ArcTechDigital Pro en

SOFTWARE
KR C...
ArcTechDigital 2.3
for power sources with program number control
Configuration for KUKA.KR C 5.2, 5.3, 5.4, 5.5
Issued: 11 April 2006

ArcTechDig_P_R23 04.07.00 en
Version: 00
1 of 68
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
1.1 1.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System requirements, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the configurable options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8 9
2
2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2
Description of the ArcTechDigital commands . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyswitch for program execution without welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program run mode GO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switching on the welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start welding -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal diagram ARC_ON and ARC_SWI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding and ending seams -- ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal diagram ARC_OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding a seam in several sections -- ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal diagram ARC_SWI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11 11 11 11 11 12 13 13 14 15 15 16 17
3
3.1 3.2
Programs of the ArcTechDigital package . . . . . . . . . . . . . . . . . . . . . . . . . .

Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the ArcTechDigital files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19 20
4
4.1 4.2 4.3 4.3.1
ArcTechDigital - basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activating the ARC 20 option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum configuration for power source interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum configuration for program number control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meaning of the variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23 23 25 28
5
5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.2.1 5.3 5.3.1 5.3.2
Principles of the definable signal table . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview, definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index tables for configuring physical outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal tables for digital outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index table for physical digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal tables for digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the signal states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index table for physical digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal tables for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29 29 29 30 30 31 31 32 32 33
6
6.1
Assignment of the signal grouping in normal operation . . . . . . . . . . . .

Assignment of the outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
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ArcTechDigital 2.3 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 Output group O_WELD_START [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_ACK_START [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_STROB_PGNO [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_SEAM_END [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_ACK_WELD_E[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal output groups for fault service function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_ARC_ON [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_WELD [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_CLEAN [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_ACK_FLT [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assignment of the inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input group I_WELD_COND [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input group I_START_MOVE [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input group I_WELD_END [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input group I_WELD_FLT [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polling of the external keyswitch (Hot/Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time_out when polling the inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 36 37 37 38 39 39 40 41 41 42 42 43 43 44 45 45
7
7.1 7.2 7.3
Options for program number specification . . . . . . . . . . . . . . . . . . . . . . . . .

Signal flow of the program numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting -- parity bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing diagram program number interface (a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47 47 48
8
8.1 8.1.1 8.2 8.2.1 8.3
Setting the restart options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESTART_OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reaction to interpreter stop (STOP key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration in event of ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition repetition monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition fault message suppression option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
49 49 50 50 50
9
9.1 9.2 9.2.1 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4 9.4.1 9.5 9.5.1
Enumeration of the signal groups for fault service functions . . . . . . . .

Types of faults and causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal output group O_FLT_ARC_ON[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding faults and robot faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reaction to robot faults, EMERGENCY STOP and DRIVES OFF . . . . . . . . . . . . . . . . . . . . . Signal output group O_FLT_WELD[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal output group O_FLT_CLEAN[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal output group O_ACK_FLT [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal O_FLT_SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal APPL_RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special feature IR_STOPMESS program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joint activation/deactivation routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configurable fault service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault service functions defined by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51 51 51 51 51 52 52 52 52 53 53 53 54 54
10
10.1
Further options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program test in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55
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10.2 10.3
Ignition fault message suppression option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seam monitoring delay option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 55
11
11.1 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.2.4.1 11.2.4.2 11.2.5
Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block selection response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two--dimensional weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating the Spiral weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure--of--eight weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing and creating patterns for mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing existing weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating your own weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
56 57 59 59 61 62 62 63 64
12
12.1 12.2 12.3 12.4 12.5 12.6
Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Message groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Originator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
65 65 65 66 66 66
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ArcTechDigital 2.3
6 of 68
General
General
In the development of a welding robot that is easy and safe to use, top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control, as well as uncomplicated handling of the ArcTechDigital technology package. This is intended to allow the trouble--free operation, parameter and hardware configuration and programming of arc welding applications. The entire range of KRL commands are available to you at the expert level. Configuration requires sufficient knowledge of the KRL programming language. ArcTechDigital features: G G G G G G G G G Menu--guided creation of programs at the user level. Simple operation using application--specific softkeys and menus. Prepared programs and subroutines. Adaptation to the peripheral equipment and configurable options of the digital outputs. Simple setting of variables, entries in files and parameter lists. Use of the function generators for two--dimensional mechanical weaving as well as the possibility of configuring your own weave patterns. Adaptation to various welding controllers with program number control and their different coding systems. Various routines used for ignition faults and monitoring of the number of ignition attempts. Restart options in case of faults.
This documentation has been created as a supplement to the documentation [Arc Welding, ArcTechDigital -- Operation] for the user group Expert. In addition to fundamental descriptions accompanied by schematic sequence diagrams and screenshots of application tests, information on standard routines as well as specific ArcTechDigital applications have also been provided. This is intended to make parameter and hardware configuration and the programming of arc welding applications easier. In the development of a welding robot that is easy and safe to use, top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control, as well as uncomplicated handling of the ArcTechDigital technology package. The entire range of KRL commands are available to you at the expert level. This requires sufficient knowledge of the KRL programming language. The ARC Tech 20 commands ARC ON, ARC OFF and ARC SWITCH are described in Chapter 2. Among other things, information is provided on variable settings, entries required in files, and parameter lists. Chapter 3 provides information on the programs and files contained in the ArcTechDigital package. Information and notes on ArcTechDigital--specific basic settings are provided in Chapter 4. Chapter 5 explains adaptation to the peripheral equipment. The configuration of the digital input and output groups is dealt with in Chapter 6. The transfer of program numbers is explained in Chapter 7. Chapter 8 contains information on the restart options. Chapter 9 finally deals with fault situations and fault service functions. Types of faults that can occur during the ignition and welding processes, their possible causes and appropriate corrective measures are described. Further ArcTechDigital settings can be found in Chapter 10.
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ArcTechDigital 2.3 The mechanical weaving option included in the ArcTechDigital technology package is described in Chapter 11. There you will find fundamental information on the mode of operation of the function generators, two--dimensional mechanical weaving, and the configuration of weave patterns. Examples are used to show you how to change existing patterns and how to create your own patterns. Chapter 12 contains a list of error messages along with their causes, effects and remedial action.
1.1
System requirements, Installation

The Software ArcTechDigital can be used with the following KRC--Software: -- KR C2, KR C2ed05 -- Software Rel. 5.2, 5.3, 5.4, 5.5
From system software version 5.1 onwards, technology packages are offered exclusively as ad--on software modules. These are available on CD--ROM. The installation, uninstallation, reinstallation and update of technology packages are described in detail in the documentation [Installation/Uninstallation/Update of Tech Packages].
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General (continued)
1.2
Overview of the configurable options

The ArcTechDigital technology package also provides a range of options in addition to the basic configuration: G Adaptation to various welding controllers with program number control and their different coding systems. G Various routines used for ignition faults and monitoring of the number of ignition attempts. G Re--ignition after faults. G Restart options in case of faults in the seam. G Configurable user--specific strategies and routines in case of faults. G Selection of several defined patterns for mechanical weaving as well as the possibility of programming your own weave patterns. Most options are stored in variables that are defined in the files $CONFIG.DAT and A20.DAT. Fundamental information on operator control as well as the menu--guided creation of programs at user level is provided in the documentation [Arc Welding, ArcTechDigital -Operation].
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ArcTechDigital 2.3
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Description of the ArcTechDigital commands
2
2.1
Description of the ArcTechDigital commands

General
The general ArcTechDigital commands are described in this chapter. Softkey assignments and their meaning. Explanations of the main terms ARC ON, ARC SWI and ARC OFF with sequence diagrams and signal diagrams.
2.1.1
Keyswitch for program execution without welding

If the keyswitch function has been configured, the appropriate status must be active (I_ENB_W_EXT.STATE TRUE or FALSE according to the configuration). Otherwise welding is not possible.
2.1.2
Program run mode GO

Welding is only possible in the program run mode GO. MSTEP and ISTEP do not allow the program to run properly. More detailed information on selecting program run modes can be found in the chapter [Executing and stopping programs].
2.1.3
Switching on the welding process

After the computer runs up, (hot) welding is always deactivated, as is indicated by the welding torch being struck through on the left--hand status key bar. In order to be able to weld, this status key must be switched to the HOT position corresponding to the symbol shown on the left.
2.2
Start welding - ARC ON

The command ARC ON contains the parameters for moving the welding torch (type of motion, velocity, etc.) from the home position to the start point of the seam, the start parameters (start delay) and the program number. While the ARC ON program phase is being executed, the system scans the peripheral signal I_WELD_COND to check whether the welding controller is ready. When the welding torch reaches the ignition position, arc ignition is enabled by means of the signal O_WELD_START[ ]. When the arc has been struck, the welding power source supplies the signal I_START_MOVE[ ], as a result of which the robot starts to move in accordance with the programmed path and velocity. The signal O_ACK_START[ ] informs the welding controller that the robot is moving. The movement from the home position to the start point of the seam can be executed as a PTP, LIN or CIRC motion. Approximation is not possible for ARC ON; the torch is stopped exactly at the start of the seam.
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ArcTechDigital 2.3
2.2.1
Schematic sequence diagram ARC ON

For the purposes of simplicity, not all options are illustrated.
ARC ON
Positioning motion to ignition position
Initialization Standby test (Option polled) (Poll to see if power source ready) (Keyswitch polled) (Weld ON softkey) I_WELD_COND[ ] I_ENB_W_EXT [ ]
Prg_ON_MODE <>0
Ignition program number output
Ignition fault message

N Y
Weld start
O_WELD_START[ ]
Timeout
Current flowing
I_START_MOVE[ ] O_ACK_START[ ]
Y
Synchronization Activation of monitoring system
End ARC ON
Process continued with the next ARC OFF or ARC SWITCH command
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Description of the ArcTechDigital commands (continued)
2.2.2
Signal diagram ARC_ON and ARC_SWI
ARC_ON
PRG_SWI_MODE = 1 P0 P1 P2 I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ] I_START_MOVE [ ] (O_ACK_START [ ] )
if PRG_ON_MODE<> 0 Prog. no. = 1
ARC_SWI
Prog. no. = 2
Ignition time
O_STROB_PGNO PRG_SWI_MODE = 2
P0 P1 P2
Prog. no. = 1 Prog. no. = 2 Prog. no. = 3
2.3
Welding and ending seams - ARC OFF

The welding command ARC OFF contains the program number for the power source, the motion parameters and, if relevant, the mechanical weaving parameters used for a single seam from a weld start (ARC ON) to the end of the seam, and also parameters for crater filling. A single seam therefore requires at least two commands, namely ARC ON and ARC SWITCH. If a seam consists of several seam sections with different motion and/or weld parameters, the command ARC OFF is used for the last seam section. Motions from the ignition point (ARC ON), or in case of several seam sections from the target point of the last section of an ARC SWITCH command to the end point of the seam, can be LIN or CIRC motions. Approximate positioning to the next motion block is not possible with ARC OFF; the motion concludes with the exact positioning at the target point (end of the seam).
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2.3.1
Schematic sequence diagram ARC OFF
ARC OFF
Positioning motion to the end point with weld velocity of the ARC_OFF command
Program number output
Program number transfer
O_STROB_PGNO[ ]
Cancel weld start signal at end position
O_SEAM_END[ ]
Current off Y
Synchronization
I_WELD_END[ ]
O_ACK_WELD_E[ ]
End ARC OFF
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2.3.2
Signal diagram ARC_OFF
ARC_SWI
PRG_SWI_MODE = 1
ARC_OFF
P0 P1 Crater time + Burnback time + Gas postflow time
P2
Prog. no. = 6 PRG_SWI_MODE = 1
Prog. no. = 5
O_STROB_PGN0 [ ] O_SEAM_END [ ] I_WELD_END [ ]
O_ACK_WELD_E[ ]
PRG_SWI_MODE = 2
P0 P1 P2
Prog. no. = 5
2.4
Welding a seam in several sections - ARC SWITCH

The command ARC (shown as ARC SWITCH in the menu) is used between the commands ARC ON and ARC OFF when the seam is divided into several sections with different motion and/or weld parameters. ARC SWITCH contains the program number, the motion parameters for the current section of the seam, and also the parameters for the weld velocity and the mechanical weaving for the current section of the seam. In the interest of efficient operations, approximate positioning should be used for motions in ARC SWITCH commands if exact positioning between individual seam sections is not absolutely essential.
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2.4.1
Schematic sequence diagram ARC SWITCH
ARC SWITCH
Positioning motion to the end point with weld velocity of the ARC_SWI command
Program number output
Program number transfer
O_STROB_PGNO[ ]
End ARC SWITCH
Process continued with the next ARC OFF or ARC SWITCH command
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2.4.2
Signal diagram ARC_SWI
ARC_ON
PRG_SWI_MODE = 1 P0 P1 P2 I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ] I_START_MOVE [ ] (O_ACK_START [ ] )
if PRG_ON_MODE<> 0 Prog. no. = 1
ARC_SWI
Prog. no. = 2
PRG_SWI_MODE = 1 Ignition time
O_STROB_PGNO PRG_SWI_MODE = 2
P0 P1 P2
Prog. no. = 1 Prog. no. = 2 Prog. no. = 3
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Programs of the ArcTechDigital package
3
3.1
Programs of the ArcTechDigital package

Program structure
In the following block diagram the program structure of the KR C1 robot controller is shown in the Welding robot configuration. The interface to the welding controller is implemented in the form of a configurable handshake. Settings for analog outputs as well as digital outputs and inputs are defined in the file $Config.dat. $Config.dat. A20 GLOBALS Global and application data Cell.src Autom./Ext. organization program IR_Stopm.src General handling of robot faults
Bas.src Functions for robot motion
P00.src Functions for Autom./Ext. Handshake Check Home
Flt_serv_d.src User-definable fault service functions
.dat
Weav_def_d.src Definition and parameters for mechanical weaving
A20.src Functions for arc welding
.dat
Sps.sub Switch--off routine after an interpreter stop
Information about the hardware periphery of the robot controller can be found in the [Operating Handbook], chapter Connector panel / Peripheral interfaces and in the [Periphery] handbook.
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3.2
Overview of the ArcTechDigital files

The files listed below are included in the ArcTechDigital package. To assist you in finding relevant information, you will always see the symbols shown on the left with their file names throughout this documentation wherever the corresponding file or parts of it are described. $Config.dat Contains data specific to ArcTechDigital within the section ;FOLD ARCTECHDIGITAL GLOBALS ; FOLD Structures and Definitions ... ; ENDFOLD (Structures and Definitions) ; FOLD Main Options ... ; ENDFOLD (Main Options) ; FOLD ArcTech Outputs ... ; ENDFOLD (ArcTech Outputs) ; FOLD ArcTech Inputs ... ; ENDFOLD (ArcTech Inputs) ; FOLD Default Datasets ... ; ENDFOLD (Default Datasets) ; FOLD Statuskey Variables ... ; ENDFOLD (Statuskey Variables) ; FOLD Peripheral Output groups ; outputs weld start ... ; outputs acknowledge start move ... ; strobe program number ... ; outputs weld end ... ; outputs acknowledge weld_end ... ; outputs fault while arc on ... ; outputs stop weld after interrupt on seam ... ; outputs stop cleaner after interrupt ... ; outputs acknowledge fault ... ; output for fault message ... ; Wirefeed control ... ; ENDFOLD (Peripheral Output groups)
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3 ; ;
Programs of the ArcTechDigital package (continued)
FOLD Peripheral Input groups inputs as condition befor weld can start ... ; inputs start moving ... ; inputs weld is ended ... ; Counter for Interrupt definition ... ; inputs telling faults while welding ... ; input for external enable weld ... ; ENDFOLD (Peripheral Input groups) ; FOLD Internal System States ... ; ENDFOLD (Internal System States) ;ENDFOLD (ARCTECHDIGITAL GLOBALS) For additional entries, the section User--defined Variables in the file $CONFIG.DAT is available. A20.src A20.dat Flt_serv_d.src Flt_serv_d.dat Main program for arc welding with ArcTechDigital. Local data list for the program A20.SRC. Program for fault strategies defined by the user, including ignition faults. Fault service function (additional START error). Contains local data list for the program FLT_SERV.SRC.
Weav_def_d.src Definition of the patterns for mechanical weaving. You will see the following symbols at various points in this documentation; they indicate whether manual changes are permitted in the section of a file being described. Within the section / block shown, the changes or entries described must be made.
Within the section / block shown, no changes or entries may be made.
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ArcTechDigital - basic settings
4
4.1
ArcTechDigital - basic settings

Activating the ARC 20 option
You must make, or check, the basic settings described below for operation with ARC Tech 20. The ARC20 option must always be activated (TRUE) when executing ArcTechDigital applications. At the same time it must be ensured that the variable A10_OPTION is inactive (DISABLED). Corresponding entries using the menu function Monitor -- Variable -- Single Variable ARC20 Value for ArcTechDigital TRUE FALSE (default) Characteristics ArcTechDigital applications Normal, except ArcTechDigital
4.2
Minimum configuration for power source interface

Signals for basic signal traffic are located in the configuration file. Digital outputs Fold ArcTech Outputs in $Config.dat Digital outputs Configure physical output
$Config.dat
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ArcTechDigital 2.3 Digitale Eingnge Fold ArcTech Inputs in $Config.dat Digital inputs Configure physical input
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ArcTechDigital - basic settings (continued)
4.3
Minimum configuration for program number control

ArcTechDigital permits a variety of coding systems for program numbers for the purpose of ensuring compatibility with the various welding controllers that are used. Some Folds from the file A20.dat (in the directory ...\R1\TP\ArcTechDigital): Fold Main Options in A20.dat
A20.dat
Info The signal declaration SIGNAL ARCD_ProgNr $OUT[from] TO $OUT[to] must correspond to the signal declaration of$Config.dat. If they do not correspond, the program number output will not function.
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ArcTechDigital 2.3 Fold Internal States in A20.dat
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ArcTechDigital - basic settings (continued)
Fold Internal States in A20.dat (Fortsetzung)
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ArcTechDigital 2.3 Fold ARC Messages in A20.dat
4.3.1
Meaning of the variables

Corresponding entry using the menu function Monitor Variable Single: Variable PRG_NO.FIRST_BIT PRG_NO.LENGTH PRG_NO.PARITY PRG_NO.CODING Type INT INT INT INT Characteristics Represents the physical output number of the first bit. Default = 0 Specification of the number of bits. Default = 4 Output number for the parity bit. Coding of the program numbers. -- Coding 1 = dual -- Coding 2 = 1 of n -- Coding 3 = 1 of (n--1)< -- Coding 4 = BCD code Default = 1
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Principles of the definable signal table
Principles of the definable signal table

This section describes the definition of the ArcTechDigital peripheral interfaces, their specific adaptation as well as configurable options:
5.1
5.1.1
Overview, definition
Index tables for configuring physical outputs and inputs
For the purpose of configuring the physical outputs and inputs, two index tables are provided in the block FOLD A20 in the file $Config.dat. G Digital outputs (DIGITAL OUTPUTS) G Digital inputs (DIGITAL INPUTS) Digital control signals from the robot controller to the welding controller -- e.g. Weld start, Gas manual; Digital control signals from the welding controller to the robot controller -- e.g. Arc struck, Weld end.
$Config.dat
In these index tables the assignment of the physical outputs and inputs is defined and references are made to the corresponding signal tables of the controller. This has the advantage that if the terminal assignments for the periphery are changed, it is merely necessary to alter the index tables accordingly.
5.1.2
Signal tables for digital outputs and inputs

The interface concepts are variable. Configuring peripheral outputs and inputs by means of signal tables (so--called triple groups) allows processes to run synchronously. The capability of setting or scanning several signals makes it possible for various welding controllers to be adapted and the timing to be optimized. Signal names of a group beginning with O_... designate digital outputs, and those with I_... designate digital inputs.
$Config.dat
These options are stored in variables that are defined in the file $CONFIG.DAT, FOLD A20 GLOBALS. Settings are stored in this file. You can use the edit function to set or change the values of the variables in $CONFIG.DAT. In addition, menu--prompted viewing and alteration of the variable values is also possible.. For this purpose, a list can be opened in the status window by means of the menu Monitor -- Variable -- Single.. The current value is shown when the variable name is entered. You change this value by entering a new value in the field New value. A syntax check is not performed (for example, MIN and MAX values) when entries are made with the menu function Monitor -- Variable -- Single or when the file is edited. Further information on the ARC 20 signal tables contained in $CONFIG.DAT is provided in the descriptions of the various welding commands (ARC ON, ARC OFF, ARC SWITCH) in Section 3.
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5.2
5.2.1
Digital outputs
Index table for physical digital outputs
Altogether 15 digital outputs (O_WELD_CTRL[1] ... [O_WELD_CTRL[15]) are available; their physical assignment (OUT_NR n) is freely definable. Fold ArcTech Outputs in $Config.dat
Physical outputs State at initialization
Comment (signal name)
Example of corresponding entries using the menu function Monitor -- Variable -- Single: Variable O_WELD_CTRL[1].OUT_NR Type INT Characteristics Assignment of the physical output, e.g. 10 (default: 0) State at initialization (default: FALSE) FALSE = LOW TRUE = HIGH 20 characters between ; please note that if the string is changed, any characters not overwritten (possibly because they are not visible in the window) will be retained.
O_WELD_CTRL[1].INI
BOOL
O_WELD_CTRL[1].NAME_NAT[ ]
STRING
All O_WELD_CTRL[1].OUT_NR array elements are set to 0 at the factory, meaning they are inactive. The element INI defines the state to which the respective physical output OUT_NR is to be set on initialization. The value FALSE sets the output to LOW, the value TRUE to HIGH. The NAME_NAT[ ] entries (signal name) are comments with a string length of 20 characters between the quotation marks (...) whose content may be altered (while retaining the string length!).
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Principles of the definable signal table (continued)
If you make any changes to the comments (signal name) NAME_NAT directly in the file $CONFIG.DAT please ensure that the length of the string between the quotation marks ( ) is exactly 20 characters long; use blanks if required. If you use the menu function Monitor -- Variable -- Single to make changes, an error message is displayed if the string exceeds 20 characters. The following example shows the assignment of the physical outputs and the signal states after initialization.
Index table
DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10,INI FALSE,NAME_NAT[] ...}
Output 10 INI
WELD START
HIGH LOW
Array O_WELD_CTRL[n] INI contains the initial value when the INIT routine is running before reaching the block coincidence movement.
5.2.2
5.2.2.1
Signal tables for digital outputs

Definition of the signal states Up to three outputs can be controlled and for each of these outputs the following parameters can be defined. Output parameters {NO 0,PULS_TIME 0.0,STATE TRUE} {NO 1,PULS_TIME 0.0,STATE TRUE} Characteristics Index disabled (ignored) Index NO 1 (refers to field 1 of the index table O_WELD_CTRL[1]) with static HIGH signal Index NO 2 (refers to field 2 of the index table O_WELD_CTRL[2]) with static LOW signal Index NO 3 (refers to field 3 of the index table O_WELD_CTRL[3]) with HIGH pulse (length: 1 s)
{NO 2,PULS_TIME 0.0,STATE FALSE}
{NO 3,PULS_TIME 1.0,STATE TRUE}
If NO is set to 0 (zero), the index is deactivated and is ignored during execution of the program.
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5.3
5.3.1
Digital inputs
Index table for physical digital inputs
Altogether 15 digital inputs (I_WELD_CTRL[1] ... I_WELD_CTRL[15]) are available; their physical assignment (IN_NRn) is freely definable. All IN_NR array elements are set to 0 at the factory, meaning they are inactive. For the purpose of assigning the physical inputs, you can enter their corresponding numbers in the index table DIGITAL INPUTS of the file $CONFIG.DAT: Fold ArcTech Inputs in $Config.dat
Physical inputs
Comment (signal name)
Example of corresponding entries using the menu function Monitor -- Variable -- Single: Variable I_WELD_CTRL[1].IN_NR I_WELD_CTRL[1].NAME_NAT[ ] Type INT STRING Characteristics Assignment of the physical input, e.g. 2 (default: 0) 20 characters between ; any characters not overwritten will be retained.
All IN_NR array elements are set to 0 at the factory, meaning they are inactive. The NAME_NAT[ ] entries (signal name) are comments with a string length of 20 characters between the quotation marks (...) whose content may be altered while retaining the string length. Also see the note in Section 5.2.1. The following example illustrates the assignment of the physical inputs. I_WELD_CTRL[1] is assigned to physical input no. 2. Index table DIGITAL INPUTS ($CONFIG.DAT, FOLD A20 GLOBALS) DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] WELD SOURCE READY}
IN_NR 0 = input disabled
Signals to: Input 2
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Principles of the definable signal table (continued)
5.3.2
Signal tables for digital inputs

Up to three inputs can be scanned. The following states can be checked for each of these inputs: Input parameter {NO 0,STATE TRUE} {NO 1,STATE TRUE} Characteristics NO 0: input disabled (ignored) A HIGH signal is awaited at the physical input referring to field 1 of the index table I_WELD_CTRL[ ]. A LOW signal is awaited at the physical input referring to field 2 of the index table I_WELD_CTRL[ ].
{NO 2,STATE FALSE}
The following example shows a signal table from the file $CONFIG.DAT for a digital input. The element I_WELD_COND[1].NO with the value 2 refers to array 2 of the index table DIGITAL INPUTS (I_WELD_CTRL[15]) and thus to the physical input configured in it (see Section 5.3). The element STATE specifies the awaited state, in this case TRUE. ; inputs as condition before weld can start DECL FCT_IN_T I_WELD_COND[3] I_WELD_COND[1]={NO 1,STATE TRUE} I_WELD_COND[2]={NO 0,STATE FALSE} I_WELD_COND[3]={NO 0,STATE FALSE} Signal name Status (TRUE = HIGH) Index for addressing in index table I_WELD_CTRL[1 ] Index table DIGITAL INPUTS ($CONFIG.DAT, FOLD A20 GLOBALS) DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] WELD SOURCE READY}
IN_NR 0 = Input disabled
Signals to: Input 2
Example of corresponding entries using the menu function Monitor -- Variable -- Single: Variable I_WELD_COND[1].NO I_WELD_COND[1].STATE Type INT BOOL Characteristics Assignment of the physical input, e.g. 2 (default: 0) Awaited state Default: FALSE
Two other input signals are defined in this example as the second and third conditions that have to be met before welding can be started.
Information on the definition of the terms index table and signal table can be found in Section 6.1.
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Assignment of the signal grouping in normal operation
Assignment of the signal grouping in normal operation

The signal tables provide the capability of defining up to three signals, i.e. of activating up to three different physical outputs with different signal levels by means of one event. There is of course no practical application for this setting; this example is merely intended to illustrate that the reason for missing or incorrect peripheral signals can be an incorrect value assignment. In such cases, it is therefore advisable to check the setting of the variables before looking for faults in the hardware.
6.1
Assignment of the outputs

The blocks with a gray background show the pre--configuration and do not normally need to be changed. See also Section 4.2 Minimum configuration for power source interface.
6.1.1
Output group O_WELD_START [ ]

The Weld Start signal should be assigned to physical output 10. The signal level should be LOW at initialization and statically HIGH at the start of welding. In the index table Digital Outputs, the designation (NAME_NAT) Weld Start and INI = FALSE are already entered in the first line O_WELD_CONTROL[1]. Assign the value 10 to the variable OUT_NR.
Index table
DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10,INI FALSE,NAME_NAT[] ...}
Output 10 INI
WELD START HIGH

LOW
In the signal table outputs weld start, assign the value 1 to the variable NO in the first line O_WELD_START[1]. The signal level should be static, so enter the value 0.0 for PULS_TIME. The element PULSE_TIME allows the programming of pulse times, if they are not overwritten by the current programming by means of inline forms or parameter lists. An output can be static (PULSE_TIME 0.0) or be output in the form of a pulse, in which case the pulse duration is programmed in seconds. For example, PULSE_TIME 0.3 corresponds to a pulse duration of 0.3 seconds.
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ArcTechDigital 2.3 Entries made using the menu function Monitor -- Variable -- Single: Variable O_WELD_START[1].NO O_WELD_START[1].PULS_TIME O_WELD_START[1].STATE Type INT REAL BOOL Characteristics Assignment to element in index table, e.g. 1 (default: 0) Pulse duration in seconds Default: 0.0 (static) Active state Default: FALSE
6.1.2
Output group O_ACK_START [ ]

The O_ACK_START[ ] signal informs the welding controller that the robot has started to move. Assign the value 11 to the variable OUT_NR and set INI = TRUE.
Index table DIGITAL OUTPUTS O_WELD_CTRL[2]={OUT_NR 11,INI FALSE,NAME_NAT[] ...}
Output 11 INI
ACK START
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_ACK_WELD_E[1]={NO 12, PULS_TIME 0.5,STATE TRUE}
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Assignment of the signal grouping in normal operation (continued)
6.1.3
Output group O_STROB_PGNO [ ]

The TRIGGER PROGRAM NO. signal to the welding controller defines the validity of the program number. Assign the value 12 to the variable OUT_NR.
Output 12 INI
STROB_PGNO
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_STROB_PGNO[1]={NO 3, PULS_TIME 0.3,STATE TRUE}
6.1.4
Output group O_SEAM_END [ ]

End of seam reached, crater filling can begin -- O_SEAM_END[ ]. Assign the value 10 to the variable OUT_NR. The configured signal cancels the WELD_START signal following the ARC_OFF command.
Output 10 INI
ARC_ON
HIGH LOW
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6.1.5
Output group O_ACK_WELD_E[ ]

Activated when the weld is finished and the crater has been filled, this output signal enables the program to be continued. Assign the value 14 to the variable OUT_NR.
Output 14 INI
ACK_WELD_E
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_ACK_WELD_E[1]={NO 12,PULS_TIME 0.5,STATE TRUE}
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6.2
6.2.1
Signal output groups for fault service function

Output group O_FLT_ARC_ON [ ]
This output signal group means that a fault occurred during the ARC_ON command. An ignition fault output is set and, at the same time, the WELD_START signal is cancelled. Assign the value 15 or 10 to the variable OUT_NR.
Output 10 INI Index table DIGITAL OUTPUTS

HIGH LOW
O_WELD_CTRL[13]={OUT_NR 15,INI FALSE,NAME_NAT[] ...}
Output 15 INI
FLT_ARC_ON
ARC_ON
HIGH LOW
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6.2.2
Output group O_FLT_WELD [ ]

This output signal switches the welding off and sets an error message for the PLC. Assign the value 10 or 13 to the variable OUT_NR.
Output 10 INI
HIGH LOW
Output 13 INI
FLT_WELD
HIGH LOW
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6.2.3
Output group O_FLT_CLEAN [ ]

These output signals are used to reset the outputs for torch cleaning. Assign the value 9 to the variable OUT_NR.
Output 9 INI
FLT_CLEAN
HIGH LOW
6.2.4
Output group O_ACK_FLT [ ]

These output signals are used to acknowledge error states. Assign the value 8 to the variable OUT_NR.
Output 8 INI
ACK_FLT
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_ACK_FLT[1]={NO 4,PULS_TIME 1.0,STATE TRUE}
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6.3
Assignment of the inputs

The signal tables provide the capability of assigning up to three input signals to a condition. References to the index table Digital Inputs can of course also be made from other signal tables. If several conditions must be met, accordingly more signals must be configured. The inputs are polled using logical ANDing. The signal input groups with a gray background represent the pre--configuration from V2.3 onwards and do not normally need to be adapted. See also Section 4.2 Minimum configuration for power source interface.
6.3.1
Input group I_WELD_COND [ ]

A precondition for welding is a successful check that the peripheral interface signal WELDING SOURCE READY is set. The signal table for I_WELD_COND[ ] reads as follows:
Index table DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 1,NAME_NAT[] ...}
Signals awaited at: Input 1 HIGH signal
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6.3.2
Input group I_START_MOVE [ ]

After successful ignition the welding source supplies the ARC STRUCK signal. This signal is a precondition for the robot to start moving along the path, i.e. for continuation of the process. The corresponding signal table for I_START_MOVE[ ] is as follows:
6.3.3
Input group I_WELD_END [ ]

The WELD END signal is issued on completion of welding and end crater filling. The corresponding signal table for I_WELD_END[ ] is as follows:
Signals awaited at: Input 2 LOW signal
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6.3.4
Input group I_WELD_FLT [ ]

The current welding process (ARC OFF, ARC SWITCH) is monitored, the welding controller supplying a signal in the event of a welding fault or malfunction occurring. The corresponding signal table for I_WELD_FLT[ ] is as follows:
Index table DIGITAL INPUTS I_WELD_CTRL[2]={IN_NR 3,NAME_NAT[] ...} I_WELD_FLT[1] generally monitors the current flow. I_WELD_FLT[2] and [3] generally monitor the following: shielding gas, cooling or wire feed.
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6.3.5
Polling of the external keyswitch (Hot/Cold)

This keyswitch is used for executing programs without hot welding and can only be configured if the welding system is equipped accordingly. For this purpose, configuration of the physical input in the index table DIGITAL INPUTS (see Section 5.3) is required, as too is the reference to this input in the section input for external enable weld of the $CONFIG.DAT file. ; input for external enable weld DECL FCT_IN_T I_ENB_W_EXT={NO 6,STATE TRUE} Corresponding entry using the menu function Monitor -- Variable -- Single: Variable I_ENB_W_EXT.NO I_ENB_W_EXT.STATE Type INT BOOL Characteristics Reference to the physical input in the index table DIGITAL INPUTS I_WELD_CTRL[ ]. Default: 6 Default: TRUE This entry must be made
I_WELD_CTRL[6] = {IN_NR 7........}
6.3.6
Time_out when polling the inputs

The wait time for digital input signals is limited by the variable ; time out while waiting (until fault message) REAL TIME_OUT1=3.0 ; [s] After this configurable wait time, the program is stopped and a corresponding error message is displayed in the message window. Entries made using the menu function Monitor -- Variable -- Single: Variable TIME_OUT1 Type REAL Characteristics Wait time in seconds, default = 3s
A20.DAT
If you receive the message Object not found (no. 2047) while viewing or modifying variables in the file A20.DAT, you must set the value of the variable $DATAPATH[] to /R1/A20 (the characters are part of the string).
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Options for program number specification
7
7.1
Options for program number specification

Signal flow of the program numbers
Variable Type Characteristics Function for ARC ON. -- PRG_ON_MODE=1: The program number is set when the point is reached. -- PRG_ON_MODE=2: The program number is set before the point is reached, during the advance run. Default: 1 Function for ARC SWITCH. -- PRG_SWI_MODE=1: The program number is set when the point is reached. -- PRG_SWI_MODE=2: The program number is set before the point is reached, during the advance run. Default: 1 Defines the smallest program number. Default: 0 Defines the largest program number. *) Default: 15 corresponding to PRG_NO.LENGTH = 4 Current program number
PRG_ON_MODE
INT
PRG_SWI_MODE
INT
PRGNO_MIN PRGNO_MAX PRGNO
INT INT INT
PRG_ON_MODE and PRG_SWI_MODE are normally identical. If PRG_ON_MODE=0, no O_ACK_START[ ] group is set.
7.2
Setting - parity bit

A20.DAT
Parity 0 = default n = output number positive even negative odd
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7.3
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Program number handshake
ArcTechDigital 2.3
ARC_ON
ARC_SWI ARC_SWI
ARC_SWI ARC_OFF
O_ACK_WELD._E [ ]
O_ACK_START [ ]
P0
P1
P2 Prog. = 2 Prog. = 3 Prog. = 4

PRG_SWI_MODE=1 Default
O_STROB _PGNO [ ]
P0 Prog. no. = 3
Prog. no. = 4
Timing diagram program number interface (a)
P1
P2 Prog. no. = 2 Prog. = 2 for SGL

but prog. no. 3 is already set!
PRG_SWI_MODE= 2
Prog. = 3 for SGL

but prog. no. 4 is already set!
Setting the restart options
8
8.1
Setting the restart options

RESTART_OPTION
Possible reactions to welding faults on the seam are defined by means of the variable RESTART_OPT. A20.DAT ; Variables: INT RESTART_OPT=1 Default: 1 (range 0 - 3)
Corresponding entries using the menu function Monitor -- Variable -- Single and characteristics: Variable Value 0 Characteristics -- Remedial action In the event of control or welding faults, the seam is completed without welding after a restart. After welding has been interrupted, the robot repositions the torch to the point of interruption. Welding is subsequently restarted. If welding is interrupted by pressing the STOP key (interpreter stop), the program cannot be restarted. Remedy: release the Start key after releasing the enabling switch. The same function as with RESTART_OPT=1, with the restriction that the number of permissible welding interruptions is limited to a maximum value. This maximum value is defined in the variable MAX_REA20. If this value is exceeded, the seam is completed without welding and a corresponding message is generated. The value specified in MAX_REA20 (default = 3) is valid for the entire seam between the commands ARC ON and ARC OFF. One or more user--defined fault service functions can be specified. Occurrence of a fault triggers a branch to the program FLT_SERV.SRC. Users can define their own fault service functions in this program.
RESTART_OPT 2
8.1.1
Reaction to interpreter stop (STOP key)

Pressing the STOP key triggers an interpreter stop. The welding process and torch cleaning station are switched off by the constantly--running parallel program SPS.SUB. Welding is not restarted when the Start key on the KCP is pressed.
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8.2
8.2.1
Configuration in event of ignition faults

Ignition repetition monitoring
The following variables are available for repeat ignition attempts on a seam: The number of permissible restart attempts is programmed with the variable MAX_AUTO_R, and the maximum number of welding faults per seam before an error message is generated is programmed with MAX_REA20. A20.DAT ; Variables: INT MAX_AUTO_R=3 Maximum number of ignition attempts
Corresponding entries using the menu function Monitor -- Variable -- Single: Variable MAX_AUTO_R Value 3 (default) Meaning for repeat ignition attempts Maximum number of restart attempts
8.3
Ignition fault message suppression option

The file FLT_SERV.SRC contains a fault service function with the designation CASE 0 as well as five other examples (CASE 1 ... 5) that can be freely configured. The selection of the fault service subroutine to be used is made in the file $CONFIG.DAT by means of the variable A_FLT_SV_FCT (default setting: 0): INT A_FLT_SV_FCT=0 ; Number of user defined FLT_SERV-Subroutine
The entry A_FLT_SV_FCT=0 corresponds to the subroutine CASE 0 in the file FLT_SERV.SRC. This procedure is suitable, for instance, for cutting through insulating oxide layers (for example during aluminum welding) when the wire contacts the workpiece in order to allow a fault--free ignition process in a restart.
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Enumeration of the signal groups for fault service functions
Enumeration of the signal groups for fault service functions

If a welding or robot fault occurs during ignition or welding, the process is interrupted. Due to the variety of causes and types of faults, different fault service subroutines are required. In addition to the standard measures included in the technology package, the user can configure his own fault service subroutines tailored to specific requirements. The descriptions and information in this chapter require the error--free installation, commissioning and configuration of the robot and the hardware and software of the robot controller, the proper functioning of all peripheral equipment (welding controller, bus systems, etc.) according to their specifications, and correct programming and parameter settings.
9.1
Types of faults and causes

A distinction is made between application--specific seam faults caused by peripheral equipment (ignition faults, path faults), and faults attributable to the robot controller (e.g. IR_STOPMESS faults). The possible causes of faults may be, for example: G Ignition and seam faults resulting from unreliable operating states of the torch and/or welding equipment; G Ignition and seam faults resulting from workpiece characteristics (e.g. oxidation); G Media faults (e.g. shielding gas, welding wire, cooling); G Controller faults (e.g. IR_STOPMESS faults, EMERGENCY STOP actuation); G Operator control function Interpreter STOP.
9.2
9.2.1
Ignition faults
Signal output group O_FLT_ARC_ON[ ]
If the Arc struck signal (I_START_MOVE[ ]) is missing after a weld start, welding is switched off and an ignition fault signal is set. The following signal table is used for this purpose:
9.3
9.3.1
Welding faults and robot faults

Reaction to robot faults, EMERGENCY STOP and DRIVES OFF
The EMERGENCY STOP and DRIVES OFF states are monitored by means of the system variable $STOPMESS. Normally $STOPMESS=FALSE. In the case of $STOPMESS=TRUE, an interrupt call is made within A20.SRC for the programs IR_STOPMESS or TECH_STOP1. When this state occurs, the welding process or torch cleaning station is switched off. For this purpose, the corresponding outputs must be defined in the signal tables O_FLT_WELD[ ] and O_FLT_CLEAN[ ]. See also Sections 9.3.2 and 9.3.3.
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9.3.2
Signal output group O_FLT_WELD[ ]

Welding is stopped if a seam error is detected or an interrupt function is triggered. The signal table for this reads as follows:
9.3.3
Signal output group O_FLT_CLEAN[ ]

The torch cleaning process is switched off if interrupt functions are triggered. The following signal table must be taken into account with regard to the torch cleaning device:
9.3.4
Signal output group O_ACK_FLT [ ]

These output signals are used to reset the outputs for torch cleaning.
The ignition fault output can additionally be reset here. O_ACK_FLT[2] = {NO 13,PULS_TIME 0.0,STATE FALSE}
9.3.5
Signal O_FLT_SIGNAL
This output signal is reset when the corresponding fault has been acknowledged. This reference manages general fault signals to the PLC.
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Enumeration of the signal groups for fault service functions (continued)
9.3.6
Signal APPL_RUN
This output signal is defined and configured in the Fold AUTOEXT Globals. The signal state is managed exclusively in the IR_STROPMESS program.
Default $OUT [34]
9.4
9.4.1
Special feature IR_STOPMESS program

Joint activation/deactivation routines
All technologies are deactivated. The interrupt program is subsequently located in the Fold BASIS_STOP in the IR_STOPM.SRC file.
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ArcTechDigital 2.3 Once the causes have been eliminated, the technologies are switched back on again one after the other. Opened Folds:
The user must integrate his applications into the USER blocks in order to avoid impairing other technologies.
9.5
9.5.1
Configurable fault service functions

Fault service functions defined by the user
If ignition is not successful, the welding torch is moved back by X=100 mm. Program continuation: the torch is moved back by X=50 mm. Torch is returned to its start position.
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10
Further options
10
10.1
Further options
Program test in manual mode
For testing programs in manual mode T1 under real welding conditions, the variable PROC_IN_T1 (default value = FALSE) in the block ;FOLD BAS GLOBALS ;%{E}%V2.3.0,%MKUKATPBASIS,%CGLOBALS,%VGLOBALS,%P in the file $CONFIG.DAT can be set to TRUE. BOOL PROC_IN_T1=FALSE Corresponding entry using the menu function Monitor -- Variable -- Modify: Variable PROC_IN_T1 Type BOOL Characteristics Default: FALSE
If a hot welding attempt is made with the setting FALSE, the message Welding in operation mode T1 impossible! appears in the message window.
10.2
Ignition fault message suppression option

Default = 0
The ignition fault messages are suppressed if the condition START_CNT< MAX_AUTO_R is met and AUTO_RETRY = 1. If AUTO_RETRY = 0, an error message appears in the message window after every ignition fault.
10.3
Seam monitoring delay option
A_CTRL_DELAY= 800 [ms] means that the seam monitoring begins after a delay of 800 ms. This command can be used to optimize the ignition process reliability and always force an active edge for the seam fault monitoring interrupt. Monitoring is carried out using $TIMER[1] and $CYCFLAG[3]. This time can be increased if ignition faults occur too often following an unstable ignition process.
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11
Mechanical weaving
Mechanical weaving is used, for example, to compensate for tolerances or to bridge gaps in a seam. The torch moves across the seam in this instance and the weave oscillation is thus superposed on the seam motion. It is also possible to rotate the torch in relation to the plane of the weld (direction of welding). Mechanical weaving is executed in the coordinate system TTS (tool--based technological system). In this way, the weaving function is independent of the position of the torch in relation to the seam and of the torch angle, and irrespective of whether welding is by the pushing or dragging technique.
11.1
Block selection response

If a block selection is made to a motion command other than ARC_SWI or ARC_OFF, mechanical weaving is switched off. In the event of a weld command, the corresponding weld data set with its weave parameters is taken into consideration. This ensures the continuous monitoring of the torch motion to the component when moving in Test mode.
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11
Mechanical weaving (continued)
11.2
Weave patterns
The following weave patterns are included in the ArcTechDigital package:
s Lateral deflection (amplitude) Direction of welding s Weave length
No weaving (No Weave)
Triangular weaving (Triangle) Triangular weaving double frequency (Dbl Triangle) Trapezoidal weaving (Sgl Trapec) Trapezoidal weaving double frequency (Dbl Trapec) Trapezoidal weaving unsymmetrical (Uns Trapec) Spiral weaving (Spiral)
Figure-of-eight weaving (Double 8)
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ArcTechDigital 2.3 These weave patterns are defined in the file Weav_def_d.src. DEF WEAV_DEF (GENERATOR :IN,FIGUR :IN ) Triangular weaving (SGL_TRI) Triangular weaving, double frequency (DBL_TRI) Trapezoidal weaving (SGL_TRP) Trapezoidal weaving, double frequency (DBL_TRP) Trapezoidal weaving, unsymmetrical (UNSYM_TRP) Spiral weaving (SPIRAL) Figure-of-eight weaving (DBL_8) ... CASE 1 ;triangle CASE 2 ;double triangle CASE 3 ;trapezoid CASE 4 ;double trapezoid CASE 5 ;unsymmetrical trapezoid CASE 6 ;spiral CASE 7 ;eight
The Triangle weave pattern (SGL_TRI) is described in the following example; on the left is the entry taken from the file Weav_def_d.src, and on the right is the assignment to the individual control points (1 ... 4) with the corresponding X and Y values. Weav_def_d.src SWITCH
FIGUR
n = control points (CPNUM) Y 1 2
CASE 1 ;triangle IF FG_NR1>0 THEN $TECH[FG_NR1].FCT.ORDER=1 $TECH[FG_NR1].FCT.CPNUM=4 $TECH[FG_NR1].FCT.CPS1.X1=0.0 $TECH[FG_NR1].FCT.CPS1.Y1=0.0 $TECH[FG_NR1].FCT.CPS1.X2=0.25 $TECH[FG_NR1].FCT.CPS1.Y2=1.0 $TECH[FG_NR1].FCT.CPS1.X3=0.75 $TECH[FG_NR1].FCT.CPS1.Y3=-1.0 $TECH[FG_NR1].FCT.CPS1.X4=1.0 $TECH[FG_NR1].FCT.CPS1.Y4=0.0 ENDIF
0.5 0.0 1 0.25
0.75
1.0 X 4
--1
The value for X can be between 0.0 and 1.0. Xn=1.0 corresponds to the weave length entered in the W--parameter list 2 (Mechanical Weaving), i.e. the length over which a pattern is executed. The value for Y can be between --1.0 and 1.0. Yn=1.0 corresponds to the lateral deflection (weave amplitude -- zero to peak) entered in the W--parameter list 2 (Mechanical Weaving). The weave length X, the lateral deflection Y and the angle of the torch in relation to the welding plane (weave angle) can be programmed for each weave pattern in the W--parameter list 2 Mechanical Weaving with menu prompting. Additional information on menu--guided programming can be found in the documentation [Arc Welding, ArcTechDigital -- Operation].
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11
11.2.1
Two-dimensional weaving
Weave patterns such as triangular and trapezoidal patterns result from the lateral deflection of the torch during motion along the seam. Complex patterns are possible by means of a second function generator that causes the torch to weave in the welding direction (X--axis). Two practical functions (for thin sheet welding, for example), namely spiral weaving and figure--of--eight weaving, are already included in the technology package. You can also develop your own patterns. The following diagram illustrates the mode of operation of the function generator using the example of spiral weaving.
Weav_def_d.src
Lateral deflection (amplitude) 1) $TECH[FG_NR1].FCT.CPS1.Xn=x (0.0 ... 1.0) $TECH[FG_NR1].FCT.CPS1.Yn=x (0.0 ... 1.0) Deflection in direction of path 2) $TECH[FG_NR2].FCT.CPS1.Xn=x (0.0 ... 1.0) $TECH[FG_NR2].FCT.CPS1.Yn=x (0.0 ... 1.0)
Lateral deflection (amplitude) 1) (-Y)
(Y) (Y) (-Y) Torch
Weave width
1) Lateral deflection (amplitude) = half weave width 2) Deflection in direction of path= weave length The ratio of the deflection in the welding direction (...FCTCTRL.SCALE_IN) to the weave length (A.WEAVLEN_MECH) is 1:1. The lateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for half the weave width (A.WEAVAMP_MECH). A20.src $TECH[N].FCTCTRL.SCALE_IN=1 $TECH[N].FCTCTRL.SCALE_OUT=1 The Weave amplitude value is defined as zero to peak, i.e. it corresponds to half the weave width (peak to peak). The magnitude of the deflection in the welding direction (...FCTCTRL.SCALE_IN) in relation to the weave length (W.WEAVLEN_MECH) is set in the file A20.SRC at a ratio of 1:1. The lateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for the half weave width (W.WEAVAMP_MECH).
11.2.2
Creating the Spiral weave pattern

The following illustration depicts the development of the Spiral weave pattern. As a result of the superposition of a lateral weave motion sin(x) with an orthogonally--acting weave motion of the same frequency in the welding direction cos(x), the torch describes a motion in the form of a circle (with the same amplitude) or of an ellipse (with different amplitudes). The spiral form results because the torch is moved by the amount of the weave length (from X=0 to X=1) during one period (360) in the direction of welding.
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ArcTechDigital 2.3 Superposition of cosine on sine Without path motion

0 1 sin(x) cos(x)
With path motion

Welding direction 1
The following diagram shows the curve shapes of the function generators derived from the sine function. This is approximately a sine for the lateral deflection ($TECH[FG_NR1]...) and a cosine for the deflection in the direction of the path ($TECH[FG_NR2]...). The corresponding control point parameters are stored under CASE 6 ;spiral in the file Weav_def_d.src. The figure of a spiral results from the superpositioning of these two motions.
Y 1
Lateral deflection (amplitude)

2 3
$TECH[FG_NR1]... (X 1 ... 6; Y 1 ... 6)

6 X 1,0
Y 1
Deflection in direction of path

3 4
$TECH[FG_NR2]... (X 1 ... 6; Y 1 ... 6)

0 X 1,0
--1 Y 1 2 0 1 1
Resultant: spiral
2 (--Y) 6, 6 5 3 (Y) 3 X 4 5 4 --1 1 2 5 6
--1
Weave length
The control points for the Spiral weave pattern are defined in the file Weav_def_d.src. The parameters for the lateral deflection are stored in the first block (...NR1...).
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11 Weav_def_d.src CASE 6 ;spiral IF FG_NR1>0 THEN $TECH[FG_NR1].FCT.ORDER=1 $TECH[FG_NR1].FCT.CPNUM=6 $TECH[FG_NR1].FCT.CPS1.X1=0.0 $TECH[FG_NR1].FCT.CPS1.Y1=0.0 $TECH[FG_NR1].FCT.CPS1.X2=0.166666 $TECH[FG_NR1].FCT.CPS1.Y2=1.0 $TECH[FG_NR1].FCT.CPS1.X3=0.333333 $TECH[FG_NR1].FCT.CPS1.Y3=1.0 $TECH[FG_NR1].FCT.CPS1.X4=0.666666 $TECH[FG_NR1].FCT.CPS1.Y4=-1.0 $TECH[FG_NR1].FCT.CPS1.X5=0.833333 $TECH[FG_NR1].FCT.CPS1.Y5=-1.0 $TECH[FG_NR1].FCT.CPS1.X6=1.0 $TECH[FG_NR1].FCT.CPS1.Y6=0.0 ENDIF
The second block (A_FG_MECH2...) contains the parameters for the deflection in the direction of the path. IF FG_NR2>0 THEN $TECH[FG_NR2].FCT.ORDER=1 $TECH[FG_NR2].FCT.CPNUM=6 $TECH[FG_NR2].FCT.CPS1.X1=0.0 $TECH[FG_NR2].FCT.CPS1.Y1=-1.0 $TECH[FG_NR2].FCT.CPS1.X2=0.083333 $TECH[FG_NR2].FCT.CPS1.Y2=-1.0 $TECH[FG_NR2].FCT.CPS1.X3=0.416666 $TECH[FG_NR2].FCT.CPS1.Y3=1.0 $TECH[FG_NR2].FCT.CPS1.X4=0.58 $TECH[FG_NR2].FCT.CPS1.Y4=1.0 $TECH[FG_NR2].FCT.CPS1.X5=0.916666 $TECH[FG_NR2].FCT.CPS1.Y5=-1.0 $TECH[FG_NR2].FCT.CPS1.X6=1.0 $TECH[FG_NR2].FCT.CPS1.Y6=-1.0 ENDIF
11.2.3
Figure-of-eight weave pattern

An additional weave pattern, an asymmetrical figure--of--eight, is defined in the file Weav_def_d.src under the designation CASE 7 ;eight. This pattern results from the superposition of a lateral weave motion with an orthogonally--acting weave motion in the direction of welding with double frequency. Lateral deflection Y (amplitude)
1 2 0 1 6 --1 7 8 --0,5 4 8 --1 3 0,5 4 5 9 X 0 3 1 5 7 9 X
Deflection in Y direction of path

2 6 1 3 0
Resultant: eight
Y 4 2 5 1 8 7 9 X 6
$TECH[FG_NR1]... (X 1 ... 6; Y 1 ... 6)

$TECH[FG_NR2]... (X 1 ... 6; Y 1 ... 6)
Weave length
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11.2.4
Changing and creating patterns for mechanical weaving

The weave patterns defined by the manufacturer can be changed by the user, and new patterns can be created.
11.2.4.1 Changing existing weave patterns You can adapt the weave patterns defined in the file Weav_def_d.src to your own requirements by changing the number of control points and their parameters. You want to shift the Triangle pattern -- contained in the file Weav_def_d.src -- by 180 in the phase angle. The settings for the Triangle weave pattern are contained in the file Weav_def_d.src.
Weav_def_d.src CASE 1 ;triangle IF FG_NR1>0 THEN $TECH[FG_NR1].FCT.ORDER=1 $TECH[FG_NR1].FCT.CPNUM=4 $TECH[FG_NR1].FCT.CPS1.X1=0.0 $TECH[FG_NR1].FCT.CPS1.Y1=0.0 $TECH[FG_NR1].FCT.CPS1.X2=0.25 $TECH[FG_NR1].FCT.CPS1.Y2=1.0 $TECH[FG_NR1].FCT.CPS1.X3=0.75 $TECH[FG_NR1].FCT.CPS1.Y3=-1.0 $TECH[FG_NR1].FCT.CPS1.X4=1.0 $TECH[FG_NR1].FCT.CPS1.Y4=0.0 ENDIF Represented graphically: Y 1 2
0.0
0.25 1
0.5
0.75
1.0 4
--1
n = control points (CPNUM) In order to achieve a phase shift of 180, it is merely necessary to change the parameters for control points Y2 and Y3. The required changes have been made in the following list and are underlined for ready identification.
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11 Weav_def_d.src CASE 1 ;triangle (phi = 180 degrees) IF FG_NR1>0 THEN $TECH[FG_NR1].FCT.ORDER=1 $TECH[FG_NR1].FCT.CPNUM=4 $TECH[FG_NR1].FCT.CPS1.X1=0.0 $TECH[FG_NR1].FCT.CPS1.Y1=0.0 $TECH[FG_NR1].FCT.CPS1.X2=0.25 $TECH[FG_NR1].FCT.CPS1.Y2=-1.0 $TECH[FG_NR1].FCT.CPS1.X3=0.75 $TECH[FG_NR1].FCT.CPS1.Y3=1.0 $TECH[FG_NR1].FCT.CPS1.X4=1.0 $TECH[FG_NR1].FCT.CPS1.Y4=0.0 ENDIF Y 1 1 0.25 0.5 3
0.0
0.75
1.0 4
--1
2 n = control points (CPNUM)
11.2.4.2 Creating your own weave patterns The following example shows the practical approach for creating your own weave patterns. A weave pattern is to be created as a combination of a trapezoid and a triangle. It is recommendable to start by drawing the desired pattern. A range from 0.0 to 1.0 for the path X covered within a period and 1 for the lateral deflection Y are predefined. Y 1 0.0 1 2 3
0.2
0.4
0.6 4
0.8
1.0 6
--1
5 n = control points (CPNUM)
The first value for X must be 0 (zero) and the last value must be 1. Multiple X values that are identical cannot be used. The number of control points determined (CPNUM) as well as the X and Y values can be entered, for example, in the block CASE 8 ;default as minimums and flag for beginning of the file Weav_def_d.src, as shown in the following.
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ArcTechDigital 2.3 Weav_def_d.src CASE 8 ;Trapez - Dreieck $TECH[A_FG_MECH1].FCT.ORDER=1 $TECH[FG_NR1].FCT.CPNUM=6 $TECH[FG_NR1].FCT.CPS1.X1=.0 $TECH[FG_NR1].FCT.CPS1.Y1=.0 $TECH[FG_NR1].FCT.CPS1.X2=.2 $TECH[FG_NR1].FCT.CPS1.Y2=1.0 $TECH[FG_NR1].FCT.CPS1.X3=.4 $TECH[FG_NR1].FCT.CPS1.Y3=1.0 $TECH[FG_NR1].FCT.CPS1.X4=.6 $TECH[FG_NR1].FCT.CPS1.Y4=.0 $TECH[FG_NR1].FCT.CPS1.X5=.8 $TECH[FG_NR1].FCT.CPS1.Y5=-1.0 $TECH[FG_NR1].FCT.CPS1.X6=1.0 $TECH[FG_NR1].FCT.CPS1.Y6=.0 ENDIF Number of control points Value X for control point 1 Value X for control point 1 Value X for control point 2 Value Y for control point 2 ... ...
11.2.5
Notes on mechanical weaving

The quality of a seam welded with mechanical weaving is influenced by a variety of physical and mechanical factors, such as the mechanical play in the gears, axis torsion, robot position, path tangent, etc. In addition, interdependencies with the interpolation cycle as well as the set robot--specific $Filter value also exist. The weave motion is superposed on the path motion. In case of weave patterns such as Trapezoid or Spiral, this leads to an irregular welding speed during a period. This can vary between the set path velocity and a multiple of it, depending on the relation of the weave length (frequency) to the lateral deflection (amplitude). The maximum weave frequency for mechanical weaving is depending on the robot type concerned influenced by several factors, for example by the resonant frequency of the robot/tool mechanical unit. Weave frequencies of up to 3 Hz (corresponding, for example, to a weave length of 3.33 mm at a travel speed of 0.6 m/min) are possible without causing problems according to previous experience. With higher weave frequencies, undesirable effects are liable to result in certain conditions (depending on the tool design and/or tool orientation). With weave frequencies > 3 Hz, the motion characteristics of the robot should therefore be individually tested in each case.
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12
Error messages / troubleshooting
12
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
12.1
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.
12.2
Message time
The message time indicates the time at which the message was generated.
12.3
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.
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12.4
Originator
The origin of the error is indicated in this field. In the case of ArcTechDigital, the entry is TPA20.
12.5
Message text
The text of the error message is shown here.
12.6
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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12 1 Message text Cause Monitor Effect Remedy 2 Message text Cause Monitor Effect Remedy 3 Message text Cause Monitor Effect Remedy 4 Message text Cause
Error messages / troubleshooting (continued)
Option bit ARC20 not set -- ARC20 = FALSE -- In ARC ON command -- Endless loop always with this message -- Set ARC20 to TRUE, stop and restart Submit interpreter, data backup Submit is not running -- Submit interpreter has been stopped, etc. -- In ARC ON command -- Endless loop always with this message -- Restart Submit interpreter Wrong submit routine selected -- No SPS.SUB submit program running while ARC20=TRUE -- During initialization of A20_INIT commands -- Endless loop with this message, as deactivation not otherwise possible in event of interpreter stop -- $PRO_I_O[ ] = R1/SPS ( ) Weld controller not ready -- The inputs configured in the signal input group I_WELD_COND [ ] are missing when welding is activated -- Position of the keyswitch (incorrect status for welding) -- In ARC ON command -- Endless loop with this message -- Move the keyswitch to the correct position -- Switch on power source (I_WELD_COND [ ]) Ignition failure, no arc -- Configured signals not returned to input group I_START_MOVE [ ] Current flow not established Power source sends this output too late or not at all Weld current connections broken -- ARC_ON command -- Ignition process is cancelled and restarted, once message acknowledged, in accordance with configured option and number of ignition attempts set -- For test purposes or start--up, the I_START_MOVE [ ] condition may be deactivated
Monitor Effect Remedy 5 Message text Cause
Monitor Effect
Remedy
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ArcTechDigital 2.3 6 Message text Cause Monitor Effect Remedy 7 Message text Cause Continue without welding -- Too many ignition attempts; too many seam faults or interruption with RESTART_OPT = 0 (continue Cold) -- In ARC ON command -- Seam not welded -- Clean ignition position and make new block selection to ARC_ON position Switch off welding -- Power source does not switch welding off or does so too late -- Incorrect configuration -- Incorrect burnback parameters -- In ARC OFF command -- Single message for user -- Optimization of the burnback parameters Weld controller fault -- Periphery error: robot waiting for the inputs expected in I_WELD_FLT [ ]. Normally configured as current flow Gas present, coolant monitoring -- Configuration error (OK state configured) -- Continuous between ignition process and ARC_OFF command if welding -- Welding is switched off; weld process is restarted, once message acknowledged, depending on RESTART_OPTION -- Complete the configuration Reconnect gas, water, etc. or check respective sensor Welding in operation mode T1 impossible! -- T1 mode and PROC_IN_T1 = FALSE -- In advance run section of ARC ON command -- Program remains in this loop after message acknowledged -- Set the above variable to TRUE ($config.dat)
Monitor Effect Remedy 8 Message text Cause
Monitor Effect Remedy 9 Message text Cause Monitor Effect Remedy

1
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Index
Zeichen
$CONFIG.DAT, 29 $Config.dat, 19, 20 $STOPMESS, 51
A
A.WEAVAMP_MECH, 59 A.WEAVLEN_MECH, 59 A_FLT_SV_FCT, 50 A10.SRC, 59 A20.dat, 21 A20.src, 21 Activating, 23 Adaptation to the periphery, 29 ARC OFF, 13, 14 ARC ON, 11, 12 ARC SWITCH, 15, 16 ARC20, 23
Fault service functions, 54 Fault situations and fault service functions, 51 Figure--of--eight weave pattern, 61 Figure--of--eight weaving, 57 Files for ARC Tech 20, 20 Flt_serv_d.dat, 21 Flt_serv_d.src, 21 Fold ARC Messages in A20.dat, 28 Fold ArcTech Inputs in $Config.dat, 24, 32 Fold ArcTech Outputs in $Config.dat, 23, 30 Fold Internal States in A20.dat, 26, 27 Fold Main Options in A20.dat, 25
I
I_ENB_W_EXT.NO, 45 I_ENB_W_EXT.STATE, 45 I_WELD_CTRL[ ], 32 Ignition faults, 51 Ignition repetition, 50 IN_NR, 32 Index table for physical digital inputs, 32 Index table for physical digital outputs, 30 Index tables, 29 Input group I_START_MOVE [ ], 43 Input group I_WELD_COND [ ], 42 Input group I_WELD_END [ ], 43 Input group I_WELD_FLT [ ], 44 Installation, 8 Interpreter stop (STOP key), 49 IR_STOPMESS program, 53
B
Basic settings, 23 Block selection response, 56
C
Changing existing weave patterns, 62 Control points (CPNUM), 58 Coordinate system TTS, 56 Crater filling, 37 Creating your own weave patterns, 63
D
DIGITAL INPUTS, 32 Digital inputs, 29 Digital inputs (physical), 32 Digital outputs, 23, 29 Digital outputs (physical), 30 Digitale Eingnge, 24 DRIVES OFF, 51
L
Lateral deflection (weave amplitude), 58
M
MAX_AUTO_R, 50 Maximum weave frequency, 64 Mechanical weaving, 56 Minimum configuration, 23, 25 Motion characteristics of the robot, 64
E
EMERGENCY STOP, 51 External keyswitch, 45
N
NAME_NAT[ ], 30, 32 Notes on mechanical weaving, 64
F
FAULT SERVICE FUNCTION, 50
O
Index -- i
Index O_SEAM_END[ ], 37 O_WELD_CTRL[ ], 30 OUT_NR, 30 Output group O_ACK_FLT [ ], 41 Output group O_ACK_START [ ], 36 Output group O_ACK_WELD_E[ ], 38 Output group O_FLT_ARC_ON [ ], 39 Output group O_FLT_CLEAN [ ], 41 Output group O_FLT_WELD [ ], 40 Output group O_SEAM_END [ ], 37 Output group O_STROB_PGNO [ ], 37 Output group O_WELD_START [ ], 35 Signal grouping in normal operation, 35 Signal O_FLT_SIGNAL, 52 Signal output group O_ACK_FLT [ ], 52 Signal output group O_FLT_CLEAN[ ], 52 Signal output groups for fault service function, 39 Signal tables for digital inputs, 33 Signal tables for digital outputs, 31 Signal tables for digital outputs and inputs, 29 Spiral weave pattern, 59 Spiral weaving, 57 Start welding -- ARC ON, 11 Power source interface, 23 PRG_NO.CODING, 28 PRG_NO.FIRST_BIT, 28 PRG_NO.LENGTH, 28 PRG_NO.PARITY, 28 PRG_ON_MODE, 47 PRG_SWI_MODE, 47 PRGNO_MAX, 47 PRGNO_MIN, 47 PROC_IN_T1, 55 Program number control, 25 Program number specification, 47 Program run mode GO, 11 Program structure, 19 Program test, 55 PULS_TIME, 31 STATE, 31 STOP key, 49 Switching on the welding process, 11 System requirements, 8
T
Time_out, 45 Timing diagram, 48 Trapezoidal weaving, 57 Triangular weaving, 57 Triple groups, 29 Two--dimensional weaving, 59 Types of faults, 51
R
Resonant frequency, 64 RESTART_OPT, 49 RESTART_OPTION, 49
W
WEAV_DEF.SRC, 58, 62 Weav_def_d.src, 21 Weave length, 58 Weave patterns, 57 Weave patterns, changing of, 62 Weave patterns, creating of, 63 Weaving, 56 Weaving, two--dimensional, 59 Welding a seam in several sections -- ARC SWITCH, 15 Welding and ending seams -- ARC OFF, 13 Index -- ii
S
Schematic sequence diagram ARC OFF, 14 Schematic sequence diagram ARC ON, 12 Schematic sequence diagram ARC SWITCH, 16 Seam error, 52 Signal APPL_RUN, 53 Signal diagram ARC_OFF, 15 Signal diagram ARC_ON, 13 Signal diagram ARC_SWI, 17 Signal flow of the program numbers, 47

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SOFTWARE

Configuration for KUKA.KR C 5.2, 5.3, 5.4, 5.5

Issued: 11 April 2006

KUKA Roboter GmbH

Description of the ArcTechDigital commands . . . . . . . . . . . . . . . . . . . .

Programs of the ArcTechDigital package . . . . . . . . . . . . . . . . . . . . . . . . . .

ArcTechDigital - basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Principles of the definable signal table . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assignment of the signal grouping in normal operation . . . . . . . . . . . .

Options for program number specification . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the restart options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enumeration of the signal groups for fault service functions . . . . . . . .

Ignition fault message suppression option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seam monitoring delay option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System requirements, Installation

Overview of the configurable options

Description of the ArcTechDigital commands

Description of the ArcTechDigital commands

Keyswitch for program execution without welding

Program run mode GO

Switching on the welding process

Start welding - ARC ON

Schematic sequence diagram ARC ON

Ignition program number output

Ignition fault message

Description of the ArcTechDigital commands (continued)

Signal diagram ARC_ON and ARC_SWI

Welding and ending seams - ARC OFF

Schematic sequence diagram ARC OFF

Program number output

Program number transfer

Cancel weld start signal at end position

End ARC OFF

Description of the ArcTechDigital commands (continued)

Signal diagram ARC_OFF

P0 P1 Crater time + Burnback time + Gas postflow time

Prog. no. = 6 PRG_SWI_MODE = 1

O_STROB_PGN0 [ ] O_SEAM_END [ ] I_WELD_END [ ]

Welding a seam in several sections - ARC SWITCH

Schematic sequence diagram ARC SWITCH

Program number output

Program number transfer

End ARC SWITCH

Description of the ArcTechDigital commands (continued)

Signal diagram ARC_SWI

PRG_SWI_MODE = 1 Ignition time

Programs of the ArcTechDigital package

Programs of the ArcTechDigital package

Bas.src Functions for robot motion

P00.src Functions for Autom./Ext. Handshake Check Home

Flt_serv_d.src User-definable fault service functions

Weav_def_d.src Definition and parameters for mechanical weaving

A20.src Functions for arc welding

Sps.sub Switch--off routine after an interpreter stop

Overview of the ArcTechDigital files

Programs of the ArcTechDigital package (continued)

Within the section / block shown, no changes or entries may be made.

ArcTechDigital - basic settings

ArcTechDigital - basic settings

Minimum configuration for power source interface

ArcTechDigital - basic settings (continued)

Minimum configuration for program number control

ArcTechDigital 2.3 Fold Internal States in A20.dat