215; Start--up 69, 75
Industrial robot: Safety 5
Infinitely rotating axes: User Programming 22
Info: Introduction 7; Operator Control 189
Injury: Safety 7
Inline form: Operator Control 40
Input mark: Operator Control 127

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Appendix

Inputs: Operator Control 146


Inputs/Outputs: Operator Control 210
Inputs/outputs: Operator Control 143
INS key: Operator Control 35
Installation: Safety 8, 18
Interface characteristics: Safety 16
Interrupts: Operator Control 211
Introduction: Start--up 36
Italics: Introduction 8

J
Jog keys: Operator Control 49, 57, 71
Jog mode: Operator Control 38, 44, 49, 55, 57, 132
Jog OV steps: Operator Control 61
Jog override: Operator Control 44, 61, 207
Jog velocity: Safety 10
Jog--OV: Start--up 44
Jog--OV--Steps on/off: Operator Control 207
Jogging: Operator Control 49, 57, 207
Jogging the robot: Operator Control 55
Joint: Operator Control 49, 157
Joint coordinate system: Operator Control 71
jump to: Operator Control 90
JX, JY, JZ: Start--up 68, 106

K
KCP: Operator Control 29
KCP connection: Operator Control 12
KCP front: Operator Control 29
KCP rear: Operator Control 37
Keyboard: Operator Control 36
Kinematic number: Start--up 115
KR 3: Start--up 27
KRL Assistant: Operator Control 194
KRL assistant: Operator Control 220
KUKA Robot Group: Introduction 5
KUKA--Cross: Operator Control 174

L
Language: Operator Control 208
Last command: Operator Control 219; User Programming 20
LDEL key: Operator Control 35
Liability: Safety 5
Lifting gear: Safety 18
Light barriers: Safety 14
Light curtain: Safety 14, 16

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3 Overall index (continued)

LIN: Operator Control 219; User Programming 21, 28


Line breaks: Operator Control 127
Line/column: Operator Control 128
Linear motions: User Programming 28
Linear unit: Introduction 9
Linebreak on/off: Operator Control 208
Load corr.: Operator Control 217
Load data determination: Operator Control 218
Load ratings: Safety 14
Loading and saving programs: User Programming 9
Log book: Operator Control 168, 169, 196, 211
Log Data: Operator Control 104
Logic: Operator Control 219; User Programming 38
Logic commands: Operator Control 194
Long text: Operator Control 218; User Programming 40, 41, 43, 45, 49
LPT1: Operator Control 10

M
M: Start--up 67, 105
MADA: Start--up 131
Main axes: Operator Control 67
Main switch: Safety 8; Operator Control 10, 11
Mains connection conditions: Safety 18
Maintenance: Safety 8
Maintenance cycles: Safety 11
Maintenance specifications: Safety 6
Maintenance work: Safety 19
Manual gripper operation: Operator Control 150
Manual mode: Operator Control 44
Manual program execution: Operator Control 132
Manufacturer’s declaration: Safety 5, 6
Mark all: Operator Control 199
Master: Operator Control 216
Master load: Operator Control 217
Master/Slave: Operator Control 210
Master/slave display: Operator Control 159
Mastered: Start--up 6
Mastering: Start--up 13
Mastering the KR 3: Start--up 27
Mastering with consideration of load: Start--up 12
Mastering with the dial gauge: Start--up 7
Mastering with the EMT: Start--up 10
Mastering without consideration of load: Start--up 12
Material damage: Introduction 6
Maximum braking: Operator Control 130
MC: Introduction 8
Measure: Operator Control 215

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Appendix

Measurement error too big: Start--up 110


Measurement Points: Operator Control 216; Start--up 107
Mechanical zero position reached: Start--up 6
Memory dump: Introduction 9
Menu: Operator Control 193
Menu bar: Operator Control 38, 193
Menu key: Introduction 8; Operator Control 193
Menu keys: Operator Control 34
Message window: Operator Control 40
Messages in the status bar: Operator Control 43
Miscellaneous: Operator Control 208
Mode selector switch: Operator Control 31, 55
Modification: Safety 11
Modifications or entries not permissible: Introduction 7
Modifications or entries required: Introduction 7
Modify: Operator Control 202
Modul info: Operator Control 81
Module: Operator Control 161
Modules: Operator Control 78
Monitor: Operator Control 119, 143, 194, 209
”Monitor” menu: Operator Control 119
Monitoring working envelope: Operator Control 208
Motion: Operator Control 219; User Programming 21, 39, 51
Motion commands: Operator Control 194; User Programming 21
Motion parameters: User Programming 37
Mouse configuration: Operator Control 66, 69, 207
Mouse position: Operator Control 62, 207
Move the axis/axes of the external kinematic system: Start--up 118
Move the TCP to the reference mark: Start--up 117
Moveparams: Operator Control 219

N
Name: Operator Control 115, 160, 165
Navigator: Operator Control 75
New: Operator Control 83, 95, 196; User Programming 5
New name: User Programming 57
New text: User Programming 57
New time: User Programming 57
New Value: Operator Control 160
Normal: User Programming 56, 57, 58
Note: Introduction 7; Safety 7
Notices: Operator Control 164, 211
NUM: Operator Control 43, 80
NUM key: Operator Control 35
Numeric Input: Operator Control 215, 216; Start--up 40, 41, 62, 69, 79, 82, 101
Numeric keypad: Operator Control 35

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3 Overall index (continued)

O
Office GUI on/off: Operator Control 208
Offset: Operator Control 216; Start--up 114, 122
Offset (numeric): Start--up 114, 127
Offset external kinematic: Operator Control 216; Start--up 82, 94, 129
Offset voltage: User Programming 55
On/Off options: Operator Control 208
On/off switch: Operator Control 12
Online help: Operator Control 180, 184, 224
Open: Operator Control 196; User Programming 6
Operating instructions: Safety 5
Operating mode: Operator Control 44; Start--up 131
Operation: Safety 18, 19
Operator control: Safety 8
Operator control elements: Operator Control 10, 30
Orientation: Start--up 37; User Programming 28, 32
Oscilloscope: Operator Control 168, 211
OUT: Operator Control 219; User Programming 41, 43, 45
Outputs: Operator Control 144
Overloaded: Start--up 66

P
Padlock: Safety 8
Page +: Operator Control 171
Page --: Operator Control 171
Paint markings: Safety 9
Parameter: Operator Control 200
Parameters: Operator Control 116
Parts catalog: Safety 11
Paste: Operator Control 113, 199, 203
PATH: User Programming 46, 50
Path--maintaining braking in event of operator safety violation: Operator Control 131
Path--maintaining Emergency Stop: Operator Control 130
Payload: Safety 10
Payload data: Operator Control 215
PDAT1: User Programming 25, 33
Personal injury: Introduction 6
Personal protection: Safety 18
PGDN key: Operator Control 35
PGUP key: Operator Control 35
Planning: Safety 14
Plates: Safety 13
Point too near to origin point: Start--up 109
Point too near to other point: Start--up 109
Point too near to reference point: Start--up 109
Point--to--point motions: User Programming 24
Points in TTS: Operator Control 202

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Appendix

Position: Operator Control 194; Start--up 36


Position marks: Safety 13
POV: Operator Control 44
Power failure: Operator Control 15
Power OFF function: Operator Control 14
Pre--mastering position: Start--up 6, 13
Presetting of outputs: Safety 17
Previous: Operator Control 150
Print: Operator Control 100, 196
Process pointer: Operator Control 175
Program: Operator Control 194, 199
Program creation: Operator Control 194
Program editing: User Programming 5
Program editor: User Programming 15
Program key: Introduction 8
Program name: Operator Control 128
Program OV steps: Operator Control 129
Program override: Operator Control 44, 129, 207
Program pointer: Operator Control 126
Program run mode: Operator Control 132
Program start backwards: Operator Control 132, 136
Program start backwards key: Operator Control 33
Program start forwards: Start--up 16, 17, 19, 21, 23, 26
Program start forwards key: Operator Control 32, 37
Program stop key: Operator Control 32
Program window: Operator Control 39, 126
Program--OV--Steps on/off: Operator Control 207
Programmed velocity: User Programming 27, 31, 35
Programming: User Programming 38, 52
Programming a LIN motion: User Programming 29
Programming a PTP motion: User Programming 25
Programming movements: User Programming 21
Programs: User Programming 5
Protection from dirt: Safety 18
Protection from dirt and UV radiation: Safety 18
Protective barriers: Safety 14
Protective cap: Start--up 5
Protective clothing: Safety 11, 18
PTP: Operator Control 219, 220; User Programming 21, 24
PTP motions with approximate positioning: User Programming 24
PTP motions with exact positioning: User Programming 24
PULSE: Operator Control 219; User Programming 41, 43, 49
Put into operation: Safety 6

Q
Quotation marks: Introduction 8

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3 Overall index (continued)

R
Ramp--down braking: Operator Control 130
Range limit switches: Safety 16
RDC: Start--up 131
Reduced velocity: Operator Control 150
Reference coordinate system: Operator Control 59
Reference point: Start--up 38
Reference point mastering: Start--up 33
Reference tool: Start--up 40, 116
Refresh: Operator Control 171
Regulations: Safety 17
Reinitialization: Operator Control 209
Releasing EMERGENCY STOP: Operator Control 30
Rename: Operator Control 109, 197
Repair: Safety 8
Repair work: Safety 19
Replace: Operator Control 204
Reset: Operator Control 12, 137
Reset Encoder: Start--up 28
Reset program: Operator Control 200, 202
Resetting a program: Operator Control 137
Resolver: Start--up 36
Restore: Operator Control 105, 197
Restricted envelope – working space limitation: Safety 11
Return key: Operator Control 33
Reverse traversing: Operator Control 132
Risk to life and limb: Safety 5
Rob. Position: Operator Control 156
Rob. position: Operator Control 210
Robot: Safety 5
Robot coordinate systems: Start--up 36
Robot coordinates: User Programming 26, 30, 34
Robot flange coordinate: Start--up 36
Robot mastering: Start--up 5
Robot name: Operator Control 218; Start--up 131
Robot serial number: Introduction 9
Robot system: Safety 5
Root point: Operator Control 216; Start--up 114
Root point (numeric): Start--up 114, 119
Rotation about the X--axis: Start--up 37
Rotation about the Y--axis: Start--up 37
Rotation about the Z--axis: Start--up 37
Running up the controller: Operator Control 9, 13

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Appendix

S
Safety (exclusion) zones: Safety 14
Safety circuit: Operator Control 168
Safety equipment: Safety 10, 19
Safety fences: Safety 14
Safety footwear: Safety 18
Safety functions: Safety 11
Safety instruction: Safety 11
Safety instructions: Safety 8; Operator Control 131
Safety labeling: Safety 13
Safety mat: Safety 16
Safety mats: Safety 16
Safety measures: Safety 8, 19
Safety regulations: Safety 19
Safety symbols: Introduction 6; Safety 7, 13
Caution: Introduction 6
Warning: Introduction 6
Save: Start--up 24; User Programming 27, 31, 35
Save the current robot coordinates: User Programming 26, 30, 34
Save the point: Start--up 118
Screwed connections: Safety 20
Section: Introduction 8
Security circuit: Operator Control 211
Securitycircuit: Operator Control 168
See also: Introduction 7
Select: Operator Control 116, 125, 200
Select/open/save a program: User Programming 5
Selecting the kinematic system: Operator Control 58
Selection list: Operator Control 76, 82
Sensor--assisted operation: Safety 10
Serial number: Introduction 10; Safety 6; Start--up 131
Serif: Introduction 8
Serif bold: Introduction 8
Service: Operator Control 217
Service centers: Introduction 14
Service requests: Introduction 9
Set mastering: Operator Control 217
Set Robot Position: Start--up 30
Setup: Operator Control 194, 213
Shift key: Operator Control 36
Short--circuit braking: Operator Control 131
Shut--down: Safety 19
Shutting down the controller: Operator Control 9, 14
Signal states: Operator Control 144, 146
Signs: Safety 9
Simultaneous motion: Operator Control 50
Single Step: Operator Control 132
Skeleton program: Operator Control 97, 98, 116

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3 Overall index (continued)

Skilled electrician: Safety 9


Softkey: Introduction 8
Softkey bar: Operator Control 39
Softkeys: Operator Control 35, 150
Software: Safety 19
Software limit switches: Operator Control 56
Software Update: Operator Control 217
Software version numbers: Introduction 12
Space Mouse: Operator Control 34, 49, 57, 62; Start--up 43
Square brackets: Introduction 8
Stamp: Operator Control 220; User Programming 57
Standard concerning the safety of industrial robots: Safety 8
Standard motions: User Programming 21
START key: Operator Control 32
Start key: Start--up 16, 17, 19, 20, 26
Start--up: Safety 19
State: User Programming 40, 42, 43, 46, 50
Static: Operator Control 220
Status bar: Operator Control 41, 43
Status key bar: Operator Control 38
Status keys: Operator Control 34, 150
Status LED: Operator Control 10
Status line: Operator Control 41, 55, 76, 88, 128
Status window: Operator Control 39, 57, 150
Statuskeys: Operator Control 206
STOP key: Operator Control 32
Stopping program execution: Operator Control 137, 139
Submenu key: Introduction 8
SUBMIT Interpreter: Operator Control 206
Substructures: Safety 14
Superposed motion: Operator Control 70
Supplementary load data: Operator Control 216; Start--up 104
Suspended loads: Safety 18
SYM key: Operator Control 36
Symbols: Operator Control 76
Symbols in the program window: Operator Control 126
SYN OUT: Operator Control 219; User Programming 45
SYN PULSE: Operator Control 219; User Programming 49
SYNOUT: User Programming 41, 49
SYNPULSE: User Programming 43, 45
System time: Operator Control 44

T
T1: Operator Control 44, 55
T2: Operator Control 44, 55
TAB key: Operator Control 35
TCP: Start--up 38, 42, 123

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Appendix

Teach offset: Operator Control 217


Technical data: Safety 6
Technology: Operator Control 194, 221
Technology commands: Operator Control 194
Technology parameters: User Programming 55
Technology selection: Operator Control 208
Templates: Operator Control 83
Test (T1): Start--up 15, 16, 18, 19, 22, 25
Test (T1/T2): Start--up 7
Text emphasis: Introduction 6
Text style
Bold: Introduction 8
Italics: Introduction 8
Quotation marks: Introduction 8
Serif: Introduction 8
Serif bold: Introduction 8
Square brackets: Introduction 8
Text styles: Introduction 8
Time: User Programming 44, 50
Timer: Operator Control 211
Tip: Introduction 7
Toggling to the Windows interface: Operator Control 45
Tolerance limits: Start--up 108
Tolerances: Operator Control 216; Start--up 108
TOOL: Operator Control 49
Tool: Operator Control 53, 215
Tool (BASE): Start--up 82, 88
Tool Center Point: Start--up 38, 123
Tool change: Safety 16
Tool definition: Operator Control 207
Tool load data: Start--up 40, 66
Tool number: Start--up 43
Tool OK: Start--up 116
Tool type: Operator Control 207, 216
Torquemon: Operator Control 219
Torques: Safety 14
Touch Up: User Programming 26, 30, 34
Trade association: Safety 17, 18
Transport position: Safety 18
Transportation: Safety 18
Traversing velocity: Start--up 44
Types of motion: User Programming 21

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3 Overall index (continued)

U
Unauthorized start--up: Safety 19
UNDO key: Operator Control 35
Unmaster: Operator Control 217
Unmastered: Start--up 6
Unmastering an axis: Start--up 34
User data: Operator Control 81
User group: Operator Control 175, 177, 207
USER Tech reinitialize: Operator Control 209

V
Variable: Operator Control 161, 210
Variables: Operator Control 194
Vel: User Programming 25, 29, 33
Velocity: Start--up 44
Velocity parameters: User Programming 55
Vernier: Start--up 5
Version: Operator Control 224
Version information: Operator Control 194
Version numbers of the software: Introduction 9
Virus protection: Operator Control 22
Viruses: Safety 19
Voltage: Safety 18

W
W_F/IBUS: User Programming 39
WAIT: Operator Control 219; User Programming 38
WAIT FOR: User Programming 39
Wait functions: User Programming 38
WAIT/W_F: User Programming 51
WAITFOR: Operator Control 219
Warning: Introduction 6
Warning and safety instructions: Operator Control 131
Warning labels: Safety 13
Warning remarks: Safety 11
Web Diagnosis: Operator Control 211
Web Diagnosis: Operator Control 178
Weight difference: Start--up 12
Weights: Safety 14
Window selection key: Operator Control 32, 95
Windows: Operator Control 212
Windows interface: Operator Control 45
Windows mouse: Operator Control 47
With offset: Operator Control 217
Without offset: Operator Control 217
Work cell: Operator Control 51
Working direction: Start--up 50

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Appendix

Working platforms: Safety 20


Working range limitation: Safety 14
Working with the product documentation: Introduction 5
Working zones: Safety 14
Workpiece: Operator Control 215
Workpiece (TOOL): Start--up 82
WORLD: Operator Control 49
WORLD coordinate system: Start--up 36

X
X axis: Operator Control 53
X Y Z -- 4 Point: Start--up 40, 42
X Y Z -- Reference: Start--up 40, 45
X, Y, Z: Start--up 37, 47, 63, 67, 102, 105, 121, 128
X32: Start--up 6
XYZ--4 Point: Operator Control 215
XYZ--Reference: Operator Control 215

Z
Z--Y--X Euler angles: Start--up 37
Zero position: Start--up 5
Zip file: User Programming 9
Zone scanners: Safety 14
1

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SOFTWARE

KR C...

Error messages / troubleshooting

KUKA System Software (KSS)

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e Copyright 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.

PD Interleaf

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Contents

1 Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


1.1 Message groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Message time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Message number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Originator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Message text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 List of error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Error messages / troubleshooting

1 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

COMMAND ACCELERATION EXCEEDED A2


ACTIVE COMMANDS INHIBITED

1.1 Message groups

Hint 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 a status (operational) message. An
acknowledgement message stops a movement or prevents further operation.

Dialog messages
require confirmation by the operator (“Yes” or “No” softkeys). The message is cleared after
it has been confirmed.

1.2 Message time


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

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1 Error messages / troubleshooting (continued)

1.3 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.

1.4 Originator
The origin of the error is indicated in this field.

1.5 Message text


The text of the error message is shown here.

1.6 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 conditions for generation of the message are checked.

Effect
describes how the controller reacts to the error.

Remedy
describes what action the user can take to eliminate the error.

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Error messages / troubleshooting

1 Message text EMERGENCY STOP

Cause -- Emergency Stop pushbutton pressed.


-- Emergency Stop initiated by the software.
Monitor -- Cyclic.
Effect -- Path--maintaining stop.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton and Emergency Stop circuit.
-- Release the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.
2 Message text Internal error

Cause -- Internal KRL software test.


Monitor -- Within the KRL software.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
3 Message text MESSAGE BUFFER OVERFLOW

Cause -- The message buffer, which contains the currently active messages
(acknowledgement and status messages), is full up to a specific limit.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Rectify and acknowledge the signalled faults.
4 Message text BUFFER BATTERY VOLTAGE LOW xx

Cause -- Voltage of the backup battery too low.


Monitor -- At “Power off”.
-- Cyclic.
Effect -- The battery voltage is checked when the power is switched off. When
the message is displayed, it is necessary to wait until the battery has
recharged. Only then may the controller be switched off.
-- Cyclic --> none.
Remedy -- Change the battery.
-- After the battery has been charged, the message “Ackn. batt. voltage”
is displayed --> acknowledge.
5 Message text Malfunction <HPU or RCP>

Cause -- KCP defective.


Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace KCP.

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1 Error messages / troubleshooting (continued)

6 Message text Transmission error <HPU or RCP>

Cause -- Fault in KCP connection.


Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the KCP cable.
7 Message text TPBASIS

Cause -- The point could not be created


8 Message text System time invalid

Cause -- The system time is invalid after TIME_HW_FAILURE and has been
set to the initial value.
Monitor -- When the controller is booted.
Effect -- The system time is initialized with 01.01.93 00:00:00,00.
Remedy -- Update the system time with the form “systime”.
9 Message text MFC overtemperature

Cause -- The temperature sensor on the MFC has been triggered.


Monitor -- Cyclic.
Effect -- Path--maintaining braking.
Remedy -- Check fan. Exchange MFC if necessary.
10 Message text ERROR DIGITAL OUTPUTS @P1@

Cause -- Short circuit at outputs 1--8 or 9--16.


Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy --
11 Message text PROGRAM STACK OVERFLOW

Cause -- KRL program contains too many nested structures or too many recur-
sive subprogram calls! The C--stack of the R--INT would otherwise
overflow.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Change the structure of the program.
12 Message text TOO MANY MESSAGES

Cause -- Too many messages have been cyclically generated.


Monitor -- When a message is generated.
Effect -- All active commands are cancelled and cannot be restarted.
Remedy -- The KRC has to be booted.

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Error messages / troubleshooting

13 Message text ERROR SAFETY LOOP

Cause -- A channel has failed or more than one enabling switch has been
pressed.
Monitor -- Cyclic.
Effect -- Path--maintaining braking, active commands inhibited.
Remedy --
14 Message text SOFTPLC: @P1@

Cause --
Monitor --
Effect --
Remedy --
15 Message text OUTPUT MONITORING DC BUS VOLTAGE KPS: @P1@

Cause -- DC bus voltage of a KPS overloaded.


Monitor --
Effect --
Remedy --
16 Message text Error while reading “O file”

Cause -- Error during loading/reading of “ident_vx.o”: memory or file not found.


Monitor -- In the write function “w_ident_state”.
Effect -- Jump to the end in load data program.
Remedy -- Copy the file “ident_vx.o” to the directory “/ir_spec/l_ident”,
or increase memory by changing the value “VxWinRAM” in the registry.
17 Message text WRONG/UNKNOWN HARDWARE FOUND

Cause -- During setup, the wrong control hardware (KR C1, KR C1A, KR C2)
was selected or the hardware configuration is invalid.
Monitor --
Effect -- The controller is inoperable.
-- Robot traversing not possible.
Remedy -- Carry out setup again or make appropriate changes to
hardware configuration.
18 Message text Servobus DSE--No. %1 participant No. %2 unknown

Cause -- An unknown device which cannot be supported has been inserted in


Interbus
Monitor -- DSE ID, device ID
Effect -- The robot can no longer be traversed
Remedy -- Remove unknown device from servo bus

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1 Error messages / troubleshooting (continued)

19 Message text FAILURE OF MOTOR PHASE <axis>

Cause -- Power module, intermediate circuit voltage discharged.


Monitor -- Cyclic.
Effect -- Dynamic braking.
-- All active commands inhibited.
Remedy -- Switch on drives.
-- Check power module, DSE.
20 Message text EXTERNAL EMERGENCY STOP PRESSED

Cause -- Emergency Stop button pressed.


-- Emergency braking triggered by software.
Monitor -- Cyclic.
Effect -- Path--maintaining braking.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.

21 Message text Second motorcable not connected

Cause -- Second motor cable is not connected or is incorrectly connected; the


additional cable contains two wires which are connected to the robot;
the return signal is connected to the KPS X114, pin 7
Monitor -- Cyclic.
Effect -- The robot cannot be traversed
Remedy -- Check second motor cable and return signal at KPS X114, pin 7

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Error messages / troubleshooting

100 Message text RDW ** BOOT UP FAILURE

Cause -- The resolver/digital converter (RDW) could not be initialized when


the controller was booted.
Monitor -- At runup.
Effect --
Remedy -- Replace RDW, DSE or cable between RDW and DSE.
101 Message text DSE ** BOOT UP FAILURE

Cause -- The DSE could not be initialized when the controller was booted.
Monitor -- At runup.
Effect -- Maximum braking (dynamic braking).
Remedy -- Replace DSE, MFC or motherboard.
102 Message text ENCODER CABLE FAILURE **

Cause -- Cable defective (e.g. loose connection).


-- RDW defective.
-- Encoder defective.
Monitor -- Cyclic.
Effect -- Maximum braking (dynamic braking).
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check encoder cable.
-- Check motor, resolver.
-- Possibly replace RDW.
103 Message text WATCHDOG INTERPOLATION CYCLE **

Cause -- DSE has not triggered software watchdog in the DP--RAM.


Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Software error.
104 Message text SYNCHRONIZATION ERROR WITH DSE **

Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Error in the DSE or PC area.
-- Software error.

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1 Error messages / troubleshooting (continued)

105 Message text TRANSMISSION ERROR DSE -- RDW **

Cause -- Open--circuit between RDW and DSE.


-- Transmission malfunctions.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
106 Message text PERFORM MASTERING ** !

Cause -- Position actual value difference after restart too great and sensor
mastering not possible because sensor location run has not been
performed.
Monitor -- At “Power on”.
-- During mastering.
Effect -- All active commands inhibited.
Remedy -- Perform mastering.
107 Message text EMERGENCY STOP DUE TO DIAL ADJUSTMENT

Cause -- Softkeys for dial adjustment pressed.


-- Value assignment “$TURN = 1”.
-- Encoder setting, absolute or incremental.
Monitor -- When “$TURN” instruction is executed.
Effect -- Dynamic braking.
-- 0 signal at “$ALARM_STOP” output
-- All active commands inhibited.
Remedy -- Leave the mastering menu by pressing the Recall key twice.
108 Message text DYNAMIC BRAKING ACTIVE

Cause -- If the controller detects a request for maximum (dynamic) braking, it


geneates the status (operational) message “DYNAMIC BRAKING
ACTIVE”, which remains active until all axies have stopped.
Monitor -- Cyclic.
Remedy -- The status message “DYNAMIC BRAKING ACTIVE” is reset by the
controller when the robot is at standstill without a secondary message
being generated.
109 Message text CLEAR FAST MEASURING INPUT @P1@

Cause -- Rapid gauging has been switched on.


Monitor -- During rapid gauging.
Effect -- Rapid gauging becomes active when measuring tool has been
moved free.
Remedy -- Move measuring tool free.

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Error messages / troubleshooting

110 Message text ADVANCED PATH PROFILE NOT POSSIBLE WITH LINKED EXTER-
NAL AXES
Cause -- Coupling of external axes in higher motion profile.
Monitor -- During command and program execution.
Effect --
Remedy --
111 Message text TEPRO INACTIVE

Cause -- SBC no longer sending a signal to KRC.


Monitor -- Cyclic.
Effect -- SBC interface inoperable.
Remedy -- Re--initialize SBC program.
112 Message text INVALID $TOOL: WORKING ENVELOPE SURVEILLANCE NOT
POSSIBLE
Cause -- “$TOOL” invalid when working envelope monitoring is activated.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Assign “$TOOL” or switch off working envelope monitoring.
113 Message text RANGE OVERFLOW ** **

Cause -- Overflow of the actual value of an endless axis: actual value > +/--
90*10E15 increments or --99999000 < $REVO_NUM < 999999000
Monitor -- Cyclic in the interpolation cycle.
Effect -- Path--maintaining Emergency Stop.
Remedy -- Turn back or remaster the axis concerned.
114 Message text WORKING ENVELOPE NO. @P1@ VIOLATED

Cause -- TCP is inside a working envelope with MODE INSIDE STOP or outside
a working envelope with MODE OUTSIDE STOP.
Monitor -- Cyclic.
Effect -- Path--maintaining braking;
-- All active commands inhibited.
Remedy -- Switch off working envelope or use key on the KCP to override work
envelope monitoring, move free in T1 mode.
115 Message text DRIVE FREE WORK ENVELOPE %1

Cause -- TCP is inside a working envelope with


MODE INSIDE STOP or outside a working envelope with MODE
OUTSIDE STOP and the working envelope monitoring is overridden.
Monitor -- Cyclic.
Effect --
Remedy -- Free work envelope.

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1 Error messages / troubleshooting (continued)

116 Message text DSE WATCHDOG COMMAND **

Cause -- DSE has not executed a command.


Monitor
Effect -- Ramp--down braking.
Remedy -- Check hardware in the DSE, MFC area.
117 Message text TORQUE EXCEEDED AXIS @P1@

Cause
Monitor
Effect
Remedy
118 Message text HEAT SINK TEMPERATURE **

Cause -- Thermostatic switch on the heat sinks of the servo output stage is
tripped due to overheating of the output stage transistors.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Clean the heat sinks.
119 Message text MOTOR TEMPERATURE **

Cause -- PTC thermistor (measuring shunt) in the motor winding has been
tripped (motor temperature too high).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Program more movement breaks.
120 Message text ACKN. MOTOR BLOCKED **

Cause -- As soon as the torque command value supplied by the speed controller
exceeds 30% of the max. torque command value, integration is
started, and when the value of i*t reaches approx. 0.75 [(torque
command value / max. torque command value) * sec] the control is
switched off (i*t -- monitoring).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Check that the axis is moving freely.
121 Message text OVERCURRENT **

Cause -- The current of each axis is monitored and the amplifier--internal current
protection is tripped if the power consumption is too high.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.

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Error messages / troubleshooting

Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
122 Message text BRAKE FAULT **

Cause -- The brake cable is monitored for short--circuit, overload and cable
break.
-- With the PM6, all axes are supplied from one brake driver.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
123 Meldungstext UNDERVOLTAGE <axis number>

Cause -- The internal operating voltage (+15V) of the servo output stage is
monitored. Undervoltage results in power failure.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
124 Message text OVERVOLTAGE <power module number>

Cause -- The intermediate--circuit voltage is too high. Possible causes are a de-
fective ballast (feedback) resistor or ballast fuse, a defective power
module, brake ramp too steep etc.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
125 Message text i2--t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string1> AFTER <string2> s EXCEEDED 100%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
126 Message text REGULATOR LIMIT EXCEEDED <axis number>

Cause -- Following error too great. The axis does not follow the command value.
Monitor -- Cyclic in the position controller.
Effect -- Maximum braking.
Remedy -- Check the axis.
127 Message text <axis number> DETACHED EXTERNAL AXIS

Cause -- Auxiliary (external) axis is operated as an asynchronous axis.


Monitor -- Cyclic.
Effect

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1 Error messages / troubleshooting (continued)

Remedy
128 Message text SOFTWARE LIMIT SWITCH OF DETACHED EXTERNAL AXIS
<motion direction> <axis number>
Cause -- Asynchronous axis has tripped the pos. or neg. software limit
switch.
Monitor -- The software limit switch is checked cyclically if the axis is operated
as an asynchronous axis.
Effect
Remedy
129 Message text i2--t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string1> AFTER <string2> s EXCEEDED 95%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
130 Message text K1 CONTACT FAIL TO OPEN <KPS number>

Cause -- The K1 contact is welded.


Monitor --
Effect -- The energy supply system is not interrupted.
Remedy -- Exchange contactor, KPS.
131 Message text BUS VOLTAGE CHARGING UNIT IS DEFECTIVE <KPS number>

Cause -- The optocoupler on the KPS is not registering current flow.


Monitor --
Effect -- Intermediate circuit cannot be loaded.
Remedy -- Exchange KPS.
132 Message text BRAKE DEFECTIVE <axis ...>

Cause -- Wear on brakes, defective brake.


Monitor --
Effect -- Axis moves in an uncontrolled manner.
Remedy -- Exchange motor.
133 Message text MONITORING OF THE ACTUAL VELOCITY @P1@

Cause -- Fault in control loop:


-- motor cables of two axes interchanged;
-- error in the axis assignment;
-- power module defective;
-- resolver unmastered.
Monitor -- Cyclic.
Effect -- Robot remains motionless.
Remedy -- Rectify the corresponding error in the control loop.

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Error messages / troubleshooting

134 Message text DN CH ... WRONG FASTWRITE MACID IN INI FILE

Cause --
Monitor --
Effect --
Remedy --
135 Message text DN CH ... MODULE ERROR ...

Cause --
Monitor --
Effect --
Remedy --
136 Message text DN CH ... SLAVE ERROR ...

Cause --
Monitor --
Effect --
Remedy -- Exchange contactor, KPS.
137 Message text DN CH ... FIRMWARE ERROR

Cause --
Monitor --
Effect --
Remedy --
138 Message text DN CH ... HARDWARE ERROR

Cause --
Monitor --
Effect --
Remedy -- Exchange contactor, KPS.
139 Message text DN CH ... BUS ERROR ...

Cause --
Monitor --
Effect --
Remedy --
140 Message text DN CH ... WATCHDOG ERROR

Cause --
Monitor --
Effect --
Remedy --

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1 Error messages / troubleshooting (continued)

141 Message text DN CH ... USER ERROR ...

Cause --
Monitor --
Effect --
Remedy --
142 Message text DN CH ... CONFIGURATION MODE ENABLED

Cause --
Monitor --
Effect --
Remedy --
143 Message text Ixt servo drive %1 exceed value %2 %%

Cause -- If the defined Ixt monitoring warning value of a drive servo is exceeded,
the robot must be brought to a standstill; otherwise, the drive servo is
deactivated when the maximum value of 100% is exceeded
Monitor -- Cyclic, the warning bit on the drive servo
Effect -- The robot is stopped in a controlled manner.
Remedy -- Verify load data
-- If necessary, reduce the load cycle (wait time)
-- Use stronger robot

146 Message text Wrong amplifier %1

Cause -- Drive module of a slave axis does not correspond to drive module on
the associated master axis
Monitor -- Cyclic.
Effect -- Traversing not possible
Remedy -- Shut down controller, exchange drive module for one corresponding to
the master axis and reboot controller

147 Message text DRIVE FREE AXIS WORK ENVELOPE NO. %1

Cause -- The robot is inside a working envelope with MODE INSIDE STOP or
outside a working envelope with MODE INSIDE STOP and the working
envelope monitoring is overridden.
Monitor -- Cyclic.
Effect --
Remedy -- Free axis work envelope

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Error messages / troubleshooting

148 Message text Axis work envelope No. %1 violated

Cause -- The robot is inside a working envelope with MODE INSIDE STOP or
outside a working envelope with MODE OUTSIDE STOP
Monitor -- Cyclic.
Effect -- Path--maintaining braking, all active commands inhibited
Remedy -- Switch off axis working envelope or override work envelope monitoring
in T1 mode and move free

155 Message text <axis> DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
200 Message text DRIVES CONTACTOR OFF

Cause -- Power module, intermediate--circuit voltage discharged.


Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Switch drives on.
-- Check power module, check DSE.
-- Emergency Stop is active, drives circuit is interrupted.
201 Message text KCP DEADMAN SWITCH

Cause -- The safety (deadman) switch has been released during an active
function (motion of an axis) in mode T1 or T2.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Press safety switch.
-- Check KCP, safety logic.
202 Message text I/O RECONFIGURATION

Cause -- An I/O reload command has been transmitted via the KCP.
Monitor --
Effect -- Path--maintaining braking.
Remedy -- After successful reconfiguration, the normal operating state is
automatically restored.

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1 Error messages / troubleshooting (continued)

203 Message text GENERAL MOTION ENABLE

Cause -- Low signal at $MOVE_ENABLE input.


Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the input.
204 Message text HARDWARE LIMIT SWITCH / +24V MISSING

Cause -- The hardware limit switch has been tripped.


Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Shunt out the hardware limit switch and move axis off limit switch.
205 Message text SOFTWARE LIMIT SWITCH <motion direction> <axis number>

Cause -- The software limit switch of the axis indicated has been tripped in the
direction indicated. (The message is effective only after “Robot
synchronized”).
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Movement in the direction indicated is inhibited.
Remedy -- Move the axis in the opposite direction (no change to the robot--specific
coordinate system takes place).
206 Message text SERVO PARAMETERS <axis> LINE <integer> INCORRECT

Cause -- The parameters in the servo file are incorrect.


Monitor -- While loading machine data.
Effect --
Remedy -- Correct the parameters.
207 Message text OPERATOR SAFETY / GATE OPEN

Cause -- Operator safety has been tripped in the AUTOMATIC or EXTERNAL


mode (input at the peripheral interface).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch to mode T1 or T2 (in these modes the robot can be moved
when the signal is low).
-- Close the safety gate.
-- Check the input.
208 Message text FAILURE IN ESC SAFETY LOOP

Cause -- Emergency Stop button pressed.


-- Emergency braking triggered by software.
Monitor -- Cyclic.

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Error messages / troubleshooting

Effect -- Path--maintaining braking.


-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton;
-- Rectify and acknowledge the signalled fault.
209 Message text PASSIVE STOP <RCP or teach pendant>

Cause -- Stop from a passive operator control unit (the message is displayed
only if an active process has been stopped).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge the message “Passive Stop”.
210 Message text STOP KEY <RCP or teach pendant>

Cause -- The start key or a traversing key has been actuated while the stop
key is depressed.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the stop key.
211 Message text CHECK SAFETY LOGIC. DRIVES OFF TIMEOUT DURING EMER-
GENCY STOP OCCURRED
Cause --
Monitor --
Effect --
--
Remedy --
212 Message text ERROR WRITING TO PERCEPTRON

Cause --
Monitor --
Effect --
--
Remedy --
213 Message text ERROR WRITING TO BOSCH

Cause --
Monitor --
Effect --
--
Remedy --
214 Message text COMMON DRIVES ERROR <axis number>

Cause --
Monitor --

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1 Error messages / troubleshooting (continued)

Effect --
--
Remedy --
215 Message text COMMON DRIVES ERROR <axis number>

Cause --
Monitor --
Effect --
--
Remedy --
216 Message text DRIVES ERROR ... NO.: ...

Cause -- The Start key or a direction key was activated while the Stop key
was pressed.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check Stop key.
217 Message text EMERGENCY STOP FROM KRC ( ALARM STOP )

Cause -- An alarm stop has been initiated by the KRL system software;
another serious error has occurred.
Monitor -- Cyclic.
Effect -- Maximum braking. All active commands inhibited.
Remedy -- Eliminate and acknowledge the signalled fault (serious error).

218 Message text FEEDBACK SWITCH TOO LONG ON **

Cause -- The energy of the axis to be braked was too high.


Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
219 Message text CABINET TEMPERATURE TOO HIGH **

Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.

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Error messages / troubleshooting

220 Message text DRIVES CONTACTOR OFF, INTERMEDIATE CIRCUIT LOADED !!!

Cause -- The drives contactor drops out. The energy in the intermediate circuit
is sufficient to ensure a path--maintaining stop. Caution: the
intermediate circuit is still charged! The intermediate circuit is
discharged after about 2 minutes. The message “DRIVES NOT
READY” is then displayed.
Monitor -- Cyclic.
Effect -- Path--maintaining Emergency Stop
Remedy -- Switch drives on again.
-- Check drives circuit for faults.
221 Message text MODE NOT ALLOWED

Cause -- E2 keyswitch in AUTO mode.


Monitor
Effect
Remedy
222 Message text PARITY ERROR POWERMODULE **

Cause -- A parity error has occurred more than five times in succession when
reading the power module register.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Too much interference at the power module interface, or power module
defective. Check cable, check shielding, replace power module.
223 Message text POWER MODULE AXIS ** NOT OR WRONGLY PLUGGED

Cause -- The axis is incorrectly plugged into the power module or not connected
at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect the axis correctly (high or low power).
224 Message text POWER FAIL

Cause -- The cabinet voltage has been switched off, the mains voltage is
interrupted.
Monitor
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.
225 Message text MOTOR CABLE **

Cause --
Monitor --
Effect --
Remedy --

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1 Error messages / troubleshooting (continued)

226 Message text FAILURE OF HEAT SINK TEMPERATURE SENSOR **

Cause --
Monitor --
Effect --
Remedy --
227 Message text FAILURE OF CABINET INTERIOR TEMPERATURE SENSOR <AXIS
NUMBER>
Cause --
Monitor --
Effect --
Remedy --
228 Message text DRIVES PARAMETER DATA ** INVALID

Cause --
Monitor --
Effect --
Remedy --
229 Message text FAILURE OF MOTOR TEMPERATURE SENSOR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
230 Message text WRONG DRIVES PARAMETER <AXIS NUMBER> **

Cause --
Monitor --
Effect --
Remedy --
231 Message text ERROR SYNC. INPUT DRIVE <AXIS>

Cause --
Monitor --
Effect --
Remedy --
232 Message text SYNCHRONISATION ERROR DRIVE <AXIS>

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

233 Message text <AXIS> WITHOUT POWER

Cause --
Monitor --
Effect --
Remedy --
234 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
235 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
236 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
237 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
238 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
239 Message text LOADING ** SERVO PARAMETERS **

Cause -- Loading drive servo parameters


Monitor --
Effect --
Remedy --

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1 Error messages / troubleshooting (continued)

240 Message text PLEASE SWITCH OFF THE CABINET

Cause -- The drive servo parameters have been loaded, but will not take effect
until the next reboot.
Monitor --
Effect --
Remedy --
241 Message text SERVOFILE CONFIGURATION ** DOES NOT FIT THE ** RELEASE
**
Cause -- The servo file configuration contains parameters for the drive servos
which are not supported by the firmware.
Monitor --
Effect --
Remedy -- Upgrade drive servo firmware or servo files.
242 Message text ** FIRMWARE RELEASE **

Cause -- Information about the firmware release of the axis in question.


Monitor --
Effect --
Remedy -- Upgrade drive servo firmware or servo files.
243 Message text SOFTWARE OF DSE ** DOES NOT FIT THE HARDWARE OR
DEFECTIVE DSE
Cause -- The wrong software was configured for the DSE
DSEAT and KR C1A/KR C2.
Monitor --
Effect --
Remedy -- Configure the correct software.
244 Message text ** SOFTWARE VERSION INCORRECT

Cause -- DSE software and kernel system do not work together.


Monitor --
Effect --
Remedy -- Configure the correct DSE software.
245 Message text SERVO BUS DISTURBANCE DSE **

Cause -- Defective bus cable.


Defective bus module.
Defective bus driver.
Monitor -- Rectify fault.
Effect --
Remedy --
246 Message text SERVO BUS DISTURBANCE DSE **, NO BUFFERING AND
AUTOMATIC DATA STORAGE POSSIBLE
Cause -- Buffering is activated via the servo bus on the KPS. If communication
with the KPS is faulty, the buffering cannot be activated and switch--off
takes place immediately.

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Error messages / troubleshooting

Monitor --
Effect --
Remedy -- Re--establish communication with the KPS.
247 Message text SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
248 Message text SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
249 Message text $MOVE_ENABLE INPUT (1025) NOT ALLOWED

Cause --
Monitor --
Effect --
Remedy --
250 Message text INCORRECT SERVO PARAMETER <AXIS>

Cause --
Monitor --
Effect --
Remedy --
251 Message text <variable> OVERLAPPING OUTPUT SIGNALS

Cause -- Interface unit outputs assigned twice.


Monitor -- At “Power On”.
After editing the machine data.
After loading the machine data.
Effect -- No RC Ready.
Remedy -- Value assignment.
252 Message text <variable> INTERFACE--I/O ASSIGNMENT ERROR <correct index>

Cause -- Double assignment of interface controller output.


Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the indicated machine datum.

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1 Error messages / troubleshooting (continued)

253 Message text ERRONEOUS DSE AXIS ASSIGNMENT <axis number>

Cause -- Machine datum $IFACE_DRV[6] has been assigned twice to a drive


interface, or a non--existent interface has been addressed.
-- KTL encoders have been entered in IFACE_DRV[6] without connect-
ing APC interfaces, or ADAR axes have been entered in $ADAR_AXIS
without connecting ADAR interfaces.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the machine datum.
254 Message text DSE FILE <program name> NOT AVAILABLE

Cause -- The DSE program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter or alter the DSE program.
255 Message text <$ variable> INVALID VALUE

Cause -- The machine data loader has detected that a variable contains an
incorrect value:
a) Limit monitoring tripped.
b) Machine data not logically coherent.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the value assignment.
256 Message text CHECK MACHINE DATA !

Cause -- It cannot be assured that the machine data loaded during a cold
start are valid for the connected robot.
Monitor -- Generated at cold start.
Effect -- No RC ready.
-- Controller is in its initial state, i.e. tasks dependent on machine data
are not generated.
Remedy -- Either edit or copy the machine data or option data file.

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Error messages / troubleshooting

257 Message text ERRONEOUS USER DATA

Cause -- The user data loader has detected that a variable contains an incorrect
value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the user data.
-- After loading the user data (DEFDAT $CUSTOM PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
258 Message text ERRONEOUS OPTION DATA

Cause -- The option data loader has detected that a variable contains an incor-
rect value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the option data.
-- After loading the option data (DEFDAT $OPTION PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
259 Message text ** MACHINE DATA LOADER ABORTED

Cause -- The errors detected by the machine data loader exceed the capacity
of the message buffer.
Monitor -- At “POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
260 Message text USER DATA LOADER ABORTED

Cause -- The errors detected by the user data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the user data.
-- After loading the user data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.

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1 Error messages / troubleshooting (continued)

261 Message text OPTION DATA LOADER ABORTED

Cause -- The errors detected by the option data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the option data.
-- After loading the option data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
262 Message text ERRONEOUS <path> MACHINE DATA

Cause -- The machine data loader has detected a variable with an illegal value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
263 Message text ERRONEOUS CORRECTION DATA

Cause -- The correction data loader has detected a variable with an illegal value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- POWER ON after editing the correction data, after loading the
correction data (DEFDAT $ROBCOR).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
264 Message text <path> CORRECTION DATA LOADER ABORTED

Cause -- The errors detected by the correction data loader exceed the capacity
of the message buffer.
Monitor -- At “POWER ON”.
-- After editing the correction data.
-- After loading the correction data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
265 Message text RDW FILE <program name> NOT AVAILABLE

Cause -- The RDW program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter the RDW program correctly in the INI file.

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Error messages / troubleshooting

266 Message text OVERTEMPERATURE FEEDBACK RESISTOR <power module no.>


OR FAN
Cause -- The ballast (feedback) resistor has overheated. In the motion program
the robot is cyclically accelerated and decelerated without a break.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.
267 Message text WATCHDOG POWER MODULE <power module number>

Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Dynamic braking.
Remedy -- Troubleshooting in the DSE and power module area.
268 Message text MEMORY TEST ERROR DSE <DSE number 1--4>

Cause -- The memory test on the DP--RAM of the DSE detected an error.
Monitor -- Runup.
Effect -- Active commands inhibited.
Remedy -- Replace DSE or MFC.
269 Message text DSE <DSE number 1--4> NOT AVAILABLE

Cause -- The bit on the MFC indicating whether a DSE is inserted is not set
although axes are allocated to this DSE.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Insert DSE, replace MFC or DSE.
270 Message text INCORRECT POWER MODULE SETTING <axis>

Cause -- Double assignment of $PMCHANNEL or incorrect channel.


Monitor -- When loading the robot machine data.
Effect -- Machine data loader aborted.
Remedy -- Correct $PMCHANNEL.
271 Message text ROBOT NO. ** DOES NOT CORRESPOND TO CALIBRATION FILE
**
Cause --
Monitor --
Effect --
Remedy --

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1 Error messages / troubleshooting (continued)

272 Message text NO ROBOT NUMBER PROGRAMMED

Cause --
Monitor --
Effect --
Remedy --
273 Message text MORE THAN ONE CALIBRATION FILE AVAILABLE

Cause --
Monitor --
Effect --
Remedy --
274 Message text Check robot number

Cause --
Monitor --
Effect --
Remedy --
275 Message text SET ROBOT NUMBER – PROGRAM ROBOT NAME

Cause --
Monitor --
Effect --
Remedy --
276 Message text WRONG MACHINE DATA FOR THIS ROBOT TYPE

Cause -- The machine data do not correspond to the robot type stored in the
robot base.
Monitor -- Run--up.
Effect --
Remedy -- Load the correct machine data.
-- Reprogram the robot type.
277 Message text AUTOMATIC REPOSITIONING

Cause -- $MOT_STOP_OPT = TRUE. Robot not on path.


In EXTERN, $MOT_STOP (flag that the robot is not on path) has
been set by the user (via the GUI) to FALSE, so that the robot auto-
matically moves on path at process velocity.
Monitor --
Effect -- Only a message that the robot is moving on the path in EXTERN.
Remedy -- The message is deleted as soon as BCO is reached.

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Error messages / troubleshooting

286 Message text Warning: PC fan below nominal speed

Cause -- PC controller cooling is still sufficient, but could soon become critical
Monitor -- Cyclic.
Effect -- None
Remedy -- Check PC fan and exchange if necessary

287 Message text PC fan error

Cause -- PC controller cooling is no longer sufficient; continued operation


could cause damage to components
Monitor -- Cyclic.
Effect -- The robot is stopped and can no longer be traversed
Remedy -- Check PC fan immediately and exchange if necessary

288 Message text Over temperature feedback resistor %1

Cause -- The feedback resistor has got too hot


-- The robot is cyclically accelerated and braked in the motion program
without a pause
Monitor -- Cyclic.
Effect -- Ramp--down braking
Remedy -- Reduce acceleration, introduce wait times

289 Message text Overtemperature fan %1

Cause -- One of the two fans in the cabinet is defective


Monitor -- Cyclic.
Effect -- Ramp--down braking
Remedy -- Exchange the fan in question

300 Message text OPERATING MODE CHANGE

Cause -- The mode selector switch is set to an illegal position.


Monitor -- In command processing.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Set mode selector switch to a permissible position. The status
(operational) message is then reset.

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1 Error messages / troubleshooting (continued)

301 Message text STOP WHILE MEASUREMENT ACTIVE -- MOVEMENT WILL BE


HANDLED AS TEST
Cause --
Monitor --
Effect --
Remedy --
302 Message text *<command name> ACTIVE

Cause -- OBJH command is being executed.


Monitor -- In command processing.
Effect -- None.
Remedy -- Wait until OBJH is free again.
303 Message text LIMIT <signal name>

Cause -- The value for the corresponding analog output lies outside the standard
range and has therefore been limited to the maximum or minimum
value.
Monitor -- Cyclic, when writing to analog outputs.
Effect -- None.
Remedy -- The message remains set until the value of the analog output
concerned lies within the standardized range and therefore no
limitation occurs.
304 Message text START UP

Cause -- Startup (setup) menu selected.


Monitor -- In command processing.
Effect -- Program processing not possible.
Remedy -- Quit the setup menu using the ESC key.
305 Message text COMPLETE COMPILATION ACTIVE

Cause --
Monitor --
Effect --
Remedy --
306 Message text SELECTION ACTIVE

Cause -- New selection requires deselection/linking.


Monitor -- Command processing (RUN command).
Effect -- None.
Remedy -- Wait until the linking procedure is finished, i.e. until the message
disappears.
307 Message text ERRORS AT COMPLETE COMPILATION -- ERR FILES EXIST

Cause --
Monitor --

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Effect --
Remedy --
308 Message text PALLETIZING MODE: MOVE AXIS <axis> <motion direction> INTO
POSITION
Cause -- Axes 4 and 5 have palletizing mode ( $PAL_MODE = TRUE ), but
not the right position, i.e. A4=0 degrees and A5=90 degrees.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Move axes into position in the specified direction.
309 Message text BLOCK SELECT : BCO REACHING IN T1/T2 REQUIRED

Cause --
Monitor --
Effect --
Remedy --
1000 Message text USER--MEMORY DELETED (**)

Cause --
Monitor --
Effect --
Remedy --
1001 Message text INTERNAL ERROR (DEFAULT MESSAGE)

Cause -- Internal; the message data have not been correctly set.
Monitor
Effect
Remedy
1002 Message text REBOOT AFTER POWERFAIL

Cause -- Controller is turned on again or voltage has returned.


Monitor --
Effect --
Remedy --
1003 Message text LEVEL OVERFLOW <IP,PCP>

Cause -- Computing time overload of CPU.


Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Increase basic cycle.
-- Increase interpolation cycle or position control cycle, depending on the
indicated parameter.

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1 Error messages / troubleshooting (continued)

1004 Message text CAN CONTROLLER @P1@ FAILURE

Cause --
Monitor --
Effect --
Remedy --
1005 Message text NO MORE SYSTEM MEMORY AVAILABLE

Cause -- There is not enough memory available for the command “SHOW VAR”
or “SET INFO” to be executed (the control requires a certain amount
of memory for these commands, dependent on the length of the output
value.)
Monitor -- In form processing.
Effect -- Command is not executed.
Remedy -- Save and delete programs that are not required.
1006 Message text NO MORE USER MEMORY AVAILABLE

Cause -- No more memory is available for copying objects.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Delete objects that are not required.
1007 Message text CHANNEL <channel name> CANNOT BE ASSIGNED

Cause -- The selected channel cannot be assigned.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Free channel at another point (should occur only with printer channel).
1008 Message text CONTROLLER BOOTED

Cause -- Controller is booted for the first time (not reboot after power failure).
Monitor --
Effect --
Remedy --
1009 Message text POINT CONVERSION IMPOSSIBLE WITHOUT ABSOLUTE
ACCURACY MODEL
Cause -- $ABS_ACCUR = FALSE and $ABS_CONVERT = TRUE conversion
impossible without model. If $ABS_CONVERT is TRUE, then
$ABS_ACCUR must also be TRUE!
Monitor --
Effect --
Remedy -- $ABS_ACCUR = TRUE or $ABS_CONVERT = FALSE

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1010 Message text INTERNAL ERROR <system error number> (<task ID>, <status>)

Cause -- Internal test of KRC.


-- Software.
Monitor -- Within the KRC.
-- Software.
Effect -- RC Ready reset during processing.
Remedy -- Acknowledge message.
1011 Message text SYNTAX ERROR IN FILE <filename> IN ROW <contents of the line>

Cause -- Syntax error when interpreting the parameter file (absolutely accurate
robot).
Monitor -- When loading $OPTION.DAT or defining $LOAD or $LOAD_A3.

Effect --
Remedy -- Load file, boot controller.
1012 Message text GENERAL ERROR: <error no.> <function> <additional info>

Cause -- Unknown feedback from a function in the object.


Monitor -- In command processing.
Effect -- None.
Remedy -- Inform service department.
1013 Message text FILE <file name> NOT FOUND

Cause -- Parameter file for absolutely accurate robot is not available.


Monitor -- When loading $OPTION.DAT.
Effect --
Remedy -- Load file, boot controller.
1014 Message text UNKNOWN COMPILER ERROR: <error class>

Cause -- Compiler software has detected an error.


Monitor -- In command processing.
Effect -- None.
Remedy -- Inform service department.
1015 Message text OBJH ERROR: <localization>

Cause -- Internal error in the OBJH.


Monitor -- In command processing.
Effect -- None.
Remedy -- Inform service department.

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1 Error messages / troubleshooting (continued)

1016 Message text HARDWARE LIMIT--SWITCH / +24V MISSING

Cause -- The interface module monitoring function has detected that a common
input for hardware limit switches has been set.
Monitor -- Cyclic in interface module monitoring.
Effect -- The roboter is stopped with maximum braking and the active
commands are inhibited until this message has been acknowledged.
Remedy -- Move robot off limit switch and acknowledge message.
!!!Caution!!! Moving the robot off the limit switch correctly is the
operator’s responsibility, since no axis--specific interlocks are set.
1017 Message text ABSOLUTE ACCURACY ROBOT: POINT CONVERSION ONLY POS-
SIBLE IN T1 MODE
Cause -- $ABS_CONVERT = TRUE and no T1 mode
Point conversion must be carried out carefully.
Monitor --
Effect -- Ramp--down braking.
Active commands inhibited.
Remedy -- Set variable $ABS_CONVERT in $CUSTOM.DAT to FALSE or select
T1 mode.
1018 Message text ERROR OCCURRED WHILE READING IDF FILE

Cause --
Monitor --
Effect --
Remedy --
1019 Message text PALLETIZING MODE NOT POSSIBLE WITH THIS ROBOT TYPE

Cause -- Palletizing is only possible with floor and ceiling--mounted robots. If


$ROBROOT A or B <> 0, palletizing is not possible.
Monitor -- Write function.
Effect -- Maximum braking.
Remedy -- Enter correct $ROBROOT or $PAL_MODE = FALSE.
1020 Message text INTERNAL ERROR <error number> (<task ID>, <return status>)

Cause -- Internal software error.


Monitor
Effect
Remedy
1021 Message text INTERNAL ERROR WHEN ACCESSING <object name>

Cause -- An internal error has occurred when accessing a file (acknowledge-


ment message already set). The action was not correctly carried out.
Monitor -- In object processing.
Effect
Remedy

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1022 Message text COMMUNICATION <operator control device> – KRC INTERRUPTED

Cause -- Communication between the active operator control unit and the KRC
has been interrupted while a motion was being executed in the test
mode.
Monitor -- In command processing.
Effect -- Maximum braking.
Remedy -- Re--establish the connection.
1023 Message text INPUT BUFFER OVERFLOW **

Cause --
Monitor --
Effect --
Remedy --
1024 Message text ERROR DURING READING OF INI FILE ** **

Cause -- Error in INI file.


Monitor -- At system start.
Effect -- All commands are inhibited.
Remedy -- Correct INI file.
1025 Message text CONFIGURATION ERROR I/O DRIVER <driver name>

Cause -- Error in the INI file.


Monitor -- In system runup.
Effect
Remedy -- Check io_int.ini.
1026 Message text ERROR DIGITAL INPUT READING PORT: **

Cause
Monitor
Effect
Remedy -- Check I/O components.
1027 Message text ERROR WRITE DIGITAL OUTPUTS PORT: **

Cause
Monitor
Effect -- Maximum braking.
Remedy -- Check the corresponding I/O hardware.
1028 Message text ERROR RESTART I/O <bus/driver name>

Cause -- Field bus error is still present.


Monitor
Effect -- Bus I/O still not available.
Remedy -- Eliminate field bus error (hardware).

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1 Error messages / troubleshooting (continued)

1029 Message text SEN: <string> ** **

Cause -- Hint message of a sensor that does not require a stop.


Monitor
Effect
Remedy
1030 Message text SEN: <string> ** **

Cause -- Sensor error that requires ramp--down braking.


Monitor
Effect
Remedy -- Depends on sensor concerned.
1031 Message text SEN: <string> ** **

Cause -- Sensor error that requires ramp--down braking.


Monitor
Effect
Remedy
1032 Message text SEN: **

Cause -- Sensor error that requires ramp--down braking.


Monitor
Effect
Remedy
1033 Message text ERROR ON READING, DRIVER: ** **

Cause --
Monitor --
Effect --
Remedy --
1034 Message text ERROR ON WRITING, DRIVER: ** **

Cause --
Monitor --
Effect --
Remedy --
1035 Message text SINGULARITY--LESS MOTION: MAX. ORIENTATION ERROR

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

1036 Message text CHECK SAFETY LOGIC. DRIVES OFF TIMEOUT DURING EMER-
GENCY STOP
Cause --
Monitor --
Effect --
Remedy --
1037 Message text LOCAL EMERGENCY STOP BUTTON PRESSED

Cause --
Monitor --
Effect --
Remedy --
1038 Message text INVALID OPERATING MODE

Cause -- START MINUS was pressed in AUT or EXT. Only possible in T1 or


T2.
Monitor -- Command execution.
Effect --
Remedy --
1039 Message text BACKWARD MOTION EXECUTION NOT POSSIBLE: TRACE EMPTY

Cause -- All recorded motions have already been executed.


Monitor -- Command execution.
Effect --
Remedy -- Forward motion.
1040 Message text BACKWARD MOTION EXECUTION NOT POSSIBLE: NO TRACE

Cause -- No points were executed and recorded in the forwards direction, or


the traces were rejected.
Monitor -- Command execution.
Effect --
Remedy -- Forward motion.
1041 Message text SOFTPLC: **

Cause --
Monitor --
Effect --
Remedy --
1042 Message text ACKN K1 CONTACT FAIL TO OPEN <KPS number>

Cause -- The K1 contact is welded.


Monitor --
Effect -- The energy supply is not interrupted.
Remedy -- Exchange contactor, KPS.

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1 Error messages / troubleshooting (continued)

1043 Message text ACKN BUS VOLTAGE CHARGING UNIT IS DEFECTIVE <KPS number>

Cause -- The optocoupler on the KPS is not registering current flow.


Monitor --
Effect -- Intermediate circuit cannot be loaded.
Remedy -- Exchange KPS.
1044 Message text ACKN BRAKE DEFECTIVE **

Cause -- Wear on brakes, defective brake.


Monitor --
Effect -- Axis moves in an uncontrolled manner.
Remedy -- Exchange motor.
1045 Message text SERVO INDEPENDENT COMMAND EXECUTION

Cause --
Monitor --
Effect --
Remedy --
1046 Message text BLOCKING OF OUTPUTS IN AUT/EXT IS ENABLED

Cause -- Variable $BLK_IO_AUT is set to TRUE (setting outputs in AUT/EXT


is blocked). The user nevertheless tries to set the outputs by hand.
Monitor --
Effect --
Remedy --
1047 Message text SERVO INDEPENDENT COMMAND EXECUTION ONLY POSSIBLE
IN TESTING MODE
Cause -- Robot simulation not allowed in operating modes #AUT or #EXT.
Monitor --
Effect -- No program execution/simulation possible.
Remedy -- Change operating mode.
1048 Message text ACKN. OUTPUT MONITORING DC BUS VOLTAGE KPS: **

Cause -- DC bus voltage of a KPS overloaded.


Monitor --
Effect --
Remedy --
1049 Message text PROFIBUS MASTER IS IN STATE AUTOCLEAR. PLEASE EXECUTE
RESET COMMAND
Cause -- Bus error in Profibus. Option AUTOCLEAR is set. This means that the
bus no longer starts again automatically. A Profibus reset is necessary.
Monitor --
Effect -- Indication that a bus reset is necessary since the bus does not start
again automatically (the corresponding option is not set).
Remedy -- Rectify bus error and carry out RESET via the menu.

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Error messages / troubleshooting

1050 Message text PROFIBUS : ERROR IN MASTER CIRCUIT ** **

Cause --
Monitor --
Effect --
Remedy --
1051 Message text PROFIBUS: ERROR IN SLAVE CIRCUIT

Cause --
Monitor --
Effect --
Remedy --
1052 Message text KCP: CAN BUS ERROR

Cause -- Transmission error in CAN BUS.


Monitor -- Teach pendant task.
Effect -- Path--maintaining braking.
Remedy -- Acknowledge.
1053 Message text CP VEL. REDUCTION POINT ** ** BY **

Cause --
Monitor --
Effect --
Remedy --
1054 Message text ACKN. DN CH ** TOO MANY MODULE ERRORS **

Cause --
Monitor --
Effect --
Remedy --
1055 Message text TRACE BUFFER EMPTY, START WITH BACKWARD SCAN

Cause -- Empty trace for backward motion, switching to SCAN method.


Monitor -- When START minus is pressed.
Effect -- Active commands inhibited.
Remedy -- Acknowledge.
1056 Message text ACKN. SERVOBUS DSE--NO.: <DSE no.> PARTICIPANT NO.: <IBS
device> UNKNOWN
Cause -- An unknown device which is not supported was inserted in Interbus.

Monitor -- DSE ID, device ID.


Effect --
Remedy -- Remove the device causing the fault from the bus system.

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1 Error messages / troubleshooting (continued)

1057 Message text ACKN. FAILURE OF MOTOR PHASE <axis>

Cause -- Backup battery voltage low.


Monitor -- At “Power on”.
-- Cyclic.
Effect -- At “Power on” --> automatic general reset, and in addition the message
“User memory deleted” is displayed (machine data, user data, applica-
tion programs must be reloaded).
-- Cyclic --> none.
Remedy -- Exchange battery. After exchange, the message
“Ackn. check accumulator” appears --> acknowledge.
1058 Message text BCO MOTION: PRESS START PLUS

Cause -- An attempt was made to carry out BCO motion with START MINUS.
Monitor -- When START MINUS is pressed.
Effect -- The robot does not start.
Remedy -- Use START PLUS or set Implicit_BCO = TRUE in BACKWARD.INI.
1059 Message text FINISHED SUBROUTINE: SKIP MOTIONS

Cause -- During backward motion, the interpreter encounters a subprogram


which has already been completely executed.
Monitor -- Each time before backward motion is started.
Effect -- Active commands inhibited.
Remedy -- Acknowledge.
1060 Message text $BWDSTART NOT IN FOLD. NO TOOL AND BASE INFORMATION
FOUND
Cause -- Backward motion in SCAN method: a $BWDSTART assignment must
be programmed as the first instruction in a motion fold. From this line
onwards, all following instructions up to the motion are executed before
backward motion is carried out.
Monitor -- Each time before backward motion is started.
Effect -- Active commands inhibited.
Remedy -- Correct program or set the entry BACKWARDSTART = FALSE in
BACKWARD.INI. In this case, however, BASE and TOOL changes
cannot be carried out during backward motion.
1061 Message text Rapid EMERGENCY STOP with fixed braking ramps

Cause -- In the event of EMERGENCY STOP with dynamic model, the fixed
braking ramp strategy is used as this brakes the robot significantly
more quickly
Monitor -- In the event of EMERGENCY STOP with dynamic model
Effect -- EMERGENCY STOP brakes the robot more quickly than the strategy
based on the dynamic model
Remedy -- Verify load data and correct if necessary
-- Verify machine data

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1062 Message text Ackn. second motorcable not connected

Cause -- Second motor cable was not connected or was connected incorrectly
Monitor --
Effect --
Remedy -- Acknowledge message
1063 Message text Ackn. over temperature feedback resistor %1

Cause -- The feedback resistor has got too hot


-- The robot is cyclically accelerated and braked in the motion program
without a pause
Monitor -- Cyclic.
Effect --
Remedy -- Acknowledge message
1064 Message text Ackn.: over temperature fan %1

Cause -- One of the two fans in the cabinet is defective


Monitor -- Cyclic.
Effect -- Ramp--down braking
Remedy -- Acknowledge message
1065 Message text Ackn. mainboard overtemperature

Cause -- The cabinet fan has failed


-- The ambient temperature is too high
Monitor -- Cyclic.
Effect --
Remedy -- Acknowledge message
1066 Message text Mainboard temperature reached warning level

Cause -- PC controller cooling is still sufficient, but could soon become critical
Monitor -- Cyclic.
Effect -- None
Remedy -- Check fan
-- Exchange fan filter

1067 Message text Mainboard temperature check not available

Cause -- Motherboard does not support temperature monitoring


Monitor -- Once
Effect -- No monitoring
Remedy -- Exchange motherboard
-- Switch temperature monitoring off

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1 Error messages / troubleshooting (continued)

1068 Message text INTERBUS: Watchdog Time expired!

Cause -- The Interbus driver read function was not called in the time defined
Monitor -- Cyclic.
Effect -- Inputs and outputs are not set
Remedy -- Terminate the Watchdog by reconfiguring the I/Os
-- De--energize controller board
-- Watchdog cycle time possibly set too low
-- Fault in the KRC system since the read function of the driver was not
called cyclically
1071 Message text MOTOR HOLDING TORQUE %1 EXCEEDED

Cause -- The motor holding torque of the axis is not sufficient to keep the robot
motion permanently stopped at a point.
Monitor -- Not cyclic, during path planning
Effect -- Interpreter stop
Remedy -- Correct or reduce load data
-- Verify machine data

1072 Message text BRAKE HOLDING TORQUE %1 EXCEEDED

Cause -- The brake holding torque on the axis is not sufficient to keep the robot
motion permanently stopped at a point.
Monitor -- Not cyclic, during path planning
Effect -- Interpreter stop
Remedy -- Correct or reduce load data
-- Verify machine data

1073 Message text COMMANDED GEAR TORQUE %1

Cause -- Permissible gear torque exceeded, dependent on dynamic data


$DYN_DAT()
Monitor -- Cyclic.
Effect -- Path--maintaining braking
-- Output ”$ALARM_STOP” 0 signal
-- Active commands inhibited.
Remedy -- Verify load data and reduce if necessary, reduce programmed accel-
eration, reduce programmed velocity; acknowledge message

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Error messages / troubleshooting

1074 Message text COMMANDED MOTOR TORQUE %1

Cause -- Permissible motor torque exceeded, dependent on dynamic data


$DYN_DAT()
Monitor -- Cyclic.
Effect -- Path--maintaining braking
-- Output ”$ALARM_STOP” 0 signal
-- Active commands inhibited.
Remedy -- Verify load data and reduce if necessary, reduce programmed accel-
eration, reduce programmed velocity; acknowledge message
1075 Message text MAXIMUM KINETIC ENERGY %1

Cause -- Permissible kinetic energy for crash exceeded, dependent on dynamic


data $DYN_DAT()
Monitor -- Cyclic.
Effect -- Path--maintaining braking
-- Output ”$ALARM_STOP” 0 signal
-- Active commands inhibited.
Remedy -- Verify load data and reduce if necessary, reduce programmed velocity;
acknowledge message
1078 Message text Ackn. servobus DSE--No. %1 participant No. %2 not available

Cause -- The device number in the servo bus was too low
Monitor --
Effect --
Remedy -- Acknowledge message
1079 Message text Ackn. servobus DSE--No. %1 participant No. %2 not available

Cause -- The device number in the servo bus was higher than the number
defined in the machine data
Monitor --
Effect --
Remedy -- Acknowledge message
1100 Message text STOPPED <axis number>

Cause -- Axis has beeen moved out of the standstill position according to the
machine data. Positioning window ($IN_POS_MA) times standstill
window minus factor ($IN_STILL_MA).
Monitor -- With robot “in position”.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check manipulator.
-- Check output stage, check motor brake.
-- Acknowledge message.

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1 Error messages / troubleshooting (continued)

1101 Message text COMMAND ACCELERATION EXCEEDED <axis number>

Cause -- Permissible command acceleration exceeded; e.g. because robot


has been moved through singularity in cartesian mode.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check program for alpha5 transitions (singularity).
-- Reduce path velocity.
-- Reduce path acceleration.
-- Acknowledge message.
1102 Message text COMMAND VELOCITY EXCEEDED <axis number>

Cause -- Permissible command velocity exceeded; e.g. because robot has


been moved through singularity in cartesian mode.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Reduce path velocity.
-- Reduce path acceleration.
1103 Message text DATA EXCHANGE WITH TEPRO MISSING

Cause -- The SBC is not transmitting cyclic data on time (TEPRO =


Technological Process).
Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Re--initialize the SBC program or eliminate the error in the SBC program.
1104 Message text ACKN. REGULATOR LIMIT EXCEEDED <axis number>

Cause -- The set value of the machine datum $COM_VAL_MI has been exceed-
ed. The position controller output has gone into limitation. The axis
does not follow the command value.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check power module.
-- The brake control must be checked (LED on PM) if the error occurs on
more than one axis.
1105 Message text POSITIONING MONITOR <axis number>

Cause -- Positioning window $IN_POS_MA has not been reached within the
set positioning time $TIME_POS.
Monitor -- When positioning.

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Error messages / troubleshooting

Effect -- Maximum braking.


-- All active commands inhibited.
-- The axis has the status “in position” after the message has been
acknowledged.
Remedy -- Enlarge positioning window.
-- Lengthen positioning time.
-- Check power module.
-- Acknowledge message.
-- Check manipulator.
1106 Message text TOOL WEIGHT NOT YET LEARNT

Cause -- During EMT mastering a check run was carried out for a tool whose
weight has not yet been learnt.
Monitor -- During EMT mastering.
Effect --
Remedy -- “Learn” tool weight.
1107 Message text WORKING ENVELOPE SURVEILLANCE CAN ONLY BE OVERRIDDEN
IN T1 MODE
Cause -- An attempt was made to define the variable $WBOXDISABLE in
mode T2, AUT, EXT.
Monitor -- Cyclic.
Effect --
Remedy -- Change operating mode.
1108 Message text DYNAMIC BRAKING ERROR <axis number>

Cause -- Actual value does not decrease although braking ramp is predefined
in terms of command values.
Monitor -- Cyclic.
Effect -- Short--circuit braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
1109 Message text COMMUNICATION WITH TEPRO FAULTY

Cause -- The SBC is not collecting cyclic data on time.


Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Re--initialize the SBC program.
1110 Message text SENSOR LOCATION SEARCH FOR <axis>

Cause -- During the sensor location search, the sensor switching point was
detected.
Monitor -- Command execution.
Effect -- None.
Remedy -- None.
1111 Message text DRIFT COMPLETED

Cause -- Drift is completed.

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1 Error messages / troubleshooting (continued)

Monitor --
Effect -- None.
Remedy -- None.
1112 Message text PERFORM SENSOR LOCATION SEARCH <axis number> !

Cause -- Sensor location search was not carried out or $ROBCOR.DAT not
available.
Monitor -- During command execution.
Effect -- None.
Remedy -- Notify customer support.
1113 Message text SENSOR LOCATION SEARCH INVALID <axis number>

Cause -- Command “Sensor location search”:


a) axis was not mastered
b) last mastering type was sensor adjustment
Monitor -- When command “ADJUST SENSOR”.
Effect -- Command is not executed.
Remedy -- Master axis with EMT or dial gauge.
-- Leave menu via Recall.
-- Acknowledge message.
1114 Message text INVALID MASTERING SEQUENCE

Cause -- Mastering sequence defined in machine datum $SEQ_CAL has not


been observed.
Monitor -- In mastering.
Effect
Remedy -- Master axis with EMT probe or depth gauge.
-- Press ESC to quit menu.
-- Acknowledge message.
1115 Message text SERVO PARAMETERS NOT TRANSFERRED!

Cause -- Servo parameters were not sent to DSE.


Monitor -- When defining the structure $SERVOPARA.
Effect --
Remedy -- Define $SERVOPARA correctly.
1116 Message text SENSOR ADJUSTMENT INVALID <axis number>

Cause -- When selecting sensor adjustment for an axis with incremental or


absolute encoder.
Monitor -- During sensor adjustment.
Effect -- Command is not executed.
Remedy -- Set axis with DIAL or TURN.
1117 Message text ACYCLIC DATA NOT RELEASED BY TEPRO

Cause -- Semaphore is inhibiting access to acyclic data.


Monitor -- In acyclic data transfer.
Effect -- Ramp--down braking; interruption of the SBC interface.

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Error messages / troubleshooting

Remedy -- Eliminate the error in the SBC program.


1118 Message text CYCLIC DATA NOT RELEASED BY TEPRO

Cause -- Semaphore is inhibiting access to acyclic data.


Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1119 Message text WRONG DATA TYPE FROM TEPRO

Cause -- SBC is cyclically sending incorrect data.


Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1120 Message text INCOMPLETE INSTRUCTION

Cause -- The interface with the SBC is not initialized.


Monitor -- In KRL interface instruction.
Effect -- None.
Remedy -- Initialize the interface.
1121 Message text DATA EXCHANGE

Cause -- The SBC stops data exchange because of an error.


Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1122 Message text ANALOG OUTPUT : DELAY REDUCTION

Cause -- The memory provided internally for the output function with a delay
is not adequate for the programmed delay.
Monitor
Effect -- The programmmed delay is automatically reduced.
Remedy -- Program a shorter delay.
1123 Message text APPROXIMATION NOT POSSIBLE

Cause -- Approximation (approximate positioning) is not possible for computing


time reasons.
Monitor -- When the approximate positioning criterion is reached in the interpolator.
Effect -- None.
Remedy -- Program $ADVANCE > 0.
-- Switch off axis simulation.
1124 Message text WRONG START POSITION

Cause -- 1. EMT mastering starts in the groove rather than before it.
-- 2. Cable for EMT mastering connected during sensor location run or
sensor mastering.
Monitor -- In command processing.

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1 Error messages / troubleshooting (continued)

Effect -- Command aborted.


Remedy -- 1. Move axis to correct starting position.
-- 2. Disconnect cable for EMT mastering.
1125 Message text EMT SENSOR FAULTY

Cause -- Sensor supplies a zero signal because it is not properly tightened.


Monitor -- In command processing.
Effect -- Command aborted.
Remedy -- Check screwed connection of sensor.
-- Check robot--EMT connection.
-- Check A3/DSE module.
1126 Message text STOP COMMAND IGNORED

Cause -- Axis does not stop within a certain time after a stop command.
Monitor -- After command processing.
Effect -- Command aborted.
Remedy --
1127 Message text MASTERING PERFORMED <axis number>

Cause -- Attempt to remaster an axis that has already been mastered.


Monitor -- After command processing.
Effect -- Ramp--down braking.
Remedy -- Press ESC to cancel.
-- Repeat measurement.
1128 Message text STOP, APPROXIMATION NOT POSSIBLE

Cause -- Approximation not possible for reasons of planning or time. Robot


stops because $STOP_NOUES = TRUE is set and operating mode
= T1 or T2.
Monitor --
Effect -- Ramp--down braking.
Remedy -- Reduce the velocity and/or acceleration in the instruction until approxi-
mation is possible.
1129 Message text TOO MANY ASYPTP COMMANDS

Cause --
Monitor -- During program execution of ASYPTP commands.
Effect -- Program execution is stopped.
Remedy -- Fewer ASYPTP commands.
1130 Message text ACKN. MOTOR TEMPERATURE <axis number>

Cause -- A motor temperature fault is signalled by the DSE board if the tem-
perature exceeds 155 degrees.
Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.

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Error messages / troubleshooting

1131 Message text ACKN. TORQUE EXCEEDED <axis>

Cause -- The motor torque is not located in the specified monitoring tunnel.
Monitor -- Cyclic in interpolation cycle.
Effect -- Motion is stopped.
Remedy -- Verify load data, increase size of tunnel.
1132 Message text REFPO DETERMINES AXIS <axis>

Cause -- Output after reference point for axes 1--6 has been calculated.
Monitor -- In program mode.
Effect -- None.
Remedy -- None.
1133 Message text GEAR TORQUE EXCEEDED AXIS <axis>

Cause -- The calculated gear torque is larger than the maximum permissible
gear torque.
Monitor -- Cyclic in interpolation cycle.
Effect -- Motion and program are stopped.
Remedy -- Reteach points.
1134 Message text ACKNOWLEDGE ERROR 6SC620 <axis number>

Cause -- Malfunction/error in drive module or on processor module in Simodrive


6SC620 acknowledgement.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Acknowledge message.
1135 Message text TORQUE MODE VELOCITY LIMIT EXCEEDED <axis>

Cause -- Velocity limit exceeded in torque mode.


Monitor -- In torque mode.
Effect -- Short--circuit braking.
Remedy --
1136 Message text ACKN. HEATSINK TEMPERATURE <axis number: AX>

Cause -- A heat sink temperature fault is signalled by the DSE board if the
temperature exceeds 80 degrees.
Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
-- Clean heat sink.
1137 Message text EMT MASTERING DISTANCE EXCEEDED

Cause -- Groove not located, axis position not before groove prior to start.
Monitor
Effect -- Axis stops.
Remedy -- Move axis into mastering position; check EMT and groove.

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1 Error messages / troubleshooting (continued)

1138 Message text DYNAMIC BRAKING

Cause -- If during an activated Emergency Stop a fault occurs that permits only
maximum (dynamic) braking, this message is additionally displayed.
Monitor -- With the following messages: 100, 101, 102, 103, 104, 105, 110,
111, 114, 200, 202, 206, 1100, 1108.
Effect -- Maximum braking.
Remedy -- Acknowledge message.
1139 Message text SYNACT NOT POSSIBLE <block number>

Cause -- The programming of synchronous actions with the variable $M_TIME


or $M_TIME_APO causes the message to be output when the
program is resumed after ramp--down braking, a path--maintaining
Emergency Stop ramp or maximum braking.
1140 Message text BLOCK CHANGE AT STOP

Cause -- Maximum braking or a path--maintaining stop and a simultaneous


block change which makes calculation of $POS_RET and the system
time impossible, with the result that the system time and $POS_RET
are determined by the beginning of a new block.
Monitor -- (e.g. cyclic; in command processing; in mastering).
Effect -- (e.g. ramp--down braking; program processing stopped; etc.).
Remedy -- (e.g. eliminate fault, correct operator action).
1141 Message text TTS NOT EXISTING

Cause -- The X--axis of the tool coordinate system and the path tangent are
parallel. (TTS = tool--based technological system).
Monitor -- Cyclic in the interpolation cycle when calculating the path correction.
Effect -- Maximum braking.
Remedy -- Reprogram the movement. Correct the point.
1142 Message text DEVIATION AT TARGET POINT

Cause -- An exact stop point has been approached with a deviation.


Monitor -- Function generator becomes active during positioning.
Effect -- Ramp--down braking.
Remedy -- SCALE_IN must be corrected.
1143 Message text REFERENCE OFFSET NOT VALID

Cause -- Mastering is not possible by transferring the reference offset as this


is not valid in $ROBCOR.DAT.
Monitor
Effect
Remedy

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Error messages / troubleshooting

1144 Message text V--GROOVE HAS WRONG PROFILE

Cause -- The mastering groove for EGP adjustment does not have a V or U
profile.
Monitor -- In EMT mastering.
Effect -- Ramp--down braking; mastering procedure is aborted.
Remedy -- Replace EMT groove.
-- Clean EMT.
1145 Message text STOP DUE TO VALUE OUT OF RANGE OVERFLOW, <motion direc-
tion> <axis number>
Cause -- Overflow of the actual value of an endless axis.
Monitor -- Cyclic in the interpolation cycle.
Effect -- The motion is stopped by a path--maintaining Emergency Stop.
Remedy -- Remaster the axis concerned.
1146 Message text ACKN. MOTOR BLOCKED <axis number>

Cause -- I*t monitoring is signalled by a DSE.


Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
1147 Message text PERFORM INITIAL MASTERING <axis number>

Cause -- An attempt was made to carry out a sensor location search for an axis
on which initial mastering has not yet been performed.
Monitor -- When selecting the function “dat_ueb” for the corresponding axis.
Effect -- The sensor location search is not carried out.
Remedy -- Perform initial mastering (e.g. dial gauge or EMT mastering) for the
corresponding axis.
1148 Message text INVALID AXIS COUPLING RATIO <axis number>

Cause -- An attempt was made to carry out “Extended sensor adjustment” for
an axis when the coupling axes are not in the same position as was
reported in the data transfer.
Monitor -- When selecting the function “Extended sensor adjustment” for the
corresponding axis.
Effect -- The function “Extended sensor adjustment” is not carried out.
Remedy -- Move coupling axes to the same position as in the data transfer.
1149 Message text ADJUSTMENT PROCEDURE NOT POSSIBLE <axis number>

Cause -- An attempt is made to carry out sensor adjustment or the axis is not
equipped with a KTL encoder and DSE.
Monitor -- When selecting the function “Extended sensor adjustment” for the
corresponding axis.
Effect -- The sensor adjustment is not carried out.
Remedy -- Cancel via Recall or master axis with EMT / dial gauge.
1150 Message text DATA TRANSFER INVALID <axis number>

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1 Error messages / troubleshooting (continued)

Cause -- An attempt is made to carry out a sensor location search for an axis
which is not equipped with a KTL encoder and DSE.
Monitor -- When selecting the sensor location search function for the correspond-
ing axis.
Effect -- The sensor location search for the axis is not carried out.
Remedy -- Cancel via Recall.
1151 Message text PERFORM DATA TRANSFER <axis number>

Cause -- An attempt was made to carry out sensor adjustment for an axis on
which no sensor location search has been performed.
Monitor -- When selecting the function “Extended sensor adjustment” for the
corresponding axis.
Effect -- The function “Sensor location search” is not carried out.
Remedy -- Carry out sensor location search for the corresponding axis.
1152 Message text DATA TRANSFER PERFORMED <axis number>

Cause -- The sensor location search has been properly carried out.
Monitor -- When the function “Sensor location search” for the corresponding
axis is selected and the Enter key is pressed.
Effect -- None.
Remedy --
1153 Message text DEVIATION IN THE START POINT

Cause -- A PTP motion is to be executed with a sensor offset value.


Monitor -- Interpolator.
Effect -- Ramp--down braking.
Remedy -- Sensor offset must be eliminated before a PTP block is executed.
1154 Message text SBC ERROR: <Watchd.,Transf.,Corr>

Cause -- Error in communication between SBC and KRC32.


Monitor -- Cyclic in the TEP task.
Effect -- Maximum braking.
Remedy -- Check SBC (SW, HW).
1155 Message text APPROXIMATION NOT POSSIBLE, TORQUE TOO HIGH

Cause -- For an approximate positioning block to be executed, the velocity must


already be reduced in the preceding block. However, this block is not
long enough to allow that.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter.
Remedy -- Increase the length of the individual block by:
decreasing the approximate positioning radius at the end point of the
current motion block or, if the start point is approximated, by decreas-
ing this approximate positioning radius.
Decreasing the velocity and acceleration of the individual block.

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Error messages / troubleshooting

1156 Message text APPROX. NOT POSSIBLE INTERNAL ERROR IN PTP MOTION
PLAN
Cause -- Error in planning of the approximate positioning block.
Monitor -- Not cyclic, in motion planning.
Effect -- Approximate positioning is not executed; exact stop.
Remedy -- Modify profile data (rounding factor, velocity, acceleration). Please
consult KUKA.
1157 Message text OVERLOAD OF GEAR TORQUE <axis number> BY <percentage
value>
Cause -- The max. gear torque of the axis is statically exceeded by ....%.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Check load data (mass, center of gravity, moments of inertia).
1158 Message text STATIC MOTOR TORQUE OVERLOAD <axis number> BY <percentage
value>
Cause -- The max. motor torque of the axis is statically exceeded by ....%.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Check load data (mass, center of gravity, moments of inertia).
1159 Message text INTERNAL ERROR IN PTP MOTION PLANNING <number>

Cause -- Error in planning of the PTP motion profile.


Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Modify profile data (rounding factor, velocity, acceleration). Please
consult KUKA.
1160 Message text TRACE: RECORDING TIME IS TOO LONG

Cause -- The recording time in TRACE.DEF is too long. There is not enough
memory available for recording.
Monitor -- When starting the TRACE.
Effect -- TRACE is not recorded.
Remedy -- Shorten TRACE recording time or reduce the number of channels.
1161 Message text ACKN MONITORING OF THE ACTUAL VELOCITY **

Cause -- Fault in control loop:


-- motor cables of two axes interchanged;
-- error in the axis assignment;
-- power module defective;
-- resolver unmastered.
Monitor -- Cyclic.
Effect -- Robot remains motionless.
Remedy -- Rectify the corresponding error in the control loop.

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1 Error messages / troubleshooting (continued)

1162 Message text SEPARATE BREAK CONTROL OF AUXILIARY AXIS NOT ENABLED

Cause --
Monitor --
Effect --
Remedy --
1163 Message text AXIS COUPLING NOT POSSIBLE (DSE/PM--CHANNEL ASSIGNMENT)

Cause --
Monitor --
Effect --
Remedy --
1164 Message text COUPLE PROCESS ACTIVE

Cause --
Monitor --
Effect --
Remedy --
1165 Message text ERROR ON AXIS COUPLING

Cause --
Monitor --
Effect --
Remedy --
1166 Message text ERROR ON AXIS DECOUPLING

Cause --
Monitor --
Effect --
Remedy --
1167 Message text <axis> DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
1168 Message text <axis> DECOUPLED AUXILIARY AXIS, MOVE NOT PERMITTED

Cause --
Monitor --
Effect --
Remedy --
1169 Message text <axis> DECOUPLED AUXILIARY AXIS, MASTERING NOT PERMITTED

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Error messages / troubleshooting

Cause --
Monitor --
Effect --
Remedy --
1170 Message text ASYPTP COMMAND INCLUDES DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
1171 Message text VALUE OF $ASYNC_AXIS CONTAINS DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
1172 Message text VALUE CANNOT BE CHANGED, PROGRAM IS SELECTED

Cause --
Monitor --
Effect --
Remedy --
1173 Message text Ackn. deviation warning master--slave %1

Cause -- Positional deviation between master and slave exceeds lower limit
value
Monitor -- Cyclic.
Effect -- None
Remedy -- Acknowledge message
1174 Message text Ackn. deviation alarm master--slave %1

Cause -- Positional deviation between master and slave exceeds middle limit value
Monitor -- Cyclic.
Effect -- Maximum braking
Remedy -- Acknowledge message; the drives synchronize themselves automati-
cally
1175 Message text Ackn. deviation critical master--slave %1

Cause -- Positional deviation between master and slave exceeds upper limit value
Monitor -- Cyclic.
Effect -- Maximum braking
-- Loss of mastering of the corresponding axis
Remedy -- Dial mastering of the axis

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1 Error messages / troubleshooting (continued)

1176 Message text Ackn. speed deviation master--slave %1

Cause -- Speed deviation between master and slave exceeds limit value
Monitor -- Cyclic.
Effect -- Maximum braking
Remedy -- Acknowledge message
1200 Message text ACKN. EMERGENCY STOP

Cause -- Emergency Stop was active.


Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
1201 Message text BUFFER BATTERY VOLTAGE LOW **

Cause -- The battery voltage is too low for backup purposes. Do not switch
off until battery has recharged.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Acknowledge message.
1202 Message text ACKN. RDW <axis number> BOOT UP FAILURE

Cause -- Secondary message following the status (operational) message


“RDW BOOT UP FAILURE”.
Monitor
Effect
Remedy -- Acknowledge message.
1203 Message text ACKN. DSE <DSE number> BOOT UP FAILURE

Cause -- Secondary message following the status (operational) message


“DSE BOOT UP FAILURE”.
Monitor -- Runup.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace encoder.
-- Acknowledge message.
1204 Message text ACKN. ENCODER CABLE FAILURE <axis number>

Cause -- Secondary message following the status (operational) message


“ENCODER CABLE FAILURE”.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Acknowledge message.

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Error messages / troubleshooting

1205 Message text ACKN. WATCHDOG INTERPOLATION CYCLE <DSE number>

Cause -- Secondary message following the status (operational) message


“WATCHDOG INTERPOLATION CYCLE”.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Acknowledge message.
1206 Message text ACKN. SYNCHRONIZATION ERROR WITH DSE <axis number>

Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect
Remedy -- Acknowledge message.
1207 Message text ACKN. TRANSMISSION ERROR DSE -- RDW <DSE number>

Cause -- Open--circuit between RDW and DSE.


-- Transmission malfunction
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
-- Acknowledge message.
1208 Message text ACKN. MASTERING PERFORMED <axis number>

Cause -- Follow--up message for status message “PERFORM MASTERING”


Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Perform mastering
-- Acknowledge message.
1209 Message text ACKN. GENERAL SERVO ENABLE

Cause -- There was a low signal at $SERVO_RDY input.


Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
1210 Message text ACKN. GENERAL MOTION ENABLE

Cause -- There was a low signal at $MOVE_ENABLE input.


Monitor -- Cyclic.
Effect -- All active commands inhibited.

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1 Error messages / troubleshooting (continued)

Remedy -- Acknowledge message.


1211 Message text STOP DUE TO SOFTWARE LIMIT SWITCH <motion direction> <axis
number>
Cause -- Overrun of a sofware limit switch (command value) has been detected.
Monitor -- Cyclic, not with axis--specific manual traversing.
Effect -- Maximum braking.
Remedy -- If necessary acknowledge message, move robot in the opposite
direction.
1212 Message text ACKN. OPERATOR SAFETY

Cause -- Operator safety has been tripped in the AUTOMATIC or EXTERNAL


mode.
Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message. (The robot can then be started in the AUTO-
MATIC or EXTERNAL mode again.)
1213 Message text ACKN. PASSIVE STOP <RCP or teach pendant>

Cause -- The originator of the passive stop has acknowledged the message.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message. (Acknowledgement possible only on active
unit.)
1214 Message text POWER FAILURE

Cause -- The cabinet voltage has been switched off, the mains voltage is
interrupted.
Monitor --
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.
1215 Message text <command name> <action>

Cause -- OBJH command finished.


Monitor -- Command processing.
Effect -- None.
Remedy -- None.
1216 Message text ACKN. DRIVES ERROR <axis number> NO.: **

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

1217 Message text ACKN. SBX--HPU CONNECTED INPUT

Cause -- Safety box has detected a fault in signal input “teach pendant
plugged in”.
Monitor -- Cyclic.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Acknowledge message.
1218 Message text ACKN. SBX--HPU DEPOSITED INPUT

Cause -- Safety box has detected a fault in the input unit of the permanently
installed input.
Monitor -- Cyclic.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Acknowledge message.
1219 Message text ACKN. SBX--HPU CONNECTED

Cause -- The software has detected that in the dual--channel evaluation of the
signal “Teach pendant plugged in” the two channels (MPC interface
and safety box) have different statuses.

Monitor -- Cyclic.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Acknowledge message.
1220 Message text ACKN. EMERGENCY STOP DUE TO DIAL MASTERING

Cause -- Softkeys for dial mastering pressed.


Monitor -- When $TURN instruction is executed.
Effect -- Dynamic braking.
-- All active commands inhibited.
-- Low signal at “$ALARM_STOP 0” output; ramp--down braking.
Remedy -- Press the Recall key twice.
1221 Message text ACKN. POWER MODULE AXIS <axis number> NOT /OR INCOR-
RECTLY CONNECTED
Cause -- The axis is incorrectly plugged into the power module or not connected
at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect axis correctly.
-- Acknowledge message.
1222 Message text ACKN. BRAKE ERROR <axis number>

Cause --
Monitor --
Effect --
Remedy --
1223 Message text ACKN. UNDERVOLTAGE <power module>

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1 Error messages / troubleshooting (continued)

Cause --
Monitor --
Effect --
Remedy --
1224 Message text ACKN. OVERVOLTAGE <power module>

Cause --
Monitor --
Effect --
Remedy --
1225 Message text ACKN. OVERCURRENT <axis number>

Cause --
Monitor --
Effect --
Remedy --
1226 Message text ACKN. E<2 or 7 keyswitch> SWITCH CLOSED

Cause --
Monitor --
Effect --
Remedy --
1227 Message text ACKN. E<2 or 7 keyswitch> SWITCH OPEN

Cause --
Monitor --
Effect --
Remedy --
1228 Message text ACKN. FEEDBACK SWITCH ON TOO LONG **

Cause -- The energy of the axis to be braked was too high.


Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
1229 Message text ACKN. WATCHDOG POWER MODULE <number>

Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Troubleshooting in the DSE and power module area.
1230 Message text ACKN. OVERTEMPERATURE, BALLAST RESISTOR <number> OR
FAN
Cause -- The ballast (feedback) resistor has overheated. In the motion program
the robot is cyclically accelerated and decelerated without a break.

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Error messages / troubleshooting

Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.
1231 Message text ACKN. CABINET OVER TEMPERATURE **

Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.
1232 Message text ACKN. MOTOR CABLE **

Cause --
Monitor --
Effect --
Remedy --
1233 Message text ACKN. FAILURE OF HEAT SINK TEMPERATURE SENSOR <axis
number>
Cause --
Monitor --
Effect --
Remedy --
1234 Message text ACKN. CABINET INTERIOR TEMPERATURE SENSOR FAILURE
<axis number>
Cause --
Monitor --
Effect --
Remedy --
1235 Message text ACKN. DRIVES PARAMETER DATA <axis number> INVALID

Cause --
Monitor --
Effect --
Remedy --
1236 Message text ACKN. FAILURE OF MOTOR TEMPERATURE SENSOR <axis number>

Cause --
Monitor --
Effect --
Remedy --

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1 Error messages / troubleshooting (continued)

1237 Message text ACKN. WRONG DRIVES PARAMETER <axis number> **

Cause --
Monitor --
Effect --
Remedy --
1238 Message text ACKN. ERROR SYNC. INPUT DRIVE <axis>

Cause --
Monitor --
Effect --
Remedy --
1239 Message text ACKN. SYNCHRONISATION ERROR DRIVE <axis>

Cause --
Monitor --
Effect --
Remedy --
1240 Message text ACKN. <axis> WITHOUT POWER

Cause --
Monitor --
Effect --
Remedy --
1241 Message text ACKN. i2 t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string> AFTER <string>s EXCEEDED 100%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
1242 Message text ACKN. i2 t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
** AFTER ** EXCEEDED 95%
Cause --
Monitor --
Effect --
Remedy --
1243 Message text LINE ** IN ** TOO LONG. LINE WAS CUT OFF.

Cause -- An excessively long program line was cut off in order to avoid deletion
of the rest of the program.
Monitor -- Triggered during line compilation.
Effect -- The line is cut off. The program is retained.
Remedy -- Modify the incorrect line in expert mode.

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Error messages / troubleshooting

1244 Message text SUCCESS LOADING ** SERVO PARAMETERS **

Cause -- Completed loading of servo parameters.


Monitor --
Effect --
Remedy --
1245 Message text ACKN SERVO BUS DISTURBANCE DSE **

Cause --
Monitor --
Effect --
Remedy --
1246 Message text ACKN SERVO BUS DISTURBANCE DSE **, NO BUFFERING AND
AUTOMATIC DATA STORAGE POSSIBLE
Cause --
Monitor --
Effect --
Remedy --
1247 Message text ACKN SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
1248 Message text ACKN SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
1254 Message text Ackn. PC fan error

Cause -- PC fan speed was below the alarm threshold and is now back in the
nominal range
Monitor -- Cyclic.
Effect -- None
Remedy -- Acknowledge message
1255 Message text Ackn. Ixt servo drive %1 exceed value of %2 %%

Cause -- If the defined Ixt monitoring warning value of a drive servo is exceeded,
the robot must be brought to a standstill; otherwise, the drive servo is
deactivated when the maximum value of 100% is exceeded
Monitor --
Effect --
Remedy -- Acknowledge message

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1 Error messages / troubleshooting (continued)

1300 Message text PARITY ERROR

Cause -- Parity incorrectly set.


Monitor -- On transmission.
Effect -- None.
Remedy -- Check parity setting on controller and operator control unit (PC).
1301 Message text PROCEDURE ERROR

Cause -- Transmission error in LSV2 procedure which was not detected by


the parity monitor.
Monitor -- On transmission.
Effect -- None.
Remedy -- Repeat transmission.
-- Increase procedure repetition counter.
-- Check cable.
1302 Message text CHANNEL NOT AVAILABLE

Cause -- Procedure monitoring time elapsed.


Monitor -- On transmission.
Effect -- None.
Remedy -- Increase procedure monitoring time.
1303 Message text SCC OVERFLOW

Cause -- Baud rate set too high (SCC = Serial Communication Controller).
Monitor -- On transmission.
Effect -- None.
Remedy -- Reduce baud rate.
1304 Message text REFERENCING AXIS <axis number> INADMISSIBLE

Cause -- Attempt to reference a non--incremental axis.


Monitor -- During single--axis referencing.
Effect -- The specified axis is not referenced.
Remedy -- Master the axis.
1305 Message text RCP SWITCH POSITION INADMISSIBLE

Cause -- Too many transfer processes started (a maximum of 4 transfer pro-


cesses can be started.)
Monitor -- During transfer.
Effect -- None.
Remedy -- Wait until one process has been completed.
-- Stop one process.

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Error messages / troubleshooting

1306 Message text DEVICE NOT READY

Cause -- Cable defective or not connected.


-- Device switched off (e.g. printer).
Monitor -- During transfer.
Effect -- None.
Remedy -- Check cable and device.
1307 Message text FORMAT ERROR

Cause -- Hardware error of the interface on I--CPU.


Monitor -- During transfer.
Effect -- None.
Remedy -- If the error occurs repeatedly, change the board (interface CPU).
1308 Message text CHANNEL NOT ALLOWED IN COMMAND

Cause -- Command does not support any channels.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1309 Message text OBJECT IS NOT AVAILABLE

Cause -- Objects that are not available in the KRC cannot be addressed.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Wrong object selected.
1310 Message text TOO MANY OBJECTS ARE SELECTED

Cause -- Too many objects selected.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select only the permitted number of objects (approx. 150).
1311 Message text <object name> NOT CORRECTLY COPIED

Cause -- Errors have been detected in the line analysis.


Monitor -- In command processing.
Effect -- Error token in the object.
Remedy -- Correct object.

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1 Error messages / troubleshooting (continued)

1312 Message text <object name> ASSIGNED

Cause -- Object cannot be processed in this state (object already assigned).


-- Module package cannot be linked since at least one of the objects
of the module package is assigned.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1313 Message text INVALID STATEMENT

Cause -- The source and target specifications do not conform to the convention
for “COPY”.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Specify the source and target correctly.
1314 Message text DATA NOT ALLOWED

Cause -- Extension not compatible.


-- copy *.* (copy *.* is possible into a directory only).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Specify extension correctly.
1315 Message text <module name> IS NOT A MODULE

Cause -- The name represents a directory.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Take a different module.
1316 Message text RUNTIME VALUES FOR TRIGGER IN SUBROUTINES INADMISSIBLE

Cause -- In a subroutine a trigger is defined which is possibly not activated until


the main program. If runtime values are used in trigger assignment,
they are not valid at the time of activation.
Monitor -- During program execution.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Alter program, use only global variables, acknowledge message.
1317 Message text DELETING OF SYSTEM FILES IS INADMISSIBLE

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

1318 Message text FILE DESCRIPTION CANNOT BE PROCESSED

Cause -- Module information that cannot be evaluated has been received in a


COPY operation from an external source.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check interface software.
1319 Message text <object> CANNOT BE CORRECTED

Cause -- An invalid extension has been specified (only “DAT” is allowed).


-- An attempt has been made to transmit or edit a protected file.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select data list.
-- Set INIT switch on I--CPU to position 3.
1320 Message text EXTENSION NOT ALLOWED

Cause -- An extension has been specified in a command where it is not allowed


(e.g. analyse otto.src).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.
1321 Message text <path> IS NOT A DIRECTORY

Cause -- Command contains an invalid subdirectory (e.g. dir /R1/otto/abc,


/abc not allowed).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.
1322 Message text <module> NOT LINKED

Cause -- “UNLINK” has been applied to an object that is not a program.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1323 Message text <path> INVALID DATA MODULE NAME OR EXTENSION

Cause -- An invalid path, module name or extension has been specified.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.

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1 Error messages / troubleshooting (continued)

1324 Message text <object> NOT AVAILABLE

Cause -- An object that is not available has been addressed.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Create the object.
1325 Message text <object> CANNOT BE PROCESSED

Cause -- An object that has already been assigned has been addressed.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Free the assignment (/R1/CONFIG>DAT).
1326 Message text <object> : <number of errors> COMPILATION ERROR

Cause -- The indicated number of errors have been detected in the indicated
object during total compilation.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct the errors.
1327 Message text <module> LINKING ERROR

Cause -- One or more errors have been detected in the indicated module
during linking.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Using the error list, correct the error(s).
1328 Message text FAULTY FILE

Cause -- Module is not correct for TTS calculation.


Monitor -- In command processing.
Effect -- None.
Remedy --
1329 Message text ACCESS TO IMPORTED VARIABLE IS NOT POSSIBLE

Cause -- The search path has not been extended to the external data list.
Monitor -- In command processing.
Effect -- Command has not been executed.
Remedy -- Extend the search path.
1330 Message text SOURCE AND TARGET OBJECT ARE IDENTICAL

Cause -- The source and target specifications define the same object.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Change target object.

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1331 Message text <module> NOT CORRECT

Cause -- An incorrect module has been selected in a linking operation.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct the error in the indicated module (perform ANALYSE).
1332 Message text Line selection not possible: too many Interrupts

Cause -- An attempt has been made to carry out a block selection in a local
subprogram that is not in the caller stack. At this point, the maximum
permissible number of interrupts that can be declared or activated was
exceeded.
Monitor --
Effect -- Block selection to the subprogram is not possible.
Remedy -- Reduce the number of KRL interrupts accordingly.
1333 Message text <object> CANNOT BE DELETED

Cause -- Object cannot be deleted because it is write--protected.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1334 Message text MORE THAN 16 INTERRUPTS DEFINED

Cause -- Program instruction INTERRUPT ON can switch on a maximum of


16 defined interrupts but more than 16 are defined.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Reduce number.
1335 Message text <module> SELECTED

Cause -- Program cannot be unlinked; module is selected with “RUN”.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Terminate program run (CANCEL).
1336 Message text COR ARE FOR DATA LISTS ONLY

Cause -- COR is allowed for data lists only.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select a data list.
1337 Message text TOO COMPLEX

Cause -- Copying from one channel to another (not allowed in SWP1).


Monitor -- In command processing.
Effect -- Command is not executed.

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1 Error messages / troubleshooting (continued)

Remedy -- None.
1338 Message text BLOCK CANNOT BE CORRECTED

Cause -- TTS or BASE calculation cannot be performed. (TTS = tool--based


technological system).
Monitor -- In command processing.
Effect -- None.
Remedy
1339 Message text UNKNOWN EXTERNAL MESSAGE (<external message number>)

Cause -- It has not been possible to convert an external message (e.g. from
the interface CPU, PSX) into an RCX message.
Monitor -- In command processing.
Effect -- None.
Remedy -- Acknowledge message.
1340 Message text NOT ALLOWED REFERENCE SYSTEM

Cause -- The reference system for manual motion is not possible for the kine-
matic system.
Monitor -- At start.
-- With traversing keys.
Effect --
Remedy -- Select a different reference system (TRANSSYS).
1341 Message text REFERENCE SYSTEM DEFINITION NOT COMPLETE

Cause -- At least one frame required for calculating the reference matrix has
not been assigned.
Monitor -- In cartesian motion commands (e.g. MOVE, PTP, LIN).
Effect
Remedy
1342 Message text WORK ENVELOPE EXCEEDED

Cause -- Working zone limit has been exceeded.


Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1343 Message text SYNC()--CALL NOT PROGRAMMED

Cause -- In IRSTOPMESS, the user has failed to respond to $Power--Fail by


calling the SYNC() function.
Monitor -- During power failure.
Effect -- None.
Remedy -- Correct the application program.
1344 Message text Robot system is not available

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Cause -- No second robot system activated in the machine data (command:


$HOME = “/R2”)
Monitor -- During command execution.
-- During program execution.
Effect -- In command execution
a) The command is not executed.

-- In program execution
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter machine data.
-- Acknowledge message.
1345 Message text CHANGE REFERENCE DIRECTION <axis number>

Cause -- During single--axis referencing the wrong direction key was pressed,
depending on machine datum $DIR_CAL.
-- All axes are mastered.
Monitor -- During referencing.
Effect -- Axis cannot be referenced in this direction.
Remedy -- Carry out referencing in the other direction.
1346 Message text INADMISSIBLE MASTERING SEQUENCE

Cause -- The mastering sequence was not adhered to (depending on machine


datum $SEQ_CAL).
Monitor -- During mastering.
Effect -- Axis cannot be mastered.
Remedy -- Observe mastering sequence.
1347 Message text ROBOT NOT MASTERED

Cause -- Selection of a program without the robot being mastered.


-- Start of a program without the robot being mastered.
Monitor -- In command processing.
-- In program processing.
Effect --
Remedy -- Master the robot.
-- Acknowledge message.
1348 Message text <axis number> AXIS SYNCHRONIZED

Cause -- In single--axis referencing, an attempt has been made to reference


an axis which has already been referenced.
Monitor -- During referencing.
Effect -- The axis is not referenced.
Remedy -- Select the next axis which has not been referenced.
1349 Message text ROBOT MASTERED

Cause -- All axes mastered.

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1 Error messages / troubleshooting (continued)

Monitor -- In mastering.
Effect -- Robot is mastered.
Remedy --
1350 Message text BCO REACHED

Cause -- After the first position in the user program has been reached.
-- After repositioning ($POS_RET, $AXIS_RET, $POS_FOR,
$AXIS_FOR, etc.).
Monitor -- With BCO travel.
Effect -- Signalling that BCO has been achieved.
Remedy -- None.
1351 Message text DRIFT COMPENSATION ABORTED

Cause -- The drift compensation was interrupted by a stop (Stop key, message
triggering a stop).
Monitor -- Cyclic for the duration of drift compensation.
Effect -- Drift compensation failed (dynamic braking).
Remedy -- Repeat drift compensation.
1352 Message text AXIS <axis number> INHIBITED

Cause -- An attempt has been made to move an axis in the inhibited direction
(inhibited by software limit switch).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Move axis off limit switch in other direction.
1353 Message text KEY COMBINATION <KCP> INADMISSIBLE

Cause -- Simultaneous pressing of more than one key on the KCP.


Monitor -- Cyclic.
Effect -- KCP operation momentarily interrupted.
Remedy -- Release all keys on the KCP.
1355 Message text DEADMAN SWITCH REQUIRED

Cause -- The safety (deadman) switch has not been pressed while actuating
the start or traversing key in mode T1 or T2.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Press safety switch.
1356 Message text START KEY REQUIRED

Cause -- The “START” command has been entered textually.


-- Execution of the command requires the start key to be pressed.
Monitor -- In command processing.
Effect -- None.

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Error messages / troubleshooting

Remedy -- Press start key.


-- External computer: check job identification.
1357 Message text RESET REQUIRED

Cause -- RUN has been applied to a process in the end state.


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- RESET program.
-- In program processing the message has to be acknowledged.
1358 Message text SELECTION REQUIRED

Cause -- Start key pressed without a program being selected.


-- “RUN” without path specification and no program is selected.
Monitor -- When start key is pressed.
-- At RUN command.
Effect -- Command is not executed.
Remedy -- Select program.
1359 Message text TTS CANNOT BE DETERMINED

Cause -- Termination of search for the path direction point. (TTS = tool--based
technological system).
Monitor -- In command processing.
Effect -- None.
Remedy --
1360 Message text SELECTION NOT ALLOWED

Cause -- Selected block does not exist in the program.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select correct block number.
1361 Message text STOP DUE TO NODE SWITCHOVER

Cause -- The node setting has been changed during actuation of a traversing
key or execution.
Monitor -- In command processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1362 Message text STOP DUE TO OPERATING MODE CHANGE

Cause -- Active processes are stopped if the mode is changed.


Monitor -- Cyclic.

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1 Error messages / troubleshooting (continued)

Effect -- Path--maintaining Emergency Stop.


Remedy -- Acknowledge message.
1363 Message text OPERATOR CONTROL UNIT DISABLED

Cause -- Command cannot be executed because the KCP settings do not


fulfil the conditions.
a) For RCP and stationary KCP the mode AUT is required.
b) For non--stationary KCP the mode T1 or T2 is required.
c) For host computers the mode EXT is required.
Monitor -- In command processing.
Effect -- Command cannot be executed.
Remedy -- Fulfil the “active” conditions.
1364 Message text OUT PARAMETERS INADMISSIBLE

Cause -- Trigger with subprogram call where reference parameters are trans-
ferred.
Monitor --
Effect --
Remedy -- Correct program, acknowledge.
1365 Message text PATH TRIGGER WITH PTP MOTION INADMISSIBLE

Cause -- Path triggers are not permissible with PTP motions.


Monitor --
Effect -- Program execution is stopped.
Remedy -- Correct program, acknowledge, reboot.
1366 Message text CARTESIAN TARGET NOT POSSIBLE

Cause -- When using a 5--axis robot ($DEF_A4FIX=TRUE) and palletizing


mode is deactivated ($PAL_MODE=FALSE), only PTP motions with
an axis--specific target may be carried out.
Monitor -- In the line interpreter.
Effect -- Path--maintaining braking.
Remedy --
1367 Message text ACTIVE STATUS REQUIRED

Cause -- The command entered may only be issued from an active operator
control unit (modes T1, T2, AUT).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to active status.
1368 Message text <operator control device> IS ACTIVE

Cause -- Indicated operator control unit is active.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch indicated operator control unit to passive status.

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Error messages / troubleshooting

1369 Message text ACTIVE ALLOWED IN <mode> ONLY

Cause -- For RCP and stationary KCP the mode AUT is required.
-- For non--stationary KCP the mode T1 or T2 is required.
-- For host computers the mode EXT is required.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set the correct mode.
1370 Message text PASSIVE STOP

Cause -- Stop from a passive operator control unit (the message is displayed
only if an active process has been stopped).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message (acknowledgement possible only on the
originating unit, even in passive status).
1371 Message text STOP DUE TO UNIT PASSIVE

Cause -- The operator control unit has been deactivated during actuation of
the start key or a traversing key in mode T1 or T2, or during the
BCO run.
Monitor -- In command processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch operator control unit to active status.
-- Acknowledge message.
1372 Message text PROCESS ACTIVE

Cause -- An attempt has been made to start an active command during an


active process.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Wait until end of processing.
-- Stop active processing.
-- In program processing the message has to be acknowledged.
1373 Message text PROCESS BUSY

Cause -- Program already selected.


Monitor -- In command processing.
-- In program processing.

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1 Error messages / troubleshooting (continued)

Effect -- In command processing


-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Deselect program already selected.
-- In program processing the message has to be acknowledged.
1374 Message text PROCESS DISABLED

Cause -- All selected processes have the program mode “DISABLED” or a


non--disabled process is finished.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Alter program mode.
1375 Message text COMMAND NOT ALLOWED

Cause -- Impermissible or unknown command.


Monitor -- In command processing.
Effect -- None.
Remedy -- Enter command correctly.
1376 Message text ACTIVE COMMANDS INHIBITED

Cause -- A message which causes the active commands to be inhibited has


been set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Acknowledge active messages in the message window.
1377 Message text COMMAND EXECUTION NOT POSSIBLE

Cause -- A preceding command is still being processed.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Cancel command.
-- Wait until end of preceding command.
1378 Message text COMMAND NOT BEING PROCESSED

Cause -- The command that is to be cancelled has already been processed.


Monitor -- In command processing.
Effect -- None.
Remedy -- None.
1379 Message text COMMAND ABORTED

Cause -- The command has been cancelled.


-- During editing abort has been selected by the editor kernel before
the command concerned (ERASE,GET,FIND) is called.

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Error messages / troubleshooting

Monitor -- In command processing.


-- In editing.
Effect --
Remedy --
1380 Message text BACKGROUND PROCESS BUSY WITH <operator control device>

Cause -- The background is exclusively assigned to another operator.


Monitor -- In command processing.
Effect -- Background cannot be exclusively assigned.
Remedy -- Cancel the exclusive assignment of the indicated device.
-- Provide complete specifications in $OPTION.DAT.
1381 Message text BACKGROUND OCCUPIED

Cause -- A command is already being processed in the background.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Cancel command.
-- Wait until command has been executed.
1382 Message text ABORTED

Cause -- “BREAK” has been repeated.


Monitor -- In command processing.
Effect -- None.
Remedy -- None.
1383 Message text ** IS NOT A MEMORY DUMP

Cause -- When writing a data block (a file received from the controller or a
temporary file created by the server), it has been discovered that there
is not enough space available on the storage medium (hard disk).
Monitor
Effect -- The currently edited file is deleted.
Remedy -- Create space on the storage medium
(delete files that are no longer required).
1384 Message text PARAMETER NOT PROCESSED

Cause -- A RUN command with a parameter has been executed for a program
that is already selected.
Monitor -- In command processing.
Effect -- The parameter is not evaluated.
Remedy -- Cancel and reselect the program.
1385 Message text PROTOCOL ERROR

Cause -- Error in the protocol software of the operator control unit or output
device.
Monitor -- In command processing.
Effect -- The command is aborted.

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1 Error messages / troubleshooting (continued)

Remedy -- Check protocol software.


1386 Message text INTERRUPT--UP: MAX. 10 ARGUMENTS ADMISSIBLE

Cause -- More than 10 arguments have been specified.


Monitor --
Effect --
Remedy -- Reduce the number of arguments to the maximum permissible number.
1387 Message text VARIABLE TOO LARGE

Cause -- The variable specified in SHOW VAR or SET INFO is too complex
or too large (e.g. field is larger than the display).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Subdivide the request into several sections.
1388 Message text <string> VARIABLE WRITE PROTECTED IN MODULE <string> LINE
<string>
Cause -- In a program module an attempt was made to change a write--
protected variable.
Monitor -- In program mode.
Effect --
Remedy --
1389 Message text OPTION <option name> MISSING

Cause -- The option has not been entered.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Enter the option.
1390 Message text CIRC ANGLE NOT ACCEPTED

Cause
Monitor
Effect -- None.
Remedy
1391 Message text Access to component not allowed

Cause -- Illegal access to a component of the program/motion trace


(e.g. SHOW VAR $PRO_TRACE[5].NAME[2]).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy
1392 Message text WRITE PROTECTION DUE TO PROCESS STATUS

Cause -- Write access to a “$” variable with an illegal process status


(active, not active, RC Ready).
Monitor -- In command processing.

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Effect -- Command is not executed.


Remedy -- Set a permissible process status.
1393 Message text WRITE PROTECTION DUE TO OPERATOR CONTROL UNIT
STATUS
Cause -- An attempt has been made to write a “$” variable with the operator
control unit status incorrectly set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to “active” status.
1394 Message text READ PROTECTION DUE TO PROCESS STATUS

Cause -- Reading of a “$” variable with an inadmissible process status


(active, not active, RC ready).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set a permissible process status.
1395 Message text READ PROTECTION DUE TO OPERATOR CONTROL UNIT STATUS

Cause -- Reading of a “$” variable with the operator control unit status incorrectly
set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to “active” status.
1396 Message text PROGRAM NOT LINKED

Cause -- Selection of a non--linked program.


Monitor -- At selection.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Link the program.
-- In program processing the message has to be acknowledged.
1397 Message text MEMORY REQUEST FOR PARAMETER LIST TOO LARGE

Cause -- The transfer parameters of the program require too much memory.
Monitor -- During command execution.
Effect --
Remedy -- Acknowledge message, correct program, reselect program.
1398 Message text Check rcp selector switch

Cause -- The selector switch on the RCP is not set to “RUN” in the case of
selection or start from another operator control unit.
Monitor -- In command processing.
Effect -- Command is not executed.

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1 Error messages / troubleshooting (continued)

Remedy -- Turn the selector switch on the RCP to “RUN”.


1399 Message text MESSAGE CANNOT BE ACKNOWLEDGED

Cause -- Acknowledgement of a status (operational) message.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None. Read the message.
1400 Message text Message not available

Cause -- Textual acknowledgement of a message that is not available.


Monitor -- In command processing.
Effect -- Command cannot be executed.
Remedy --
1401 Message text Control structure next block <block number>

Cause -- Selection into a control structure.


Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
-- The control structure is exited when the end is identified.
Remedy -- Acknowledge message.
1402 Message text Select startup

Cause -- A command has been entered that is only allowed in the startup mode.
Monitor -- With all commands of the startup mode.
Effect -- Command is not executed.
Remedy -- Select the startup mode.
-- Acknowledge message.
1403 Message text Interrupt instruction aborted

Cause -- Motion instruction in the interrupt routine that is executed after an error
stop. The interrupt module that is called after an error stop may not
contain any motion instructions.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Modify interrupt module accordingly.
-- Acknowledge message.
1404 Message text Edit commands now allowed

Cause -- The user is in the mode “Editing without implicit block selection”, and
after completion of the current motion block has received an editor
enable. The object is write--protected.
Monitor -- During command execution.
Effect --
Remedy -- Note: editing is now possible.

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1405 Message text <object name> is write protected

Cause -- Object is write--protected.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check object status (e.g. unlink or deselect object).
1406 Message text Error in path

Cause -- Error in path specification e.g. /R5.


Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check and correct path specification.
1407 Message text Edit commands inadmissible, finish movement first

Cause -- The user tries to edit a program while in mode “Editing without implicit
block selection”. The user is still located in a motion instruction.
Monitor -- During command execution.
Effect -- Editing is not possible.
Remedy -- Press the Start key again until the message “Edit commands now
allowed” appears. Editing is then possible.
1408 Message text Line compilation or decompilation error

Cause -- Message will soon be deleted.


Monitor
Effect -- No effect.
Remedy
1409 Message text No trigger allowed in ISR or *.SUB

Cause -- Trigger was programmed in interrupt or SUB module.


Monitor -- Program execution.
Effect -- Program execution stopped, all active commands inhibited.
Remedy -- Correct program, acknowledge message.
1410 Message text Program line does not exist

Cause --
Monitor --
Effect --
Remedy --

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1 Error messages / troubleshooting (continued)

1411 Message text Line selection beyond buffer: Next start deletes buffer.

Cause -- Line selection outside the trace.


Monitor -- During line selection.
Effect -- When the Start key is pressed, the buffer for backward motion is
deleted.
Remedy -- Before pressing the Start key, make another line selection within the
buffer. After that the backward motion can be carried out.
1412 Message text Axis <axis number> acceleration not programmed

Cause -- No value has been assigned to the program datum “$ACC_AXIS”.


Monitor -- When starting a PTP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1413 Message text Axis <axis number> velocity not programmed

Cause -- No value has been assigned to the program datum “$VEL_AXIS”.


Monitor -- When starting a PTP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1414 Message text Path acceleration not programmed

Cause -- No value has been assigned to the program datum “$ACC.CP”.


Monitor -- At the first CP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1415 Message text Path velocity not programmed

Cause -- No value has been assigned to the program datum “$VEL.CP”.


Monitor -- At the first CP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1416 Message text Orientation acceleration not programmed

Cause -- No value has been assigned to the program data “$ACC.ORI1” and
“$ACC.ORI2”.
Monitor -- At the first CP block.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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Error messages / troubleshooting

1417 Message text Orientation velocity not programmed

Cause -- No value has been assigned to the program data “$VEL.ORI1” and
“$VEL.ORI2”.
Monitor -- At the first CP block.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1418 Message text <X,Y,Z,A,B,C> BASE not programmed

Cause -- No value has been assigned to the program datum “$BASE”.


-- in a user program
-- after overall reset of the control for a cartesian command.
Monitor -- With a cartesian motion.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- In command processing
-- Assign a value to “$BASE”.
-- In program processing
-- Alter the program accordingly
-- Acknowledge message.
1419 Message text <X,Y,Z,A,B,C> TOOL not programmed

Cause -- No value has been assigned to the program datum “$TOOL”


-- in a user program
-- after overall reset of the control for a cartesian command.
Monitor -- With a cartesian motion.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- In command processing
-- Assign a value to “$TOOL”.
-- In program processing
-- Alter the program accordingly
-- Acknowledge message.
1420 Message text Approximation not programmed <approximation criterion>

Cause -- No value has been assigned to the program data “$APO.VEL”,


“$APO.ROB”, “$APO.DIS”, and/or “$APO.ORI”.
Monitor -- When starting the first motion block with approximate positioning.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1 Error messages / troubleshooting (continued)

1421 Message text <file> : <number> compilation error

Cause -- Compilation error due to unrecognized data type can occur in the case
of global self--defined data types and ENUMs. This means that the GUI
must initiate a second download.
Monitor -- During command execution.
Effect -- When this error is caused by global types, it can be corrected by down-
loading the files twice.
Remedy -- The GUI filters out the error number and initiates the double download
for the file in question.
1422 Message text <$ variable> invalid value

Cause -- Read access to a variable that is not initialized or that has an invalid
value, e.g. reading of “$POS_INT” outside an interrupt routine.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1423 Message text Overflow

Cause -- Value is not compatible with the specified data type, e.g. value
assignment of a number >255 to the data type “char”.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter data type.
-- Acknowledge message in program processing.
1424 Message text PROGRAM STACK OVERFLOW

Cause -- The nesting depth for subprograms and functions has been
exceeded.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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Error messages / troubleshooting

1425 Message text Instruction not allowed

Cause -- Program instruction that is not allowed as a command.


-- Program instruction that is only allowed in an interrupt routine.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1426 Message text Variable stack depth exceeded

Cause -- The nesting depth of the variable has been exceeded.


Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the variable accordingly.
-- Acknowledge message.
1427 Message text $OUT_C[N] IS NOT PERMISSIBLE IN INTERRUPT PROGRAMS

Cause -- Instruction not permissible here


Monitor --
Effect -- Interpreter stop
Remedy -- Revise SRC file and acknowledge message
1428 Message text Function value not defined

Cause -- RETURN instruction missing in the function module.


Monitor -- In the program.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Insert a RETURN instruction.
1429 Message text String too long

Cause -- In a value assignment to arrays, the string consists of more characters


than the existing array.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1 Error messages / troubleshooting (continued)

1430 Message text <Interrupt or Trigger> not defined

Cause -- An interrupt that has not been defined has been switched on.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Define interrupt.
-- Acknowledge message.
1431 Message text Selection not possible

Cause -- Selection of the editor is not possible.


The file may not exist or it may have the attribute “hidden”.
Monitor
Effect
Remedy -- Check whether the file exists (e.g. when attempting to open a file
in the view mode) or has the attribute “hidden”.
1432 Message text Max. no. of interrupts defined

Cause -- More than 32 interrupts have been defined.


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program accordingly.
1433 Message text Max. no. of interrupts on

Cause -- More than 8 interrupts have been switched on.


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program accordingly.

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Error messages / troubleshooting

1434 Message text Target point not reached

Cause -- The contour cannot be determined when selecting a CIRC block


with a circle angle. A LIN motion to the programmed target point is
executed when the robot is started.
Monitor -- In program processing.
Effect -- The next motion is also a BCO run.
Remedy -- None.
1435 Message text Read protection

Cause -- A “$” variable that is not admissible for the selected interpreter type
has been read.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- In program processing the message has to be acknowledged.
1436 Message text Disk write protected

Cause -- The write protection is activated.


Monitor
Effect -- It is not possible to save data on the floppy disk.
Remedy -- Remove the write protection.
1437 Message text Reposition

Cause -- BCO was not achieved on returning from the interrupt routine. The
robot must be repositioned to the interrupt point before the end of the
interrupt routine, e.g. with LIN $POS_RET.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1438 Message text Data storage device not ready: ...

Cause -- There is no disk inserted or the floppy disk drive is defective.


Monitor
Effect -- It is not possible to save to floppy disk.
Remedy -- Insert floppy disk into the disk drive in; check disk drive.

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1 Error messages / troubleshooting (continued)

1439 Message text <variable name> argument inadmissible

Cause -- At least one argument in the function is inadmissible; e.g. SQRT


(negative value).
Monitor -- In interpretation of C functions.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1440 Message text Mailbox identification not allowed

Cause -- An incorrect MBX_ID is specified in the C function “MBX_REC”.


Monitor -- In interpretation of “MBX_REC”.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1441 Message text Interrupt priority not allowed

Cause -- Interrupt priority greater than 128 or less than 1


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program accordingly.
1442 Message text Approximation not allowed for instructions

Cause -- “DRIFT”, “$TOOL” or “$FILTER” is programmed between two motion


instructions.
Monitor -- In program processing.
Effect -- Approximate positioning is not performed for the motion instructions.
Remedy -- Alter the program accordingly.

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Error messages / troubleshooting

1443 Message text Start movement not allowed

Cause -- The first motion instruction in the program is relative.


-- The first motion instruction in the program is not programmed
completely, e.g. PTP [33.33].
Monitor -- In program processing.
Effect -- No program motion.
Remedy -- Alter the program.
-- Acknowledge message.
1444 Message text Array index inadmissible

Cause -- An attempt has been made to access an array element that does
not exist.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
Acknowledge message.
1445 Message text Angle status inadmissible

Cause -- After repositioning with LIN the angle status does not agree with the
status of the programmed block.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Perform repositioning with PTP.
1446 Message text Value assignment not allowed

Cause -- Inadmissible value assignment for predefined variables,


e.g. $SPEED.ORI1 <= 0.0 or > $SPEED_MA.ORI1.
-- Assigned $BASE or $TOOL not possible for the kinematic system.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1 Error messages / troubleshooting (continued)

1447 Message text Software limit <motion direction> <axis number> out of range

Cause -- Target point cannot be reached due to a software limit switch.


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1448 Message text <Name> ambiguous

Cause -- The specified memory dump name contains wildcards. Expansion of


these wildcards has resulted in more than one valid file name. This is
not allowed however.
Monitor
Effect -- Data transfer is not carried out.
Remedy -- Specify an unambiguous name.
1449 Message text <$variable> variable write protected

Cause -- Write access to a write--protected variable e.g. “$POS_ACT”.


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1450 Message text Transformation not configured

Cause -- $BASE or $TOOL has been assigned although no transformation is


configured.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.

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Error messages / troubleshooting

1451 Message text Division by 0

Cause -- An attempt has been made to divide a value by “0”.


Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1452 Message text Backward motions not active

Cause -- Backward motion is deactivated ($VW_BACKWARD = FALSE).


Monitor -- When START MINUS key is pressed.
Effect -- Command is rejected.
Remedy -- Set variable $VW_BACKWARD to TRUE.
1454 Message text Start continue not possible

Cause -- BSTEP
Monitor -- In command processing.
Effect -- None.
Remedy --
1455 Message text Inadmissible in this edit mode

Cause -- A command that would alter the object has been entered in the listing
mode of the editor.
-- An attempt has been made in the data correction mode to delete or
copy a range of blocks or to delete a block consisting of only one line.
Monitor -- In the editor.
Effect -- The attempted action is not executed.
Remedy -- Edit in full edit mode.
1456 Message text Start point equal to end point

Cause -- Distance between start point and end point is too small.
Monitor -- During preparation.
Effect -- Ramp--down braking.
-- Active commands inhibited.
Remedy -- Reprogram start point and/or end point.
-- Acknowledge message.

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1 Error messages / troubleshooting (continued)

1457 Message text Start point equal to mid point

Cause -- Distance between start point and auxiliary point is too small.
Monitor -- During preparation.
Effect -- Ramp--down braking.
-- Active commands inhibited.
Remedy -- Reprogram start point and/or auxiliary point.
1458 Message text Mid point equal to end point

Cause -- Distance between auxiliary point and end point is too small.
Monitor -- During preparation.
Effect -- Ramp--down braking.
-- Active commands inhibited.
Remedy -- Reprogram auxiliary point and/or end point.
1459 Message text Backward motions not possible: finished subroutine

Cause -- An attempt was made to carry out backward a motion located inside
a subprogram which has already been executed.
Switching to forwards in this subprogram would not be possible.
Backward motion is thus also disabled.
Monitor -- When the “Start backwards” key is pressed.
Effect -- Command is not executed.
Remedy -- Forward motion.
1460 Message text Deleting Trace: no backward motions possible

Cause -- Editing was carried out or a block selection was made at a position
which causes the trace to be discarded.
From now on backward motion is no longer possible.
Monitor -- When the “Start backwards” key is pressed.
Effect -- Command is not executed.
Remedy -- Forward motion.
1462 Message text Command syntax error

Cause -- The command contains a syntax error.


Monitor -- In the editor.
Effect -- Command is not executed.
Remedy -- Correct the command.
1463 Message text Object not ready

Cause -- Program cannot be processed by the editor.


Monitor -- In the editor.
Effect -- Command is not executed.
Remedy -- Select program with “Edit”.

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Error messages / troubleshooting

1464 Message text $OUT_C[N] IS NOT PERMISSIBLE IN SUBMIT

Cause -- Instruction not permissible here


Monitor --
Effect -- Interpreter stop
Remedy -- Revise SRC file and acknowledge message
1465 Message text ONLY 8 $OUT_C[N] ASSIGNMENTS PER MOTION PERMISSIBLE

Cause -- Instruction not permissible here


Monitor --
Effect -- Interpreter stop
Remedy -- Revise SRC file and acknowledge message
1468 Message text Key not assigned

Cause -- An unassigned softkey or function key has been pressed during


prompted operation.
Monitor -- When a softkey is pressed.
-- When a function key is pressed.
Effect -- None.
Remedy -- None.
1472 Message text Key not allowed

Cause -- Impermissible key (e.g. softkey) pressed in textual operation.


-- Alphanumeric key pressed in prompted operation when no input field
is available.
Monitor -- When a key is pressed.
Effect -- Entry is ignored.
Remedy -- Acknowledge the message.
1474 Message text Change of direction not possible

Cause
Monitor -- In command processing.
Effect -- None.
Remedy
1477 Message text Main process not available

Cause -- Main run display (motion trace) selected but no main run block inter-
preted yet.
Monitor -- In command processing.
Effect -- None.
Remedy -- Start the program.

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1 Error messages / troubleshooting (continued)

1478 Message text Pre process not available

Cause -- Advance run display (program trace) selected but no program is in the
STOP or END state.
Monitor -- In command processing.
Effect -- None.
Remedy -- Start the program.
1481 Message text No runtime data access

Cause -- Access to an invalid or non--existent object value memory or runtime


data area via the hierarchy table (search path).
Monitor -- In the interpreter (prim -- init).
Effect -- None.
Remedy -- Set the search path to the current interpreter environment.
1482 Message text Volume too small

Cause -- Monitoring of the dispensed volume has been triggered. Insufficient


adhesive has been dispensed.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1483 Message text Excessive volume

Cause -- Monitoring of the dispensed volume has been triggered. Too much
adhesive has been dispensed.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1484 Message text Wrong adhesive pressure

Cause -- The initial pressure of the adhesive is continuously monitored by the


PLC during dispensing. A pressure value outside the permissible
tolerance range has been detected. Possibly there are bubbles in the
adhesive supply line, or the outlet nozzle is clogged.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1485 Message text Oil filter dirty

Cause -- The hydraulic pressure is no longer adequate because the hydraulic


oil filter is dirty.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Clean or replace oil filter.

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Error messages / troubleshooting

1486 Message text Max. oil temperature exceeded

Cause -- The maximum permissible hydraulic oil temperature has been ex-
ceeded.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Wait until the hydraulic oil has cooled down.
-- If this situation occurs frequently, check the hydraulic unit.
1487 Message text General system air pressure

Cause -- The required air supply pressure for the pneumatic valves is not
available.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Ensure that the air pressure and quantity are sufficient.
1488 Message text Vacuum error

Cause -- Vacuum missing or insufficient.


In the application of adhesive to glass, the glass is held in position by
means of a vacuum. If this vacuum is not available, the glass cannot
be held in position after it has been centered.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the vacuum pump and hoses.
1489 Message text Centering error

Cause -- The workpiece is not correctly positioned or clamped. There is possibly


a fault in the feed equipment, or the fixture is defective.
Monitor -- From the PLC application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check fixture, feed equipment or workpiece position.
1490 Message text Component check error

Cause -- Component damaged or no longer clamped to the fixture.


-- In the application of adhesive to glass, the adhesive nozzle is pressed
onto the glass. If this pressure is missing during adhesive application,
the glass might be damaged or might no longer be clamped to the
fixture.
In this case, the robot motion and adhesive application must be
stopped immediately!
Monitor -- From the PLC application program (bonding technology).
Effect -- Maximum braking. All active commands inhibited. Emergency Stop.
Remedy -- Check the workpiece.

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1 Error messages / troubleshooting (continued)

1491 Message text CP/PTP approximation not feasible

Cause -- In the CP block the traversing distance of an axis is greater than 180
degrees; S change in the CP block; software limit switch violated in
travel along “shortest path”.
Monitor
Effect
Remedy
1492 Message text Channel not compatible with protocol

Cause -- PLC protocol is set and channel declaration is not set to SER1.
Monitor -- In command processing.
Effect -- None.
Remedy -- Alter the channel declaration protocol.
1493 Message text Channel assigned to PLC

Cause -- An attempt has been made to access the channel that has already
been parameterized for the PLC link.
Monitor -- In command processing.
Effect -- None.
Remedy -- Reparameterize the channel. Close the channel and open it again.
1495 Message text Timeout during filling

Cause -- The maximum time for filling the dispenser with adhesive has been
exceeded.The time for filling the dispensing unit with adhesive is
monitored by the PLC. If the maximum time is exceeded, there is a
fault in the adhesive application hardware.
Monitor -- From the PLC application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware.
1496 Message text Adhesive level

Cause -- The adhesive drum is empty.


Monitor -- From the PLC application program (bonding technology).
Effect -- None.
Remedy -- Prepare a new adhesive drum or switch over to a filled drum.
1497 Message text All analog functions assigned

Cause -- More than 2 cyclic analog outputs have been switched on.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Set ANOUT OFF, or cancel the instruction.

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Error messages / troubleshooting

1498 Message text <Signal name> not an analog output

Cause -- Non--existent analog output signal or incorrect signal index accessed.


Monitor -- In command and program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1499 Message text Analog output already assigned

Cause -- A cyclic analog output is assigned a second time in the program,


e.g. SIGNAL SIG1 $ANOUT[1]; SIGNAL SIG2 $ANOUT[1]; ANOUT
ON SIG1 = ....; ANOUT ON SIG2 = ....
Monitor -- In the program.
Effect -- Ramp--down braking.
Remedy -- Switch off cyclic analog output: ANOUT OFSIG.
1504 Message text Invalid SYNACT variable <variable name> <block number>

Cause -- In logical comparison of value assignments during cyclic Synact moni-


toring, an error occurred when accessing a variable, e.g. variable
write--protected.
Monitor -- Cyclic.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Correct the data or the program.
-- Acknowledge the message.
1505 Message text Combination of variables not allowed <block number>

Cause -- In a synact instruction, variables for individual blocks and approximate


positioning blocks are combined in the logic comparison or value
assignment.
Monitor -- In program processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Program synact instruction differently.
1506 Message text CIRC parameter not allowed

Cause -- Distance between starting point and/or auxiliary point and/or end point
is too small, or all points lie on a straight line. Formation of a circle is
not possible.
Monitor -- In the individual CIRC block.
Effect -- CIRC block is not executed;
-- Ramp--down braking;
-- All active commands inhibited.
Remedy -- Program auxiliary point and/or end point correctly.

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1 Error messages / troubleshooting (continued)

1507 Message text Hydraulic level

Cause -- The oil level in the hydraulic system has fallen below the minimum limit.
Monitor -- In PLC program processing.
Effect -- None.
Remedy -- Top up hydraulic oil and check hydraulic system for leaks.
1508 Message text No file available

Cause -- No file is available that meets the search criteria specified in the DIR
command.
Monitor -- In command processing.
Effect -- None.
Remedy -- Check specifications and spelling in the DIR command.
1509 Message text Program exec. mode inadmissible

Cause -- The selected program execution mode is not permissible.


Monitor -- In command processing.
Effect -- None.
Remedy -- Change program execution mode.
1510 Message text Error at format selection no. <number of incorrect format selection>

Cause -- Parameter inconsistent with format specification, or incorrect format


specification in CWRITE instruction.
Monitor -- Program processing in S_INT function CWRITE.
Effect -- Program execution is stopped.
Remedy -- Program the correct format specification.
1511 Message text Access denied

Cause --
Monitor --
Effect --
Remedy --
1513 Message text Range for <path> <axis number> exceeded

Cause -- 32--bit word is exceeded.


Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Alter the program accordingly.
1514 Message text Insert another disk

Cause -- Request for next floppy disk.


Monitor --
Effect --
Remedy -- Insert floppy disk in the disk drive.

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Error messages / troubleshooting

1515 Message text <object> copy refused (--S.)

Cause -- System file has been transmitted via an interface without the option
“--S” being set
“--S” is the code for the download command.
Monitor -- In command processing.
Effect -- File is not transmitted.
Remedy -- Set the option “--S”.
1516 Message text Reference system not programmed

Cause -- $BASE is programmed incompletely or not at all.


Monitor -- In program processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Program $BASE correctly.
1517 Message text BCO move to aux. point required

Remedy -- Carry out BCO run to end point.


1518 Message text Default parameter

Cause -- A default parameter or no parameter has been transferred to a pre-


defined C function.
Monitor -- In program processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Call the C function with a parameter.
1519 Message text Pressure sensor cable failure

Cause -- The current flow of the analog signal for pressure sensing has fallen
below the minimum limit (4 -- 20 mA interface).
Monitor -- In command processing.
Effect -- Ramp--down braking.
Remedy -- Check connecting cable, connectors and current source.
1520 Message text Volume actual value cable failure

Cause -- The current flow of the analog input channel for volume sensing has
fallen below the minimum limit (4 -- 20 mA interface).
Monitor -- In command processing.
Effect -- Ramp--down braking.
Remedy -- Check connecting cable, connectors and current source.
1521 Message text Change of segment is erroneous

1522 Message text Selected axis is not adjustable

Cause -- The axis selected for mastering is inactive.


Monitor -- In command processing.
Effect -- The command is aborted.
Remedy -- Master only active axes.

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1 Error messages / troubleshooting (continued)

1523 Message text EXTFCTP instruction inadmissible

Cause -- An EXTFCTP instruction has been programmed in the program.


Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Delete the EXTFCTP instruction in the program.
1524 Message text Max. active triggers reached

Cause -- Too many Trigger commands programmed in a block.


Effect -- Command is not executed.
Remedy -- Reduce number of active Trigger commands in the program.
1525 Message text Invalid trigger -- “PRIO”

Cause -- An inadmissible value was entered for Trigger--PRIO.


Remedy -- Correct the value.
1526 Message text Max. triggers (50) defined

Cause -- The maximum number of Trigger commands has been defined.


Remedy -- Alter the program.
1527 Message text Sensor mastering inadmissible

Cause -- No sensor location run has been performed for the axis.
Monitor -- In command processing.
Effect -- Command is aborted.
Remedy -- Perform sensor location run for the axis.
1528 Message text Brakes open during mastering selection

Cause -- A brake is still open after the preceding motion.


Monitor -- In command processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Wait until all brakes are closed and the servos are disabled.
1529 Message text Segment exchange successful

1530 Message text Reduced velocity during sensor location search

Cause -- The velocity defined by the user for the sensor loction run in
$RED_JUS_UEB is greater than the possible maximum at which the
sensor can be detected. The controller automatically reduces the
velocity to allow the sensor to be detected.
Monitor -- In command processing.
Effect -- None.
Remedy -- Reduce the permissible velocity for manual traversing in the machine
data.

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Error messages / troubleshooting

1531 Message text Adjustment possible only in mode T1

Cause -- The operating mode of the controller is not set to mode T1.
Monitor -- In command processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Set the mode to T1. Perform mastering again.
1532 Message text CIRC is executed as LIN

Cause -- An attempt has been made to execute a CIRC motion as a BCO run.
Monitor -- In program processing.
Effect -- Program execution is stopped.
Remedy -- Acknowledge message, after the start the CIRC block is then executed
as a LIN motion.
1533 Message text Program line changed

Cause -- Message that the program line has been corrected.


Monitor --
Effect --
Remedy --
1534 Message text COR.dat check sum error

Cause -- The correction data have been altered.


Monitor -- In command processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Sensor location run/referencing, execution/archiving of the correction
data.
1535 Message text Delay <block number> inadmissible

Cause -- Neg. delay in the synact instruction has not been used in combination
with one of the 4 position trigger variables (M_SC_F, M_SC_B,
M_SCAPO_F, M_SCAPO_B).
Monitor -- In the program.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Change the logic condition of the synact instruction.
1536 Message text Array parameter inadmissible

Cause -- Undefined array parameter or complete “call--by--value” array in the list


of current parameters when function is called.
Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Do not use undefined array parameters and transfer complete arrays
as current parameters only on a “call--by--reference” basis.
1537 Message text Stop due to loading new custom data

Cause -- Loader for the file “$CUSTOM.DAT” has been called. No process may
be active at the same time since the system is fully occupied with the
loader.

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1 Error messages / troubleshooting (continued)

Monitor -- In command processing.


Effect -- Maximum braking. All active commands inhibited.
Remedy -- Acknowledge message. Do not edit “$CUSTOM.DAT” during an
“active process”
1538 Message text Invalid “DISTANCE” value

Cause -- The value for “DISTANCE” is not permissible.


Remedy -- Acknowledge message; enter permissible value.
1539 Message text Invalid “DELAY” value

Cause -- The value for “DELAY” is not permissible.


Remedy -- Acknowledge message; enter permissible value.
1540 Message text Interrupt expression complexity exceeded

Cause -- In total more than 16 “slow” variables have been used in the logical
expressions of the INTERRUPT DECL instructions on the control and
robot levels.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Use fewer predefined variables.
1541 Message text Machine data error

Cause -- Machine data have not yet been checked.


Monitor -- With active commands.
Effect -- None.
Remedy -- Edit the machine data or copy the machine data or option data file.
1542 Message text Error in “UPCALL” token

1543 Message text No more dynamic analog inputs available

Cause -- A third dynamic analog input has been switched on in the program.
Monitor -- In program processing.
Effect -- Stop.
Remedy -- One of the dynamic analog inputs must first be switched off.
1544 Message text Digital input already assigned

Cause -- A digital input has been cyclically switched on in the program for a
second time.
Monitor -- In program processing.
Effect -- Stop.
Remedy -- Switch off the dynamic digital input.
1545 Message text All pulse outputs assigned

Cause -- More than 16 impulse outputs have been switched on.


Monitor -- In program processing.
Effect -- Ramp--down braking; program execution stopped.

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Error messages / troubleshooting

Remedy -- Alter program accordingly.


1546 Message text Invalid pulse duration

Cause -- The permissible range for the pulse duration extends from 0.05 to
3049. A value outside this range has been specified.
Monitor -- In program processing.
Effect -- Ramp--down braking; program execution stopped.
Remedy -- Program values in the permissible range.
1547 Message text Target variable must be of type REAL

Cause -- Incorrect data type of a target variable or wrong format in a CREAD or


SREAD instruction.
Monitor --
Effect --
Remedy -- Correct CREAD or SREAD instruction: change format specification
or use variable of type REAL.
1548 Message text <name of the displayed program> reselection not possible

Cause -- Program that must be linked for reselection causes linking error.
Monitor -- Command processing (RUN command).
Effect -- None.
Remedy -- Eliminate the error using the error list containing the linking errors.
1549 Message text Invalid handle

Cause -- An invalid HANDLE has been programmed into CWRITE or CREAD.


Monitor -- Program.
Effect -- Ramp--down braking.
Remedy -- Specify a valid HANDLE.
1550 Message text No more data/variables available

Cause -- With SREAD/CREAD there is no more text to be read or there are no


variables available for storing the values.
Monitor --
Effect --
Remedy --
1552 Message text Channel already open

Cause -- An attempt has been made to open a channel that is alraedy open.
Monitor -- In command processing.

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1 Error messages / troubleshooting (continued)

1553 Message text Channel cannot be opened/closed

Cause -- The operator has attempted to open a SINEC H1 channel by means of


the OPEN command or to close it by means of the CLOSE command.
Monitor -- In command processing.
Effect -- None.
Remedy -- None; SINEC H1 channels are opened and closed automatically.
1554 Message text Wrong type of parameter variable

Cause -- The parameter variable for the channel is of the wrong type.
Monitor -- In command processing.
Effect -- None.
Remedy -- Correct CHANNEL declaration for the channel.
1555 Message text Channel parameters faulty or incomplete

Cause -- At least one channel parameter in the parameter variable of the


channel in “$CUSTOM.DAT” is faulty or not initialized.
Monitor -- In command processing.
Effect -- None.
Remedy -- Correct or initialize the parameter variable.
1556 Message text SINEC L2 bus channel not opened

Cause -- An attempt has been made to open a SINEC L2 connection without


the SINEC L2 bus channel being open.
Monitor -- In command processing.
Effect -- None.
Remedy -- Open SINEC L2 bus channel.
1557 Message text Channel already fully assigned

Cause -- The maximum number of jobs have already been assigned to the
channel.
Monitor -- In command processing.
Effect -- None.
Remedy -- Wait until at least one of the jobs is finished.
1558 Message text Channel has to be opened/closed

Cause -- The channel parameters used for assigning the channel do not
correspond to the current channel parameters.
Monitor -- In command processing.
Effect -- None.
Remedy -- Close the channel prior to assignment.

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Error messages / troubleshooting

1559 Message text Channel specification inadmissible

Cause -- An attempt has been made to transmit a productive command via


the SINEC L2 bus channel.
-- An attempt has been made to output the listing or the message
buffer through the SINEC H1 channel to a third station.
Monitor -- In command processing.
Effect -- None.
Remedy -- None.
1560 Message text Channel already closed

Cause -- An attempt has been made to close a channel that is already closed.
Monitor -- In command processing.
Effect -- None.
Remedy -- Abort.
1561 Message text SINEC L2 communication channels not closed

Cause -- An attempt has been made to close the SINEC L2 bus channel without
all the SINEC L2 communication channels being closed first.
Monitor -- In command processing.
Effect -- None.
Remedy -- Close all the SINEC L2 communication channels.
1562 Message text <SINEC L2, SINEC H1> board not available

Cause -- An attempt has been made to access a SINEC L2 or SINEC H1


channel without the corresponding board being installed.
Monitor -- In command processing.
Effect -- None.
Remedy -- Install the corresponding board.
1564 Message text Value range exceeded

Cause -- The wait time in the WAIT_SEC command, expressed in basic clock
rate cycles, exceeds the long range, i.e. is greater than 2147483647.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Enter shorter wait times.
1565 Message text SINEC L2 CONFIGURATION ERROR **

Cause -- The opening or closing of a SINEC L2 channel is refused on account


of a configuration error detected by the SINEC L2 module.
Monitor -- In command processing.
Effect -- None.
Remedy -- Check and correct the channel parameters (e.g. baud rate).

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1 Error messages / troubleshooting (continued)

1566 Message text SINEC L2 TRANSMISSION ERROR <error no. SINEC L2--M>

Cause -- Data transmission via SINEC L2 is not possible on account of an error


detected by the SINEC L2 module.
Monitor -- In data transmission.
Effect -- None.
Remedy -- Check the transmission link and rectify the error.
1567 Message text NO CONNECTION TO SINEC L2 BOARD

Cause -- The connection of the IFC to the SINEC L2 board is faulty.


Monitor -- Cyclic
Effect -- None.
Remedy -- Carry out warm start;
-- If fault recurs, exchange board (IFC with SINEC L2 board).
1568 Message text Maximum no. of processes assigned to channel

Cause -- Too many processes are running through the serial interface.
Monitor --
Effect --
Remedy -- Wait until a process is finished.
1569 Message text Parameter change inadmissible, channel assigned

Cause -- An attempt has been made to allocate parameters differing from the
current ones to a channel that is already assigned.
Monitor --
Effect --
Remedy -- Correct the data used for the channel as required, or close the channel
and re--open it with the appropriate parameters.
1570 Message text Invalid parameter value

Cause -- The maximum value of a channel parameter has been exceeded.


Monitor --
Effect --
Remedy -- Correct the channel parameter.
1571 Message text Baud rate summation exceeded

Cause -- The aggregate baud rate of both channels has been exceeded (it is
limited to 19200 bauds).
Monitor --
Effect --
Remedy -- Alter the baud rate.

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Error messages / troubleshooting

1572 Message text Protocol timeout

Cause -- The defined protocol time has been exceeded.


Monitor --
Effect --
Remedy -- Check whether the physical connection to the periphery still exists.
Increase the timeout setting appropriately if it is too low.
1573 Message text IFC syntax error

Cause -- During an attempt to open or close a channel, a syntax error has


occurred in the interface CPU with regard to the command generated
by the control.
Monitor --
Effect --
Remedy -- Close and re--open the channel.
1574 Message text KRC system error <error number> <originator>

Cause -- KRC system error (core system, not acknowledgeable). “KRC system
error 0” indicates that a task has crashed.
Monitor --
Effect -- Maximum braking, all active commands inhibited.
Remedy -- Reboot the KRC controller.
1576 Message text BASE change inadmissible

Cause -- During conveyor operation an attempt has been made to change the
BASE.
Monitor --
Effect -- Maximum braking.
Remedy -- Alter the program accordingly.
1577 Message text <Name> already exists

Cause -- A SUB module cannot be created in the editor if an SCR module of


the same name already exists and vice versa.
Monitor -- Command processing.
Effect --
Remedy -- Change the name of the module.
1578 Message text <Value> inadmissible

Cause -- An inadmissible value has been entered.


Monitor -- Command processing.
Effect --
Remedy -- Enter an admissible value.

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1 Error messages / troubleshooting (continued)

1579 Message text APS system error

Cause -- Internal error in APS detected by APS.


Monitor --
Effect --
Remedy -- Request confirmation from APS, reboot probably required.
1580 Message text Tech. function $TECH[<parameters 1--3>].FCT inadmissible

Cause -- The function parameters programmed in $TECH[i].FKT i=1..3, are


incompatible with the function definition.
Monitor -- The function parameters are checked by the interpreter in the advance
run.
Effect -- Ramp--down braking.
Remedy -- Correct the function parameters.
1581 Message text Tech mode inadmissible

Cause -- The “CYCLE” mode has been programmed for the technology cate-
gory “VEL”.
Monitor -- In the interpreter when changing CLASS or MODE.
Effect -- Ramp--down braking.
Remedy -- Alter the program.
1582 Message text Kinematic instruction inadmissible

Cause -- A non--existent external kinematic system has been assigned to the


system variable “$BASE” with the function EK.
Monitor --
Effect --
Remedy --
1583 Message text <SER_1> block size error

Cause -- The received data block is too large.


Monitor --
Effect --
Remedy -- Alter the buffer length in the external data storage device to the control--
internal size or smaller.
1584 Message text Program structure for resume inadmissible

Cause -- An interrupt has occurred in the program section where the interrupt
with RESUME was declared. The return is therefore executed to the
advance run pointer, which is not defined.
Monitor --
Effect -- Ramp--down braking.
Remedy -- RESUME may be used only in conjunction with the subprogram
technique. The interrupt must not be triggered on the level where the
interrupt was declared.

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Error messages / troubleshooting

1585 Message text CA parameter out of range

Cause -- Too large a value has been programmed for the parameter CA
(complete angle) in the CIRC block.
Monitor --
Effect --
Remedy -- Correct the value of the CA appropriately.
1586 Message text SINEC AP/TF ERROR <SINEC AP/TF--Fhlcode>

Cause -- See “SINEC AP Technological Functions, Part B”.


Monitor -- In command processing.
Effect --
Remedy -- See “SINEC AP Technological Functions, Part B”.
1587 Message text Application comm. interrupted (File server)

Cause -- The application communication with the file server has been inter-
rupted or disconnected.
Monitor -- In command processing.
Effect --
Remedy -- Check the transmission link between the ACR and the file server.
1588 Message text Path inadmissible

Cause -- The path specification for SINEC H1 contains “wildcards”.


Monitor -- In command processing.
Effect --
Remedy -- Copy just one file at a time.
1589 Message text ... closing channel inadmissible, channel active

Cause -- The channel concerned cannot be closed during transmission.


Monitor --
Effect --
Remedy -- Wait for the transmission to finish or abort the transmission.
1590 Message text ENUM not declared in $CONFIG

Cause -- A SET INFO is being applied to an ENUM variable from a user data list.
The search path extension has been altered again --> no access to
ENUM type information.
Monitor -- Command processing.
Effect --
Remedy -- Enter ENUM declaration and variable declaration in the
“$CONFIG.DAT” file.

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1 Error messages / troubleshooting (continued)

1591 Message text MINIMUM MUST BE LESS THAN MAXIMUM

Cause -- The minimum value defined for an ANOUT command was greater
than the maximum
Monitor --
Effect -- Interpreter stop
Remedy -- Set minimum to a value less than the maximum
1595 Message text Load dependent ACC. adaption not possible for PTP <...>

Cause -- The simulation calculation of the integrated dynamic model exceeds


the given limit values of the continuous gear torque.
Monitor -- At every PTP preparation with activated load--dependent acceleration
adaptation.
Effect -- Operator information; no effect.
Remedy -- If allowed: increase the max. permissible continuous gear torque
“$DYN_DAT[50..]”.
-- Lower the optimization limit “$OPTEXCLUDE”.
1596 Message text Tacho balance only possible for one axis

Cause -- An attempt has been made to carry out a DSE tacho balance for
several axes at the same time.
Monitor -- On value assignment to “$PROG_EEPOT”.
Effect -- Value assignment is not carried out.
Remedy -- Carry out tacho balance for one axis only.
1597 Message text Not a DSE axis

Cause -- An attempt to carry out a tacho balance for an axis which is not present
on the DSE board.
Monitor -- On value assignment to “$TACH_CHANGE”.
Effect -- Value assignment is not carried out.
Remedy -- Carry out tacho balance for DSE axes only.
1598 Message text Load not programmed

Cause -- With the acceleration adaptation activated, the load has not been
completely programmed.
Monitor -- In every motion in the program or interrupt.
Effect -- Program stop.
Remedy -- Correctly program “$LOAD”.
1599 Message text No axis selected

Cause -- An attempt has been made to carry out a tacho balance even though
no axis has been selected.
Monitor -- On value assignment to “$TACH_CHANGE”.
Effect -- Value assignment is not carried out.
Remedy -- First select an axis, then carry out tacho balance.
1600 Message text CONTROL : **

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Error messages / troubleshooting

1601 Message text No block coincidence, step mode first

Cause -- No block coincidence when changing mode to AUTO.


Monitor --
Effect --
Remedy -- Achieve block coincidence in the SINGLE--STEP mode first.
1602 Message text BCO run in step mode required

1603 Message text Safety fence open

1604 Message text Error in trace definition

Cause -- The trace has been incorrectly defined in the “TRACE.DEF” file.
Monitor -- When starting a trace.
Effect --
Remedy -- Correct “TRACE.DEF”.
1605 Message text Error reading TRACE.DEF

Cause -- The “TRACE.DEF” file could not be read at the start of trace recording.
Monitor -- When starting a trace.
Effect --
Remedy -- Make “TRACE.DEF” available, start or check FTP server.
1606 Message text InterBus : bus error <segment, position>

Cause -- Error or malfunction in data transmission on the Interbus.


Monitor --
Effect -- Data transmission on the Interbus is stopped, outputs are reset.
Remedy -- Troubleshooting with CMD (Phoenix diagnostic tool).
1607 Message text InterBus : bus warning <segment, position>

Cause -- Malfunction in the bus module specified (Segment Position).


Monitor --
Effect -- Outputs are reset.
Remedy -- Eliminate the error in the specified module, diagnosis with CMD
software (Phoenix).
1608 Message text Assignment of function value to $CYCFLAG inadmissible

Cause -- Return value of a BOOL function has been assigned directly to a


$CYCFLAG.
Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Alter the program, acknowledge message.

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1 Error messages / troubleshooting (continued)

1609 Message text Assignment of runtime value to $CYCFLAG inadmissible

Cause -- A $CYCFLAG has been assigned local runtime data.


Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Alter the program (use global variables only), acknowledge message.
1610 Message text ERROR IN CONFIGURATION FILE

1611 Message text MAC--ID IN USE

1612 Message text ERROR DURING TASK START

1613 Message text ERROR DURING ALLOCATE DEVICE **

1614 Message text ERROR DURING SCAN DEVICE **

1615 Message text “PRIO” 40--80 CLOSED

1616 Message text Start locked <string>

Cause -- Start is inhibited during insertion of one or more blocks in PROCOR.


1617 Message text InterBus: bus error in slave ring

Cause -- Bus error in the ring of the higher--level controller (PLC, etc.).
Monitor --
Effect -- Automatic External interface deactivated.
Remedy -- Rectify bus error in higher--level ring.
2000 Message text NEW BLOCK IS NOT A DECLARATION

2001 Message text BINARY OUTPUT SIGNAL EXPECTED

2002 Message text INCORRECT INITIALIZATION

2003 Message text FAULTY INITIALIZATION VALUE

2004 Message text “DEFDAT” EXPECTED

2005 Message text VARIABLE NOT INITIALIZED

2006 Message text “CA” EXPECTED

2007 Message text “DEF” OR “DEFFCT” EXPECTED

2008 Message text BLOCK CANNOT BE MODIFIED

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Error messages / troubleshooting

2009 Message text GLOBAL SR/FCT CANNOT BE RENAMED

2010 Message text DATA LIST CANNOT BE RENAMED

2011 Message text DIFFERENT TYPES WITH CHANGE OF INITIAL VALUE

2012 Message text SUB CANNOT BE LINKED TO SRC

2013 Message text VARIABLE CANNOT BE RENAMED

2014 Message text INDEX CANNOT BE CHANGED

2015 Message text NOT A SYSTEM SUBROUTINE

2016 Message text NOT A SYSTEM FUNCTION

2017 Message text SYNTAX ERROR IN P_PATH

2018 Message text UNUSED EXTERNALLY DECLARED SUBROUTINE

2019 Message text EXPECTED EXT. SUBROUTINE, FOUND FUNCTION

2020 Message text EXTERNAL FUNCTION EXPECTED, SUBROUTINE FOUND

2021 Message text DATA LIST NOT “PUBLIC”

2022 Message text IMPORTED VARIABLE NOT DECLARED IN DATA LIST

2023 Message text IMPORTED VARIABLE NOT DECLARED IN DATA LIST

2024 Message text IMPORTED VARIABLE TYPE/DIMENSION CONFLICT

2025 Message text EXTERNAL AND SR/FCT DECLARATIONS DO NOT MATCH

2026 Message text EXTERNAL AND SR/FCT DECLARATIONS DO NOT MATCH

2027 Message text IMPORT INTERFACE NOT CORRECT

2028 Message text EXT[FCT] AND DEF[FCT] PARAMETERS ARE INCOMPATIBLE

2029 Message text SYNTAX ERROR IN MODULE

2030 Message text MODULE USED BY ANOTHER PROCESS

2031 Message text MODULE PACKAGE NOT AVAILABLE

2032 Message text ILLEGAL COMMAND

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1 Error messages / troubleshooting (continued)

2033 Message text END OF BLOCK OR COMMENT EXPECTED

2034 Message text INSERT BEFORE FIRST BLOCK NOT ALLOWED

2035 Message text INVALID BLOCK NUMBER

2036 Message text ONLY COMMENT MAY BE ENTERED AFTER “ENDDAT”

2037 Message text ILLEGAL OR UNKNOWN BLOCK

2038 Message text DECLARATION NOT IN DECLARATION SECTION

2039 Message text INSTRUCTION NOT IN INSTRUCTION SECTION

2040 Message text INITIAL VALUE BLOCK NOT INITIALIZATION SECTION

2041 Message text ERROR IN “DEFDAT”, INSERT NOT SUCCESSFUL

2042 Message text “DEFDAT” NOT ALLOWED

2043 Message text ERROR IN GLOBAL “DEF”/“DEFFCT”

2044 Message text “DEF”/“DEFFCT” NOT ALLOWED

2045 Message text “END”/“ENDFCT”/“ENDDAT” NOT ALLOWED HERE

2046 Message text “EXT”/“EXTFCT”/“IMPORT” NOT ALLOWED HERE

2047 Message text FILE NOT FOUND

2048 Message text ERROR ON ENTERING THE DATA LIST

2049 Message text INITIAL VALUE NOT ALLOWED HERE

2050 Message text INITIAL VALUE SYNTAX INCORRECT

2051 Message text NAME IN FIRST LINE MUST BE SAME AS MODULE NAME

2052 Message text ARRAY NAME ENTERED NOT ALLOWED HERE

2053 Message text INITIAL VALUE OF INDEX ALREADY EXISTS

2054 Message text ’=’ EXPECTED

2055 Message text REAL CONSTANT EXPECTED

2056 Message text ’{’ EXPECTED

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Error messages / troubleshooting

2057 Message text COMPONENT NOT PART OF VARIABLE TYPE

2058 Message text CONSTANT NAME NOT PART OF VARIABLE TYPE

2059 Message text STRING CONSTANT TOO LONG

2060 Message text ARRAY INDEX ENTERED INADMISSIBLE HERE

2061 Message text AGGREGATE COMPONENT INITIALIZED MORE THAN ONCE

2062 Message text INFORMATION LOSS POSSIBLE ON CHANGE OF TYPE

2063 Message text INTEGER, REAL OR CHARACTER CONSTANT EXPECTED

2064 Message text CHARACTER OR INTEGER CONSTANT EXPECTED

2065 Message text “TRUE” OR “FALSE” EXPECTED

2066 Message text ENUM CONSTANT TYPE DOES NOT MATCH ENUM VARIABLE

2067 Message text COMPONENT ARRAY SPEC. MULTIDIMENSIONAL

2068 Message text ARRAY SUBSCRIPT MISSING

2069 Message text COMPONENT IS NO ARRAY

2070 Message text ’#’ OR ENUM TYPE NAME EXPECTED

2071 Message text STRUCTURE TYPE NAME EXPECTED

2072 Message text TYPENAME INCOMPATIBLE WITH TEXT

2073 Message text COMPONENT NEITHER PART OF “FRAME” OR “POS”

2074 Message text ASCENDING INDICES EXPECTED

2075 Message text NUMBER TOO LOW

2076 Message text ’IS’ EXPECTED

2077 Message text INTEGER CONSTANT EXPECTED

2078 Message text IDENTICAL PREDEFINED SIGNAL NAMES EXPECTED

2079 Message text COMPONENT TYPE UNKNOWN

2080 Message text PROTOCOL VARIABLE DECLARED IMPLICITLY

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1 Error messages / troubleshooting (continued)

2081 Message text “POS”, “FRAME”, OR “AXIS” EXPECTED

2082 Message text VARIABLE WITH STRUCTURE TYPE EXPECTED

2083 Message text PREDEFINED SIGNAL EXPECTED

2084 Message text PREDEFINED CHANNEL NAME EXPECTED

2085 Message text ’[’ EXPECTED

2086 Message text ARRAY LIMIT MISSING

2087 Message text ’,’ EXPECTED

2088 Message text SIGNAL INDEX TOO LARGE

2089 Message text ’..’ EXPECTED

2090 Message text ONE DIMENSIONAL CHAR FIELD EXPECTED

2091 Message text “IN” OR “OUT” EXPECTED

2092 Message text SYNTAX ERROR IN ARRAY SPECIFICATION

2093 Message text POS. INTEGER, “]” OR “,” EXPECTED

2094 Message text NO MORE THAN THREE DIMENSIONS ALLOWED

2095 Message text RELATIVE P_PATH NOT COMPATIBLE WITH NODE

2096 Message text “]” OR “,” EXPECTED

2097 Message text STRUCTURE TYPE VARIABLE NOT ALLOWED

2098 Message text VARIABLE NOT DECLARED IN DATA LIST

2099 Message text ARRAY INDEX EXCEEDS ARRAY LIMITS

2100 Message text POSITIVE INTEGER EXPECTED

2101 Message text ARRAY INDEX NOT COMPATIBLE WITH INDEX

2102 Message text ARRAY LIMIT EXCEEDED

2103 Message text NO VARIABLE EXISTS WITH THIS NAME

2104 Message text PARAMETER SPECIFICATION NOT ALLOWED IN DATA LIST

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Error messages / troubleshooting

2105 Message text LOCAL PARAMETER TYPE DEFINED LOCALLY

2106 Message text BLOCK CANNOT BE DELETED

2107 Message text DELETE MODULE BY MEANS OF DEDICATED FUNCTION

2108 Message text “ERROR” TOKEN IN I--CODE

2109 Message text END STATEMENT MISSING

2110 Message text INCORRECT END OF CONTROL STRUCTURE

2111 Message text SUBROUTINE/FUNCTION INCORRECTLY COMPLETED

2112 Message text IDENTIFIER NOT DECLARED

2113 Message text PROTOCOL VARIABLE MUST BE OF STRUCTURE TYPE

2114 Message text CORRECT TYPE ENTRY UNAVAILABLE

2115 Message text COMPONENT TYPE NOT DEFINED OR CORRECTLY DEFINED

2116 Message text TYPE OF A PARAMETER IS DEFINED LOCALLY

2117 Message text ENDDAT STATEMENT MISSING

2118 Message text TYPE CHANGE FOR INITIAL VALUE NOT POSSIBLE

2119 Message text COMPILE LOC. NOT COMPATIBLE WITH CALL LOCATION

2120 Message text OBJECT MUST BE DECLARED IN DATA LIST OR IMPLICITLY

2121 Message text INCORRECT DIMENSION

2122 Message text NAME NOT DECLARED AS ARRAY

2123 Message text NAME NOT DECLARED AS FUNCTION

2124 Message text VARIABLE NOT DECLARED IN DATA LIST

2125 Message text COMPONENT NOT PART OF TYPE

2126 Message text NO STRUCTURE DATA TYPE

2127 Message text FORMAL PARAMETER DECLARATION MISSING

2128 Message text MORE ACTUAL THAN FORMAL PARAMETERS SPECIFIED

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1 Error messages / troubleshooting (continued)

2129 Message text FORMAL PARAMETER NOT DEFINED

2130 Message text NOT ALLOWED EXPRESSION AFTER RETURN INSTRUCTION

2131 Message text EXPRESSION AFTER RETURNING INSTRUCTION MISSING

2132 Message text NO INTERFACES ALLOWED

2133 Message text TYPE MUST BE “POS”,“FRAME”,“AXIS”

2134 Message text OBJECT TYPE NOT VALID

2135 Message text NAME NOT DECLARED AS SUBROUTINE

2136 Message text LOCAL SUBROUTINE NOT ALLOWED IN PROCESS COMMANDS

2137 Message text NAME NOT DECLARED AS SIMPLE VARIABLE

2138 Message text NO NAME OF SUCH A CONSTANT TYPE

2139 Message text SPECIFIED TYPE IS NOT ENUM TYPE

2140 Message text NO ENUM TYPE SPECIFIED

2141 Message text INDEXING OR [] NOT ALLOWED

2142 Message text INDEXING OR [] EXPECTED

2143 Message text END OF CONTROL STRUCTURE NOT ALLOWED HERE

2144 Message text “ENDLOOP” MISSING

2145 Message text “ENDWHILE” MISSING

2146 Message text “ENDFOR” MISSING

2147 Message text “UNTIL” MISSING

2148 Message text “ENDIF” MISSING

2149 Message text “ENDSWITCH” MISSING

2150 Message text “SWITCH” CONTAINS NO “CASE”

2151 Message text NO “CASE” AFTER “SWITCH”

2152 Message text “CASE”/“DEFAULT” AFTER “DEFAULT”

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Error messages / troubleshooting

2153 Message text “EXIT” NOT IN LOOP BODY

2154 Message text NAME NOT DECLARED AS CHANNEL

2155 Message text NAME NOT DECLARED AS LABEL

2156 Message text JUMP DESTINATION NOT DECLARED LOCALLY

2157 Message text JUMP DESTINATION NOT DECLARED GLOBALLY

2158 Message text JUMP TO LABEL NOT ALLOWED

2159 Message text THERE EXISTS AN INVALID JUMP TO THIS LABEL

2160 Message text “THEN” EXPECTED

2161 Message text “DO” EXPECTED

2162 Message text INVALID INPUT CHARACTER

2163 Message text COUNT EXCEEDED

2164 Message text NO “/” IN P_PATH

2165 Message text WILDCARD NOT ALLOWED

2166 Message text NO FILE NAME

2167 Message text NAME TOO LONG

2168 Message text INVALID EXTENSION

2169 Message text PATH INCORRECT

2170 Message text BLANK CHARACTER INVALID

2171 Message text EXTENSION NOT ALLOWED

2172 Message text CHANNEL HANDLE EXPECTED

2173 Message text ABSOLUTE PATH EXPECTED

2174 Message text ’TO’ EXPECTED

2175 Message text USER, DEVICE OR NODE TYPE NAME EXPECTED

2176 Message text “OBJ”, “NODE”, “USER”, “PERI” EXPECTED

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1 Error messages / troubleshooting (continued)

2177 Message text “NODE”, “USER”, “PERI” EXPECTED

2178 Message text VALUE MISSING

2179 Message text “NODE” MUST FOLLOW

2180 Message text “BVS” OR “MSD” MUST FOLLOW

2181 Message text “DEV” MUST FOLLOW

2182 Message text CONSTANT OR VARIABLE EXPECTED

2183 Message text OPTION ENTERED TWICE

2184 Message text OPTION EXPECTED AFTER MINUS SIGN

2185 Message text BLOCK NUMBER EXPECTED

2186 Message text BLOCK NUMBER MUST BE POSITIVE

2187 Message text STRING EXPECTED

2188 Message text STRING EXPECTED

2189 Message text INITIAL BLOCK NUMBER > FINAL BLOCK NUMBER

2190 Message text ATTRIBUTE NAME MUST FOLLOW

2191 Message text CONSTANT FOR KEY MUST FOLLOW

2192 Message text EXTENSION MISSING

2193 Message text EXTENSION OR ’.*’ INVALID

2194 Message text “WHEN” EXPECTED

2195 Message text CHANNEL NAME EXPECTED

2196 Message text ABSOLUTE PATH AFTER DEVICE/CHANNEL NAME EXPECTED

2197 Message text “INFO” EXPECTED

2198 Message text “MESSAGE” EXPECTED

2199 Message text INTEGER CONSTNT EXPECTED

2200 Message text KI EXPECTED: 1<=I<=12

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Error messages / troubleshooting

2201 Message text “+” OR “--” EXPECTED

2202 Message text “VAR” EXPECTED

2203 Message text ONLY “I”, “B”, “H”, “V” ALLOWED AS OPTION ONLY

2204 Message text ERROR AT END OF BLOCK

2205 Message text “SEC”, “FOR” OR “CLOCK” EXPECTED

2206 Message text CHANNEL NAME MISSING

2207 Message text NAME NOT DECLARED AS CHANNEL

2208 Message text “DEL” MUST FOLLOW

2209 Message text TOO MUCH MEMORY REQUIRED FOR DYNAMIC VARIABLE

2210 Message text “,” EXPECTED

2211 Message text SYMBOL IS NOT AT BEGINNING OF EXPR./VALUE ASSIGNMENT

2212 Message text LABEL NOT DECLARED LOCALLY

2213 Message text “WAIT CLOCK” NOT AVAILABLE IN PACKAGE 1

2214 Message text ARRAY CONTAINS TOO MANY ELEMENTS

2215 Message text TYPE TOO LARGE

2216 Message text ENTRY IN SYMBOL TABLE IS NOT LABEL

2217 Message text “USER”, “ACCESS” OR “COMMENT” EXPECTED

2218 Message text NESTING DEPTH EXCEEDED

2219 Message text OPERAND OR EXPRESSION EXPECTED

2220 Message text “)” EXPECTED

2221 Message text NAME OF LOOP VARIABLE EXPECTED

2222 Message text EXPRESSION TYPE NOT EQUAL TO STAT_T

2223 Message text EXPRESSION TYPE NOT EQUAL TO INT, REAL, CHAR, BOOL,
ENUM
2224 Message text CONSTANT EXPECTED

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1 Error messages / troubleshooting (continued)

2225 Message text POSITIVE INTEGER CONSTANT EXPECTED

2226 Message text INVALID SIGN

2227 Message text LEFT OPERAND NOT EQUAL TO INT, REAL

2228 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL

2229 Message text BOTH OPERANDS NOT EQUAL TO INT, REAL

2230 Message text LEFT OPERAND NOT EQUAL TO INT, CHAR

2231 Message text RIGHT OPERAND NOT EQUAL TO INT, CHAR

2232 Message text BOTH OPERANDS NOT EQUAL TO INT, CHAR

2233 Message text LEFT OPERAND NOT EQUAL TO BOOL

2234 Message text RIGHT OPERAND NOT EQUAL TO BOOL

2235 Message text BOTH OPERANDS NOT EQUAL TO BOOL

2236 Message text LEFT OPERAND NOT EQUAL TO INT, REAL, CHAR, ENUM

2237 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL, CHAR, ENUM

2238 Message text BOTH OPERANDS NOT EQUAL TO INT, REAL, CHAR, ENUM

2240 Message text LEFT OPERAND NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2241 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2242 Message text OPERANDS NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2243 Message text OPERAND TYPES NOT COMPARABLE

2244 Message text LEFT OPERAND NOT EQUAL TO POS, FRAME

2245 Message text RIGHT OPERAND NOT EQUAL TO POS, FRAME

2246 Message text OPERANDS NOT EQUAL TO POS, FRAME

2247 Message text BOTH SIDES OF THE VALUE ASSIGNMENT ARE NOT
COMPATIBLE
2248 Message text EXPRESSION NOT EQUAL TO INT, REAL

2249 Message text EXPRESSION NOT EQUAL TO INT

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Error messages / troubleshooting

2250 Message text EXPRESSION NOT EQUAL TO BOOL

2251 Message text EXPRESSION NOT EQUAL TO POS, FRAME

2252 Message text EXPRESSION NOT EQUAL TO POS, FRAME, AXIS

2253 Message text VARIABLE OR ARRAY ELEMENT EXPECTED

2254 Message text SELECTION INVALID HERE

2255 Message text EXPRESSION NOT EQUAL TO CHAR, INT, ENUM

2256 Message text OPERAND NOT EQUAL TO INT, REAL

2257 Message text OPERAND NOT EQUAL TO, CHAR

2258 Message text OPERAND NOT EQUAL TO BOOL

2259 Message text LEFT OPERAND: ARRAY OR PATH INVALID

2260 Message text RIGHT OPERAND: ARRAY INVALID

2261 Message text RIGHT OPERAND: ARRAY WITH DIMENSION > 1 INVALID

2262 Message text ARRAY AS OPERAND INVALID

2263 Message text TYPE OF LOOP VARIABLE NOT EQUAL TO INT

2264 Message text EXPRESSION TYPE NOT “MODUS_T”

2265 Message text COMMA OR “)” EXPECTED

2266 Message text TYPE COMPONENT INCOMPATIBLE WITH TYPE INITIAL VALUE

2267 Message text LEFT SIDE: ARRAY INVALID

2268 Message text RIGHT SIDE: ARRAY INVALID

2269 Message text RIGHT STRING CONSTANT => LEFT INDEXING

2270 Message text TYPE OF LEFT AND RIGHT HAND SIDE INCOMPATIBLE

2271 Message text PATH EXPRESSION REQUIRED! (ARRAY!)

2272 Message text PATH EXPRESSION INVALID

2273 Message text ARRAY INVALID

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2274 Message text TYPE ACTUAL/FORMAL PARAMETER INCOMPATIBLE

2275 Message text TYPE ACTUAL/FORMAL PARAMETER INCOMPATIBLE

2276 Message text DIMENSION INCOMPATIBLE

2277 Message text ARRAY DIMENSION GREATER THAN 1 NOT ALLOWED

2278 Message text RETURN VALUE: STRING CONSTANT ARRAY INVALID

2279 Message text TYPE RETURN VALUE INCOMPATIBLE WITH TYPE FUNCTION

2280 Message text RIGHT OPERAND: PARENTHESES INVALID IN PATH


EXPRESSIONS
2281 Message text PARENTHESES NOT ALLOWED FOR PATH EXPRESSIONS

2282 Message text FIRST CONSTANT INCOMPATIBLE WITH THIS CONSTANT

2283 Message text CONSTANT TYPE INCOMPATIBLE WITH EXPR. TYPE IN SWITCH

2284 Message text NO SELECTION OF ENTIRE ARRAYS

2285 Message text COMPONENT NAME EXPECTED

2286 Message text COMPONENT SPECIFIED TWICE

2287 Message text “,” OR “}” EXPECTED

2288 Message text “]” EXPECTED

2289 Message text INCORRECT RANGE SPECIFICATION

2290 Message text CONSTANT EXPECTED

2291 Message text NAME OF A STRUCTURE DATA TYPE EXPECTED

2292 Message text NO DATA TYPE NAME: CREATION NOT ALLOWED

2293 Message text COMPONENT NOT DECLARED AS ARRAY

2294 Message text “#”EXPECTED

2295 Message text ARRAY COMPONENTS CANNOT BE INDEXED

2296 Message text NOT A NAME OF A CONSTANT OF THIS TYPE

2297 Message text COMPONENT DECLARED AS ARRAY: INDEXING EXPECTED

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Error messages / troubleshooting

2298 Message text AGGREGATE TYPE (POS) INCOMPATIBLE WITH CONTEXT

2299 Message text EXPECTED CONSTANT TYPE UNKNOWN

2300 Message text NOT A NAME OF AN ENUM DATA TYPE

2301 Message text NOT AN AXIS COMPONENT

2302 Message text NOT A FRAME COMPONENT

2303 Message text NOT A POS COMPONENT

2304 Message text INCORRECT END OF PARAMETER LIST

2305 Message text NAME OF A SUBROUTINE EXPECTED

2306 Message text RELATIVE PATH INVALID

2307 Message text ANALOG INPUT EXPECTED

2308 Message text DIGITAL INPUT EXPECTED

2309 Message text “(”EXPECTED

2310 Message text DIGITAL INPUT NOT ALLOWED HERE

2311 Message text TYPE OF FORMAL PARAMETER INVALID

2312 Message text PROGRAM NOT AVAILABLE

2313 Message text NO ERROR

2314 Message text NO FILE NAME SPECIFIED

2315 Message text FILE NAME TOO LONG

2316 Message text FILE NAME MAY NOT CONTAIN “.”

2317 Message text HIERARCH. NO. NOT IN SEARCH PATH

2318 Message text PARAMETERS TO BE DECLARED IN MODULE

2319 Message text “ON”,“OFF”,“ENABLE”,“DISABLE”,“DECL” EXPECTED

2320 Message text SIGNAL NAME CANNOT BE CHANGED

2321 Message text PREDEFINED SIGNAL CANNOT BE CHANGED

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2322 Message text SIGNAL TYPES ARE DIFFERENT

2323 Message text SIGNAL TYPE CANNOT BE CHANGED

2324 Message text DUAL DECLARATION

2325 Message text TYPE UNKNOWN

2326 Message text NAME EXPECTED

2327 Message text TYPE EXPNAME OF A SIGNAL EXPECTED

2328 Message text “:” EXPECTED

2329 Message text COMBINED ANALOG SIGNALS INADMISSIBLE

2330 Message text NAME OF A SIGNAL EXPECTED

2331 Message text ANALOG OUTPUT EXPECTED

2332 Message text ARRAY ELEMENT/VARIABLE NOT TYPE REAL

2333 Message text “*” EXPECTED

2334 Message text REAL CONSTANT, VARIABLE OR ARRAY ELEMENT EXPECTED

2335 Message text COMBINED SIGNAL MORE THAN 32 BITS

2336 Message text “ON” OR “OFF” EXPECTED

2337 Message text ARRAY LIMITS INVALID IN PARAMETER SPECIFICATION

2338 Message text ARRAY LIMITS INVALID IN PARAMETER SPECIFICATION

2339 Message text TEACH--IN FOR TYPE INVALID

2340 Message text RECOMPILE BLOCK

2341 Message text INT. CONSTANT NOT EQUAL 0 EXPECTED

2342 Message text NO MORE THAN 12 CHARACTERS

2343 Message text NO GLOBAL PROCEDURE AVAILABLE

2344 Message text “DISTANCE” EXPECTED

2345 Message text “DELAY” EXPECTED

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Error messages / troubleshooting

2346 Message text “PRIO” EXPECTED

2347 Message text “PRIO” BETWEEN 40 AND 80 NOT ALLOWED

2348 Message text “DISTANCE”: ONLY 1 OR 0 ALLOWED

2349 Message text ASSIGNMENT TO CONSTANT NOT PERMISSIBLE

2350 Message text RUNTIME DATA OF THE MAIN PROGRAM CANNOT BE USED

2351 Message text RUNTIME DATA CANNOT BE USED

2700 Message text <object name> BLOCK NOT AVAILABLE

2701 Message text <object name> BLOCK TOO LONG

2702 Message text <object name> BLOCK TOO LONG OR INCORRECTLY COMPLETED

2703 Message text TOO MANY ELEMENTS IN <object name> ARRAY

2704 Message text <object name> NO DYNAMIC MEMORY AVAILABLE

2705 Message text BLOCK <object name> CANNOT BE FORMATED

2706 Message text BLOCK <object name> CANNOT BE DECOMPILED

2707 Message text BLOCK <object name> UNAVAILABLE

2708 Message text STACKING DEPTH <object name> EXCEEDED

2709 Message text <object name> LINK LIST CANNOT BE EXTENDED

2710 Message text <object name> TOO MANY LOCAL SUBROUTINES

2711 Message text <object name> has reached maximum size

Cause -- When a module has reached the maximum size (65536 bytes) the
message “SRC HAS REACHED MAXIMUM SIZE AND CANNOT
BE ENLARGED”, for example, is displayed.
2712 Message text <object name> NOT ENOUGH MEMORY, FILE OPEN ERROR

2713 Message text <object name> NO FREE PHYSICAL MEMORY

2714 Message text <object name> NO FREE VIRTUAL MEMORY

2800 Message text INTERNAL COMPILER ERROR <object name>

2801 Message text <object name> ERROR IN MEMORY MANAGER <error number>

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2803 Message text UNDEFINED SYNTAX ERROR

2821 Message text $ORI_TYPE implicitly set to #VAR

Cause -- The external TCP is activated for operating mode “T1” or “T2”
($IPO_MODE = TCP) and the orientation control $ORI_TYPE is set
to #JOINT. This combination is not permissible.
Monitor --
Effect -- $ORI_TYPE is implicitly set to #VAR.
Remedy -- Set $IPO_MODE to #BASE
-- Set $ORI_TYPE to #VAR or #CONSTANT
2822 Message text Blending $ORI_TYPE=#VAR/#CONSTANT to $ORI_TYPE=#JOINT
not possible
Cause -- Inconsistent axis angle in CP--CP approximation from $ORI_TYPE
= #VAR or #CONSTANT to $ORI_TYPE = #JOINT. This happens if
one of the wrist axis angles turns too greatly during a non--OriJoint
CP motion (see also message #1491).
Monitor --
Effect -- Exact stop
Remedy -- Avoid excessive rotation of the wrist axis angles during non--OriJoint
motions.
2829 Message text OriJoint not possible: Configuration of start and target position differs

Cause -- This occurs when the TCP is moved over the extension of the line
A 2 – A 3 (“elbow configuration”). This prevents the TCP from moving
with a different orientation to a programmed point.
Monitor --
Effect -- Ramp--down braking; the motion block cannot be executed with
$ORI_TYPE = #JOINT.
Remedy -- Set $ORI_TYPE to #VAR or “CONSTANT”
-- Change the orientation of the end point
4300 Message text <object name> COMPILE ?

4301 Message text <object name> COPY ?

4302 Message text <object name> OVERWRITE ?

Cause -- A file that is to be copied already exists.


Monitor -- In command processing.
4303 Message text <object> DELETE ?

4304 Message text <object> LINK ?

4305 Message text <object> UNLINK ?

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Error messages / troubleshooting

4307 Message text DELETE COMPLETE PROCEDURE ?

Cause -- DEF block is to be deleted. The DEF block can be deleted only
together with the complete procedure.
Monitor -- In command processing.
Effect -- None.
Remedy -- None.
4308 Message text DELETE COMPLETE INITIALIZATION ?

Cause -- An array declaration is to be deleted for which there is a subsequent


initialization (also subsequent blank lines). These have to be deleted too.
Monitor -- In command processing.
Effect -- None.
Remedy -- None.
4309 Message text <object name> PROGRAM, OVERWRITE ?

Cause -- The file already exists and the operator intends to recreate it (COPY).
Monitor -- None.
4310 Message text <object name> SELECTED, OVERWRITE ?

Cause -- The file already exists, is selected and the operator intends to recreate it.
Monitor -- Command processing (COPY command).
Effect -- None.
4311 Message text <object name> PROGRAM DELETE ?

Cause -- The file that is to be deleted is a program.


Monitor -- Command processing (DELETE command).
Effect -- None.
4312 Message text <object name> SELECTED, DELETE

Cause -- The file that is to be deleted is selected.


Monitor -- Command processing (DELETE command).
Effect -- None.
4314 Message text DIRECTORY NOT FOUND ! CREATE ?

Cause -- The destination directory has not yet been created on the PC.
Monitor --
Effect --
Remedy -- Create the directory.
4315 Message text <file name> ACTIVE : PROCESS STOP ?

Cause -- Reloading of machine data.


Monitor --
Effect -- Program processing is stopped.

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1 Error messages / troubleshooting (continued)

Remedy -- The program must be restarted after the machine data have been
loaded.
9000 Message text ******

Cause -- User--programmable message.


Monitor --
Effect --
Remedy --

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