SOFTWARE

KR C2

Operating Handbook

New Features
KUKA System Software (KSS) Release 5.2

Issued: 14 Jan 2004 Version: 00

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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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Part 1: Operating Handbook

Introduction
Safety
Operator Control
Start--up
User Programming
Appendix

Part 2: Programming Handbook

Configuration
Expert Programming
Additional Functions
Applications
Appendix

Teil 3: Administratorhandbuch

Installation
Bedienoberfläche konfigurieren
Programmierumfeld konfigurieren
Überwachung / Verhalten der
Steuerung Anhang

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SOFTWARE

KR C2

Operator Control

New Features
KUKA System Software (KSS) Release 5.2

Issued: 14 Jan 2004 Version: 00

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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 . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 .............................................................................. 7
1.2 .............................................................................. 7
1.3 Running up the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 .............................................................................. 8
1.5 Controller response when switched back on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.1 .............................................................................. 8
1.5.2 Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.2.1 .............................................................................. 8
1.5.2.2 Power failure with the system running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.3 Setting external power supply and user outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 The KUKA Control Panel (KCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1 Operator control elements of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 WORLD coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 BASE coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 TOOL coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 ROBROOT coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Jogging the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 .............................................................................. 18
4.2 .............................................................................. 18
4.3 .............................................................................. 18
4.4 .............................................................................. 18
4.5 Jog override (jog velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Graphical user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.1 .............................................................................. 19
5.1.2 Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.3 .............................................................................. 19
5.1.4 Directory and file list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.4.1 Pop--up menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 “File” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.1 .............................................................................. 20
5.2.2 .............................................................................. 20
5.2.3 .............................................................................. 20
5.2.4 Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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5.2.5 Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5.2.5.1 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5.3 “Edit” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.3.1 ............................................................................. .23
5.3.2 ............................................................................. .23
5.3.3 ............................................................................. .23
5.3.4 ............................................................................. .23
5.3.5 ............................................................................. .23
5.3.6 ............................................................................. .23
5.3.7 ............................................................................. .23
5.3.8 Cancel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.3.9 Reset program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

6 Executing, stopping and resetting a program . . . . . . . . . . . . . . . . . . . . . . 24

6.1 ............................................................................. .24
6.2 Program velocity (Programm override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3 Stop reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3.1 ............................................................................. .24
6.3.2 ............................................................................. .24
6.3.3 Maximum braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3.4 Short--circuit braking (dynamic braking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.4 Manual program execution (jog mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.4.1 ............................................................................. .25
6.4.2 ............................................................................. .25
6.4.3 ............................................................................. .25
6.4.4 Executing individual program lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.5 Automatic program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.5.1 BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.5.2 Complete program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.5.3 Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.5.4 Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.5.5 Resetting a program (Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

7 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.1.1 ............................................................................. .29
7.1.2 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.2 ............................................................................. .30
7.3 ............................................................................. .30
7.4 ............................................................................. .30
7.5 ............................................................................. .30
7.6 Hardware Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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 1 Running up / shutting down the controller

1 Running up / shutting down the controller

1.1
1.2
1.3 Running up the controller
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.

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

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Operator Control

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.

If the robot controller logs onto the network, this has a significant effect on the time the
controller takes to boot.

1.4
1.5 Controller response when switched back on
1.5.1
1.5.2 Cold start
1.5.2.1
1.5.2.2 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. 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 are backed up on the hard disk. Once the files are saved, the system
waits until the PowerOff delay has elapsed. This is then followed by one of two eventualities:
G Power is restored before the PowerOff delay has elapsed
The robot system is not shut down, but an acknowledgment message is generated
which must be acknowledged. Work can then be resumed.
G Power is still absent when the PowerOff delay has elapsed
The status of the kernel system is backed up on the hard disk and the controller is
shut down, in a controlled manner, by the battery back--up. The control system is
then switched off.

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 1 Running up / shutting down the controller (continued)

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

be destroyed. In this case, a cold start is carried out.
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 at the point at which the
pro-gram was interrupted. Once again, 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,
under certain circumstances, be necessary at the point where the path was left (RET
position).

1.5.3 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 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 deactivated as standard. If the system is configured accordingly, however, the
user outputs are restored when power returns.

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Operator Control

2 The KUKA Control Panel (KCP)

KCP2
E--STOP

The “KUKA Control Panel”, referred to hereafter as “KCP”, forms the human--machine
inter-face and is used for easy operation of the “KR C... ” robot controller. 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. The LCD screen is used to visualize
operator and programming actions.

2.1 Operator control elements of the KCP

Mode selector switch
Using this keyswitch you can switch between
the different operating modes.
The current setting of the mode selector
switch is displayed in the status line.

Operating Jogging Program mode

mode
Jog velocity Jog velocity
Keep enabling switch held down Keep enabling switch held down
(Test 1) Press jog key or Space Mouse Keep Start key held down

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 2 The KUKA Control Panel (KCP) (continued)

Jog velocity Programmed velocity

Keep enabling switch held down Keep enabling switch held down
(Test 2) Press jog key or Space Mouse Keep Start key held down
Programmed velocity
Not possible Drives ON
(Automatic) Press Start key briefly
Programmed velocity
Not possible Drives ON
(Automatic External start
External)

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

Automatic operation is only possible with the safety circuit closed.

Enabling switches
For certain actions, such as jogging the
robot, one of the enabling switches must
be held down.
The enabling switches are situated on the
back of the KCP and on one of the holding
domes.
They are all designed as two--position
buttons. For program execution, a button
must be held in the middle position.
Releasing the button or pressing it hard
triggers dynamic braking.

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Operator Control

3 Coordinate systems
In jog mode, the robot is moved in accordance with the selected coordinate system.

Joint coordinate system

WORLD coordinate system

BASE coordinate system

TOOL coordinate system

As jog mode, select “jog keys” or “Space Mouse”. Then use the +/-- status key to select
the desired coordinate system.

Further information on jogging with the Space Mouse and jog keys can be found in the
chapter [Jogging the robot].

3.1 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.

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

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 3 Coordinate systems (continued)

3.2 WORLD coordinate system

The WORLD coordinate system is a stationary, Cartesian coordinate system. It
serves as the root coordinate system for the BASE and ROBROOT coordinate
systems.

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

The World coordinate system only corresponds with that of the Space Mouse if the
operator with the KCP is standing directly in front of the robot.

Position of
operator Robot
As standard, the origin of the WORLD coordinate system is located at the center of the
robot base.

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Operator Control

3.3 BASE coordinate system

The BASE coordinate system is a Cartesian coordinate system which is
calibrated in such a way that the origin is located in or at a workpiece or fixture.

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

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

The BASE coordinate system is relative to the WORLD coordinate system.

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 3 Coordinate systems (continued)

3.4 TOOL coordinate system

The TOOL coordinate system is a Cartesian coordinate system which is
calibrated in such as way that the origin is located in the tool.

Example: servo gun Example: torch

-- +

-- +

-- +

-- +

-- +

-- +

Jog keys Space Mouse

The TOOL coordinate system is generally orientated in such a way that its X axis is
identical to the working direction of the tool (tool direction).

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

The TOOL coordinate system is relative to the BASE coordinate system.

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 3 Coordinate systems (continued)

3.5 ROBOT coordinate system

The origin of the ROBROOT coordinate system is always located in the base of the robot
and is relative to the WORLD coordinate system. This allows the definition of an offset of
the robot relative to the WORLD coordinate system.

On delivery, the origin of the ROBROOT coordinate system is identical to that of the
WORLD coordinate system and is located in the base of the robot.

Detailed information on the subject “ROBROOT” may be found in the Programming

Handbook, in the main chapter [Expert Programming], chapter [Motion program-
ming].

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Operator Control

4 Jogging the robot

4.1

4.2

4.3

4.4

4.5 Jog override (jog velocity)

In some cases, it is of vital importance to reduce the velocity of the robot. Only in this way
is it possible to address points precisely and avoid collisions between the workpiece and
the tool.

The jog override value can be

modified using the “+/--” status
key. The current setting is
displayed above the symbol.

...

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

Depending on the configuration, the HOV value last used is restored when the system
is switched to “T1” mode.

With the Space Mouse, the jog velocity can be further decreased by reducing the
deflection of the mouse (velocity proportional to the deflection).

The jog override increment can be increased. To do this you must activate the option
“Jog OV Steps on/off” 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 defined in the machine data.

Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging Program OV Steps
User group Jog OV Steps
Cur. tool/base Mouse position
Tool definition Mouse configuration
On/Off Options
Miscellaneous

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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 5 Navigator

5 Navigator
5.1 Graphical user interface
5.1.1

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

The filter setting and template selection are not available in the user group “User”.

Filter

The current filter setting is The current drive or directory is

displayed above the directory displayed in the directory or file list.
structure.
The filter can be set to
“Modules” or “Detail view”.

Information on the user group “Expert” can be found in the Programming Handbook in
the main chapter [Configuration], chapter [Configuring the system].

Template

The template selection is displayed The current drive or directory is

above the directory structure. displayed in the directory or file list.

5.1.3

5.1.4 Directory and file list

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Operator Control

5.1.4.1 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
are available for selection which can actually be executed at a given moment.
The menu can be opened in one of the following ways:

Pressing the “!” arrow key;

Pressing the right mouse button (if a computer mouse is connected);

Pressing the application key (if a corresponding keyboard is connected

to the system).

Select Without parameters The pop--up menu opens. This menu only offers
Open With parameters
Archive those functions that are actually available.
Cut File/Folder
Copy Data list
Delete Error list
Rename
Duplicate
Attributes

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.

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.

5.2 “File” menu

5.2.1

5.2.2

5.2.3

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 5 Navigator (continued)

5.2.4 Archive
This function allows you to save important data to floppy disk. With Navigator, the user
can see what is stored in these archives.
File New
Open
Print
Archive All
Restore Applications
Rename Machine data
Format floppy disk Configure Drivers

Attributes Log Data I/O Longtexts

Filter Current selection KUKA TechPack

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

Date Wednesday, 30 July 2003 15:35:36

Source: FILEHANDLER No.: 35
Do you really want to archive the selected file(s)?

Yes The selected files are archived.

No The selected files are not archived.

If you try to insert a file in an existing 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.

Date Monday, 4 August 2003 11:42:29

Source: C3ARC No.: 0
Wrong robot archive: Archive: RName System: Rob--1

Ignore The selected files are added to the archive.

Cancel The selected files are not added to the archive.

The status line of the Navigator indicates the current status:

Date Wednesday, 30 July 2003 15:38:08

Source: FILEHANDLER No.: 8

Save files...

Cancel The archiving can be terminated at any time by pressing the “ESC” key or
the softkey “Cancel”.

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Operator Control

5.2.5 Restore
This command allows you to restore archives.
File New
Open
Print
Archive All
Restore Applications
Rename Machine data
Format floppy disk Configure Drivers

Attributes Current selection I/O Longtexts

Filter KUKA TechPack

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 files are restored.

Date Wednesday, 30 July 2003 15:50:21

Source: FILEHANDLER No.: 34
Do you really want to restore the selected file(s)?

Yes The selected files are restored.

No None of the selected files is restored.

The action will then be displayed in the message window:

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

In the event of a version conflict between the archive files and the system files, an error
message is generated. Depending on the configuration, it may still be possible to copy
the affected files.

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 5 Navigator (continued)

5.2.5.1 All
All data, with the exception of log files, are loaded from the floppy disk back onto the hard
disk.
“KRC:\”
“C:\KRC\Data\”
“C:\KRC\Roboter\Init\”
“C:\KRC\Roboter\IR_Spec\”
“C:\KRC\Roboter\Template\”
The I/O drivers are also reconfigured. The user interface is then reinitialized in order to
up-date any changes, e.g. to the menu structure (MenueKeyUser.ini).
Depending on the configuration, the directory “R1”, including all files and subdirectories,
can be deleted before the files are restored. The request for confirmation before the R1
directory is deleted also depends on the configuration. The directory structure and files
are restored exactly as they were when they were originally archived.

Date Friday, 1 August 2003 11:02:13

Source: C3ARC No.: 0
Delete folder R1 before restore?

No The directory “R1” is not deleted; the existing programs are overwritten
individually during the restore function.

Yes Before the files are restored, the directory “R1”, including all files and
subdirectories, is deleted.

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

Restore Restr. All Open Save all

5.3 “Edit” menu

5.3.1

5.3.2

5.3.3

5.3.4

5.3.5

5.3.6

5.3.7

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Operator Control

5.3.8 Cancel program

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

5.3.9 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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 6 Executing, stopping and resetting a program

6 Executing, stopping and resetting a program

6.1
6.2 Program velocity (Programm 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 key can
be found in the right--hand status key bar, can be used for this purpose. The
value can be increased or decreased using the +/-- key.

It is possible to alter the POV value not only in increments of 1%, but also directly
between values of 1, 3, 10, 30, 50, 75 and 100 per cent.
Configure I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging Program OV Steps

User group Jog OV Steps

Cur. tool/base Mouse position
Tool definition Mouse configuration
On/Off Options
Miscellaneous

Depending on the configuration, the program override is automatically set to 10 percent

when the mode selector switch is switched to “T2”. If the mode is changed back to “T1”,
the last value used for “T1” is restored.

6.3 Stop reactions

6.3.1

6.3.2

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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Operator Control

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.

6.4 Manual program execution (jog mode)

Select a program and set the mode selector switch to mode T1 or T2.

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.
If the option “AutoAck” has been activated, all the acknowledgeable messages
displayed are acknowledged the first time 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).

Depending on the configuration, the program override is automatically set to 10 percent

when the mode selector switch is switched to “T2”. If the mode is changed back to “T1”,
the last value used for “T1” is restored.

6.4.1

6.4.2

6.4.3

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 6 Executing, stopping and resetting a program (continued)

6.4.4 Executing individual program lines

First of all, ensure that the mode selector switch is in the test mode
position (T1 or T2).

Edit cursor
Block pointer (program poin-
ter)

Line Sel.

Program execution starts at the line indicated by the block pointer on the left. For the
purpose of selecting a particular block in the program, move the edit cursor to the desired
program line with the aid of the arrow keys. Then press the softkey “Line Sel.”. The block
pointer now jumps to the selected line.
Now start the program from the selected line. Press one of the enabling
switches and the “Program start forwards” key. During program execution, the
program pointer moves to the line that is currently being executed.

If the option “AutoAck” has been activated, all the acknowledgeable messages
displayed are acknowledged the first time 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).

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.

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Operator Control

6.5 Automatic program execution

In manufacturing processes, programs or program sections are often executed cyclically.
For example, if the end of the program has been reached, the program can be executed
again.
To start automatic program execution, select a program and then switch the
robot drives on.

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

6.5.1 BCO run

A BCO run is now necessary. Press the “Program start forwards” key.

If the option “AutoAck” has been activated, all the acknowledgeable messages
displayed are acknowledged the first time 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).

6.5.2 Complete 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” mode, press the “Program start forwards” key.

In “Automatic External” mode, a PLC assumes control of the system.

6.5.3 Stopping program execution

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

Quitt In “Automatic External” mode, the acknowledgement message “Passive

STOP” is displayed in the message window. This message must be
acknowledged before the program can be resumed.
C... Time No. Source Message
11:09:16 209 Passive STOP KCP
11:09:16 1370 KCP Passive 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.

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 6 Executing, stopping and resetting a program (continued)

6.5.4 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.

In “Automatic” mode, press the “Program start forwards” key.

In “Automatic External” mode, a PLC assumes control of the system.

It may be necessary to carry out a BCO run at this point. This always takes place
by the direct route from the current position to the end 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!

6.5.5 Resetting a program (Reset)

If you wish to reset a program, ensure first of all that the mode selector
switch is in the “T1”, “T2” or “Automatic” position

Program FOLD
Copy
Paste
Cut
Delete
Find
Replace
Cancel program
Reset program
Modify

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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Operator Control

7 Monitor
7.1 Inputs/Outputs
7.1.1

7.1.2 Digital outputs

When this option has been selected, a status window is opened, displaying the signal
states of the robot controller’s inputs.
The input values (ranging from --10 V to
+10 V) and their long texts are displayed in
the boxes. The values of these inputs
cannot be changed.

Tab + You can open the status window for displaying the 32 outputs using this
softkey.

The output values (ranging from --10 V to

+10 V) and their long texts are displayed in
the boxes.

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

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 7 Monitor (continued)

If the name of an input or output or the value of an output is selected using

the arrow keys, it can be edited by pressing the Enter key.

Enter the new value by

means of the keyboard or
numeric keypad.

Accept the modified value by pressing the Enter key again.

Pressing “ESC” rejects the change and closes the status

ESC window.

7.2
7.3
7.4
7.5

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Operator Control

7.6 Hardware Info

Monitor I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info

The operator can use the command Hardware Info to obtain further information about the
individual components of the robot system.

Refresh Refreshes the display.

Export Outputs the hardware information as an XML file.

Close Exits the “Hardware Info” display.

The following hardware components can be displayed:

Cabinet Robot

PC 1st RDC/1st PM

MFC 2nd RDC/2nd PM

1st DSE

2nd DSE

1st KPS

1st KSD
...

8th KSD

2nd KPS

1st KSD
...

8th KSD

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A
Archive, 19
Automatic program execution, 26

B
BASE coordinate system, 10 BCO run, 26

C
Continuing a program, 27
Coordinate systems, 10

D
Detail view, 17
Directory list, 17
Drives OFF, 26
Dynamic braking, 24

E
Edit, 21
“Edit” menu, 21
Enabling switches, 9
Executing program lines, 25
Executing, stopping and resetting a program, 23

F
File, 18
File list, 17
“File” menu, 18

G
Graphical user interface, 17

H
Header, 17

J
Jog mode, 24
Jog OV Steps, 16
Jog override, 16
Jogging the robot, 16
Joint coordinate system, 10
 Index

M
Manual program execution, 24
Maximum braking, 23
Mode selector switch, 8
Modules, 17
Monitor, 28

N
Navigator, 17

O
Operator control elements, 8

P
Program override, 23
Program velocity, 23

R
Reactivation, 6
Reset, 27
Reset program, 27
Restore, 20
Running up the controller, 5

S
Short--circuit braking, 24
Signal states, 28
Simultaneous motion, 10
Status line, 8
Stop reactions, 23
Stopping program execution, 26

T
TOOL coordinate system, 10

W
WORLD coordinate system, 10

X
X axis, 13

Index --i