SOFTWARE

KR C1

Operating Handbook

Release 3.2

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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 Introduction
1. KUKA Roboter GmbH
2. About this documentation
3. Service

2 Safety
1. Liability
2. Safety symbols
3. Safety
4. Planning and construction
5. Installation, operation and other work
6. Safety labelling

3 Robot System
1. Manipulator
2. Control system
3. Software concept
4. Jumpers for stand--alone operation X11

4 Initial Start--up

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

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Operating Handbook

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

The gray sections refer to documentation in the Programming Handbook

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

8 User Programming
1. Program editing
2. Program commands

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

10 Diagnostic Functions
1. DSE--RDW
2. Oscilloscope

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11 Additional Functions
1. UserTech

12 Applications

13 Appendix
1. Error messages / troubleshooting
2. Glossary
3. System variables
4. Keywords
5. History of Operating Handbook from V2.3 --> V3.2
6. Overall index

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Operating Handbook

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PRODUCT DOCUMENTATION

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

Introduction

Issued: 16 Nov 2004 Version: 00

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e Copyright 2004

KUKA Roboter GmbH

Zugspitzstr. 140
D--86165 Augsburg
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions. Subject to technical alterations without an effect
on the function.

2 of 16
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Contents

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

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

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

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

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 Introduction

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 1 Foreword

1 Foreword

This document is part of the operating instructions.

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

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 Introduction

2 How to use this documentation

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

2.1 Safety symbols

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

WARNING
Following these safety warnings carefully can prevent personal injury.

CAUTION
Following these safety warnings carefully can prevent material damage.

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 2 How to use this documentation (continued)

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

NOTE
Indicates special features for particular attention.

Tip
Indicates recommendations and advice to make your work easier.

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

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

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

Modifications or entries required

Indicates process steps requiring operator entries.

Modifications or entries not permissible

Indicates process steps in which operator entries are not permissible.

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 Introduction

2.3 Text styles

Font style Meaning

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

2.4 Cross references

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

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

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

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 3 Service requests

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

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

The following information is required for processing a service request:

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

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 Introduction

3.1 Device type and serial number

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

Fig. 1 Robot identification plate

Fig. 2 Linear unit identification plate

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 3 Service requests (continued)

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

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

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

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 Introduction

3.2 Software version numbers

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

Fig. 6 Version numbers of the software

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 3 Service requests (continued)

3.3 We value your opinion

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

If you have any questions about the documentation (suggestions, corrections), please send
them to one of the following addresses:
Fax: +49 821 797 1087
e--mail: documentation@kuka--roboter.de

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 Introduction

3.4 Service centers

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

Australia
Marand Precision Engineering Pty. Ltd (Agency) Tel.: +61--3 / 85 52 06 00
153 Keys Road Fax: +61--3 / 85 52 06 05
Moorabbin, Victoria 31 89 E-- Mail: robotics@marand.com.au
Australia

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

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

Brazil
KUKA Roboter do Brasil Ltda. Tel.: +55--11 / 64 13 49 00
Rua Dom Feliciano no 63 Fax: +55--11 / 64 11 15 65
Cidade Satélite, Guarulhos E-- Mail: info@kuka--roboter.com.br
CEP 07224 240
São Paulo, SP Brasil

China
KUKA Automation Equipment Tel.: +86--21 / 58 66 51 39
(Shanghai) Co.,Ltd. Fax: +86--21 / 58 66 75 71
Part B, Ground Floor, No. 211, Fu te Road (North) E-- Mail: franz.poeckl@kuka--sha.com.cn
Waigaoqiao Free Trade Zone
Shanghai 200 131, China

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

Germany Tel.: 0190 / 88 19 26

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

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 3 Service requests (continued)

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

Hungary
KUKA Robotics Hungaria Kft. Tel.: +36--24 / 50 16 09
2335 Taksony Fax: +36--24 / 47 70 31
Fö út 140 E-- Mail: info@kuka--robotics.hu

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

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

Malaysia
KUKA Robot Automation Sdn Bhd Tel: +60--3 / 80 61--06 13
South East Asia Regional Office / 80 61--06 14
24, Jalan TPP 1/10, Taman Industri Puchong Fax: +60--3 / 80 61--73 86
47100 Puchong, Selangor, Malaysia E-- Mail: info@kuka.com.my

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

Norway
KUKA Svetsanläggningar + Tel.: +47--61 / 13 34 22
Robotar AB Avd. Norway Fax: +47--61 / 18 62 00
Hadelandsveien 2 E-- Mail: geir.ulsrud@kuka.no
Postbox 17
NO--2801 Gjövik, Norway

Portugal
KUKA Sistemas de Automatización S.A. Tel.: +351--21 / 238 80 83
Urbanização do Vale do Alecrim, Lote 115--B Fax: +351--21 / 238 80 86
2950 Palmela, Portugal E-- Mail: kuka@mail.telepac.pt

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

KUKA-- VAZ Engineering
445633 Togliatti / 37 05 64
Jushnoje Chaussee, 36 VAZ, PTO Fax: +7--84 82 / 73 67 30
Tx: +7--21 41 06
E-- Mail: y.klychkov@vaz.ru

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 Introduction

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

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

Sweden
KUKA Svetsanläggningar + Robotar AB Tel.: +46--31 / 72 66 200
A. Odhners gata 15 Fax: +46--31 / 72 66 201
S--42130 Västra Frölunda E-- Mail: info@kuka.se

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

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

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

U.K.
KUKA Welding Systems + Robot Ltd. Tel.: +44--121 / 58 50 800
Hereward Rise, Halesowen Fax: +44--121 / 58 50 900
UK--West Midlands B62 8AN GB E-- Mail: sales@kuka.co.uk

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

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 Index

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

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

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

Q
H Quotation marks, 8

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

Index -- i
 Index

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

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

V
Version numbers of the software, 9

W
Warning, 6
Working with the product documentation, 5

Index -- ii
SAFETY

ROBOT SYSTEM

General

All Robot Types KR

Robot Controller KR C2 or Higher

Issued: 12 Mar 2004 Version: 00

SicherheitKRC 02.04.00 en

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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

SicherheitKRC 02.04.00 en

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Contents

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

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

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

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

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

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

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

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General

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

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

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

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

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

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

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 1 Liability

Valid for all robot types KR

robot controller KR C2 or higher

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

1 Liability
The device described in these operating instructions is an industrial robot -- called “robot
system” in the following text --, consisting of robot, connecting cables and control cabinet.
The robot system -- the subject matter of these operating instructions -- has been built
in accordance with state--of--the--art standards and the recognized safety rules.
Nevertheless, improper use of the robot system or its employment for a purpose
other than the intended one may constitute a risk to life and limb of operating
personnel or of third parties or cause damage to the robot system and to other
material property.
The robot system may only be used in technically perfect condition in accordance
with its designated use and only by safety--conscious persons who are fully aware
of the risks involved in its operation. Use of the robot system is subject to compliance
with these operating instructions and with the manufacturer’s declaration* supplied
together with the robot system. Any functional disorders affecting the safety of the
robot system must be rectified immediately.
The design and rating of the mechanical and electrical equipment of the robot system is
based on the EC machinery directives together with their annexes and associated standards.
Harmonized standards were taken into account with regard to the safety of the robot system:
The electrical part of the robot system additionally conforms to the “EC low voltage directive”
and the directive on “Electromagnetic compatibility”.
A list of the applied directives and standards can be found in the chapter “Applied directives
and standards”.

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

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General

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

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 3 Safety symbols

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

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

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

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

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General

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

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

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

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

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

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

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 4 Safety measures (continued)

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

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

4.1.2 Operating personnel

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

4.2 Danger zone

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

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General

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

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

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

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

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

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

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

4.3 Safety equipment

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

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

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

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 4 Safety measures (continued)

4.4 Installed equipment, attachments and conversion

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

4.5 Safety instruction

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

4.6 Safety functions

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

4.6.1 Restricted envelope – working space limitation

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

4.6.2 EMERGENCY STOP

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

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General

4.6.2.1 External EMERGENCY STOP

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

4.6.3 Enabling switches

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

4.6.4 Guard interlock (operator safety)

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

4.7 Emergency axis override device

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

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

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

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

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

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 5 Safety labeling

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

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

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

5.3 Control cabinet

See control cabinet Doc. Module “Maintenance”.

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General

6 Planning and construction

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

6.1 Foundations and substructures

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

6.2 Load ratings of the robot

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

6.3 Safety (exclusion) zones and working zones

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

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 6 Planning and construction (continued)

L+ A1 (+) Safety gate monitor

Ue e.g. PST3, manuf.: Pilz

L --- A2 ( ---)

= safety gate open

S11
= safety gate closed

= actuated element
S12

Gate position switches S23

S24

X1

Pushbutton for enable

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

7 8 25 26
Peripheral connector X11

Safeguard channel B
Safeguard channel A

Test output B
Test output A

KR C2

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

Test output B

Operator safety, channel B

Test output A

KR C3

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

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

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General

6.4 Collision protection

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

6.5 Counterbalancing system

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

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

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

The hydropneumatic counterbalancing systems are manufactured in

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

6.6 Tool change

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

6.7 Safety mats

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

6.8 Interface characteristics

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

6.9 EMERGENCY STOP system

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

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 6 Planning and construction (continued)

6.10 Presetting of outputs

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

6.11 Tooling and additional equipment

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

6.12 Laser systems

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

Lasers can cause serious damage to health.

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

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General

7 Installation, operation and other work

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

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

7.1 Mains connection conditions

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

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

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

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

Never work or stand under suspended loads!

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

7.3 Protection from dirt and UV radiation

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

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

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 7 Installation, operation and other work (continued)

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

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

7.5 Software

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

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

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

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

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General

7.8 Additional remarks

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

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 8 ESD directives

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

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

8.2 Handling ESD modules

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

Work surface Module Instruments,

Module Person
(conductive) packaging tools

R: protective resistor 1 MOhm

Fig. 1 Handling ESD modules

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General

8.3 Packaging suitable for ESDs

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

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 9 Applied directives and standards

9 Applied directives and standards

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

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General

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

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

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 Index

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

Index -- i
 Index

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

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

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

Index -- ii
3 Robot system
SOFTWARE

KR C1

Robot System

Release 3.2

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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 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Wrist axis motor units A 4 to A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Link arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.1 Main axis motor units A 1 to A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Rotating column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Hydropneumatic counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Working range limitation for A 1 to A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8 Working range monitoring for A 1 to A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Drive concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 Block diagram of the KR C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.2 Description of the drive concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Processor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.1 Tasks of the processor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.2 Processor unit modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.1 Power unit modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3.2 Servo module PM6--600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 External axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Cooling the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Maintenance of the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3 Software concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4 Jumpers for stand--alone operation X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Robot System

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 1 Manipulator

1 Manipulator
The following illustrations and descriptions are purely for information purposes and do not
necessarily claim to be complete. They are merely intended to aid understanding and are
not type--specific.
For precise information, e.g. Technical Data or Installation of the Control System, please
refer to the relevant hardware descriptions.

The robot system consists of the manipulator (= robot), control cabinet and connecting
cables.

1 Manipulator
4 2 Control cabinet
3 Connecting cables
4 Counterweight A 1

Fig. 8 Robot system

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Robot System

This section is subdivided in accordance with the breakdown of the manipulator into its main
subassemblies.

1.1 Wrist
The robot is equipped with a triple--axis in--line wrist, specific to the particular type. In this
way (depending on the robot type) payloads up to 350kg are possible.
The in--line wrist is fastened onto the arm via the flange (4). The axes 5, 6, 4 are driven by
shafts (1, 2, 3). An end effector can be attached to the mounting flange (6) of axis 6. Each
axis has a measuring device (5), through which the mechanical zero position of the respec-
tive axis can be checked by means of an electronic probe (accessory) or a vernier and trans-
ferred to the controller. In--line wrists with the designation “F” meet higher specifications with
regard to the temperatures to which they may be subjected.

4 5 6

2
A5
1

Fig. 9 In--line wrist

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 1 Manipulator (continued)

1.2 Arm
The arm assembly embodies the driven element of axis 3 of the robot. The arm is flange--
mounted to the side of the link arm (6) through a gear unit with integrated bearings and is
driven by main axis motor unit A 3 (5). The rotational axis (7) of the arm has been so selected
that with a rated payload of up to 125 kg there is no need for an additional counterweight to
balance the masses on the arm.
The effective software swivel range extends in the example from +58 to --210, referred to
the mechanical zero position of axis 3, which is given when there is an angle of 90˚ between
the longitudinal axes of the arm and link arm (as shown in Fig. 10). The swivel range is limited
by mechanical limit stops with a buffer function in addition to the software limit switches.
Attached to the rear of the arm housing (2) are the motor units for wrist axes 4 to 6. It consists
— as do the housings of the link arm and rotating column — of a light alloy construction
optimized by means of CAD and FEM.
Mounted on the front end of the arm via a standardized interface is the in--line wrist (3), which
is driven by the wrist axis motor units (1) through push--on shafts (4) located inside the arm.
1 2 3

--210˚

+58˚

4 7 6 5 4
1 Motor units for wrist axes 6 Link arm
2 Arm 7 Rotational axis 3
3 In--line wrist 8 Counterweight A 3 (only for 150 kg and
4 Shaft 200 kg payload)
5 Main axis motor unit A 3

Fig. 10 Arm with turning range

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Robot System

1.2.1 Wrist axis motor units A 4 to A 6

The wrist axes are driven by three motor units screwed to the arm. The motor units (1) for
axes 4 and 5 are of the same design and drive the respective wrist axes via universal shafts
(4). Wrist axis 6 is driven directly by the motor unit A6 (2) through a push--on shaft.
Each motor unit for the wrist axis drives consists of a brushless AC servomotor with a
permanent--magnet single--disk brake and a hollow--shaft resolver (both integrated). The
permanent--magnet single--disk brake performs a holding function when the motors are at
rest and contributes to the braking of the respective axis in an EMERGENCY STOP. The
EMERGENCY STOP function must therefore not be used to stop the robot under
normal circumstances.

1 A4
4

2 A6

1 A5

1 Motor units A 4, A 5
2 Motor unit A 6
3 Arm
4 Universal shaft 4

Fig. 11 Wrist axis motor units A 4 to A 6

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 1 Manipulator (continued)

1.3 Link arm

The link arm is the driven element of axis 2. It pivots through an effective software range from
+93 to --40 — referred to the mechanical zero position of axis 2, which corresponds to the
vertical position of the link arm in Fig. 12 — about rotational axis 2 (3). The effective software
swivel range is limited by mechanical limit stops with a buffer function in addition to the
software limit switches.

+93

--40˚

1 Link arm
2 Main axis motor unit A 2
3 Rotational axis 2

Fig. 12 Link arm with turning range

The link arm contains the gear unit A 3 (5) at its upper end, and the gear unit A 2 (1) at its
lower end. The gear units (5, 1) are used both as drive elements and to support the arm (4)
and link arm (6). Reference notches (2, 3) are provided to define the mechanical zero position
of axes 2 and 3. The cables for energy supply and signal transmission are routed in the
interior of the link arm housing from the rotating column to the arm (see robot Doc. Module
“Description, Electrical Installations”).

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Robot System

4
5

3
6
2

1 Gear unit A2 5 Gear unit A 3

2 Reference notch A 2 6 Link arm
3 Reference notch A 3 7 Rotational axis 2
4 Arm

Fig. 13 Structure of link arm

1.3.1 Main axis motor units A 1 to A 3

Robot axes 1, 2 and 3 are driven by motor units as per the diagram. Each motor unit for the
main axis drives consists of a brushless AC servomotor (1) with a permanent--magnet
single--disk brake and hollow--shaft resolver (2), both integrated. The motor units for axes
1 to 3 are of the same design.
The permanent--magnet single--disk brake performs a holding function when the servo
motors are at rest and contributes to the braking of the respective axis in an EMERGENCY
STOP. The EMERGENCY STOP function must therefore not be used to stop the robot
under normal circumstances.

2 1

Fig. 14 Motor unit for main axis drive

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 1 Manipulator (continued)

1.4 Rotating column

The rotating column is the assembly located between the link arm and the base frame. It is
screwed to the base frame (4) through a special reduction gear unit (3), which allows it to
rotate. The rotating column performs movements about rotational axis 1 (1). It has an
effective software turning range of 185 in both the (+) and (--) directions, measured from the
mechanical zero position (6). This range is limited by mechanical limit stops with a buffer
function in addition to the software limit switches. Except for the KR 125 W/1, /2, this limit
stop system operates with a trailing stop acting on both sides, which is installed in the base
frame and mechanically limits the large turning range of 185˚ in both directions.

1 2

--185

1 Rotational axis 1
2 Rotating column
+185 3 Special reduction gear unit
4 Base frame
5 Main axis motor unit A 2
6 Zero position A 1

--90˚
+90˚ 6 5 4 3 2

Fig. 15 Rotating column with turning range

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Robot System

The main axis motor unit for axis 1 is installed in the rotating column with a special reduction
gear unit (4), and the main axis motor unit for axis 2 (2) is mounted on the side of the rotating
column with its special reduction gear unit (3).
Part of the robot electrical installations are routed within the rotating column (see robot Doc.
Module, “Description, Electrical Installations”).

1 2

1 Main axis motor unit A 1

2 Main axis motor unit A 2
3 Special reduction gear unit A 2
4 Special reduction gear unit A 1
5 Counterweight A 1

Fig. 16 Structure of rotating column

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 1 Manipulator (continued)

1.5 Base frame

The base frame is the stationary part of the robot, on which the rotating column turns with
the link arm, the arm and the wrist. Its base flange (7) features through--holes (8) for holding
the robot down and two locating boreholes (6), with which the robot can be placed on two
locating pins (accessories, see also robot Doc. Module, “Installation, Connection,
Exchange”).
Attached to the flange (5) in the base frame housing (2) is the special reduction gear (4) of
axis 1. Also integrated into this flange (5) is the double--acting trailing stop, which together
with a stop block on the rotating column mechanically safeguards the software--limited move-
ment range about rotational axis 1 of 370.
In the base frame, the installation cables leading to the rotating column are routed stress--
free about rotational axis 1 of the robot in a flexible tube. The space between the rotating
column and the base frame is provided with a detachable, one--piece cover (3).
The sockets for the connecting cables from the robot to the control cabinet are located on
the junction boxes (1).

4 5

2
6
7
3
8

1 Junction boxes (2x) 5 Flange

2 Base frame housing 6 Locating boreholes (2x)
3 Cover 7 Base flange
4 Special reduction gear unit A 1 8 Fastening boreholes (8x)

Fig. 17 Structure of base frame

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Robot System

1.6 Hydropneumatic counterbalancing system

The robot is equipped with a closed hydropneumatic counterbalancing system for compen-
sating the load moment of axis 2. The robot is provided with the appropriate system variant
depending on whether it is mounted on the floor, on the wall or on the ceiling. The system
is installed between the rotating column (2) and the link arm (1).
The principal components of the system are the hydraulic cylinder (6), the diaphragm--type
accumulator (4) with gas/oil charge and the two articulated heads (3, 5), together with the
swivel units (7, 8).

4 5
1

2
3

1 Link arm
2 Rotating column
3 Articulated head
4 Diaphragm--type
accumulator
5 Articulated head
6 Hydraulic cylinder
7 Swivel unit 1
8 Swivel unit
6

d
c g

8 7

Fig. 18 Hydropneumatic counterbalancing system

for floor--mounted robots

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 1 Manipulator (continued)

4
5
2
3

1 Link arm
2 Rotating column
3 Articulated head
4 Diaphragm--type
accumulator
5 Articulated head
6 Hydraulic cylinder
7 Swivel unit
8 Swivel unit
1

7
8

Fig. 19 Hydropneumatic counterbalancing system for ceiling and wall--mounted robots

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Robot System

1.7 Working range limitation for A 1 to A 3

Mechanical stops for task--related limitation of the respective working range for axes 1 to 3
can be supplied as the “Working range limitation” accessory.

1.8 Working range monitoring for A 1 to A 3

Axes 1 to 3 can be equipped with position switches and slotted rings as accessories to which
adjustable cams are attached. This allows the position of the robot to be continuously
monitored.
Up to three sectors of the movement range can be monitored on A1 and A2, and up to two
sectors on A3.
If axes 2 and 3 are equipped with working range monitoring, an energy supply system with
an additional control cable is required.

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 2 Control system

2 Control system
2.1 Drive concept
The controller contains all the components and functions which are required to operate the
robot. It comprises the computer and power units, which are both installed in a single control
cabinet.

2.1.1 Block diagram of the KR C1

Mains: 3x400 V

PM6--600

Logic Power supply

27 V
Parallel interface
PC
Pentium Current controller
∫ 32 MB RAM PWM
600 V
∫ 850 MB HD, 3.5” FD
CD--ROM Drivers

MFC
K--VGA
K--VGA Watchdog, temperature
DSEAT Output stages
monitoring DSEAT
Ethernet, CAN Bus user Position control

CAN Bus KCP keyboard Speed control

16 inputs, 20 outputs Commutation

Motors with
resolver
Control cable (serial interface)

Motor cable
Switches
Keyboard
Display

Ethernet

RDC

Fig. 20 Drive concept of the KR C1

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Robot System

2.1.2 Description of the drive concept

The Pentium processor calculates a new position value for each motor (and thus for each
individual axis) at the interpolation cycle rate (currently 12 ms). The individual position values
are sent to a 2nd processor on the DSEAT (fitted on the multi--function card (MFC)). This
performs the functions of position control, speed control and commutation (phase shift for
rotating--field generation) using special software. Control is thus digital.
Advantage: this eliminates the need for complex hardware circuitry. Controller settings
which previously had to be made by adjusting components can here be set via software
(machine data).
The DSEAT transfers the digital current setpoints to the PM6--600 power module via a paral-
lel interface in a 125 μs cycle. This digital transfer is not susceptible to interference. An
inexpensive ribbon cable thus suffices as transfer medium.
The current setpoints are converted to analog values in the power module and supplied to
the output stages via the current controllers and pulse width modulation. Analog technology
is used in the current controller as this can be implemented relatively easily and the controller
parameters rarely need to be adapted.
The intermediate circuit voltage for the output stages is generated directly (without a trans-
former) by rectifying the mains voltage (3x400 V). The intermediate circuit voltage is thus
565 V in the idle state. Output stages and motors must therefore be designed for 600 V.

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 2 Control system (continued)

2.2 Processor unit

The processor unit includes the modules highlighted in Fig. 21.

CD and floppy drives Swing frame

Q1
Interfaces

A1

Fig. 21 Processor unit

2.2.1 Tasks of the processor unit

With its fitted components, the processor unit performs all the functions of the control
hardware. These are:
-- Windows user interface
-- Program creation, correction, archiving, and maintenance
-- Diagnosis, start--up assistance
-- Sequence control
-- Trajectory planning
-- Control of the servo power unit
-- Monitoring functions
-- Parts of the safety logic
-- Communication with external units (other controllers, host computers, PCs, network)

2.2.2 Processor unit modules

G Standard PC hardware
With its powerful Pentium processor and ≥32MB main memory, the standard PC hardware
forms the basis of the processor unit. The standard PC also includes a hard disk for storing
the entire control software, including online help and online documentation, a floppy disk
drive for archiving purposes and a CD--ROM drive for reading the CD--ROM supplied in the
cabinet.
The CD--ROM contains the “Windows” operating system and the control software with tech-
nologies.

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Robot System

G Multi--function card (MFC)

The multi--function card incorporates system and user I/Os, an Ethernet connection, a
DeviceNet/CAN bus connection and forms the interface between the KCP, PC and safety
logic. The card is designed as a PC plug--in card and accommodates up to two DSEAT
modules.
The so--called LP Real Time Accelerator is also situated on the MFC. This generates the
NMIs (non--maskable interrupts) which are necessary for switching between Windows 95
and the VxWorks real time system.

Fig. 22 MFC with plug--on DSEAT card

G Digital servo--electronics (DSEAT)

The DSEAT module fitted on the multi--function card with its own DSP (digital signal proces-
sor) is responsible for digital control of up to 8 axes and the control of a servo power module
with phase current setpoints and parameterization data. The DSEAT also processes the
actual values from the RDC and the error and status information read by the servo power
module.

Fig. 23 DSEAT card

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 2 Control system (continued)

G Resolver/digital converter (RDC)

Installed on the robot base, the R/D converter with its own DSP (digital signal processor)
performs the functions of resolver power supply, R/D conversion, open--circuit monitoring of
the resolvers and monitoring of the motor temperature. This converter communicates with
the DSEAT via a serial interface.

Fig. 24 RDC at the base of the robot

G KUKA VGA Card (K--VGA)

This is a standard VGA card, to which an interface for an LCD display has been added. The
KCP color LCD display (640x480, 256 colors) is connected here.
A normal VGA monitor can also be connected in parallel.

Fig. 25 KUKA VGA

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Robot System

G KUKA CONTROL PANEL (KCP)

The KCP is the interface between man and machine -- i.e. it is an input/output unit.
Components:
-- LCD color display in VGA mode (640x480, 256 colors)
-- Keyboard as input unit
-- Space Mouse for moving the robot, as alternative to moving with the keys
-- Connection for a standard MFII keyboard
-- Ethernet connection port
As an alternative to the KCP, the robot can also be operated and programmed using a stan-
dard MFII keyboard (connected to the motherboard), an external mouse (COM2 port) and
a standard VGA monitor (connected to the KUKA VGA card).

Fig. 26 KCP

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 2 Control system (continued)

2.3 Power unit

The power unit comprises the areas highlighted in Fig. 27.
Front view of cabinet Rear view of cabinet
with door closed with door open Ballast resistor

Transformer
External fan

Transformer
(optional)
Main switch
Front view of cabinet
with swing frame without swing frame
Internal fan

Q1
PM6- -600

A1
Servo power
module

Power infeed with

mains filter FE201

Fig. 27 Power unit

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Robot System

2.3.1 Power unit modules

G Power infeed with mains filter, main switch, motor circuit breaker with fuse and m.c.b.
G Servo power module with mains module (600 V) and power supply unit (27 V)
G Safety module (on the PC swing frame)
G Back--up battery for control hardware
G Transformer (optional)
G Fans for cooling the cabinet

2.3.2 Servo module PM6--600

The PM6--600 is designed as a sliding frame. All the function blocks are cooled by a common
heat sink whose cooling fins, when installed, are located in the directly ventilated outer area
of the control cabinet. Hence any power dissipated by the module is routed directly outwards
and not into the interior of the cabinet.

The PM6--600 incorporates:

G Power supply
G Ballast circuit
G Low--voltage power supply
G Servo--amplifiers for 6 robot axes
G Brake switch (in common for all 6 robot axes)
G Monitoring of motor currents and short--circuit protection
G Monitoring of heat sink, air, ballast resistor and fan temperatures
G Interface with the DSEAT

Special features:
G 600 V technology; a transformer is not required with a mains voltage of 400 V -- 415 V
G All 6 servo drive units in one module
G All connections pluggable
G Connections to the PC (DSEAT) via a 40--pole ribbon cable
G Output stages are equipped with IGBTs; modern, safe technology
G Plug & Play technology: no adjustments are required on the module
G Path--oriented braking of the axes after the drives are switched off
G Controlled low voltage supply

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 2 Control system (continued)

2.4 External axes

The size of the cabinet does not permit the integration of further axis amplifiers.
A second cabinet is thus required for external axes.
-- The additional cabinet is mechanically fastened on top of the basic cabinet.
-- Each cabinet is provided with openings in the base/top panel for the electrical connections.
-- The interface to the robot is fed through to the basic cabinet.

Power module variants:

-- PM6--600 (with integrated power supply unit; can control up to 6 axes)
-- PM0--600 (power supply unit for PM1 and PM2)
-- PM1--600/16 (can control 1 axis)
-- PM1--600/25 (can control 1 axis)
-- PM2--600/16/25 (can control 2 axes)
Additional devices:
If additional devices are to be integrated, such as a welding controller, adhesive controller,
PLC, etc., the procedure is the same as that for external axes.

650 500
850

Option
(Zusatzachsen)
(external axes) Option
(axes supplémentaires)

240 340
580

1 1
850

800

1 Air conditioner
(Option)
90

Fig. 28 Main dimensions

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Robot System

2.5 Cooling the control cabinet

The control cabinet is divided into two independent cooling zones. The inner zone, containing
the entire control electronics, is cooled by a heat exchanger or an air conditioner (optional).
In the outer zone, the ballast resistor, the heat sink of the servo module and the transformer
(optional) are cooled directly by ambient air.
The controller is designed for an ambient temperature of max. +45 ˚C with a heat exchanger
or max. +55 ˚C with an air conditioner.

Upstream installation of filter mats causes an excessive rise in temperature and

hence a reduction in the life of the installed devices !
Make sure that the fan motors turn the right way!
The cabinet door must remain closed during operation, otherwise the cooling effect of the
internal airflow is lost. Failure to do so can cause the controller to overheat and fail.

3
6
1

3
4

Front view: internal and external ventilation circuit Side view: external ventilation circuit

1 Internal cooling circuit

2 Fan: internal cooling circuit
3 Heat exchanger: side
4 External cooling circuit
5 Fan: external cooling circuit
6 Heat exchanger: rear

Fig. 29 Cooling by heat exchanger

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 2 Control system (continued)

2.6 Maintenance of the control cabinet

With the exception of battery replacement, the controller (processor unit) is maintenance--
free.
Preventive maintenance is recommended wherever dirt, corrosion and wear occur.

Before maintenance or repair work is started, it must be ensured that the

incoming power cable is deenergized and that measures have been taken
to prevent it from being inadvertently energized again. It must also be
ensured that no current--carrying cables or components can be touched. In
addition, the main switch must be turned to “OFF” and locked.

All supply conductors up to the main switch are still live even when the main
switch is turned off.

Particularly important: maintenance and repair work may be performed only

by trained personnel aware of the hazards involved.

2.6.1 Cleaning

Do not use compressed air to clean the system, as this could cause dirt to
penetrate into electrical components. Compressed air may be used only
when expressly specified.
G Remove any dust deposits with a dry brush.
G Clean control cabinet with a cloth soaked with a mild cleaning agent.
G Clean cables, plastic parts and hoses with solvent--free cleaning agents.

The manufacturer’s instructions must be observed when using cleaning agents.

It must be ensured that no cleaning fluid enters electrical components.

G Remove any corrosion and, where permissible, protect the affected areas with paint,
grease or oil.
G Replace damaged, illegible or missing inscriptions, labels and plates.

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Robot System

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 3 Software concept

3 Software concept
G 2 operating systems run simultaneously in our computer:

-- VxWorks constitutes the kernel system

The kernel system executes the program and controls the
robot!
-- WIN95 takes over the control functions for the basic system.
All operating commands of the programmer pass through
Windows!

G POWER ON procedure:
During Power ON, the Windows operating system runs up and starts the program
“Cross3” which in turn executes the following programs in the order listed below:
-- cross3.exe
-- upvxwin.exe
-- kukadb.exe
-- kukabof.exe

The two systems must be thought of as entirely separate:

Operator Drives
control Basic system

Windows 95 VxWorks

Only during
KUKABOF Kukaftpd
initialization Robot Control
Editor programs programs

R1 STEU
CROSS
The two systems
communicate with
each other by TCP/IP
protocol.

Fig. 30 Software concept

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Robot System

G Program descriptions

CROSS3.EXE Directory “C:\Krc\Bin\”

WIN95 takes over the control functions and must therefore send commands to the kernel
system. The CROSS.exe program is used for this purpose. (Each activity can be logged in
the Cross window.)
One part of CROSS3 is the program Ftpd. This program enables the basic system to access
the hard disk of the PC. During power--up, for example, the basic system uses this program
to read the .ini files. The Trace function also has access to this program on the hard disk.
After the program has started, it remains active and waits for a connection to its FTP client.

UPVXWIN.EXE Directory: “C:\Krc\Util\”

This program reserves the appropriate memory capacity, loads and starts the basic system.
The transfer parameters designate the amount of space to reserve and the name of the basic
system file.

KukaDB.EXE Directory “C:\Krc\Bin\”

Access to the message and language database.

KukaBof.EXE Directory “C:\Krc\Bin\”

This program fills the screen after the controller has run up.

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 3 Software concept (continued)

G Existing directory structure

After the software has been installed, the following directory structure is provided on the hard
disk.

The “KRC” folder in detail:

Fig. 31 Structure of the directories

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Robot System

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 4 Jumpers for stand--alone operation X11

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Robot System

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 Index

A Keyboard, 22
Arm, 7, 13 KUKA CONTROL PANEL, 22
KUKA VGA Card, 21
KukaBof.EXE, 30
B
KukaDB.EXE, 30
Base frame, 11, 13
Block diagram of the KR C1, 17
L
Link arm, 7, 9, 13
C
Load moment of axis, 14
Cleaning, 27
Computer unit, 17
Control cabinet, 5 M
Control system, 17 Main axis motor unit, 7, 10
Cooling the control cabinet, 26 Maintenance of the control cabinet, 27
Counterbalancing system, 14 Manipulator, 5
Counterweight, 7 Mechanical limit stops, 7, 9, 11
CROSS.EXE, 30 MFC, 20
Multi--function card, 20
D
Digital servo--electronics, 20 O
Digital Signal Processor, 21 Overheat, 26
Drive concept, 17
DSEAT, 20 P
DSP, 21
POWER ON procedure, 29
Power unit, 17, 23
E Processor unit, 19
Existing directory structure, 31
External axes, 25
R
RDC, 20, 21
F Resolver/digital converter, 21
Filter mats, 26 Robot, 5
Robot system, 5
H Rotating column, 11, 13
Hydropneumatic counterbalancing system, 14
S
I Servo module, 24
In--line wrist, 6 Software concept, 29
Interpolation cycle rate, 18 Software limit switches, 7, 9, 11
Swivel range, 7, 9

J
Jumpers for stand--alone operation X11, 33 U
UPVXWIN.EXE, 30
K
K--VGA, 21 V
KCP, 22 VxWorks, 20, 29

Index -- i
 Index

W
WIN95, 29
Working range limitation, 16
Working range monitoring, 16
Wrist, 6, 13
Wrist axis motor units, 8

Index -- ii
4 Initial Start--up
SOFTWARE

KR C1

Initial Start--up

Release 3.2

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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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 Information on the subjects
G Robot and control cabinet,
G Transport,
G Installation,
G Connection,
G Start--up,
G Exchange
can be found in the [Control Cabinet] handbook.

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Initial Start--up

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5 Operator Control
SOFTWARE

KR C1

Operator Control

Release 3.2

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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 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Operator control elements on the control cabinet KR C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Running up the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Controller response when switched back on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.1 Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2 Warm restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2.1 Hardware conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5.2.3 Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Virus protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 The KUKA Control Panel KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Operator control elements of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 The rear of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Graphic User Interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.1 Settings for brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.2 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.3 Input/output windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.4 System status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.5 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4.6 Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.7 Toggling to the Windows interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.7.1 Alt--Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.7.2 Alt--Escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.7.3 CTRL--Escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3 Coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 WORLD coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 BASE coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.5 TOOL coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Manual traversing of the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Selecting the traversing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Selecting the kinematic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.4 Selecting the coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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4.5 Jog override (manual traversing velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.6 Moving the robot with the Space Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.6.2 Mouse position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.6.3 Degrees of freedom of the Space Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.6.3.1 Motion of the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.3.2 Motion of the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.3.3 Unlimited functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.6.4 Defining a dominant axis of the Space Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.6.4.1 Dominant axis activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.6.4.2 Dominant axis not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.7 Moving the robot with the traversing keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.7.1 Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.7.2 Coordinate systems TOOL, BASE, WORLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.7.3 Incremental manual traversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5 Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Graphic user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2.2 Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2.3 Directory structure, attributes display, selection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.2.3.1 Directory structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.2.3.2 Attributes display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2.3.3 Selection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.2.4 Directory and file list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2.4.1 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.4.2 Windows95 and kernel system attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.2.5 Status line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2.6 Error display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2.6.1 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2.6.2 Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.6.3 Data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.6.4 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.3 “File” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.3.1 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.3.1.1 Create folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.3.1.2 Create module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3.2 Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3.2.1 Open a subdirectory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3.2.2 Load file into the editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3.2.3 Edit a data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3.2.4 Open an error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3.3 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.3.3.1 Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.3.3.2 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.3.4 Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.3.4.1 Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3.4.2 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3.4.3 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3.4.4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.3.4.5 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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5.3.4.6 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.3.5 Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.3.5.1 Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.3.5.2 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.3.5.3 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.5.4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.5.5 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.6 Rename . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.3.7 Format floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.3.8 Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3.9 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.4 “Program” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.4.1 Mark all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4.2 Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4.3 Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4.4 Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.4.5 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.4.6 Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.4.7 Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.4.7.1 Without parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.4.7.2 With parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.4.8 Cancel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.4.9 Reset program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.5 “Monitor” menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.6.1 Keyboard assignment of the Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.6.2 Default settings at User and Expert levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6 Executing, stopping and resetting a program . . . . . . . . . . . . . . . . . . . . . . 112

6.1 Selecting and opening a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.1.1 Symbols in the program window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1.2 Program status line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.2 Setting work velocity (program override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.3 Stop reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.3.1 Ramp--down braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.3.2 Path--maintaining Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.3.3 Maximum braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.3.4 Short--circuit braking (dynamic braking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.3.5 Warning and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.4 Manual program execution (jog mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.4.1 Program run mode “Go”, “Single Step” or “I--Step” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.4.2 BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.4.3 Executing individual program lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.4.4 Program start backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.4.5 Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.4.6 Resetting a program (Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.4.7 Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.5 Automatic program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.5.1 BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.5.2 Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.5.3 Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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6.6 Deselecting a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

7 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.1 Inputs/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.1.1 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.1.2 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.1.3 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.1.4 Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.1.5 Automatic External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.2 Rob. Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.3 Cyclical Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.4 Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.5 Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.6 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.7 Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.7.1 Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.7.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.8 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.8.1 Oscilloscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.8.2 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.8.2.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.8.2.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.8.3 CROSS Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.8.4 Caller Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.8.5 Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.9 Refresh display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.10 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.11 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.11.1 Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.11.2 Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

8 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.2 File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.3 Program... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.3.1 In Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.3.2 At programming level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.3.3 In the editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.4 Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.5 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8.6 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.7 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.8 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8.9 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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1 Running up / shutting down the controller

1.1 General
The control cabinet KR C1 contains the power and control electronics for operating a robot.
Apart from the main switch, all the operator control elements of the controller are located on
the KCP (KUKA Control Panel) hand programming unit.

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

The meaning of the symbols, icons and particular font conventions is explained in the
documentation [Introduction], in the chapter [About this documentation].
Further information on installation and commissioning can be found in the documentation
[Start--up] or [Initial Start--up].

1.2 Operator control elements on the control cabinet KR C1

Main switch

The robot system and controller are switched

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

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Computer drives and ports

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

Control
ON

CD--ROM drive LPT1

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

It is also possible to connect a standard serial mouse to Com1. This can even be connected
during operation without having to reboot the system.

The control cabinet door may only be opened by a skilled and appropriately trained electri-
cian for the purpose of service work. On completion of the work, the control cabinet door
must be carefully closed again to avoid dirt deposits and to prevent unauthorized access!
The drives flap on the control cabinet door may only be opened for the purpose of using
the drives in order to prevent dust and moisture from entering the drives. Please make sure
that this flap remains closed and latched tight at all other times.

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

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1.3 Running up the controller

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

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

of a progress indicator bar.

o

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

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

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

If the system was switched off using the main switch, it must not be switched on again until
the status LED (Control ON) is extinguished. This LED is located behind the drives flap on
the front of the control cabinet and is extinguished approximately 1--2 minutes after the
main switch is turned off. Switching the controller on again earlier may result in the loss of
data.

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1.4 Shutting down the controller

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

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

controller was correctly and completely run up beforehand.

o

If the robot system is turned off during the execution of a program, the robot is stopped
immediately. Configuration files, such as $CONFIG.DAT, are saved. All other program files
that have not been saved will be lost.

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1.5 Controller response when switched back on

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

1.5.1 Cold start

This variant is activated by default and behaves in the same way as the earlier control soft-
ware versions. No program is selected when the system has booted and the user outputs
are set to “FALSE”.

In “Automatic External” mode, the program “CELL” is automatically loaded.

1.5.2 Warm restart

This option is provided in order to minimize production downtime in the event of a power
failure. Once the system has booted, it returns to the position reached in the program
immediately before the power failure. Outputs that were set at the time the system was
switched off are set again when the system reboots. The processing of the program can then
be resumed from this point. In most cases it is no longer necessary to move the cell free.

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

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

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

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

1.5.2.1 Hardware conditions

Only power modules from version “E” onwards support the backup routine. This can last up
to 200 seconds, while older modules automatically switch off after 70 seconds.
In the event of a warm restart, the system configuration at the time of the power failure is
restored. The interpreter is returned to the point at which the program was interrupted, for
example, and the output image is restored. The restoration of the output image places partic-
ular requirements on the system design.

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In manual mode, the output periphery is linked to the system outputs “$PERI_RDY” and
“$STOPMESS”. In this way, changes to the status of the cell can only be made if the drives
are switched (enabling switch pressed and Emergency Stop acknowledged).

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

1.5.2.2 Function
Power failure causes short--circuit braking (dynamic braking). The entire kernel system is
backed up on the hard disk in the file “vxworks.freeze” and the controller is shut down, in a
controlled manner, by the battery back--up. All system files are saved in the usual way. The
following information, specific to the software version, is also saved:
-- Selected program
-- Block pointer
-- Variables
-- Interrupts
-- Outputs

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.

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

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

When power is restored and the warm restart is activated, the system runs up automatically
until reaching the program position that was current before the PowerOff procedure.

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If, at the time of the power failure, files (e.g. programs) were being processed, data
inconsistency is possible.
If the battery back--up is not sufficient, in exceptional circumstances files could be
destroyed. In such cases the system attempts a cold start.
Loss of mastering may occur if the battery voltage fails before the mastering data
are saved.

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

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

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

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1.6 Virus protection

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

A mouse is required for the manual deletion of infected files.

When the robot system is switched on, the Ikarus Software “Virus Utilities” program is
started. An information window is briefly activated at the start of the program.

The main memory is then automatically scanned for any viruses that may be present.

The program “Guard95”, which runs in the background, is then started; this is indicated by
an icon in the Windows taskbar.

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

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If a virus is discovered during operation, a corresponding notification message is generated

in the virus list.

The virus discovery is also indicated in the Windows taskbar.

You can use the mouse to select and then delete files displayed in the virus list.

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A request for confirmation is generated which must be answered before deletion is carried
out.

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

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

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 2 The KUKA Control Panel KCP

2 The KUKA Control Panel KCP

2.1 General
The KUKA Control Panel, referred to hereafter as “KCP”, forms the interface between man
and machine and is used for easy operation of the KR C1 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. Due to its ergonomic design and its lightness,
the KCP can be used not only as a console unit but also as a handheld unit. The holding
domes and enabling switches on the back of the KCP are arranged in such a way that the
KCP can be easily used by both left--handed and right--handed people.
The VGA color--graphic LCD display helps to visualize operator and programming actions.
If you have already worked with the operating system “Windows”, you will find many familiar
features and elements on the user interface.
The following description gives you an overview of the KCP’s operator control elements and
graphic user interface.

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2.2 Operator control elements of the KCP

EMERGENCY STOP button

The EMERGENCY STOP button is the most

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

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

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

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

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 2 The KUKA Control Panel KCP (continued)

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

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

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

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

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

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

Automatic operation is only possible with the safety circuit closed.

Further information can be found in the chapter [Executing, stopping and resetting
programs].
Further information about operating modes can be found in the documentation EN 775.

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Escape key (ESC)

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

Window selection key

With this key, you can switch between the

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

Program STOP

Pressing this key stops a program that is

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

Program start forwards

This key is used to start a selected program.

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

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 2 The KUKA Control Panel KCP (continued)

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

Program start backwards

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

This function is only available

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

Enter key

This operator control element corresponds

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

Arrow keys z " # !

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

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Space Mouse

This operator control element is used for the

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

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

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

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Softkeys

These operator control elements are used to

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

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

The “NUM” box in the status line of the

display indicates the currently active function
of the numeric keypad:

Numeric input activated

Cursor control functions activated

HOME LDEL PGUP

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

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

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 2 The KUKA Control Panel KCP (continued)

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

If the shift key is pressed once, the next

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

Caps Lock inactive

Caps Lock active

Punctuation marks and special characters are available on a

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

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

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

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

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

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

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2.3 The rear of the KCP

Enabling switch
Enabling switch

Connections

Space Mouse

Enabling switch

Program start
forwards
Rating plate

Enabling switch

Reserved for
subsequent
applications.
Ethernet port

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2.4 Graphic User Interface (GUI)

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

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

2.4.1 Settings for brightness and contrast

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

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

The settings for the brightness are stored in the variable “$PhgBright”, and those for the
contrast in the variable “$PhgCont”.

2.4.2 Function keys

Menu bar

Robot controller functions are grouped

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

The option “A10 Online Optimizing” found under the menu item “Program” should not be
activated. This option is only to be used in conjunction with the “ARC Tech10” technology!

Please refer to the documentation [Arc Welding, ARC Tech10].

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Status key bars

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

Further information on the status keys can

be found in Section 2.2.

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

Further information on the softkey bar can

be found in Section 2.4.6.

2.4.3 Input/output windows

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

Edit cursor

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

You can move between the input boxes using

the “” and “” arrow keys.

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

Each type of message has a specific symbol

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

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

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

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2.4.4 System status

Status line (status bar)

The status line provides a collection of infor-

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

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

Start key required

This message appears after a program has been selected.

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

EMERGENCY STOP

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

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

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

Confirm EMERGENCY STOP

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

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

WAIT FOR $IN[1]==TRUE

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

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

Do you want to touch point “P1”?

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

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2.4.6 Status bar

The status bar gives you information about important operating states.

Numbers are entered using the numeric keypad.

The numeric keypad’s cursor control functions are activated.

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

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

Green: The “Submit” interpreter is running.

Red: The “Submit” interpreter has been stopped.

Gray: The “Submit” interpreter has been deselected.

Green: The drives are ready.

Red: The drives are not ready.

Green: A program has been selected and is currently being

executed.
Gray: No program has been selected.

Red: The selected and started program has been stopped.

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

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

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This box indicates the name of the selected program.

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

Operating mode T1 (manual mode/jog mode).

Operating mode T2 (manual mode/jog mode).

Operating mode in which a host computer or PLC assumes control

of the robot system (Automatic External).

Operating mode (Automatic).

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

at 100% of the process velocity.

The Jog override (for manual traversing); in this example the set
traversing velocity is 50%.

The name of the robot is shown here.

The current system time.

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2.4.7 Toggling to the Windows interface

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

Cursor control functions

activated

2.4.7.1 Alt--Tab
This combination makes it possible to toggle to another active program. These could include,
for example, the programs “KR C1” and “Kuka--Cross 3”. Hold the “ALT” key down and
repeatedly press the “TAB” key in the numeric keypad until the desired program is indicated.
Then release both keys.

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

+ ESC

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

+ ESC

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3 Coordinate systems
3.1 General
To move the robot manually, using the Space Mouse or the traversing keys, you must select
a coordinate system on which the robot movements are to be based.
For this purpose, you can choose from the following four systems, the use of which is
explained in greater detail further on in this chapter.
Joint coordinate system
Each robot axis can be individually moved in positive or negative direction;

WORLD coordinate system

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

BASE coordinate system

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

TOOL coordinate system

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

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

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

-- +

Further information can be found...

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

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3.2 Joint coordinate system

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

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

-- +

-- +

-- +

-- +

-- +

-- +

Traversing keys Space Mouse

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3.3 WORLD coordinate system

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

Position of
operator

Information regarding the Space Mouse:

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

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

-- +

-- +

-- +

-- +

-- +

-- +

Manual traversing keys Space Mouse

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

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3.4 BASE coordinate system

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

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

-- +

-- +

-- +

-- +

-- +

-- +

Manual traversing keys Space Mouse

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

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3.5 TOOL coordinate system

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

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

-- +

-- +

-- +

-- +

-- +

-- +

Manual traversing keys Space Mouse

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

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4 Manual traversing of the robot

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

Overview:
Position and direction of rotation
of the robot axes

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

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

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

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

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

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4.2 Selecting the traversing mode

The following traversing modes are available for manual traversing of the robot:

G Manual traversing switched off

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

G Moving the robot with the “Space Mouse”

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

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

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

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4.3 Selecting the kinematic system

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

-- +

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

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

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

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

G Robot and external axes

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

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

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

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

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4.4 Selecting the coordinate system

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

G Joint coordinate system

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

G WORLD coordinate system

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

G BASE coordinate system

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

G TOOL coordinate system

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

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

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

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

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

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

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

-- +

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

On delivery of the robot, the origin of the BASE system is located at the robot base, and
that of the TOOL system at the center of the robot flange.

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4.5 Jog override (manual traversing velocity)

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

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

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

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

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

If you have selected the joint coordinate system as the reference coordinate system, the
maximum velocity at which it is possible to move the robot is different to that when a
rectangular coordinate system is selected, since in a Cartesian (rectangular) coordinate
system several axes move at the same time and the axis with the longest distance to travel
is the determining (leading) axis.

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4.6 Moving the robot with the Space Mouse

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

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

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

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

It is only possible to move the robot manually if you first hold down one of the enabling
switches (located on the back of the KCP) and then operate the Space Mouse. If either the
enabling switch or the Space Mouse is released while the robot is moving, it is stopped
immediately.

For robot motions in the world coordinate system, the function “Mouse position” is also
available.
For certain applications, e.g. fine positioning or tool calibration, it is useful not to move the
robot in 6 axes simultaneously. For this reason, the aids “Degrees of freedom” and “Dominant
axis” are available to reduce the number.

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4.6.2 Mouse position

If the robot is moved in the world coordinate system using the Space Mouse, the operator
can inform the controller of his position.
This function is reached by pressing the menu key “Configure” and executing the option
“Jogging” --> “Mouse position”.

The default setting for the mouse position is 0 degrees. This means that in the positive X
direction the robot will move towards the operator.

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

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

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

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4.6.3 Degrees of freedom of the Space Mouse

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

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

Axis selection

all Axis (6D)

Degrees of freedom of the

Space Mouse

Dominant mode

Further information on the degrees of freedom can be found in the Programming

Handbook, in the documentation [Configuration], chapter [Configuring the system].

A total of three options are available:

Motion of the Motion of the Unlimited

main axes wrist axes functionality

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4.6.3.1 Motion of the main axes

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

4.6.3.2 Motion of the main axes

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

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4.6.3.3 Unlimited functionality

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

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

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4.6.4 Defining a dominant axis of the Space Mouse

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

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

Axis selection

all Axis (6D)

Dominant mode
Dominant axis

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

Dominant axis Dominant axis

activated not activated

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Further information on the dominant axis can be found in the Programming Handbook,
in the documentation [Configuration], chapter [Configuring the system].

4.6.4.1 Dominant axis activated

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

In this diagram, the relative deflections

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

As can be seen, the deflection for A2+

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

As soon as another axis registers a

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

4.6.4.2 Dominant axis not activated

Either 3 or all 6 axes can be moved depending on the setting of the degrees of freedom. This
is known as a so--called superposed motion. Manual traversing of 3 or 6 axes simultaneously
requires considerable experience and is only useful for rough positioning of the robot.

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4.7 Moving the robot with the traversing keys

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

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

-- +

4.7.1 Joint coordinate system

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

-- +

-- +

-- +

-- +

-- +

-- +

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4.7.2 Coordinate systems TOOL, BASE, WORLD

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

-- +

-- +

-- +

-- +

-- +

-- +

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

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

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4.7.3 Incremental manual traversing

A motion command can be executed step by step using incremental manual traversing. This
function is comparable with the program execution mode “I--Step”. In the event of an error
it enables the user to move the robot a defined distance or orientation away from the
component. The robot can then be moved back exactly to the previous position.

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

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

The following increments can be set as standard:

Incremental manual traversing switched off

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

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

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

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

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

Incremental manual traversing is only available if manual traversing with the traversing
keys has been activated.

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

The increments are executed relative to the coordinate system selected.

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 5 Navigator

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

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

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5.2 Graphic user interface

5.2.1 Fundamentals
The Navigator consists of the following four areas:

Header

Directory structure, Directory or file list

attributes display or
selection list
(templates and filters)

Status line

The following icons and symbols are used in the Navigator:

Drives

Symbol Type Default path

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

Backup drive Archive:\

*1: In the default setting, these symbols are not shown below the user group “Expert”

Directories and files

Symbol Type Meaning

Directory Normal directory
Archive ZIP file (compressed directory)
Directory open Open subdirectory

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 5 Navigator (continued)

Read directory The contents of the subdirectory are being read

Module Program at user level (*.src, *.dat, *.sub)

Module containing Program at user level which must be corrected

errors before being run in the editor
Src file *1 Program file at expert level
Src file *1 Subprogram at expert level
Src file containing Program file at expert level which must be
errors *1 corrected before being run in the editor
Dat file *1 Data list at expert level
Dat file containing Data list containing errors
errors *1
ASCII file *1 File that can be read using any editor
Other files *1 Binary files which cannot be read in the text editor
*1: These symbols are not shown below the user group “Expert”

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

Filter

The current filter setting is The current drive or directory is

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

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

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

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

Template

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

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

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5.2.3 Directory structure, attributes display, selection list

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

The current directory structure is normally shown on

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

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

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

Further drives and directories are available at expert

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

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

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5.2.3.2 Attributes display

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

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

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

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

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

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

Alternatively, you can use the Enter or ESC keys.

ESC

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 5 Navigator (continued)

General

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

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

Date and time of file creation, change and most

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

Module info

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

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

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

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

User data

Any desired additional information can be anchored

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

Parameter “Template” and associated information

Name of the parameter

Associated parameter values

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5.2.3.3 Selection list

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

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

This setting affects the output in the file window

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

Filter “Module” Filter “Detail”

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

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

Which of the templates shown here will be offered

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

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

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5.2.4 Directory and file list

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

To select a directory or file,

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

To open or close a directory

level, press the Enter key.

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

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

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

To do so, move the focus to the

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

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

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 5 Navigator (continued)

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

5.2.4.1 Additional information

The following additional information is available to the operator:

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

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Directory or file name

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

The first 10...15 characters of the comment

The existing Windows95 and kernel system attributes

File size in kilobytes

Number of changes made to the file

Date and time of the last change

Creation date including time

5.2.4.2 Windows95 and kernel system attributes

The “Windows95” operating system uses the following file attributes:

Attribute Description Meaning

r Read only File can only be read, not deleted
An attribute used, for example, by backup programs to
a Archive
decide whether or not a file should be saved
h Hidden The file is, by default, not displayed
This system file is necessary for the correct functioning of
s System
Windows95

The kernel system uses the following attributes:

Attribute Description Meaning

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

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5.2.5 Status line

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

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

Contents display (turquoise)

Selection information (turquoise)

Action information (turquoise)

Process cancelled

User dialog (yellow)

User entries (green)

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

Request for confirmation (gray)

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

which must be answered via the softkey bar.

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5.2.6 Error display

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

Module containing errors

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

5.2.6.1 Error list

This softkey opens the error display.

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

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

Source text line in which the error occurs

Error description

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

The following commands are available in the softkey bar:

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

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

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

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

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

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

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

Close
The error list is closed.

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

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

5.2.6.3 Data list

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

5.2.6.4 Delete

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

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 5 Navigator (continued)

5.3 “File” menu

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

New

Edit File/Folder

*.DAT *1

Errorlist

Print Current selection

Log book

Archive Current selection

All

Applications

System Machine data

Configuration data

I/O list

I/O Configuration data

*1
Configure All

GRIPPER Tech

ARC Tech 10

ARC Tech 20

SPOT Tech

TOUCHSENSE

Robot name

Log book

Restore Current selection

All

Applications

System Machine data

Configuration data

I/O list

I/O Configuration data

*1
Configure All

GRIPPER Tech

ARC Tech 10

ARC Tech 20
Rename
SPOT Tech
Format floppy disk
TOUCHSENSE
Attributes
Robot name
*1
Filter

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

*1

The following menu commands are available for be selection:

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

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

Folder Module

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

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

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

5.3.1.1 Create folder

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

Focus

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

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Create folder
Folder name

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

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

5.3.1.2 Create module

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

Focus

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

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Create module
Module name
Comment

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

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

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

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

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

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

The softkey “Yes” overwrites the existing file

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

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

Information on the creation of customized templates can be found in the Programming

Handbook under [Configuration], chapter [Configuring the system, expert], section
“Configuration files”.

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

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

5.3.2.1 Open a subdirectory

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

5.3.2.2 Load file into the editor

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

Example of an “SRC” file

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

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5.3.2.3 Edit a data list

Example of a “DAT” file

5.3.2.4 Open an error list

Example of an error list

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

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

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

5.3.3.1 Current selection

The selected files are sent to the printer.

File name KRC:\R1\PROG_02.SRC

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

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

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

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File name KRC:\R1\PROG_02.DAT

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

5.3.3.2 Log book

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

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

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

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

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

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5.3.4 Archive
This function allows you to save important data to floppy disk. All files are saved in
compressed form as Zip files.
Compressed data require much less storage space than the original data, but must be
decompressed before they can be read. This is carried out automatically in this case. With
Navigator, the user can see what is stored in the archives.

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

The status line of the Navigator indicates the current status:

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Completion of the operation is also indicated:

5.3.4.1 Current selection

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

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

5.3.4.2 All
The following files are saved to floppy disk:

File Path
All “C:\KRC\Roboter\Init\”
“C:\KRC\Roboter\IR_Spec\”
“C:\KRC\Roboter\KRC\”

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

5.3.4.3 Applications
All programs in the listed folders are saved:

File Path
Applications “C:\KRC\Roboter\KRC\R1\Cell.Src”
“C:\KRC\Roboter\KRC\R1\Program\”

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5.3.4.4 System
The following files and folders can be selected:

File Path
“Machine data” “C:\KRC\Roboter\KRC\R1\MaDa\$Machine”
“C:\KRC\Roboter\KRC\R1\MaDa\$Robcor”
“C:\KRC\Roboter\KRC\Steu\MaDa\$Custom”
“Configuration data” “C:\KRC\Roboter\KRC\R1\System\$Config”
“C:\KRC\Roboter\KRC\Steu\MaDa\$Machine”
“I/O list” “C:\KRC\Data\Kuka_Con.mdb”
“I/O Configuration data” “C:\KRC\Roboter\Init\”

5.3.4.5 Configure
The configurations of the following technologies are available:

“All”
“GRIPPER Tech”
“ARC Tech 10”
“ARC Tech 20”
“SPOT Tech”
“TOUCHSENSE”
“Robot name”

5.3.4.6 Log book

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

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

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

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

The action will then be displayed in the message window:

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

Process cancelled

5.3.5.1 Current selection

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

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

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

5.3.5.2 All
The following files are written back on to the hard disk:

File Path
All “C:\KRC\Roboter\Init\”
“C:\KRC\Roboter\IR_Spec\”
“C:\KRC\Roboter\KRC\”

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

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5.3.5.3 Applications
All programs located in the “Program” folder.

File Path
Applications “C:\KRC\Roboter\KRC\R1\Cell.Src”
“C:\KRC\Roboter\KRC\R1\Program\”

5.3.5.4 System
The user can choose from the following settings:

File Path
“Machine data” “C:\KRC\Roboter\KRC\R1\MaDa\$Machine”
“C:\KRC\Roboter\KRC\R1\MaDa\$Robcor”
“C:\KRC\Roboter\KRC\Steu\MaDa\$Custom”
“Configuration data” “C:\KRC\Roboter\KRC\R1\System\$Config”
“C:\KRC\Roboter\KRC\Steu\MaDa\$Machine”
“I/O list” “C:\KRC\Data\Kuka_Con.mdb”
“I/O Configuration data” “C:\KRC\Roboter\Init\”

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

5.3.5.5 Configure
The configurations of the following technologies are available:

“All”
“GRIPPER Tech”
“ARC Tech 10”
“ARC Tech 20”
“SPOT Tech”
“TOUCHSENSE”
“Robot name”

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

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

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

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

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

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Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

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

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

5.3.7 Format floppy disk

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

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

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

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

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5.3.8 Attributes

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

5.3.9 Filter

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

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5.4 “Program” menu

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

Mark all

Copy

Paste

Cut

Delete

Duplicate

Select Without parameters

With parameters *1

Cancel program

Reset program

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

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5.4.1 Mark all

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

The selection of directories or files can only be cancelled if

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

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

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

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

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

The file selection can be canceled using the Escape key.

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

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

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

Several files can be selected for deletion at the same time. To do this, hold down the “Shift”
key while you select the desired files using one of the arrow keys.

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

Pressing the softkey “Cancel” immediately terminates the function.

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

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

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

Program name
Comment

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

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

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

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

*1

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

5.4.7.1 Without parameters

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

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

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

5.4.7.2 With parameters

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

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

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

5.4.8 Cancel program

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

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5.4.9 Reset program

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

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5.5 “Monitor” menu

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

It is then possible to switch between the two windows.

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

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5.6 Appendix

5.6.1 Keyboard assignment of the Navigator

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

Function Keys

General

Change window to/from Folder list and

File list

Toggle numeric keypad to enter either

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

Directory structure

Select drive / folder

Open / close drive or folder

File list

Select folder / file

Open folder
Select / edit / display module
Edit text file

Select a number of adjacent folders or files +

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Select individual folders / files

Cancel a selection

Cancel all selections ESC

Keyboard shortcuts

Copy +

Cut +

Paste +

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

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5.6.2 Default settings at User and Expert levels

Visibility of drives and folders User Expert

KRC:\

R1

MaDa

System

TP

Program

Steu

MaDa

Floppy disk (A:\)

Hard disk (C:\)

CD--ROM drive

Network drives

Archive:\

User privileges when creating folders User Expert

KRC:\

R1

MaDa

System

TP

Program

Steu

MaDa

Filter User Expert

Detail

Module

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Templates User Expert

Cell

Module

Submit

Expert Module

Expert Submit

Function

Default direectories Available templates

R1 Cell, Module, Submit, Exp. Module, Exp. Submit,

Function
MaDa No

System Moduel, Submit, Exp. Module & Submit, Function

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

Program Cell, Module, Submit, Exp. Modul, Exp. Submit,

Function
Steu No

MaDa No

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6 Executing, stopping and resetting a program

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

6.1 Selecting and opening a program

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

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

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The “Refresh display” function makes it possible to update the Navigator display. The
function is accessed by pressing the menu key “Monitor” and executing the command
“Refresh display”.

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6.1.1 Symbols in the program window

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

Block pointer (program pointer)

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

Current program line

Block pointer (program pointer)

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

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

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

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

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

Normal arrow (yellow):

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

Normal arrow (yellow) with plus sign:

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

L--shaped arrow (red):

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

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

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

Normal arrow (red):

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

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Normal arrow (red) with plus sign:

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

Edit cursor (Input mark)

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

Edit cursor

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

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

Direction indicator

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

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

Line break

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6.1.2 Program status line

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

Program path and name Line, column Icon

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

Chain:
The opened file is linked with a different module.

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

ABC with check mark:

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

PTP:
Changes are being made to an existing inline form. This is done by selecting the desired
motion command and pressing the softkey “Change”.

PTP with star:

A new inline form is being created and opened.

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

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

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6.2 Setting work velocity (program override)

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

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

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6.3 Stop reactions

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

6.3.1 Ramp--down braking

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

6.3.2 Path--maintaining Emergency Stop

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

6.3.3 Maximum braking

The robot is no longer on its path. This occurs if...
G an axis exceeds its command velocity or acceleration (the command velocity is lower
in jog mode T1 than in T2 or automatic mode);
G a software limit switch has been reached or a command value has been exceeded.

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6.3.4 Short--circuit braking (dynamic braking)

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

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

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

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

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

6.3.5 Warning and safety instructions

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

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

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

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6.4 Manual program execution (jog mode)

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

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

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

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

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

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

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

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6.4.2 BCO run

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

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

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

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

Tool center point

P5 PTool P6

Positioning window
Programmed
path

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

Tool center point

PTool

P5 P6

Positioning window
Programmed
path

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

Tool center point Tool center point

PTool BCO run to P6

PTool

P5 P6 P5 P6

Positioning window
Programmed
path

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

Tool center point

PTool PTool
BCO run
P5 P5

P6 P6

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

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6.4.3 Executing individual program lines

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

Edit cursor
Block pointer (program pointer)

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

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

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

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

6.4.4 Program start backwards

Using the “Program start backwards” key, a program can be executed in the reverse
sequence. A prerequisite for this is that the program has already been partially executed
forwards.

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

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

If a program is executed using the “Program start

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

When the “Program start backwards” key is

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

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

Forwards and reverse traversing are only possible if BCO (block coincidence) exists.
In the case of reverse traversing, all programmed points are addressed with exact position-
ing. Approximate positioning is not possible here.
All outputs are set to “FALSE” during reverse traversing. The recorded outputs, notices
(Merker) and Flags are restored when forwards traversing is selected again. The corre-
sponding states, set when the previous point was left, thus become valid once more. The
same applies to interrupts. These are also switched off for reverse traversing and back on
again in the forward direction.

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

P2 (Exact positioning point)

Approximate positioning range

Robot position at
change of direction P3

Forward direction
P1

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

6.4.5 Stopping program execution

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

6.4.6 Resetting a program (Reset)

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

The yellow block pointer then jumps to the first line of the indicated program. The selected
program can subsequently be restarted.

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

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6.4.7 Continuing a program

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

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6.5 Automatic program execution

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

Switch the drives of the robot on.

6.5.1 BCO run

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

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

The status line then changes for automatic mode as follows:

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

6.5.2 Stopping program execution

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

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

6.5.3 Continuing a program

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

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

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

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6.6 Deselecting a program

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

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

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

After selecting the menu key, this menu is opened:

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

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

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

7.1.1 Digital inputs

After this option has been selected a status window is opened, displaying the signal states
of the robot controller’s 1024 inputs.

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

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

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

The designation “SIM” identifies simulated

inputs which may be either set or not set.

The designation “SYS” identifies inputs

whose value are saved in a system
variable.

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

7.1.2 Digital outputs

After this option has been selected a status window is opened, displaying the signal states
of the robot controller’s 1024 outputs.

The red LED symbol indicates that this

output is set.

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

You can switch the output on which the color marker bar is located by pressing the softkey
“Change”. This softkey can only be used as long as one of the enabling switches on the rear
of the KCP is held down. Furthermore, it is not displayed in the operating mode “Automatic”.

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

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

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The designation “SIM” identifies simulated

outputs which may be either set or not
set.

The designation “SYS” identifies outputs

whose value are saved in a system
variable.

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

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7.1.3 Analog Outputs

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

The output values (ranging from --10 V to +10 V) are displayed in the boxes.
When the softkey “Change” is pressed, the input box selected using the arrow keys is
opened. Enter the new value by means of the numeric keypad.

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

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

You can return to the status window for displaying the 16 outputs by pressing the softkey
“Tab +” again.

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

The red LED symbol indicates

that this output is set.
Not assigned
Not assigned

Not assigned
Not assigned
Not assigned
Not assigned

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

Using the status key “Manual

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

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

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

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

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7.1.5 Automatic External

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

You can open the status window for displaying the outputs with the aid of the softkey “Tab +”.
You can return to the status window for the inputs by pressing this softkey once more.

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7.2 Rob. Position

After selecting the menu item “Rob. Position”, the following display modes are offered:

Cartesian Axis--specific Incremental

display (joint) display display

With this display mode, the The rotational offset of each Values for the angular mo-
position of the tool center robot axis is displayed here mentum delivered by the
point (TCP) is displayed in in relation to its mechanical axis drives are displayed
relation to the workpiece zero position determined here.
reference point (BASE) and during mastering.
the rotational offset between
the two coordinate systems.
The entries for “Status” and
“Turn” are also displayed.

You can switch between the display modes “Joint”, “Incremental” and “Cartesian” at any time
by pressing the appropriate softkey.

If the status window remains open, you can constantly follow the position and orientation
while the robot is in motion.

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7.3 Cyclical Flags

After this option has been selected a status window is opened, displaying the signal states
of the cyclical flags, also called “Merker”.

The red LED symbol indicates

that the condition stored in this
notice has been met.

When the softkey “Details” is pressed, the text stored for the notice is displayed for informa-
tion purposes. When you have pressed the softkey, its label and function change.

You can return to the status window for displaying all notices (Overview) by pressing the soft-
key again.

More detailed information on the use and programming of cyclical flags can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [System variables and system files] and in the
chapter [Interrupt handling], section [Use of cyclical flags].

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7.4 Flags
After this option has been selected a status window is opened, displaying the states of the
flags.

The red LED symbol indicates

that this Flag is set.

You can switch the flag on which the color marker bar is located by pressing the softkey
“Change”.

More detailed information on the use and programming of flags can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [System variables and system files].

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7.5 Counters
After this option has been selected a status window is opened, displaying the values of the
counters already configured.

When the softkey “Change” is pressed the input boxes are opened. The message “Change
active.” is displayed in the form’s footer.

Select the counter whose value you want to modify and enter the new value using the
numeric keypad. Press the softkey “OK” in order to let the new settings take effect. The boxes
close again.

If you close the status window without having pressed the softkey “OK” beforehand, the
changes will not be saved.

More detailed information on the use and programming of counters can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [Boxes].

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7.6 Timer
After this option has been selected a status window is opened, displaying the values and
operating states of the timers.

When the softkey “Change” is pressed the input boxes are opened. The message “Change
active.” is displayed in the form’s footer.

Select the timer whose value you want to modify and enter the new value using the numeric
keypad.
You can switch the selected timer on or off using the softkey “Start/Stop”.

Press the softkey “OK” in order to let the new settings take effect. The boxes close again.

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If you close the status window without having pressed the softkey “OK” beforehand, the
changes will not be saved.

More detailed information on the use and programming of timers can be found in the
Programming Handbook in the documentation [Expert Programming], in the chapter
[Variables and declarations], section [Timer].

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7.7 Variable
7.7.1 Single
After this option has been selected a status window is opened, in which the values of the
variables are displayed and can be altered.

List boxes are opened

by means of the key
combination ALT + .

To change the value of a variable, position the cursor in the input box “Name”, using the
softkey “Name” and enter the name of the variable you wish to change. Then press the Enter
key to confirm this.

Name
Gcan have a maximum length of 24 characters,
Gcan consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
Gmust not begin with a number,
Gmust not be a keyword (see Appendix, Keywords).

The value the variable had when you pressed the Enter key is now displayed in the box
“Current value”. If this is not the case, please check the messages in the message window.
As long as the cursor remains in the box “Current value”, the arrow keys “” and “” can be
used to scroll through the list of variables being edited and/or displayed.

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Now press the softkey “New Value” to position the cursor in the input box “New Value”. Enter
the new value for the variable and confirm this by pressing the Enter key again.

After your entry has been accepted by the controller, the new value is displayed in the box
“Current value”. If this is not the case, please check the messages in the message window.
In the basic setting, the search for the specified variable begins in the program currently
selected. If it is not found here, all global data lists are searched.

If you wish to search for the variable in a program other than the one currently selected, you
need to press the softkey “Module”. The input box of the same name is opened. Enter the
file path here for the program you wish to search.

7.7.2 Overview
After this option has been selected a status window is opened. The groups of variables
entered in the file ConfigMon.ini are displayed here.

Configuration monitor
Group 4: Manual safety test

System variable Current value

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Using the softkeys “First Group”, “Group --”, “Group +” and “Last Group” you can move
between the various groups defined in the file “ConfigMon.ini”.

If you wish to modify a value in the in der variable display, first place the focus on the corres-
ponding value box using the “arrow” keys.

Configuration monitor
Group 4: Manual safety test

System variable Current value

Then press the softkey “Change”. The appearance of the status window then changes as
follows:

Configuration monitor
Group 4: Manual safety test

System variable Current value

Enter the desired value using the numeric keypad and press the softkey “Change” again. The
modified value is saved.

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 7 Monitor (continued)

The values of write--protected variables cannot be changed.

If the current user group is lower than the entry “User” in the “ConfigMon.ini” file, the softkey
“Change” cannot be pressed.

The display of the variables is constantly updated. To prevent this, you need to press the
softkey “Cancel Info”. The symbol is then displayed in the status window. Pressing the
softkey again switches the refresh function back on and the symbol reappears.
The variable display is terminated using the softkey “Close”.

Information on configuring the display via the “ConfigMon.ini” file can be found in the
Programming Handbook under [Configuration], chapter [Configuring the system,
Expert], section [Configuration files].

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7.8 Diagnosis
The following functions are grouped together under the menu item “Monitor” --> “Diagnosis”:

Menu Function
Oscilloscope Recording and displaying motion data or the signal states of
inputs and outputs.
Log book Displaying logged operator actions on the KCP.
CROSS Log book Displaying log files of the trace program “KUKA Cross” that
(only in “Expert” mode) runs in the background and (depending on the configuration)
records a number of actions.
Caller Stack Menu--assisted monitoring of the advance run and main run
(only in “Expert” mode) pointers, and also “Arrived at point” and “Move to point”.
Interrupts List of all declared robot and submit interrupts.
(only in “Expert” mode)

The diagnostic functions are accessed by pressing the menu key “Monitor” and then
selecting the submenu “Diagnosis”.

Select the desired diagnosis function from the open submenu.

The menu items “CROSS Logbook”, “Caller Stack” and “Interrupts” can only be seen in the
user group “Expert”.

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

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7.8.1 Oscilloscope
The function “Oscilloscope” is used to record motion data or the status of the controller’s
inputs and outputs. These data are required for setup, optimization and troubleshooting, for
instance.
Up to twenty channels, which can then be viewed and analyzed later, can be traced at the
same time. An additional function allows two traces to be “superposed” on each other.

A detailed description of this function can be found in the Programming Handbook, in the
documentation [Diagnosis], chapter [Oscilloscope].

7.8.2 Log book

The submenu “Log book” displays on the KCP certain logged operator actions carried out
by the user.

7.8.2.1 Display
Selecting this option opens a status window displaying, on the KCP, the operator actions that
have been carried out by the user and logged in a file.
The status window consists essentially of two main areas. The first area displays the type
and number of the log event along with a brief description, while the second area contains
more detailed information.

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Area displaying type, number and

description of the log event.

Area with detailed description of the

log event

Area in which the selected filters are

displayed.

The log book can be evaluated online or offline. Software module debug information,
process data and robot characteristic data such as motor currents, command values, etc.
are not recorded.

The symbols in the log book display have the following meaning:

Icon Shape/color Content Type of log entry

round/yellow Warning during user operation

octagonal/ Error during user operation

Arm with hand
red
square/blue Information during user operation
round/yellow Robot kernel system warning
octagonal/ Robot kernel system error
red Robot
square/blue Robot kernel system information

round/yellow Warning during boot procedure

octagon/red Arrow Error during boot procedure

square/blue Information during boot procedure
round/yellow Warning during installation
octagon/red Wrench Error during installation
square/blue Information during installation

round/yellow Program--generated warning

octagon/red Hammer Program--generated error

square/blue Program--generated information

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The user can switch between the logbook, the information display and the filter by pressing
the softkey “Tab +”. The “TAB” key on the numeric keypad can be used for the same purpose.
To do this, however, the “NUM” display in the status line must be deactivated.
The softkey “Page +” displays the next page up. Alternatively, the “PGDN” key on the numeric
keypad can also be used.
The softkey “Page --” displays the next page down. The “PGUP” key on the numeric keypad
can also be used here.

Refresh The softkey “Refresh” updates the status window with the current data. This option is very
useful if other actions have been carried out in the meantime or new entries have been
added.
The log book display can be terminated at any time using the softkey “Cancel”.

The user can view the current configuration in the Info display.

Configuration

Controller version

Robot name

Log book manager

version

The filter window is accessed using the softkey “Tab +”. All filter types and classes are listed
here, and can be selected on a user--specific basis.

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The softkey “Mark” can be used to confirm the filter type or class selected using the arrow
keys. This causes a check mark to appear or disappear in the corresponding box.
After completing your selection, press the softkey “Apply”.

At least one filter type and one filter class must be selected, otherwise a corresponding
error message will appear when “Apply” is pressed.

7.8.2.2 Configuration
After this option has been selected a status window is opened for configuring the logbook.

Number of logbook entries

Output as per filter

Path and name of the file

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The maximum number of logbook entries is defined in the upper box of the window. You can
move to the lower box “Print / Output to file” by using the arrow keys. You can then use the
SPACE key to select or deselect “Apply filter”. The path and the name of the desired logbook
file can be specified in the box “Filename”.
The softkey “OK” saves all changes and closes the configuration window.

The status window can be closed at any time by means of the softkey “Cancel”.

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7.8.3 CROSS Log book

This function displays the trace program “KUKA--Cross” that runs in the background.

This menu item is not available below the user group “Expert”.

How to change user group is described in the Programming Handbook, in the

documentation [Configuring the system], chapter [The “Configure” menu], section
[User group].

Once the command “CROSS Log book” has been called, the system program
“KUKA--Cross” running in the background will now be shown on the display instead of the
user interface.

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The controller continues to run after the “Log book” function has been called. You can follow
the course of events directly on the screen in accordance with the configuration of the
actions to be recorded.

While the log book is being displayed, operator control elements of the KUKA
Control Panel, such as menu, status or softkeys, should only be actuated if you are
absolutely familiar with the functions and are sure that no unexpected situations
can occur as a result.
Bear in mind that you are operating the controller “blind” in such circumstances!

To return to the user interface, press the “Window selection” key.

The CROSS--Log symbols have the following meaning:

Double click or
Symbol Meaning
“Enter” key
Symbols with an arrow pointing left send data
from a module, i.e. an interface or manager
Symbols with an arrow pointing right, on the
other hand, receive data
Gray symbols with a circle enable intra--Cross
communication. This can be, for example, the
exchange of data between a source interface
and a destination interface

Yellow arrows in conjunction with the ADS Segmented data and

interface indicate segmented data packets, a low--level communica-
so--called low--level communication tion (cryptic)
Green or blue symbols in conjunction with the Unsegmented data
ADS interface represent combined data pack-
ets
Green arrows belonging to the OLE interface Command parameters
indicate command execution or return values
Blue arrows belonging to the OLE interface are Message numbers and
asynchronous messages texts
Red symbols belonging to the OLE interface Message numbers and
are error messages, so--called command errors texts
Arrows with a check mark are messages from
Cross3 to OLE clients

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Operator Control

The following outputs belong together:

G Identical numbers under S#

G Identical numbers under D#

G Entries which appear both under S# and D# link an OLE job number (e.g. 15) to an ADS
job number (e.g. 800A)

An available Cross--Log located in the folder “C:\KRC\Bin\” can be viewed by double--

clicking on it. This automatically opens the KUKA Cross 3 Log viewer.

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 7 Monitor (continued)

7.8.4 Caller Stack

This menu item is not available below the user group “Expert”.

How to change user group is described in the Programming Handbook, in the

documentation [Configuring the system], chapter [The “Configure” menu], section
[User group].

This function evaluates the data for the process pointer ($PRO_IP) and displays them as
text. After this option has been selected, a status window is opened.
The following items are listed individually:
Call number

If the call is caused by an interrupt

Module name

Line number of the jump

Line contents

Path of the module

A summary of the information from above is displayed in the lower line.

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Operator Control

The softkey “-->Editor” can be used to open the selected call and display the corresponding
line with a gray background.

Pressing “Refresh” updates the display in the “Pointer” or “Caller Stack” status window.

The softkey “Close” terminates the function and closes the status window.

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 7 Monitor (continued)

7.8.5 Interrupts

This menu item is not available below the user group “Expert”.

How to change user group is described in the Programming Handbook, in the

documentation [Configuring the system], chapter [The “Configure” menu], section
[User group].

When the menu item “Interrupts” is selected, a status window opens showing a list of
declared “robot” interrupts. Information is provided about priority (from 1 to 128), scope
(global, local), type (standard, stop, measure, error stop and trigger), module name with path
specification and the line number of the individual interrupt.

The interrupts are shown as symbols, which are explained in the table below:

Icon Shape/color/contents Nature of interrupt

Square / gray / -- Inactive interrupt
Square / red / D Active, disabled interrupt
Square / green / E Active, ON interrupt

You can obtain information about the Submit interrupts with the aid of the softkey “Submit”.
They are listed in the same way as the “Robot” interrupts. This softkey changes back and
forth between Submit and Robot.
Pressing this softkey updates the display.

To exit this menu, press the softkey “Close”.

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Operator Control

7.9 Refresh display

When this option is selected, the Navigator display is updated, i.e. all drives are read and all
files present are updated.

7.10 Windows

When Navigator, Program or Editor is selected, the corresponding window will be brought
to the foreground. If no program is selected, or nothing is present in the editor, these items
will be shown as inactive in the upper menu.

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 7 Monitor (continued)

7.11 Help
The “Help” menu offers the options “Online help” and “Info”.

7.11.1 Online help

The online help function gives information about messages selected in the message window.
If the message window is inactive, first you must switch to it using the window selection key.
You can then highlight the desired message using the arrow keys.

Now select online help. A window with information on the desired subject appears. This will
usually consist of three sections: Cause, Effect and Remedy.

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Operator Control

If no message window is available, the following information window appears showing the
controller type, the online help version and KUKA’s address.

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 7 Monitor (continued)

7.11.2 Info

This command displays the following version information:

Type of controller

General version number

GUI version

Kernel system version

User text

Manufacturer

You can display the next page using the softkey “Tab +”.

Robot type

Not an absolutely accurate robot

Number of axes

List of external axes showing

axis number and name

Machine data version

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Pressing the softkey “Tab+” again brings you to the next page.

The softkey “Tab +” brings you to the next--to--last information page.

This page shows comments which are stored in a text file under
KRC\Roboter\LOG\KrcInfo.log.

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 7 Monitor (continued)

You get to the last page by pressing the softkey “Tab +” once again.

Versions of the modules present

The softkey “Save” allows you to send the module information to a text file. This, by default,
is the file “C:\KRC\Roboter\Log\ocxver.txt”.
The version display is closed using the softkey “Close”.

Should you encounter any difficulties with your robot system, please quote the relevant
version numbers when making inquiries.

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8 Menu structure
8.1 General
This chapter gives you an overview of the menus provided by the KUKA software. Further
information on the individual commands can be found in the corresponding documentation.
You can open the desired menus by pressing the appropriate menu key.

Menu bar Menu key

For further information about operator control please refer to the chapter [The KUKA
Control Panel KCP].

The following commands are available to you via the KUKA software menu bar:

Depending on whether the Navigator, Programming, or Editor level is being used, the menu
keys “Setup”, “Commands” and “Technology” will be activated or deactivated.

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 You can open the menus shown below by pressing the corresponding menu key and select
the desired function from the submenu which then opens.

Menu key Options For more details

see...
File Commands relating to the display and file ...section 8.2
operations [File]
Program Commands relating to program creation and ...section 8.3
editing [Program]
Configure Settings for inputs/outputs, drivers ...section 8.4
[Configure]
Monitor Monitor functions for inputs/outputs, position, ...section 8.5
counters, variables, diagnosis [Monitor]
Setup Commands relating to mastering, calibration ...section 8.6
and service [Setup]
Commands Motion and logic commands, KRL Assistant ...section 8.8
[Commands]
Technology Technology commands ARC Tech, SPOT Tech, ...section 8.7
GRIPPER Tech, TOUCH Sense, USER [Technology]
Help Version information and online help ...section 8.9
[Help]

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8.2 File
In Navigator, the “File” menu contains the following commands:

*2
*1 *2

*1

*1

*1 only available at the Expert level

*2 not available for program execution

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 Command Meaning Further information
New
New files and subdirectories can be Doc. Operator Control
created. Ch. [Navigator]
Section [“File” menu]
Edit
File/Folder Opens the selected folder, or loads Doc. Operator Control
the .SRC file of a selected file in the Ch. [Navigator]
editor. Section [“File” menu]
*.DAT Opens the .DAT file of a selected file
in the editor.
Errorlist If a file with errors is present, the
corresponding error list can be
opened.

Print
Current selection In user mode, the .SRC and .DAT Doc. Operator Control
files of the selected file are printed Ch. [Navigator]
out. Section [“File” menu]
Log book The logbook entries are printed.
Archive Data are saved to floppy disk
Archive --> Current selection
Saves the files which have been Doc. Operator Control
selected. Ch. [Navigator]
Section [“File” menu]
Archive --> All
Saves Doc. Operator Control
C:\KRC\Roboter\Init\ Ch. [Navigator]
C:\KRC\Roboter\IR_Spec\ Section [“File” menu]
C:\KRC\Roboter\KRC\
Archive --> Applications
Saves Doc. Operator Control
C:\KRC\Roboter\KRC\R1\Cell.src Ch. [Navigator]
C:\KRC\Roboter\KRC\R1\Pro- Section [“File” menu]
gramm\
Archive --> System
Machine data Saves Doc. Operator Control
C:\KRC\Roboter\KRC\ Ch. [Navigator]
R1\MaDa\$Machine Section [“File” menu]
R1\MaDa\$Robcor
Steu\MaDa\$Custom
Configuration Saves
data C:\KRC\Roboter\KRC\
R1\System\$Config
Steu\MaDa\$Machine
I/O list Saves
C:\KRC\Data\Kuka_Con.mdb
I/O Configuration Saves
data C:\KRC\Roboter\Init\

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Operator Control

Archive --> Configure *1

All Saves the configuration of the Doc. Operator Control
Gripper Tech selected technology. Ch. [Navigator]
ARC Tech 10 Section [“File” menu]
ARC Tech 20
SPOT Tech
Touchsense
Robot name
Archive --> Log book
The contents of the logbook are Doc. Operator Control
saved to floppy disk. Ch. [Navigator]
Section [“File” menu]
Restore
Restore --> Current selection
The selected file is loaded from the Doc. Operator Control
floppy disk onto the hard disk. Ch. [Navigator]
Section [“File” menu]
Restore --> All
All files are loaded from the floppy Doc. Operator Control
disk onto the hard disk. Ch. [Navigator]
Section [“File” menu]
Restore --> Applications
All files located in the Program folder Doc. Operator Control
are loaded from the floppy disk onto Ch. [Navigator]
the hard disk. Section [“File” menu]
Restore --> System
Machine data Only machine data are loaded from Doc. Operator Control
the floppy disk. Ch. [Navigator]
[ g ]
Configuration Only the configuration data are S ti [“File”
Section [“Fil ” menu]]
data loaded from the floppy disk.
I/O list The I/O list is loaded from the
floppy disk.
I/O Configuration Only the specified I/O configuration
data is read from the floppy disk.
Restore --> Configure *1
All The various technologies are copied Doc. Operator Control
Gripper Tech from the floppy disk onto the hard Ch. [Navigator]
ARC Tech 10 disk. Section [“File” menu]
ARC Tech 20
SPOT Tech
Touchsense
Robot name
Rename
The selected files are renamed. Doc. Operator Control
Ch. [Navigator]
Section [“File” menu]
Format floppy disk
The floppy disk in the disk drive is Doc. Operator Control
formatted. Ch. [Navigator]
Section [“File” menu]

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 Attributes
Details about type, path, size, Doc. Operator Control
creation, etc. of the selected file. Ch. [Navigator]
Section [“File” menu]
Filter *1
Display variants for file components. Doc. Operator Control
Ch. [Navigator]
Section [“File” menu]
*1 only available at the Expert level

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Operator Control

8.3 Program...
The “Program” menu appears differently at the Navigator, Programming and Editor levels.

8.3.1 In Navigator

Command Meaning Further information

Mark all
All files in the selected folder are Doc. Operator Control
highlighted. Ch. [Navigator]
Section [“Program” menu]
Copy
Selected files are copied to the clip- Doc. Operator Control
board. Ch. [Navigator]
Section [“Program” menu]
Paste
Files from the clipboard are inserted Doc. Operator Control
at the current position. Ch. [Navigator]
Section [“Program” menu]
Cut
The selected files are deleted from Doc. Operator Control
their original position and copied to Ch. [Navigator]
the clipboard. Section [“Program” menu]
Delete
All selected files are deleted after a Doc. Operator Control
request for confirmation. Ch. [Navigator]
Section [“Program” menu]
Duplicate
The selected file is copied into the Doc. Operator Control
current folder under a different Ch. [Navigator]
name. Section [“Program” menu]
Select
Without The program is selected without Doc. Operator Control
parameters function parameters. Ch. [Navigator]
[ g ]
With The function parameters are trans- S ti [“Program”
Section [“P ” menu]]
parameters ferred when the program is selected.

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 Cancel program
The selected program is closed. Doc. Operator Control
Ch. [Navigator]
Section [“Program” menu]
Reset program
The initial state of the program after Doc. Operator Control
loading is restored. Ch. [Navigator]
Section [“Program” menu]

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Operator Control

8.3.2 At programming level

*1

*2

Command Meaning Further information

FOLD *1
Current FOLD The fold in the current program line Doc. Expert Programming
opn/cls is opened or closed. Ch. [General
[ information
All FOLDs opn Opens all FOLDs in the selected on KRL programs]]
program. Section [Hiding program
sections]
All FOLDs cls Closes all FOLDs in the selected
program.
Delete
After a request for confirmation, the Doc. User Programming
line in which the edit cursor is Ch. [Program editing]
situated or the selected area is Section [Editing a selected
deleted. program]
Find...
After selecting this item, you can Doc. User Programming
enter a search string that the file will Ch. [Program editing]
be searched for. Section [Editing a selected
program]
Cancel program
The selected program is closed. Doc. User Programming
Ch. [Program editing]
Section [Editing a selected
program]
Reset program
The initial state of the program after Doc. User Programming
loading is restored. Ch. [Program editing]
Section [Editing a selected
program]
A10 Online Optimizing *2
Additional option for the “ARC Tech Additional
10” technology package. documentation
[ARC Tech 10]
*1 only available at the Expert level
*2 only available if the technology package ARCTech10 has been loaded

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8.3.3 In the editor
*1

*1
*1
*1

*1

Command Meaning Further information

FOLD *1

Current FOLD The fold in the current program line Doc. Expert Programming
opn/cls is opened or closed. Ch. [General
[ information
All FOLDs opn Opens all FOLDs in the selected on KRL programs]]
program. Section [Hiding program
sections]
All FOLDs cls Closes all FOLDs in the selected
program.
Copy *1
The program line selected via the Doc. Expert Programming
edit cursor is copied to the clipboard. Ch. [General information
on KRL programs]
Section [Altering programs]
Paste *1
The program line in the clipboard is Doc. Expert Programming
inserted at the current position of the Ch. [General information
editor cursor. on KRL programs]
Section [Altering programs]
Cut *1
The program line selected via the Doc. Expert Programming
edit cursor is cut out and pasted to Ch. [General information
the clipboard. on KRL programs]
Section [Altering programs]

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Operator Control

Delete
After a request for confirmation, the Doc. User Programming
line in which the edit cursor is Ch. [Program editing]
situated is deleted. Section [Working with the
program editor]
Find...
After selecting this item, you can Doc. User Programming
enter a search string that the file will Ch. [Program editing]
be searched for. Section [Working with the
program editor]
Replace *1
Search and replace program Doc. Expert Programming
sections in the editor Ch. [General information
on KRL programs]
Section [Altering programs]
Close
The editor is closed. Doc. User Programming
Ch. [Program editing]
Section [Working with the
program editor]
*1 only available at the Expert level

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8.4 Configure
The “Configure” menu contains the following commands:

*1

*1
*1
*1
*1
*1
*1

*1 only available at the Expert level

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Operator Control

Command Meaning Further information

I/O
Gripper
pp Gripper
pp settings.
g Doc. Configuration
g
Ch.
[Configuring the system]
Automatic External Automatic External settings. Section [The “Configure”
men ]
menu]
Long text Names of inputs/outputs.
under “Inputs/outputs”
I/O Driver
Edit Config. Doc. Configuration
Ch
Ch.
Driver Reset Resets the peripheral [Configuring the system]
interfaces. Section [The “Configure”
menu]
I/O Reconfigure under “I/O drivers”
SUBMIT Interpreter
Start/select Start/select Submit Doc. Configuration
interpreter. Ch.
[Configuring the system]
Stop Stop Submit interpreter. Section [The “Configure”
menu]
Cancel Deselect Submit interpreter. under “SUBMIT Interpreter”
Statuskeys
GRIPPER Tech Assignment of the status Doc. Configuration
keys. Ch.
ARC Tech 10 [Configuring the system]
Section [The
[ “Configure”
g
ARC Tech 20 menu]]
under “Status keys”
Jogging
Program--OV--Steps Switches program override Doc. Configuration
on/off on/off. Ch.
Jog--OV--Steps on/off Switches manual (jog) over- [C fi
[Configuring
i th
the system]
t ]
ride on/off. Section [The “Configure”
menu]
Mouse position Definition of the spatial rela- under “Jogging”
tionship between the 6D
mouse and the robot.
Mouse configuration Axis selection and dominant
mode.
User group
Access to certain user Doc. Configuration
levels. Ch.
[Configuring the system]
Section [The “Configure”
menu]
under “User group”

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 Cur. tool/base
Selection of the desired tool, Doc. Configuration
base system and/or kinema- Ch.
tics. [Configuring the system]
Section [The “Configure”
menu]
under “Cur. tool/base”
Tool definition
Tool type Display saved calibration Doc. Configuration
data. Ch.
Base type [Configuring the system]
Section [The
[ “Configure”
g
External Axis menu]]
under “Tool definition”
On/Off options
Force cold Startup The next time the controller Doc. Configuration
is run--up, a complete restart Ch.
without selection of any [Configuring the system]
programs will be forced. Section [The “Configure”
menu]
Disable PowerOff Delay before the system can under
Delay *1 be rebooted. “On/Off options”
Miscellaneous
Language The language used in the Doc. Configuration
graphic user interface. Ch.
Change password Changes the user level [C fi
[Configuring
i th
the system]
t ]
password. Section [The “Configure”
menu]
Def--line *1 Displays the DEF lines in a under “Miscellaneous”
program.
Detail view on/off *1 The program is displayed in
KRL code.
Office GUI on/off *1 Additional operator control
elements on the GUI for
mouse operation.
Pass over monitoring Switches off the monitoring
working envelope *1 of the work envelope.
Technology selection Selection of technologies
*1 (e.g. KUKA ARC, A20,
SPOT, Gripper, etc.) to be
loaded.
USER Tech USER Tech files are reinitial-
reininitialize *1 ized without rebooting the
system.
*1 only available at the Expert level

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Operator Control

8.5 Monitor
The “Monitor” menu offers the following commands:

*1
*1
*1

*1 only available at the Expert level

Command Meaning Further information

I/O
Digital Inputs Displays operating states and Doc. Operator Control
settings which can be modi- Ch [Monitor]
Ch.
Digital Outputs fied as required. Section [Inputs/outputs]
Analog Outputs Displays operating states and
settings which
hich can be modi-
modi
Gripper
fied as required.
Automatic external
Rob. Position
Cartesian View of the individual axis Doc. Operator Control
positions
positions. Ch [Monitor]
Ch.
Axis specific
Section [Rob. Position]
Incremental
Cyclic Flags
Signal states for Merker Doc. Operator Control
(flags). Ch. [Monitor]
Section [Cyclic Flags]
Flags
Signal states of the flags. Doc. Operator Control
Ch. [Monitor]
Section [Flags]

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 Counter
Displays the values of the Doc. Operator Control
counters. Ch. [Monitor]
Section [Counter]
Timer
Values and operating states Doc. Operator Control
of the timers. Ch. [Monitor]
Section [Timer]
Variable
Single Modification and display of Doc. Operator Control
variable values. Ch. [Monitor]
[ ]
Overview Displays the groups of S ti [Variable]
Section [V i bl ]
variables in “ConfigMon.ini”.
Diagnosis
Diagnosis --> Oscilloscope
Display View and analyze saved Doc. Diagnostic Functions
traces. Ch. [Oscilloscope]
[ p ]
Configure Configuration of the oscillo- S ti [Display]
Section [Di l ]
scope functions [Configure]

Diagnosis --> Log book

Display Displays logged operator Doc. Operator Control
actions. Ch. [Monitor]
[ ]
Configure Configuration of the logbook S ti [Diagnosis]
Section [Di i ]
function. under “Logbuch”

Diagnosis --> CROSS Log book *1

Log program “Kuka--Cross”. Doc. Operator Control
Ch. [Monitor]
Section [Diagnosis]
under “CROSS Log book”
Diagnosis --> Caller Stack *1
Evaluates the data for the Doc. Operator Control
process pointer “$PRO_IP”. Ch. [Monitor]
Section [Diagnosis]
under “Caller Stack”
Diagnosis --> Interrupts*1
Listing of interrupts. Doc. Operator Control
Ch. [Monitor]
Section [Diagnosis]
under “Interrupts”
Refresh display
The drives and folders are Doc. Operator Control
read again. Ch. [Monitor]
Section
[Refresh display]
Windows
Navigator Change window between Doc. Operator Control
Program Navigator, Program and Ch. [Monitor]
Editor Editor. Section [Windows]
*1 only available at the Expert level

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Operator Control

8.6 Setup
The “Setup” menu offers the following commands:

*1

*1

*1 only available at the Expert level

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 Command Meaning Further information
Measure
Measure --> Tool
X Y Z -- 4 Point Calibration programs to determine Doc. Start--up
t l position
tool iti andd orientation.
i t ti Ch [Calibration]
Ch. [Calib atio ]
XYZ
Section [Tool calibration]
-- Reference
A B C -- 2 Point
A B C -- World
Numeric Input
Payload data
Measure --> Base
3--Point Calibration programs to determine Doc. Start--up
workpiece
k i position
iti and
d orientation.
i t ti Ch [Calibration]
Ch. [Calib atio ]
Indirect
Section [Base]
Numeric Input
Measure --> Fixed tool
Workpiece Calibration programs to define an Doc. Start--up
external
t l fixed
fi d tool.
t l Ch [Calibration]
Ch. [Calib atio ]
Tool
Section [Fixed tool]
Offset external
kinematic
Numeric Input
Measure --> Supplementary load data
Entry of data for a supplementary Doc. Start--up
load on the robot. Ch. [Calibration]
Section
[Supplementary load data]
Measure --> External kinematic
Root point Calibration programs to define an Doc. Start--up
external
t l kinematic
ki ti system.
t Ch [Calib
Ch. [Calibration
atio -- E
External
te al
Root point
kinematics]
(numeric)
Offset
Offset
(numeric)
Measure --> Measurement Points
Tool type Display saved calibration data. Doc. Start--up
Ch [Calibration]
Ch. [Calib atio ]
Base type
Section
External Axis [Measurement points]
Measure --> Tolerances *1
Entry of tolerance limits for tool Doc. Start--up
calibration. Ch. [Calibration]
Section [Tolerances]

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Operator Control

Master
Master --> Dial
Mastering with a mechanical dial Doc. Start--up
gauge. Ch. [Robot mastering / un-
mastering]
Section [Mastering with the
dial gauge]
Master --> EMT --> Standard
Set mastering Mastering with the electronic Doc. Start--up
measuring tool. Ch. [Robot mastering / unun-
Check mastering]
mastering Section
[Mastering with the EMT]
Master --> EMT --> With load corr. --> First mastering
Mastering with the electronic Doc. Start--up
measuring tool. Ch. [Robot mastering / un-
mastering]
Section
[Mastering with the EMT]
Master --> EMT --> With load corr. --> Teach offset
Mastering with the electronic Doc. Start--up
measuring tool. Ch. [Robot mastering / un-
mastering]
Section
[Mastering with the EMT]
Master --> EMT --> With load corr. --> Master load
With offset Mastering with the electronic Doc. Start--up
measuring tool. Ch. [Robot mastering / un-
mastering]
Without offset Section
[Mastering with the EMT]
UnMaster
Unmastering of selected axes. Doc. Start--up
Ch. [Robot mastering / un-
mastering]
Section
[Unmastering an axis]
Software Update
automatic Load new version of program from Doc. Start--up
CD--ROM. Ch. [Software Update]
Service
DSE -- RDW *1 Settings for the “Digital Servo Doc. Diagnostic Functions
Electronics” and “Resolver--Digital Ch. [DSE--RDW]
Converter”.
Load data Determination of the load data. See additional package
determination [Load data determination]
External Editor External program for editing Doc. Expert Programming
application programs at GUI and Ch. [External Editor]
KRL levels.

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 Robot name
Changes the robot name. Doc. Start--up
Ch. [Robot name]
*1 only available at the Expert level

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Operator Control

8.7 Commands
The “Commands” menu contains the following options:

Command Meaning Further information

Last command
Repeats the last command Doc. User Programming
executed. Ch. [Program commands],
Section “Last command”
Motion
PTP Motion commands “Point--to-- Doc. User Programming
P i t” “Linear”
Point”, “Li ” and
d “Circular”.
“Ci l ” Ch [Program
Ch. [P og a commands],
co a ds]
LIN
Section “Motion”
Motion
CIRC
Moveparams
Torquemon Collision monitoring call. Doc. User Programming
Ch. [Program commands],
Section “Motion parameters”

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 Logic
Logic --> WAIT
Time--dependent wait function. Doc. User Programming
Ch [Program commands],
Ch. commands]
Logic --> WAITFOR Section “Wait functions”
Signal--dependent wait function.
Logic --> OUT
OUT Simple switching function. Doc. User Programming
Ch [Program
Ch. [P og a commands],
co a ds]
PULSE Simple pulse function.
Section “Switching
Switching functions
functions”
SYN OUT Path--dependent switching function.
SYN PULSE Path--dependent pulse function.
Logic --> IBUS--Seg. on/off
Coupling and decoupling an Inter- Doc. User Programming
bus segment. Ch. [Program commands],
Section “IBUS--Seg. on/off”
Analog output
Static Setting of analog outputs under Doc. User Programming
program control Ch [Program commands],
Ch. commands]
Dynamic Section “Analog output”
Comment
Normal Inserts a comment line into a Doc. User Programming
program. Ch. [Program
[ g ]
commands],
Stamp Comment line with the date and time S ti “Comment”
Section “C t”
in a program.
KRL assistant
PTP Absolute “point--to--point” motion Doc. User Programming
Ch [Program
Ch. [P og a commands],
co a ds]
PTP_REL Relative “point--to--point” motion
Section “KRL
KRL assistant
assistant”
LIN Absolute linear motion
LIN_REL Relative linear motion
CIRC Absolute circular motion
CIRC_REL Relative circular motion
*1 only available at the Expert level

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Operator Control

8.8 Technology
The following commands are available in the “Technology” menu:

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 Command Meaning Further information
ARC Tech 10
ARC Tech 10 --> ARC ON
PTP Start welding, Additional documentation
i l di motion,
including ti start
t t and
d [A c Welding
[Arc Weldi g ARC Tech 10]
LIN
ignition parameters.
CIRC
ARC Tech 10 --> ARC SWITCH
LIN Welding of several seam sections, Additional documentation
including
c ud g parameters
pa a ete s foro the
t e seam
sea [[Arc
c Welding
e d g ARCC Tech
ec 10]
0]
CIRC section, and also for mechanical and
thermal weaving.
ARC Tech 10 --> ARC OFF
LIN Welding and ending a seam, Additional documentation
including
c ud g end
e d parameters,
pa a ete s, crater
c ate [[Arc
c Welding
e d g ARCC Tech
ec 10]
0]
CIRC filling, the gas postflow time and
burnback.
ARC Tech 20
ARC Tech 20 --> ARC ON
PTP Start welding, Additional documentation
i l di
including motion
ti parameters,
t [A c Welding
[Arc Weldi g ARC Tech 20]
LIN
program number for the power
CIRC source and start delay.
ARC Tech 20 --> ARC SWITCH
LIN Welding of several seam sections, Additional documentation
including parameters for the seam [Arc Welding ARC Tech 20]
CIRC section, mechanical weaving.
ARC Tech 20 --> ARC OFF
LIN Welding and ending a seam, Additional documentation
including motion parameters, [Arc Welding ARC Tech 20]
program number for the power
CIRC source, velocity and weave pattern,
as well as crater filling.
SPOT Tech
SPOT Tech --> SPOT
PTP Moves the robot to a weld spot, Additional documentation
opens and
d closes
l the
th welding
ldi gun. [Spot Weldi
Weldingg SPOT Tech]
LIN
CIRC
SPOT Tech --> RETRACT
PTP Moves the robot to a weld spot, Additional documentation
opens and
d closes
l the
th welding
ldi gun. [Spot Weldi
Weldingg SPOT Tech]
LIN
CIRC

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Operator Control

GRIPPER Tech
Gripper Programming gripper functions. Additional documentation
[G ippe Tech H50]
[Gripper
Check Gripper Interrogation of any sensors fitted
on the gripper.
TOUCHSENSE
TOUCHSENSE --> SEARCH
LIN Programming a search motion. Additional documentation
[To ch Se
[Touch Sensor
so H70]
PTP
TOUCHSENSE --> CORR
Turn off Programming a correction instruc- Additional documentation
ti
tion [To ch Se
[Touch Sensor
so H70]
1 dimensional
2 dimensional
3 dimensional
Free
programmable
USER Tech
Programmable inline forms, status Doc. Additional Functions
keys and scripts. Ch. [UserTech]
*1 only available at the Expert level

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8.9 Help
The “Help” menu contains the following commands:

Command Bedeutung Further information

Online help
Help function for messages which Ch. [Monitor]
appear. Section [Help]
Info
Provides version information. Ch. [Monitor]
Section [Help]

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 Index

Symbols Brightness, 29
$PERI_RDY, 13
$PhgBright, 29 C
$PhgCont, 29 Cabinet lock, 8
$POWER_FAIL, 13 Calibration, 167
$PRO_IP, 157, 181 Caller Stack, 157, 181
$STOPMESS, 13 Cancel, 173
*.DAT, 169 Cancel Info, 147
Cancel program, 173, 174
Caps Lock, 27
Numbers
Cartesian, 180
3--Point, 183 Cartesian display, 138
CD--ROM drive, 8
A Change, 134, 140, 141, 142
Change password, 179
A B C -- 2 Point, 183
Check Gripper, 190
A B C -- World, 183
Check mastering, 184
A10 Online Optimizing, 174
CIRC, 186, 187
ALT key, 27
CIRC_REL, 187
Alt--Escape, 37
Close, 176
Alt--Tab, 36
COM1, 8
Analog output, 187
Commands, 167, 186
Analog Outputs, 134, 180
Comment, 84, 102, 187
ARC Tech 10, 189
Computer drives, 8
ARC Tech 20, 189
ConfigMon.ini, 145
Archive, 90, 169
Configuration files, 11
Arrow keys, 23 Configure, 167, 177
Attributes, 74, 98, 171 Continuing a program, 127
Attributes display, 64, 68 Contrast, 29
Aut, 35 Control cabinet, 7
Automatic, 44, 132 Control ON, 8
Automatic External, 44, 137, 178 Control--Escape, 37
Automatic external, 180 Controller switched back on, 12
Automatic program execution, 127 Coordinate system, 39, 48
Axis specific, 180 Coordinate systems TOOL, BASE, WORLD,
Axis--specific (joint) display, 138 60
Copy, 100, 172, 175
Counter, 181
B
Counters, 167
Backspace key, 26 CROSS Log book, 148, 154, 181
Backwards key, 23 CROSS--Log symbols, 155
BASE, 39, 42 CTRL key, 26, 27
Base, 183 CTRL--Escape, 37
Base type, 179, 183 Cur. tool/base, 179
BCO run, 121, 127 Current selection, 169
Block coincidence, 121 Current value, 144, 145
Block pointer, 30, 34, 114 Cut, 101, 172, 175
Braking ramp, 118 Cyclic Flags, 180

Index -- i
 Index

D Errorlist, 169
Escape key, 22
Data list, 80
Executing program lines, 123
Def--line, 179
Executing, stopping and resetting a program,
Degrees of freedom of the Space Mouse, 54
112
DEL key, 26 Expert level, 67
Delete, 80, 101, 172, 174, 176 Expert user group, 148
Deselecting a program, 129 Ext, 35
Detail view, 66 External axes, 47
Detail view on/off, 179 External Axis, 179, 183
Details, 139 External Editor, 184
Diagnosis, 92, 181 External kinematic, 42, 183
Dial, 184 External kinematic systems, 47
Digital Inputs, 180
Digital Outputs, 180
F
Direction indicator, 115
File, 81, 167, 168
Directory list, 64, 72
File attributes, 74
Directory structure, 64, 67
File list, 64, 72
Disable PowerOff Delay, 179
File manager, 63
Display, 167
”File” menu, 81
Dominant axis, 57
File name, 74
Dominant axis activated, 58
File operations, 167
Dominant axis not activated, 58
File/Folder, 169
Driver Reset, 178 Filter, 66, 70, 98, 171
Drivers, 167 Find..., 174, 176
Drives, 64 First mastering, 184
Drives off, 20, 127 Fixed tool, 183
Drives on, 20 Flags, 180
DSE -- RDW, 184 Floppy disk drive, 8
Duplicate, 102, 172 FOLD, 174, 175
Dynamic, 187 Force cold Startup, 179
Dynamic braking, 119 Format floppy disk, 97, 170

E G
Edit, 80, 86, 169 Go, 120
Edit Config., 178 Graphic user interface, 64
Edit cursor, 115 Gripper, 136, 178, 180, 190
Editor, 181 GRIPPER Tech, 190
EMERGENCY STOP button, 20 Gripper+, 136
EMT, 184 Gripper--, 136
GUI, 29
Enabling switch, 23, 28
Enabling switches, 51
END key, 26 H
Enter key, 23, 102 Header, 64, 66
Error diagnosis, 76 Help, 161, 167, 191
Error display, 76 HOME key, 26
Error list, 76 HOV, 35

Index -- ii
 Index

I Load correction, 184

I--Step, 120 Load data determination, 184
Log book, 92, 148, 149, 169, 181
I/I Driver, 178
Logic, 187
I/O, 178, 180
Logic commands, 167
I/O Reconfigure, 178
Long text, 178
IBUS--Seg., 187
LPT1, 8
Icon, 116
Icons, 64
Incremental, 180 M
Incremental display, 138 Main axes, 55
Incremental manual traversing, 61 Main switch, 7
Incremental Step, 120 Manual gripper operation, 136
Indirect, 183 Manual mode, 35
Info, 163, 191 Manual program execution, 120
Inline form, 31 Manual traversing, 39, 46
Input mark, 115 Manual traversing of the robot, 44
Inputs, 132 Mark all, 172
Inputs/outputs, 130, 167 Master, 184
INS key, 26 Master load, 184
Interrupts, 181 Mastering, 167
Maximum braking, 118
Measure, 183
J Measurement Points, 183
Jog mode, 35, 44, 120 Menu, 166
Jog OV steps, 50 Menu bar, 29, 166
Jog override, 35, 50, 178 Menu key, 166
Jogging, 178 Menu keys, 24
Joint, 39 Merker, 139, 180
Joint coordinate system, 59 Message window, 31
jump to, 77 Messages in the status bar, 34
Miscellaneous, 179
Mode selector switch, 21, 44
K
Modul info, 69
KCP, 19
Module, 145
KCP front, 19
Modules, 66
KCP rear, 28
Monitor, 106, 130, 167, 180
Keyboard, 27 ”Monitor” menu, 106
KRL assistant, 187 Motion, 186
KUKA--Cross, 154 Motion commands, 167
Mouse configuration, 178
L Mouse position, 52, 178
Language, 179 Moveparams, 186
Last command, 186
LDEL key, 26 N
LIN, 186, 187 Name, 102, 144
LIN_REL, 187 Navigator, 63, 181
Line breaks, 115 New, 71, 82, 169
Line/column, 116 New Value, 145

Index -- iii
 Index

Normal, 187 Program stop key, 22

NUM, 34, 68 Program window, 30, 114
NUM key, 26 PTP, 186, 187
Numeric Input, 183 PTP_REL, 187
Numeric keypad, 26 PULSE, 187

O R
Office GUI on/off, 179 Ramp--down braking, 118
Offset, 183 Reduced velocity, 136
Offset external kinematic, 183 Reference coordinate system, 48
On/Off options, 179 Refresh, 151
Online help, 161, 191 Refresh display, 181
Releasing EMERGENCY STOP, 20
Operating mode, 35
Rename, 96, 170
Operator control elements, 7, 20
Replace, 176
Oscilloscope, 148, 181
Reset, 125, 173
OUT, 187
Reset program, 173, 174
Outputs, 131
Resetting a program, 125
Restore, 93, 170
P Return key, 23
Page +, 151 Reverse traversing, 120
Page --, 151 Rob. Position, 138, 180
Parameters, 103 Robot name, 185
Pass over monitoring working envelope, 179 Root point, 183
Paste, 100, 172, 175 Running up the controller, 7, 9
Path--maintaining braking in event of operator
safety violation, 119 S
Path--maintaining Emergency Stop, 118
Safety instructions, 119
Payload data, 183
Safety switch, 136
PGDN key, 26
Select, 103, 112, 172
PGUP key, 26 Selecting the kinematic system, 47
Position, 167 Selection list, 64, 70
POV, 35 Service, 167, 184
Power failure, 12 Set mastering, 184
Power OFF function, 11 Settings, 167
Print, 88, 169 Setup, 167, 182
Process pointer, 157 Shift key, 27
Program, 99, 167, 172, 181 Short--circuit braking, 119
Program creation, 167 Shutting down the controller, 7, 11
”Program” menu, 99 Signal states, 130, 132
Program name, 116 Simultaneous motion, 40
Program OV steps, 117 Single Step, 120
Program override, 35, 117, 178 Skeleton program, 84, 86, 104
Program pointer, 114 Softkey bar, 30
Program run mode, 120 Softkeys, 25, 136
Program start backwards, 120, 124 Software limit switches, 44
Program start backwards key, 23 Software Update, 184
Program start forwards key, 22, 28 Space Mouse, 24, 39, 46, 51

Index -- iv
 Index

SPOT Tech, 189 UnMaster, 184

Stamp, 187 User data, 69
START key, 22
User group, 154, 157, 159, 178
Start/Stop, 142
Static, 187 User levels, 178
Status bar, 32, 34 USER Tech, 190
Status key bar, 30
USER Tech reininitialize, 179
Status keys, 24, 136
Status LED, 8, 10
Status line, 32, 44, 64, 75, 116
Status window, 31, 46, 48, 136
Statuskeys, 178
V
STOP key, 22
Variable, 145, 181
Stopping program execution, 125, 127
SUBMIT Interpreter, 178 Variables, 167
Superposed motion, 58 Version information, 167
Supplementary load data, 183 Virus protection, 15
SYM key, 27
Symbols, 64
Symbols in the program window, 114
SYN OUT, 187
W
SYN PULSE, 187
System time, 35 Warning and safety instructions, 119
Window selection key, 22, 82
T
Windows, 181
T1, 35, 44
Windows interface, 36
T2, 35, 44
TAB key, 26 With offset, 184
Teach offset, 184 Without offset, 184
Technology, 167, 188
Work cell, 41
Technology commands, 167
Workpiece, 183
Technology selection, 179
Templates, 71 WORLD, 39
Timer, 142, 181
Toggling to the Windows interface, 36
Tolerances, 183
TOOL, 39 X
Tool, 43, 183
Tool definition, 179 X axis, 43
Tool type, 179, 183 X Y Z -- 4 Point, 183
Torquemon, 186
X Y Z -- Reference, 183
TOUCHSENSE, 190
Traversing keys, 39, 46, 59
Traversing mode, 29, 39, 46

Z
U
UNDO key, 26 Zip file, 90

Index -- v
6 Start--up
SOFTWARE

KR C1

Start--up

Release 3.2

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 Robot mastering / unmastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Mastering with the dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Mastering with the EMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 Brief description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Preparation for EMT mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4.1 Set mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4.2 Check mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.5 With load correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.5.1 First mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.5.2 Teach offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.5.3 Master load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Unmastering an axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5 Variables (EMT mastering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5.1 Mastering values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5.2 First mastering/Set mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5.3 Check mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5.4 Teach offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5.5 Master load with offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5.6 Master load without offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1.2 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1.3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Tool calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.2 X Y Z -- 4 Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.3 X Y Z -- Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.4 A B C -- 2 Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.5 A B C -- World . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2.5.1 The “A B C -- World (5D)” method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2.5.2 The “A B C -- World (6D)” method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2.6 Numeric Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2.7 Tool load data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.2 3--Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3.3 Indirect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3.4 Numeric Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4 Fixed tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.4.2 Workpiece (TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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Start--up

2.4.3 Tool (BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.4.4 Offset external kinematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.4.5 Numeric Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.5 Supplementary load data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.6 External kinematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.7 Measurement Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.8 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.9 Error treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3 Calibration -- External kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1.2 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2 External kinematic calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2.2 Root point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.3 Root point (numeric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.4 Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.5 Offset (numeric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.6 Offset external kinematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

4 Software Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5 Robot name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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1 Robot mastering / unmastering

1.1 General
When mastering the robot, the axes are moved into a defined mechanical position, the so--
called mechanical zero position. This mechanical zero position represents an assignment
to the axis drive angle and is defined by a reference notch or mark.
If the robot is in this mechanical zero position, the increment counter for each axis is set to
the value corresponding to the axis angle (generally 0 increments for 0 degrees). In order
to move the robot exactly to the mechanical zero position, a dial gauge or electronic measur-
ing tool (EMT) is used.

The robot must always be mastered under the same temperature conditions in order to
avoid inaccuracies arising through thermal expansion.
This means that mastering must be carried out with the robot always cold or always at
operating temperature.

Vernier on axis 5 Gauge cartridge on axis 2

Depending on the size of the robot, the axes feature either a vernier or a gauge cartridge for
receiving a dial gauge or an electronic measuring tool (EMT).

1 Reference notch
2 Electronic
measuring tool or
4 dial gauge
3 Measuring pin
4 Gauge cartridge

1
3
Cross--section of a gauge cartridge

To locate the mechanical zero position of a robot axis precisely, it must first be aligned to its
pre--mastering position. The protective cap of the gauge cartridge is then removed and a dial

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gauge, or the supplied EMT, is fitted to it. The EMT is now plugged into the robot junction
box (connection X32) and thus connected to the robot controller.
When, on passing over the reference notch, the gauge pin reaches its lowest point, the
mechanical zero position is reached. The electronic measuring tool sends an electronic
signal to the controller.
If using a dial gauge, the zero position can be recognized by the abrupt reversal of the pointer.
The pre--mastering position makes it easier to move to the mechanical zero position. The
pre--mastering position is indicated externally by a scratch mark or “frontsight/rearsight”
markers and is located just before the zero position. The robot must be brought into this
position before the actual mastering procedure.
Axis traversing direction Axis traversing direction

EMT or EMT or
dial dial
gauge gauge

Scratch mark or
“frontsight/rear-
sight” marker

Pre--mastering position Mechanical zero position

An axis may only be moved to its mechanical zero position from “+” to “--”. If the
axis has to be moved from “--” to “+”, it must first be moved past the pre--mastering position
mark in order to move it subsequently back to the mark in the right direction. This is of vital
importance, in order to eliminate the effect of gear backlash.

The robot may have to be remastered for a number of different reasons:

The robot has to be mastered... Mastering is cancelled...

...after repairs ...automatically on booting the
(e.g. replacement of a drive motor or RDC) system1)
...when the robot has been moved without the ...automatically on booting the
controller (e.g. with hand crank) system1)
...after an impact with a mechanical end stop at
...manually by the operator
more than manual velocity (20cm/s)
...after a collision between the tool or robot and a
...manually by the operator
workpiece
1)If discrepancies are detected between the resolver data saved when shutting down the
controller and the current position, all mastering data are deleted for safety reasons.

The robot can be unmastered... Mastering is cancelled...

...if the mastering values saved for the individual
...manually by the operator
axes are to be specifically deleted

You can only master the axes if there is no EMERGENCY STOP situation and the drives are
switched on. The EMERGENCY STOP circuits of the periphery must be wired up, if applicable.
Information on the EMERGENCY STOP button can be found in the documentation
[Operator Control], chapter [The KUKA Control Panel KCP], while the wiring of the
EMERGENCY STOP circuits and the connection X32 for the EMT are described in the
documentation [Operating Handbook, Control Cabinet].

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When mastering the wrist axes, consideration needs to be given to the position of any
external energy supply system as axes 4 and 6 are defined as infinitely rotating before the
mastering process is carried out.

1.2 Mastering with the dial gauge

Information on manual traversing of the robot can be found in the documentation

[Operator Control], in the chapter [Manual traversing of the robot].

Bring the axis to be mastered to the pre--mastering position.

!
n
Pre--mastering position of axis 3

An axis may only be moved to its mechanical zero position from “+” to “--”. If the
axis has to be moved from “--” to “+”, it must first be moved past the pre--mastering position
mark in order to move it subsequently back to the mark in the right direction. This is of vital
importance, in order to eliminate the effect of gear backlash.

Remove the protective cap of the gauge cartridge and fit the dial gauge.

This function is only available in the operating mode Test (T1/T2). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

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Press the “Setup” key. A menu opens. Select here the option “Master”. In the submenu which
opens, confirm the offered selection “Dial”.

A status window opens, in which the axes to be mastered are displayed.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. More detailed information about this can be found in Section 1.4.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

Before carrying out mastering, please use jog override to reduce the traversing velocity to
1%. Move the robot axis that is to be mastered across the pre--mastering position marker,
in the negative axis direction, while watching the pointer of the dial gauge. At the lowest
position of the reference notch, recognizable by the abrupt change in direction of the pointer,
set the dial gauge to 0.
Then move the axis back to the pre--mastering position. Move the axis that is to be mastered
in the negative axis direction again. Stop when the pointer of the dial gauge is about 5--10
scale divisions before the zero position. In order to increase the accuracy of mastering, move
the robot forward more carefully now, in predefined increments. To do this, you need to switch
to the (incremental manual traversing).

The procedure for activating incremental manual traversing is described in the documenta-
tion [Operator Control], chapter [Manual traversing of the robot].

Each time the traversing keys are pressed, the axes now only advance in small steps. In this
way, move the axis in the negative axis direction until the zero position of the dial gauge is
reached.

If you overshoot this point, you must go back and move to the reference notch from the
pre--mastering position again.
The current axis position, highlighted by the colored selection bar, is saved as the mechanical
zero position by pressing the softkey “Master”. The axis that has been mastered is removed
from the window.

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Before mastering the next axis or ending the complete mastering procedure, switch back to
the normal traversing mode.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1.3 Mastering with the EMT

A number of different functions are available for mastering with the EMT. These are grouped
together under two main points: “Standard” and “With load correction”. The difference here
is that using the option “With load correction” it is possible to master the robot as if the tool
had been removed, but actually leave the tool mounted on the robot. This is done by correct-
ing the weight of the tool “arithmetically”. “Standard” mastering is used if the robot is always
mastered with the same tool or always mastered with no tool.

1.3.1 Brief description of the functions

Standard:

G Set mastering
The robot is mastered in the mechanical zero position with or without a payload.

G Check mastering
Here it is possible to check the mastering, i.e. if you are not sure whether or not the
currently valid mastering is correct, the difference from the “Set mastering” values can
be calculated. Bear in mind that the robot must be fitted with the same load as when
“Set mastering” was carried out.

With load correction:

G First mastering
The robot is mastered in the mechanical zero position without a payload. The increment
counter value for each axis is saved. First mastering serves as the basis for the other
functions listed below.

G Teach offset
Using this function, the robot is mastered with a load (tool). The encoder value for the
offset from the first mastering is determined for this load and saved.

G Master load with offset

This function is used to check the mastering of a tool mounted on the robot, for which
an “offset” has been learnt. The saved “offset” is used to recalculate the mastering value
“without load” and calculate and display the difference between this value and the cur-
rent mastering (up to this point no values have yet been saved).
Following this check function, the operator is asked whether the existing mastering
state is to be retained or whether the newly calculated mastering values are valid and
should be saved. This menu item thus allows the first mastering to be restored even
after a collision or following the replacement of a motor.

G Master load without offset

The robot can be mastered with any load (including a tool whose weight has not been
learnt), i.e. no allowance is made for an offset. Instead, only the absolute encoder value
determined in first mastering is used to recalculate the first mastering. A precondition
for this function is that nothing has been mechanically displaced (e.g. collision, replace-
ment of motor, parts, etc.) since the first mastering.

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Mastering with EMT

Set--up

Set mastering First mastering

Teach offset
Loss / Check

Master load with-

Mastering

Check mastering Master load with

offset out offset *)1

*)1 Only possible if the first mastering is still valid (i.e. no change to the drive train
e.g. replacement of a motor or parts, or following a collision, etc.)

For reasons of accuracy, the wrist axes should remain, if possible, in their mechanical zero
position during the EMT mastering function.

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1.3.2 Application examples

Example 1 Mastering without consideration of the load

You have carried out “Set mastering” and then taught a program on which you have been
working for some time. Now you are not sure if this mastering is correct. You can now check
this using the “Check mastering” function. A precondition for this is that the robot is fitted
with the same load as when “Set mastering” was carried out. Once the check has been
carried out, the difference from the currently valid mastering is displayed and you have the
option of overwriting the old mastering with the one just carried out or retaining the existing
mastering values as valid. If you decide to opt for the new mastering, you must be aware
that, in the event of a significant mastering difference, the program you have taught is no
longer correct.

Example 2 Mastering with consideration of the load

Despite having a load mounted on the robot flange, you wish to master the robot, as if no
load were present. In this way you can always precisely master a robot which works, for
example, with different loads (gripper, tool changer, etc.), irrespective of the current load
and without having to remove the load. There are two ways of doing this:
1. Taking the tool load into account by learning the weight difference:
In this case, the mastering difference caused by a load is explicitly measured and saved
in advance for the load in question. Using this value, the computer can take this difference
into consideration in the event of subsequent mastering with a load. When using this
method, the following must be carried out:
First mastering must be carried out once without a load. The weight of each tool must then
be learnt using the function “Teach offset”. Provided that this has been done, you can
subsequently carry out a “Master load with offset” run to restore the old first mastering.
2. Taking the tool load into account by saving the encoder value:
When mastering without a load (first mastering), the path calibration system value
(absolute encoder value) is read and saved for each axis. In the event of subsequent
mastering with a load, the difference is determined and corrected by comparing the current
encoder value with the saved value. The precondition for this method is that the robot has
not undergone any mechanical changes since the first mastering. When using this method,
the following must be carried out:
First mastering must be carried out once without a load. Provided that this has been done,
you can subsequently restore the old first mastering by means of the function “Master load
without offset”.

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1.3.3 Preparation for EMT mastering

When mastering with the EMT, the axis that is to be mastered is moved at a preset velocity
from + to -- under program control. When the EMT detects the bottom of the reference notch,
the controller automatically stops the robot motion and saves this point.

If during the mastering operation a specified distance is overshot, the program is aborted
and an error message is displayed. The most common reason for this happening is that
the axis was positioned to the pre--mastering position with inadequate accuracy.

Bring the axis to be mastered to the pre--mastering position.

!
n
Pre--mastering position of axis 3

Information on how to move the robot manually can be found in the documentation
[Operator Control], in the chapter [Manual traversing of the robot].

When mastering with the EMT, an axis is always moved to the mechanical zero
position from “+” to “--”. If the axis has to be moved from “--” to “+”, it must first be moved
past the pre--mastering position mark so that it can then be moved back to the mark again.
This is done in order to eliminate the effect of gear backlash.

Remove the protective cap of the gauge cartridge and fit the measuring tool.

Connect the measuring tool to the robot controller using the cable supplied with the EMT set.

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Junction box on the rota-

ting column of the robot

Connection X32
The connecting cable
for the EMT is connec-
ted here.

If you wish to remove the connecting cable from the EMT or X32, the connector on
the cable must be released. Otherwise the cable could be torn out or the EMT
damaged.

Press the “Setup” key. Select the submenus “Master” --> “EMT” and then the desired
function.

The options available here are described in more detail in the following sections.
First of all, a distinction is made between standard mastering and mastering with load correc-
tion.

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1.3.4 Standard

In the “Standard” menu, mastering with/without a load can be set and checked. This
mastering function is recommended if the robot is always mastered with the same tool (load)
or always mastered with no tool (load).

1.3.4.1 Set mastering

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Standard” from the submenu “Set mastering”.

A status window opens, in which the axes to be mastered are displayed.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background. If all axes have been mastered, the text
“No axes to master” appears in the window.

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The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. More detailed information about this can be found in Section 1.4.
Furthermore, it is also possible to initiate a new mastering procedure via the menu item
“Check mastering” (“Standard” menu).

The axis that is to be mastered is selected by pressing the softkey “Master”. The text “Start
key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

1.3.4.2 Check mastering

This function allows the old robot mastering values to be checked. The robot is mastered in
the same way as for “Set mastering”.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Standard” from the submenu “Check mastering”.

A status window is opened, in which the axes to be checked are listed.

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If, for example, axis 2 has not been mastered, or has been unmastered, it is not possible
to check the mastering of an axis with a higher number. Axis 2 must first be mastered using
“Set mastering” or “Check mastering” in order to be able to check, for example, axis 3.

The axis for which the mastering is to be checked is selected by pressing the softkey “Check”.
The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The calculated values are saved and
the status window illustrated below is opened, in which the difference from the old mastering
is displayed in increments and degrees.

Pressing the softkey “Save” saves the mastering values and enables the selection of the next
axis.

You must be aware, when accepting the new mastering, that difficulties may arise
during execution of the program, depending on the difference in increments. For
this reason, it is necessary to reteach all programs.
Acceptance of the new mastering also offsets the mastering of all subsequent
mechanically coupled axes (the wrist axes are generally mechanically coupled). In
this case, it is absolutely necessary to check the mastering of these axes and, if the
deviation is too great, set the mastering as well.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1.3.5 With load correction

The menu “With load corr.” allows you to carry out first mastering or load mastering and teach
an offset (load) for different tools and loads. A precondition for “Master load” and “Teach
offset” is first mastering.

1.3.5.1 First mastering

Please note:
The first mastering of the robot must always be carried out without a payload or a
supplementary load.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item “With
load corr.” from the submenu “First mastering”.

A status window opens, in which the axes to be mastered are displayed.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background. If all axes have been mastered, the text
“No axes to master” appears in the window.

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Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. Please refer to Section 1.4 for more information. It is also possible to
initiate a new mastering procedure via the menu item “Check mastering” in the “Standard”
menu. Refer to the section Standard in this chapter.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

The axis (highlighted in color) that is to be mastered is selected by pressing the softkey
“Master”. The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

1.3.5.2 Teach offset

If, after first mastering, the robot is fitted with a heavy tool or workpiece, the increased load
gives rise to deviations (offset) from the first mastering. In the event of a collision or the
replacement of a motor, this offset can be used to recalculate the first mastering (further
information is given in this section under “Load mastering with offset”). Where different tools
or payloads are used, in order to be able to recalculate the mastering without having to
change the tool, the offset must be taught for all tools and payloads.
For this purpose, the robot is fitted, after first mastering, with a tool or workpiece and, if
necessary, a supplementary load. In the subsequent mastering procedure, the robot “learns”
the mastering difference caused by the load (offset).

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item “With
load corr.” from the submenu “Teach offset”.

The input window for selecting a tool is opened.

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Use the status key (at the bottom right of the display) to select the tool number.

...
Press the softkey “Tool OK” (at the bottom of the display) in order to enter data for this tool.
A status window opens, in which all the axes (mastered and unmastered) are available for
selection. Select here the axis to be mastered.

The axis (highlighted in color) that is to be mastered is selected by pressing the softkey
“Learn”. The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now

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moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.
When the data for the tool or workpiece fitted to the robot flange have been successfully
determined, the status window depicted below is opened, displaying in increments and
degrees the offset from the mastering without load.

Pressing the softkey “OK” saves the mastering values and enables the selection of the next
axis. The axis whose weight has just been learnt is removed from the status window. If the
offsets have been taught for all axes, the message “No offset to teach” appears in the
window.
If you wish to delete an offset, press the softkey “Delete”. A window opens, in which the axes
to be deleted are displayed. The tool number previously selected is confirmed.
Use the arrow keys to select the axis for which the offset is to be deleted and press the softkey
“Delete”. If there are no more offsets to be deleted, the message “No offset to delete” appears
in the window.

The values for learnt tools remain valid even after the replacement of a motor or a collision,
as they contain only the difference from the first mastering.

If, at the beginning of the learning process, no first mastering has yet been carried out, this
must be done first. For this reason the program automatically opens the necessary dialog
window. Please pay particular attention to the contents of the text in the status window!

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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1.3.5.3 Master load

With the load mastering function, mastering is carried out with a load. A distinction is made
here between “With offset” and “Without offset”.

With offset
This function makes it possible to check and, if necessary, restore the robot’s old mastering
values without having to remove the tool. The robot is mastered with the tool (known offset).
The mastering data for the state “Without load” (first mastering) are recalculated using the
offset and overwritten after confirmation by the operator. This can be necessary, for example,
if a motor has been replaced or a collision has occurred.

A check is also possible in the event of loss of mastering; in this case the data are
marked as invalid, but these old values are nonetheless still available.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Master load” from the submenu “With offset”.

The input window for selecting a tool is opened.

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Use the status key (at the bottom right of the display) to select the tool number.

...
Press the softkey “Tool OK” (at the bottom of the display) in order to enter data for this tool.

If no offset has yet been taught for the tool, an error message is now generated.

A status window opens, in which all the axes (both mastered and unmastered) for which an
offset has been taught are available for selection. Select here the axis to be mastered.

A status window opens, in which all the axes (both mastered and unmastered) for which an
offset has been taught are available for selection. Select here the axis to be mastered.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.
When the mastering data for the tool or workpiece fitted to the robot flange have been
successfully determined, a status window is opened, displaying the difference from the old
mastering in increments and degrees.

No new mastering values have yet been set, however. This is done once the data have
been saved.

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Pressing “Save” saves the new mastering values and enables the selection of the next axis.
If you do not save the new data, the old mastering state is retained.

Without offset
This function makes it possible to restore mastering data that have been lost. The robot can
be mastered with any tool, for which the offset does not need to have been “taught” before-
hand. Using the data determined in first mastering and the current values, the difference is
calculated and the mastering corrected accordingly.

The robot must not have been changed mechanically, since first mastering, in the
drive train between the drive motor with resolver and the gear system of the axis
concerned (e.g. following replacement of a motor or a collision). Otherwise first
mastering must be carried out again.

Unlike the menu item “Teach offset” (which only measures the difference from first
mastering) “Restore mastering” uses exclusively the absolute encoder value determined
during first mastering to recalculate the first mastering.

First mastering must have been carried out before mastering can be restored in this way.

This function is only available in the operating mode Test (T1). If, when selecting this
function, a different operating mode is set, a corresponding error message is generated.

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 1 Robot mastering / unmastering (continued)

Prepare the robot for mastering as described in Section 1.3.3 and select the menu item
“Master laod” from the submenu “Without offset”.

A status window opens, displaying a message.

Please read the message and confirm it by pressing the softkey “OK” in order to continue.
A status window opens, in which the axes to be mastered are displayed.

The axes are displayed in the order in which they are to be mastered. The axis that is to be
mastered next is indicated by a color background.

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Axes that are already mastered are no longer listed and, if remastering is desired, must
first be unmastered. Please refer to Section 1.4 for more information. It is also possible to
initiate a new mastering procedure via the menu item “Check mastering” in the “Standard”
menu. Refer to the section Standard in this chapter.

The mastering operation will be aborted if you try to master an axis with a higher number
than this one first. Mastering must always be carried out on the axis with the lowest number.

The axis to be mastered, highlighted by the colored selection bar, is selected by pressing the
softkey “OK”. The text “Start key required” appears in the message window.
Press the enabling switch on the back of the KCP, then the “Program start forwards” key (to
the left of the display), and keep both held down. The robot axis previously selected is now
moved from “+” to “--” under program control. When the EMT detects the bottom of the
reference notch, the calibration program is stopped. The determined values are saved and
the mastered axis removed from the window.

Remember to screw the protective cap back onto the gauge cartridge once an axis
has been mastered. Do not allow foreign bodies to get inside as they would damage
this sensitive measuring device and necessitate expensive repairs.

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 1 Robot mastering / unmastering (continued)

1.4 Unmastering an axis

With the aid of this function, individual axes can be specifically unmastered.
Press the “Setup” key. A menu opens. Select the option “UnMaster” from the menu that is
opened.

A status window is then opened, in which the mastered axes are displayed. If all axes have
already been unmastered, the text “No axes to unmaster” appears in the window.

The mastering data for the axis highlighted in color are deleted by pressing the softkey
“UnMaster”.

On account of the mechanical coupling of the robot wrist axes, the data for axes 5 and 6
will also be deleted when axis 4 is unmastered, and similarly the data for axis 6 when axis
5 is unmastered.

The robot axes do not move during unmastering.

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1.5 Variables (EMT mastering)

The sequences used in mastering are described in this section.

Modifications to variables must be avoided; these can cause unpredictable

robot motions.
Changes must only be made via the menus provided.
1.5.1 Mastering values

The values determined during mastering are saved in ASCII format in the file
<KR_SERIALNO>.CAL. As with all robot--specific files, this is found in the directory
\KRC\Roboter\IR_SPEC.
This file is read when EMT mastering is selected and the values saved in it are transferred
to corresponding internal variables.
If this file is missing, or if entries are not assigned, the respective variables are indicated as
invalid. After every mastering operation in which new values are determined, these values
are saved on the hard disk.
These values are:

See
Name Characteristics
Section
First mastering en- 1.5.2
FIRST_ENCODER_VALUES[MAX_AXIS] coder value in incre-
ments. 1.5.6
Difference learnt 1.5.4
ENCODER_DIFFERENCE[MAX_TOOL][MAX_AXIS] using “Learn Tool” in
increments. 1.5.5
First difference from
previous mastering
FIRST_CALIBRATION_DIFFERENCE[MAX_AXIS] (only necessary for 1.5.2
absolutely accurate
robots) in radians.

1.5.2 First mastering/Set mastering

When carrying out “Set mastering”/”First mastering”, the axes to be mastered must be
unmastered, i.e. $AXIS_JUS = FALSE.

“Set mastering”/”First mastering” sequence for an axis:

G When the EMT passes over the reference notch, the absolute encoder value is saved
in the array “FIRST_ENCODER_VALUES”.
G The difference from the previous mastering is saved in the array “FIRST_CALIBRA-
TION_DIFFERENCE” as an angle in radians.
G The axis is mastered.

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 1 Robot mastering / unmastering (continued)

1.5.3 Check mastering

“Check mastering” sequence for an axis, in which all axes (mastered and unmastered) are
available for selection:
G The EMT passes over the reference notch.
G The current incorrect mastering for this axis is displayed.
G A corresponding query appears in the message window asking you whether the value
for the new mastering should be saved. Answering “Yes” sets the values as the current
mastering, while the answer “No” rejects the values and terminates the function.

1.5.4 Teach offset

When using the “Teach offset” function, first mastering must be present for the axes to be
taught and there must be no offset already taught for the tool on the axis concerned, i.e.
$AXIS_JUS.i = TRUE, $FIRST_MASTERED[i] = TRUE, $MASTERING_OFFSET[j,i] =
FALSE.

“Learn Tool” sequence for an axis:

G The tool number is entered by the operator.
G The EMT passes over the reference notch.
G The encoder value for the first mastering is read. The difference from the current
encoder value is calculated, saved in “ENCODER_DIFFERENCE” and written to the
disk.

1.5.5 Master load with offset

When using the function “Load mastering with offset“, only the axes for which an offset
has been taught are displayed for selection, i.e. $MASTERING_OFFSET[j,i] = TRUE.

“Master load with offset” sequence for an axis, in which all axes (mastered and unmastered)
are available for selection:
G The tool number is entered by the operator.
G A check is made to see if the tool has already been learnt for this axis. If this is the case,
the values saved in ENCODER_DIFFERENCE are used to recalculate the first master-
ing.
G The EMT passes over the reference notch.
G The current incorrect mastering for this axis is displayed.
G A corresponding query appears in the message window asking you whether the value
for the new mastering should be saved. Answering “Yes” sets the values as the current
mastering, while the answer “No” rejects the values and terminates the function.

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1.5.6 Master load without offset

When carrying out the function “Load mastering without offset”, first mastering values
must already exist for the axes that are to be processed, i.e. $FIRST_MASTERED[i] =
TRUE.
“Master load without offset” sequence for an axis:
G The first mastering encoder value is read from “FIRST_ENCODER_VALUES” and the
mastering is corrected by the difference from the current encoder value.
G The incremental actual value is determined and set.

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 2 Calibration

2 Calibration
2.1 Fundamentals
2.1.1 General
With the aid of the predefined calibration programs, you have a means of easily defining the
dimensions of an
G unknown tool or
G unknown workpiece
using several different procedures.

Tool center point Workpiece reference point

(TCP)
Robot guides the XYZ -- 4 Point
Position 3--Point
tool XYZ -- Reference Position and
orientation
i t ti
ABC -- World
indirect
Orientation
ABC -- 2 Point
Robot guides the
Position and Tool Position and workpiece
workpiece orientation orientation

The data for up to 16 tools or workpieces can be stored. These data are then called by
number in the application program and enable a tool change to be easily programmed.

For reasons of safety, the calibration programs can only be executed in the operat-
ing mode “T1” or “T2”.

2.1.2 Preconditions
Using the calibration functions requires adequate knowledge of operating the robot system.

Relevant information can be found in the documentation

 The KUKA Control Panel KCP,
 Manual traversing of the robot and
 Robot mastering/unmastering

In addition to this, the following preconditions must be met on the part of the robot:
G the correct machine data are loaded;
G all axes must be correctly mastered;
G no program may be selected;
G mode “T1” or “T2” is selected.

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2.1.3 Introduction

Axis 5
45

Axis 3
75 Axis 4
45

Axis 6 Axis 1
X 0 0

Axis 2
Z 75

X Y

Installed on each axis of the robot are so--called “resolvers”, which constantly measure the
axis angle. Together with the known distances between the robot axes, the controller can
calculate the position and orientation of the flange centerpoint.
The position of the flange center point is defined by its distance from the origin of the world
coordinate system1) (dotted line). This distance is specified in its X, Y and Z components
(dashed lines).

X
The origin of the robot
flange coordinate sys- Y
tem is situated here.
Z
Z

X
Y
The origin of the WORLD coordinate
system is situated here 1).

1) In the basic setting, the world and robot coordinate systems coincide.

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 2 Calibration (continued)

The orientation of the robot flange coordinate system, whose origin lies at the flange
centerpoint, is defined by its rotational offset (Z--Y--X Euler angles) from the world coordinate
system1).

X
Y

Z
X

1. Rotation about die Z--Achse --

Rotation about the Z--axis
Angle magnitude A Y --

X
Y

If a coordinate Z +
system is rota-
ted, a consistent
sequence must
+
be followed in
order to achieve 2. Rotation about the Y--axis
X
reproducible re- Angle magnitude B
sults. Y

Z
--
Z

X 3. Rotation about the X--axis

X
Angle magnitude C
Y --
Y
The information representing a point in space by specification of the coordinates X, Y, Z and
the rotation angles A, B, C is called a FRAME.

1) In the basic setting, the world and robot coordinate systems coincide.

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To enable the position of the reference point of a tool or workpiece mounted on the robot
flange to be calculated, its location and orientation in relation to the robot flange coordinate
system must be known to the robot controller.

The origin of the robot flange

coordinate system is situated
here. Its position and orienta-
tion are known to the robot
controller.

This is the TCP X

(Tool Center Point).

These data can be determined with the aid of an external measuring device. Having been
recorded on a form, the data can be entered into the robot controller at any time. After a
collision, however, these data are no longer valid and must be re--determined.

200

Z
Y

X X
200

TCP (Tool Center Point)

Another possible method of determining the tool data consists in measuring the tool by
means of the calibration systems and calculation functions of the robot.
For this purpose, the TCP of the tool or workpiece mounted on the robot flange is moved to
a reference point from various directions. This reference point can be located at any point
within the work envelope of the robot.

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 2 Calibration (continued)

The position of the TCP is then calculated on the basis of these various positions and orienta-
tions of the robot flange.
To enable the tool or workpiece to be moved as quickly as possible without overloading the
drive systems of the robot, the load data of the tool or workpiece must also be taken into
account.

10 kg
Load

100
kg

Maximum acceleration / velocity

For this purpose, the weight, center of gravity and mass moment of inertia of the tool or
workpiece must be entered into the controller.
Any supplementary loads mounted on the robot must not be forgotten.

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2.2 Tool calibration

2.2.1 Overview
The submenu “Tool” contains the following subprograms:

Program Calibration by...

X Y Z -- 4 Point moving the robot to a fixed reference point
X Y Z -- Reference moving the robot with a known reference tool to a reference
point
A B C -- 2 Point moving the robot to 2 points with orientation data
A B C -- WORLD positioning perpendicular to the world coordinate system
Numeric Input entering the tool data
Tool load data entering the mass, center of mass, mass moment of inertia

Each of these calibration programs is assigned forms that guide you interactively through the
program.

Methods for determining the position

These methods are used to determine the position of the TCP (tool center point) in relation
to the origin of the robot flange coordinate system.
These methods include the calibration programs “X Y Z -- 4 Point” (see Section 2.2.2), and
“X Y Z -- Reference” (see Section 2.2.3).

Methods for determining the orientation

These methods are used to determine the rotational offset (A, B and C according to the Z--
Y--X Euler angles) of the tool coordinate system from the robot flange coordinate system.
These methods include “A B C -- 2 Point” (see Section 2.2.4) and “A B C -- WORLD” (see
Section 2.2.5).

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 2 Calibration (continued)

Axis 5

Y0

Z0

Z
45
Y
X X0

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

A B C -- 2 Point
This method is used if an exact orientation of the three tool axes is required for posi-
tioning and manipulation. It requires marked points to be available on the positive side
of the XY plane and on the negative side of the X axis of the tool.
A B C -- World (5D)
This method is used if only the working direction of the tool is required for its positioning
and manipulation (MIG/MAG welding, laser or waterjet cutting).
A B C -- World (6D)
This method is used if the orientation of all three tool axes is required for positioning
and manipulation (for example: welding guns, grippers, adhesive nozzles, etc.).
Method for TOOL orientation
If a tool is known, its dimensions and angular positions are entered. This is done via the menu
item “Numeric Input” (see Section 2.2.6).

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2.2.2 X Y Z -- 4 Point
In the “4--Point” method, the TCP of the tool is moved to a reference point from four different
directions (hence “4--Point” method).

The position of the TCP (TOOL Center Point) is then calculated on the basis of the various
positions and orientations of the robot flange.
Procedure
Mount the tool to be calibrated onto the robot flange and establish a suitable reference point.
This can be the tip of the reference spike installed in the work envelope or also a distinctive
corner of a workpiece or a fixture.
Using the menu key “Setup” (at the top of the display) open the menu “Measure” (“Calibrate”)
and “Tool” and there select the submenu “X Y Z -- 4--Point”.

The dialog window for 4--point calibration is opened:

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 2 Calibration (continued)

Use the status key (at the bottom right of the display) and the +/-- key to select the desired
tool number. Calibration data for a total of 16 different tools can be stored. The current dimen-
sions or angles of the tool in question are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Tool OK” (at the bottom of the display) in order to calibrate the selected
tool. The next status window is then automatically opened.

You are now prompted to align the tool to a reference point from different directions. Either
the axis traversing keys or the Space Mouse can be used to do this. Now carry out the
following steps in the order given:
G Set the desired tool orientation.
G Move the TCP to the reference point.
G When the TCP is located exactly on the reference point, save its position by pressing
the softkey “Point OK”.
If the selected points are too close together, an error message is generated. You can now
press the softkey “Repeat” to repeat the last calibration, or the softkey “Repeat All” to repeat
all calibrations.
After the point has been accepted by the controller, you are prompted to align the TCP to
the reference point from another direction. Repeat these steps until the reference point has
been addressed from four directions and the point coordinates transferred.

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P4
P1

P3

YT
XT
P2
ZW
fixed point
in space ZW

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

For this purpose you can use increase or decrease the traversing velocity using the +/-- key
of the “Jog--OV” status key. Reducing the deflection of the Space Mouse also reduces the
velocity.

At the end of the calibration procedure, you will be offered the softkey “Save” (at the bottom
of the display). Save the tool data by pressing this softkey. The function is terminated.

2.2.3 X Y Z -- Reference
In this method, the data of a tool to be calibrated are determined by means of comparison
with a known tool by moving the TCP to a reference point.

To achieve this, a tool of known

dimensions is moved, from any
direction, to a reference point.
known tool

fixed point in space

The tool to be calibrated is then

mounted on the robot flange.
This tool is also moved to the
unknown tool reference point, again from any
direction.

fixed point in space

On the basis of the various positions and orientations of the robot flange and the known
dimensions of the tool previously used, the robot controller can now calculate the dimensions
of the tool that is to be calibrated.

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 2 Calibration (continued)

Procedure
Mount a tool whose dimensions are known to the controller onto the robot flange and estab-
lish a suitable reference point.
This can be the tip of the reference spike installed in the work envelope or also a distinctive
corner of a workpiece or a fixture.
Using the menu key “Setup” open the menu “Measure” (“Calibrate”) and “Tool” and there se-
lect the menu item “X Y Z -- Reference”.

The following dialog window is opened after this menu has been selected:

Use the status key (at the bottom right of the display) and the +/-- key to select the desired
tool number. Calibration data for a total of 16 different tools can be stored. The current dimen-
sions or angles of the tool in question are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.
Press the softkey “Tool OK” in order to edit the data for this tool. The dialog window for data
entry is then opened.

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Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

Use the numeric keypad to enter the dimensions of the reference tool, i.e. the known tool,
in the input boxes X, Y and Z.
You can move between the input boxes using the “” or “” arrow keys.

Example:
X, Y, Z Distance between the origin of the robot flange coordinate system
(located at the center of the flange) and the TCP (tool center point) of
the reference tool in relation to the robot flange coordinate system.

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 2 Calibration (continued)

Y
Z

X= + 50 X Flange
adaptor plate
as reference
tool

In the example:

If the entries have been made correctly, confirm this by pressing the softkey “Data Ok”. The
window prompting you to move to the reference point is opened.

The robot can be moved using either the traversing keys or the Space Mouse. Now carry out
the following steps in the order given:
G Set the desired tool orientation.
G Move the TCP to the reference point.
G When the TCP is located exactly on the reference point, save its position by pressing
the softkey “Point OK”.

Reduce the traversing velocity in the vicinity of the reference point in order to avoid
a collision.

To do so, repeatedly press the status key on the right of the display.

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After the point has been accepted by the controller, you are prompted to align the tool that
is to be calibrated to the reference point.

First move the tool away from the reference point. Then replace the known tool with the
unknown tool and move to the reference point again.

known tool
unknown tool
fixed point
in space

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

To do so, repeatedly press the status key “Jog override”, on the right of the display.

Now confirm the position with the softkey “Point Ok”. The X, Y and Z dimensions of the
defined tool are displayed in the form that is then opened.

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 2 Calibration (continued)

The data are saved and the calibration program is ended by pressing the softkey “Save”.

You are currently able to open the corresponding subprograms by means of the softkeys
“A B C -- 2 Point”, “A B C -- World” or “Load data”. It is also possible to view the calibrated
points by pressing the softkey “Meas. Pt.”. Further information on this can be found in the
following sections.

2.2.4 A B C -- 2 Point
In this method, the orientation of the tool coordinate system is defined in two steps.

The first step is to show the robot control

system the working direction of the tool.
Y To achieve this, the TCP is first moved
to any reference point.
Z

X Reference
point

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A point on the tool opposite the TCP (in

the reverse working direction) must
now be moved to the same reference
Z point.
Y This serves to define the working direc-
tion of the tool is determined in this way.

Reference
point X

The YZ plane can still rotate freely about

the X axis (working direction) of the tool
and is defined in the second step.
Z To achieve this, the tool is positioned in
such a way that the reference point lies
Y in the future XY plane with a positive Y
value.
Reference
point
X

Procedure
Mount the tool to be calibrated onto the robot flange and establish a suitable reference point.
This can be the tip of the reference spike installed in the work envelope or a distinctive corner
of a workpiece or a fixture.
Using the menu key “Setup” open the menu “Measure” (“Calibrate”), the submenu “Tool” and
the option “A B C -- 2 Point”.

The following dialog window is opened after this menu has been selected:

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 2 Calibration (continued)

Use the status key (at the bottom right of the display) and the +/-- key to select the desired
tool number. Calibration data for a total of 16 different tools can be stored. The current dimen-
sions or angles of the tool in question are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

If this definition procedure is called by means of the softkey “X Y Z -- Reference” (see

Section 2.2.3), the form for entering the tool number will not be opened.

Press the softkey “Tool OK” in order to edit the data for this tool. The dialog window for enter-
ing the TCP value is then opened.

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Position the TCP (tool center point) to a reference point.

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

For this purpose you can raise or lower the traversing velocity using the +/-- key of the
“Jog--OV” status key. Reducing the deflection of the Space Mouse also reduces the velocity.

When the TCP (tool center point) is located exactly on the reference point, save this position
by pressing the softkey “Point OK”. The status window then changes.

First move the tool away from the reference point.

Here also, reduce the traversing velocity in the vicinity of the reference object in or-
der to avoid a collision.

To do so, press the status key “Jog--OV” again.

Position a point located opposite the TCP in the reverse working direction to the reference
point.

Z
Y

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

To do so, repeatedly press the status key shown here (on the right of the display).

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 2 Calibration (continued)

When the TCP (tool center point) is located exactly on the reference point, save this position
by pressing the softkey “Point OK”. The status window then changes again.

Move the tool so that the reference point is located with a positive Y value on the future XY
plane of the tool.

Reduce the traversing velocity in the vicinity of the reference object in order to
avoid a collision.

To do so, repeatedly press the status key shown here (on the right of the display).

When the TCP (tool center point) is located exactly on the reference point, save this position
by pressing the softkey “Point OK”.

If the error message Point too near to reference point is displayed, the distance to the
previous point is too small. The form cannot be closed by pressing “Point Ok” until the
distance has been increased.

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You are currently able to open the corresponding subprogram by means of the softkey
“Load data”. More detailed information about this can be found in Section 2.2.7.It is also
possible to view the three different measuring points (coordinates) by pressing the softkey
“Meas. Pt.”

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is then terminated.

2.2.5 A B C -- World
The desired function is selected by pressing the menu key “Setup”, and then calling
“Measure” (“Calibrate”) and the submenu “Tool”.

The approach is different depending on whether you are using the 5D method (see Section
2.2.5.1) or 6D method (see Section 2.2.5.2).

2.2.5.1 The “A B C -- World (5D)” method

In this method, the tool must be oriented parallel to the Z axis of the world coordinate system
in the working direction. The Y and Z axes are oriented by the robot controller. The orientation
of these axes is not readily foreseeable in this instance, but it is exactly the same in each
calibration procedure.

Condition:
X parallel to Z0
Z0
Z Y
X
X0
Y0

Procedure

Mount the tool to be calibrated onto the robot flange.

Select the menu item “A B C -- World”. The dialog window for selecting the tool number is
then opened:

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Select the tool number (1...16) which can be altered by means of the +/-- keys of the
corresponding status key (at the bottom right). The current values for the selected tool are
displayed in the lower part of the status window.

...

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You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Tool OK” (at the bottom of the display), in order to enter data for this tool.

If the “6D” option is activated (i.e. is highlighted in color), you must select the “5D” method
using the status key.Then press the softkey “Data OK” in order to be able to edit the tool
data. You will now be prompted to align the tool.

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Z Y
X
Z0
Condition:
X parallel to Z0
or
Z parallel to Z0
X0
Y0

When all entries have been made, confirm them by pressing the softkey “Point OK” (at the
bottom of the display).

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At this point you can open the corresponding subprogram by means of the softkey “Load
data”.
Further information on this can be found in Sections 2.2.7. and 2.7.

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is terminated.

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2.2.5.2 The “A B C -- World (6D)” method

In this method, the tool must be oriented in alignment with the world coordinate system. The
axes of the tool coordinate system must be parallel to the axes of the world coordinate
system.

Conditions:
X parallel to Z0
Z
Y parallel to Y0
X Y
Z parallel to X0 Z0

X0
Y0

Procedure
Mount the tool to be calibrated onto the robot flange.
Select the menu item “A B C -- World”. The dialog window for selecting the tool number is
then opened:

Select the tool number (1...16) which can be altered by means of the +/-- keys of the corre-
sponding status keys (on the bottom, righthand side). The current values for the selected tool
are displayed in the bottom part of the status window.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

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Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

Press the softkey “Tool OK” (at the bottom of the display) in order to enter data for this tool.

Next select the “6--D” method by means of the status key (at the bottom right of the display).
Then press the softkey “Data OK” in order to be able to edit the tool data. You will now be
prompted to align the tool.

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Conditions:
X parallel to Z0
Y parallel to Y0
Z parallel to X0

Z
Y Z0
X

X0
Y0

When all entries have been made, confirm them by pressing the softkey “Point OK” (at the
bottom of the display).

Once again you are able to open the corresponding subprogram by means of the softkey
“Load data”.
Further information on this can be found in Sections 2.2.7. and 2.7

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is terminated.

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2.2.6 Numeric Input

This menu item enables you to enter the numeric values of a fixed tool. Open the menu item
using the softkey “Setup”, the menu “Measure” (“Calibrate”) and the menu option “Numeric
Input”.

The corresponding dialog window is then opened:

Select the tool number from 1...16 using the status key at the bottom right of the display.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

Press the softkey “Tool OK” in order to edit the data for this tool. The dialog window for data
entry is opened.

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You can move between the input boxes and make the desired entries using the “” or “”
arrow keys.

The abbreviations in the dialog window have the following meaning:

X, Y, Z Distance between the origin of the robot flange coordinate system

(located at the center of the flange) and the TCP (tool center point) in
relation to the robot flange coordinate system.

Please note !
Z= + 200
The illustrated position for the
X flange coordinate system is
only valid if axes 4, 5 and 6 are
in the zero position.

In the example:

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A, B, C Rotational offset of the tool coordinate system (Z--Y--X Euler angles)

from the robot flange coordinate system.

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

Y0

Z0

Please note !
Z
45 The illustrated position for the
Y flange coordinate system is
only valid if axes 4, 5 and 6 are
X X0 in the zero position.

In the example:

When all entries have been made, confirm them by pressing the softkey “Data OK” and save
the entries that have just been made.

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The tool number and tool data are displayed in the form. These data are saved and the form
is closed by pressing the softkey “Save”.

You are currently able to open the corresponding subprogram by means of the softkey
“Load data”. More detailed information about this can be found in the following section.

2.2.7 Tool load data

In order to optimize use of the available maximum moments of acceleration of the robot axes,
it is possible to enter the load data of the tool that is being used.

If loads lower than those actually existing are programmed, the robot system is
liable to be mechanically or electrically overloaded.

If the tool load is greater than the permissible rated load given in the payload
diagram of the robot specification, mechanical or electrical overloads of the robot
system are liable to occur in the case of LIN and CIRC motions. This is dependent
on the programmed path velocity and the position of the robot.

No liability will be accepted for any resultant damage!

The menu item “Payload data” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “Tool”.

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It is possible to branch directly to the tool load data from the calibration programs
“X Y Z -- Reference”, “A B C -- 2 Point”, “A B C -- World” and “Numeric Input”. It is not
possible, in this case, to enter a tool number.
The relevant dialog window is then opened in which you can enter the number of the tool to
be changed:

Here also a total of 16 different tools can be entered.

...
Press the softkey “Tool OK” in order to be able to edit the data for the selected tool. The status
window for data entry is then opened.

You can move between the input boxes with the aid of the “” and “” arrow keys and enter
the desired values using the number keys in the numeric keypad.

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or
Press the softkey “Default” in the bottom part of the display to accept the standard load data
defined in the basic settings of the system.

The default setting in the box “M [kg]” is --1 (load specified in the machine datum). If 0 is
entered here, there is no tool load on the robot arm.

Check beforehand by referring to the payload diagram in the robot specification

whether the tool lies within the permissible range for standard loads!

The abbreviations in the dialog window have the following meaning:

M Weight of the tool.
X, Y, Z Distance between the center of gravity of the tool and the origin of the
robot flange coordinate system (located at the center of the flange) in
relation to the robot flange coordinate system.

Y
Z

A, B, C Rotational offset of the principal inertia axes of the tool (Z--Y--X Euler
angles) from the robot flange coordinate system.

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

JX, JY, JZ Mass moments of inertia about the principal inertia axes of the tool.
When all entries have been made, confirm them by pressing the softkey “Data OK”. The tool
load data are displayed for control purposes.

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The softkey “Save” is then used to save the data and close the dialog window.

Further information on the calculation of tool load data can be found in the additional docu-
mentation Load Data Determination.

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2.3 Base
2.3.1 Overview

The menu “Base” is opened by first pressing the menu key “Setup”, and then selecting the
menu “Measure” (“Calibrate”).

The submenu “Base” contains the following subprograms:

Program Calibration by...

3--Point moving to the reference point of a workpiece
Indirect entering the inaccessible reference point of a workpiece
Numeric Input entering a reference point manually

Each of these calibration programs is assigned forms that guide you interactively through the
program.

2.3.2 3--Point
This method is used to determine the reference point of a workpiece (BASE).
This is done by positioning a tool whose dimensions are known to the controller to three spe-
cific points, which are then programmed. These three points determine both the position of
the origin and the orientation of the base coordinate system.

Z
Origin Point on the Point in the Result
X axis XY plane with
a positive Y
value
Procedure
Mount a tool whose dimensions are known to the controller onto the robot flange.
Open the menu using the menu key “Setup”, then the submenu “Base” and finally select the
command “3--Point”.

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The input window for the base system is opened:

Use the +/-- status key (at the bottom right of the display) to select the number of the base
coordinate system.

...

You can use the arrow keys to access the base system name input box and there enter a
name for the base system.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

Press the softkey “Base OK” (at the bottom of the display) in order to open the next input
window.

The input window for selecting the reference tool is then opened:

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Use the +/-- status key (at the bottom right of the display) to select the tool number.

...
Press the softkey “Tool OK” (at the bottom of the display) in order to perform the calibration
with this tool.
A window is opened.

You are prompted to position the TCP (tool center point) to the future origin of the base coordi-
nate system (BASE).

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key shown here (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired origin of the base coordi-
nate system (BASE), save this position by pressing the softkey “Point OK”.

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The next window is opened:

You are prompted to show the controller the orientation of the X axis by positioning the TCP
to a specific point.
First move the tool away from the workpiece:

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key shown here (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired point, save this position
by pressing the softkey “Point OK”.

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The following dialog window is opened:

You are prompted to show the controller the orientation of the XY plane by moving the tool
to a point with a positive Y value.

First move the tool away from the workpiece:

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key (at the top right of the display).

When the TCP (tool center point) is located exactly at the point with a positive Y value on
the XY plane, save this position by pressing the softkey “Point OK”.

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When the softkey “Meas. Pt.” is pressed, a window appears in which the values of the individ-
ual measurements are listed once again.

Save the workpiece data by pressing the softkey “Save” (at the bottom of the display).
The function is terminated.

2.3.3 Indirect

This method is used if the reference point of the workpiece (BASE) is not located inside the
work envelope of the robot (in the case of very large workpieces) or cannot be reached by
the robot (workpieces of complex shape).

In this method, the robot is moved to four points whose positions are known (manufacturing
drawing, CAD data, etc.). The tool dimensions must be known to the controller.

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Procedure
Mount a tool whose dimensions are known to the controller onto the robot flange.
The menu “Indirect” is accessed via the menu key “Setup”, and the submenu “Base”.

The input window for selecting the base coordinate system is opened:

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Use the status key (at the bottom right of the display) to select the workpiece (base) number.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Base OK” (at the bottom of the display) in order to enter data for this
workpiece.

The input window for selecting a tool is opened.

Use the +/-- status key, at the bottom right of the display, to select the tool number.

...
Press the softkey “Tool OK” in order to perform the calibration with this tool.

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The following window is opened:

You are prompted to enter the coordinates of points known to you and then to position the
TCP to these points. To do so, carry out the following procedure:

Step 1 -- Enter the values by means of the numeric keypad.

You can move between the input boxes using the “” arrow key.
X, Y, Z Distance between the calibration point and the workpiece reference point
(BASE).

Point 2

Point 1
Point 3

Point 4
Workpiece Z
reference
point (BASE)

X
Y
Step 2 -- Move the TCP to the specified point.

Reduce the path velocity in the vicinity of the workpiece in order to avoid a collision.

To do so, repeatedly press the status key shown here (at the top right of the display).

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Step 3 -- Save the point

When the TCP (tool center point) is located exactly at the point you specified beforehand,
save this position by pressing the softkey “Point OK”.

After the point has been accepted by the controller, you are prompted to move the TCP to
the next three points. Repeat steps 1 to 3 until all four points have been addressed.
At the end of the calibration procedure, you will be offered the softkey ”Save” (at the bottom
of the display). Save the workpiece data by pressing this softkey. The function is then
terminated.

2.3.4 Numeric Input

Open the menu the menu “Measure” using the softkey “Setup”, then select “Base” and finally
“Numeric Input”.

The input window for the base coordinate system is opened:

Use the +/-- status key to select the desired coordinate system.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.

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Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Base OK” in order to enter the corresponding data.
The following window is then opened:

Enter the values by means of the numeric keypad.

You can move between the input boxes using the “” arrow key.
X, Y, Z Distance between the origin of the world coordinate system and the workpiece
reference point (BASE) in relation to the world coordinate system.

Workpiece Z
reference
point

X
Y
A, B, C Rotational offset of the base coordinate system (Z--Y--X Euler angles)
from the world coordinate system.

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Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
When all entries have been made, confirm them by pressing the softkey “Data OK” (at the
bottom of the display).

Save the workpiece data by pressing the softkey “Save” (at the bottom of the display).
The function is terminated.

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2.4 Fixed tool

2.4.1 Overview
The menu “Fixed tool” is opened by first pressing the menu key “Setup”, and then selecting
the menu “Measure”.

The submenu “Fixed tool” contains the following subprograms:

Programs Calibration by...

Workpiece (TOOL) moving with the workpiece mounted on the robot flange
Tool (BASE) moving the robot to a fixed tool
Offset external kinematic moving the robot to a fixed tool on an external kinematic
system
Numeric Input entering a fixed tool manually

Each of these calibration programs is assigned forms that guide you interactively through the
program.

2.4.2 Workpiece (TOOL)

This method is used to determine the reference point (BASE) of a workpiece mounted on
the robot flange.
This is done by positioning and saving three specific points on the workpiece to a fixed tool
whose dimensions are known to the controller. These three points determine both the
position of the origin and the orientation of the base coordinate system.

Y
X

Origin Point on the Point in the Result

X axis XY plane

Procedure
Install a fixed tool whose dimensions are known to the controller.
Using the menu key “Setup” open the menu “Measure” (“Calibrate”), then the submenu
“Fixed tool” and there select the menu item “Workpiece”.

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The following input window is opened:

Use the +/-- status key to select the workpiece coordinate system.

...
You can use the arrow keys to access the tool name input box and there enter a name for
the tool.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Tool OK” in order to switch to the next input window.
This opens the following window:

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Use the +/-- status key to select the tool number.

...
Press the softkey “Base OK” in order to perform the calibration with this tool.

The next window is opened:

You are prompted to position the future origin of the base coordinate system (BASE) to the
TCP (center point) of the fixed tool.

Reduce the path velocity in the vicinity of the fixed tool in order to avoid a collision.

To do so, repeatedly press the status key (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired origin (BASE), save this
position by pressing the softkey “Point OK”.

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The next window:

You are prompted to show the controller the orientation of the X axis by positioning a specific
point to the TCP.
First move the workpiece away from the TCP.

Reduce the path velocity in the vicinity of the fixed tool in order to avoid a collision.

To do so, repeatedly press the status key (at the top right of the display).

When the TCP (tool center point) is located exactly at the desired point, save this position
by pressing the softkey “Point OK”.

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Another window is opened:

You are prompted to show the controller the orientation of the XY plane by positioning a spe-
cific point to the TCP.

First move the workpiece away from the TCP.

Reduce the path velocity in the vicinity of the fixed tool in order to avoid a collision.

To do so, repeatedly press the status key “Jog override”.

When the TCP (tool center point) is located exactly at the point with a positive Y value in the
XY plane, save this position by pressing the softkey “Point OK”.

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X
Y

At this point you can open the corresponding subprograms by means of the softkeys “Load
data” or “Meas. Pt.”.
Further information on this can be found in Sections 2.2.7. and 2.7.
Save the workpiece data by pressing the softkey “Save”. The function is then termi-
nated.

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2.4.3 Tool (BASE)

This method is used to determine the TCP (center point) of a tool that is stationary rather than
handled by the robot.

First of all, a tool of known

dimensions is moved to the
TCP of the fixed tool.

In a second step, the robot

flange is positioned perpendi-
cularly to the working direction
of the tool.

Procedure
Mount a tool whose dimensions are known to you onto the robot flange.
The corresponding menu is opened by pressing the menu key “Setup”, followed by the menu
“Measure” (“Calibrate”) and “Fixed tool”.

The following dialog window is opened:

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Use the +/-- status key (at the bottom right of the display) to select the tool number (1...16)
of the tool to be calibrated.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Tool OK” to open the next dialog window.

Use the status key to select the number of the reference tool mounted on the robot.

...
When you have selected both tools by pressing the softkey “Tool OK” you can choose
between the measurement methods 5--D and 6--D.

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It is possible to switch between the 5--D and 6--D measurement methods by pressing the soft-
key at the bottom, right edge of the display.

5--D method
This method is used if only the working direction of the tool is required for its positioning
and manipulation (MIG/MAG welding, laser or waterjet cutting).

The working direction of the

fixed tool is determined by the
position of the robot flange
alone. It is perpendicular to the
X flange. The orientation of the X
and Y axes of the tool coordi-
Z Y nate system is now determined
by the robot control system.
The orientation of these axes is
thus not readily predictable, but
is identical with every calibra-
tion.

In the event of 5D calibration, the angle “C” (corresponding to a rotation about the X--axis
of the tool direction) is set by default to “0”.

6--D method
This method is used if the orientation of all three tool axes is required for positioning
and manipulation (for example with welding guns, grippers, adhesive nozzles).

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The orientation of the tool coor-

dinate system is parallel to the
robot flange coordinate system.

Use the softkey “Data Ok” to confirm your selection and open the form for defining the TCP.

Define the working direction of the tool for the controller.

You are now prompted to move the reference tool on the robot to the fixed tool. This can be
done using the axis traversing keys or the Space Mouse.

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Reduce the traversing velocity in the vicinity of the reference point in order to avoid
a collision.

To do so, repeatedly press the status key on the right of the display.

Now carry out the following steps in the order given:

G Set the desired tool orientation.
G Move the TCP (tool center point) of the reference tool until it coincides with the point
on the fixed tool.
G The data are saved by pressing the softkey “Point OK”.

After the point has been accepted by the controller, the status window for orientating the wrist
flange is then opened:

First move the tool away from the reference point.

Reduce the traversing velocity in the vicinity of the reference point in order to avoid
a collision.

To do so, repeatedly press the status key on the right of the display.

Now move the axes in such a way as to align the wrist flange perpendicular to the fixed tool
with the axis traversing keys or with the Space Mouse.
The data are adopted and the form for saving the data is opened by pressing the softkey
“Point Ok”.

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When the softkey “Meas. Pt.” is pressed, a window appears in which the values of the individ-
ual measurements are listed once again.

Save the tool data by pressing the softkey “Save”. The function is then terminated.

2.4.4 Offset external kinematic

With this definition procedure, you can define a tool on an external kinematic system.

φV

φφφ
Here a tool has been mounted on
the external kinematic system.
The distance between coordinate
system III and coordinate system
IV must be manually entered or
calibrated.

Press the menu key “Setup”, then select the menu “Measure” (“Calibrate”) and the submenu
“Fixed tool” and finally the menu item “Offset external kinematic”.

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The following form is then opened

Use the +/-- status key (at the bottom right of the display) to select the tool number (1...6)
of the tool to be calibrated on the external kinematic system.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the external axis.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

Press the softkey “ExtBase OK” (at the bottom of the display) in order to calibrate the external
tool.

The window for selecting the reference tool is opened:

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Now select the number of the desired reference tool (1...16).

...
Press the softkey “Tool OK” in order to specify the calibration method for this tool.
The following window is opened:

Here you can select the measurement method that is to be used. The selected method
affects the orientation of the tool coordinate system.
The 5D method is used if only the working direction of the tool is required for its positioning
and manipulation (MIG/MAG welding, laser or waterjet cutting).
The 6D method is used if the orientation of all three tool axes is required for positioning and
manipulation (for welding guns, grippers, adhesive nozzles, etc.).

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5D method
In this method, the Z axis of the robot flange coordinate system tool must be oriented
parallel to the future working direction of the tool. The Y and Z axes are oriented by
the robot controller. The orientation of these axes is not readily foreseeable in this
instance, but it is exactly the same in each calibration procedure.

In the event of 5D calibration, the angle “C” (corresponding to a rotation about the X--axis
of the tool direction) is set by default to “0”.

X
Condition:
Z parallel to X0

Y
Z
X0 Robot flange
Y0 coordinate system

Z0

Resulting tool coordi-

nate system, orienta-
tion of Y and Z not
readily foreseeable.

6D method
In this method, the robot flange must be oriented in alignment with the tool. The axes
of the robot flange coordinate system must be parallel to the future axes of the tool
coordinate system.

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Start--up

X
Conditions:
X parallel to Z0
Y parallel to Y0
Z parallel to X0
Y
Z
Robot flange
X0 coordinate system
Z0

Y0
Resulting tool
coordinate system

Use the status key (at the bottom right of the display) to select the method meeting your
requirements and confirm your choice by pressing the softkey “Data OK” (at the bottom of
the display).

Use the softkey “Data Ok” to confirm your selection and open the form for defining the TCP.

You are prompted to move the TCP (tool center point) of the selected reference tool to the
future TCP (tool center point) of the tool attached to the external kinematic system.

Reduce the traversing velocity in the vicinity of the tool in order to avoid a collision.

To do so, repeatedly press the +/-- key of the status key “HOV” (on the right of the display).

When the two TCPs (tool center points) coincide exactly, save this position by pressing the
softkey “Point Ok”.

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 2 Calibration (continued)

TCP of the reference tool

TCP of the external tool

The next status window asks for a change in the orientation of the wrist flange:

Now align the robot flange perpendicular to the future working direction of the tool attached
to the external kinematic system using the axis traversing keys or the Space Mouse.

Reduce the traversing velocity in the vicinity of the tool in order to avoid a collision.

To do so, repeatedly press the status key “HOV” again.

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When the robot flange is exactly perpendicular to the working direction of the tool, save this
position by pressing the softkey “Point OK”. The next dialog window shows the number and
the data of the calibrated tool:

When the softkey “Meas. Pt.” is pressed, a status window appears in which the values of the
measuring points are listed once again.
The data are saved and the calibration program is ended by pressing the softkey “Save”.

Further information on this can be found in the documentation [Start--up], chapter

[Calibration -- External kinematics].

2.4.5 Numeric Input

The menu “Numeric Input” is opened by first pressing the menu key “Setup”, and then select-
ing the menu “Measure” (“Calibrate”) and the submenu “Fixed tool”.

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 2 Calibration (continued)

After selecting this menu item, the first dialog window for entering the tool number is opened.

It is possible to activate the relevant tool number (1...16) using the +/-- status key at the
bottom right of the display.

...
You can use the arrow keys to access the base system name input box and there enter a
name for the base system.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “Tool OK” (at the bottom of the display) in order to be able to enter data
for this tool. The status window then changes:

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Move to the desired input box with the aid of the “” or “” arrow keys and enter the tool data
using the numeric keypad.

The abbreviations in the dialog window have the following meaning:

X, Y, Z Distance between the TCP (Tool Center Point) and the origin of the world
coordinate system in relation to the world coordinate system.

TCP
(Tool
Center Z
Point)

X
Y
A, B, C Rotational offset of the tool coordinate system (Z--Y--X Euler angles)
from the world coordinate system.

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 2 Calibration (continued)

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
When all entries have been made, confirm them by pressing the softkey “Data OK” (at the
bottom of the display).

Save the tool data by pressing the softkey “Save” (at the bottom of the display). The function
is terminated and the dialog window closed.

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2.5 Supplementary load data

After selecting the menu item “Supplementary load data”, the relevant dialog window is
opened:

For entry of the supplementary load, axis 3 is displayed as standard. The desired axis (1...3)
for entry of the supplementary load can be selected using the +/-- status key at the bottom
right of the display.

Confirm your choice of axis by pressing the softkey “Axis Ok”.

It is now possible to enter the supplementary load data for your chosen axis.

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 2 Calibration (continued)

You can move between the individual input boxes with the “” or “” arrow keys and enter
the necessary data by means of the alphanumeric keypad.
or
Press the softkey “Default” in the bottom part of the display to accept the standard load data
defined in the basic settings of the system.

The default setting in the box “M [kg]” is --1 (load specified in the machine datum). If 0 is
entered here, there is no supplementary load on the robot arm.

Load center

Z
--

Flange

Z
+ Y
X

The abbreviations in the dialog window have the following meaning:

M Weight of the tool.
X, Y, Z Distance between the center of gravity of the supplementary load and the
origin of the robot flange coordinate system (located at the center of the
flange) in relation to the robot flange coordinate system.
A, B, C Rotational offset of the principal inertia axes of the supplementary load
(Z--Y--X Euler angles) from the robot flange coordinate system.

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Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
JX, JY, JZ Mass moments of inertia about the principal inertia axes of the supple-
mentary load.

Check beforehand by referring to the payload diagram in the robot specification

whether the supplementary load lies within the permissible range for standard
loads!

When all entries have been made, confirm them by pressing the softkey “Data OK”. This
closes the form and opens the form for saving the data.

The softkey “Save” is used to save the data and close the dialog window.

Further information on the calculation of load data can be found in the documentation
[Load Data Determination].

2.6 External kinematic

Information on this can be found in the chapter [Calibration -- External kinematics].

2.7 Measurement Points

With this menu item, you can view the saved calibration data.

After this selection has been made, a status window is opened displaying the respective
calibration methods used and listing the coordinates of all calibration points (measurement
points).

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 2 Calibration (continued)

You can switch between the various tools or workpieces by means of the status key (at the
bottom right of the display).

2.8 Tolerances
Here, you can use the numeric keypad to enter the tolerance limits for tool calibration.

Minimum Distance [TOOL]

The minimum distance for tool calibra-
tion. Range of values 0...200 mm.
Minimum Distance [BASE]
The minimum distance for base calibra-
tion. Range of values 0...200 mm.
Minimum Angle
The minimum angle between the straight
lines through the three calibration points
in base calibration. Range of values
0...360˚.
Maximum Calibration Error
Maximum error in calculation. Range of
values 0...200 mm.

The data in the input boxes are saved by pressing the softkey “Data OK”.

The default settings are restored by pressing the softkey “Default”. They must be saved by
pressing the softkey “Data OK”.

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2.9 Error treatment

If an error occurs during a calibration procedure, a status window is opened containing
detailed information about the error that has occurred.

In the event of the following errors:

G Point too near to reference point
G Point too near to origin point
G Point too near to other point
this status window is opened.

In the adjacent example, the fourth

point of the X Y Z -- 4 Point tool cal-
ibration was inpermissibly close to
the first point.

Error message Remedy

Point too near to reference point Move to a point that is further away from the refer-
ence point.
Point too near to origin point Move to a point that is further away from the origin.
Point too near to other point Move to a point that is further away from other
points.

Pressing the softkey “Repeat” repeats the calibration that has been queried.

If you want to repeat the whole calibration procedure from the beginning, press the softkey
“Repeat All”.

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 2 Calibration (continued)

In the event of the following errors:

G Measurement error too big
G All points in one plane
G All points in a line
this status window is opened.

Error message Remedy

Measurement error too big Positioning was too inaccurate. Repeat with
greater precision.
Further possibilities:
-- the robot was not mastered or incorrectly
mastered
-- the machine data are incorrect/no longer correct
-- mechanical defect of the robot
All points in a line The robot flange must have a greater change in
orientation.
All points in one plane The robot flange must have a greater change in
orientation.

If you want to view the coordinates of the calibration points, press the softkey “Calib.Pt”.

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Start--up

Pressing the softkey “Repeat” repeats the last calibration.

If you want to repeat the whole calibration procedure from the beginning, press the softkey
“Repeat All”.

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 3 Calibration -- External kinematics

3 Calibration -- External kinematics

3.1 Fundamentals
3.1.1 General
If the robot is mathematically coupled to an external kinematic system, such as a turntable
or a two--axis positioner, the robot controller must know the exact position of this kinematic
system to ensure correct operation.
The fixed, invariable data of this kinematic system are entered in the machine data of the
robot system.
Data that depend on the installation and setup are individually determined by calibrating the
external kinematic system with the robot.
The data for up to 6 external kinematic systems can be stored. These data are called up in
the user program by means of their number.

For reasons of safety, the calibration programs can only be executed in the
“Manual” operating mode (Single Step (T1) or Single Step (T2)).

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

3.1.2 Preconditions

Using the calibration functions requires adequate knowledge of operating the robot
system. Information on this can be found in the Operating Handbook in the chapters
 [The KUKA Control Panel KCP],
 [Manual traversing of the robot]
 [Robot mastering/unmastering] and
 [Calibration -- Tools and workpieces].

The following preconditions must be met on the part of the robot:

G the data of the external kinematic system must be correctly entered in the machine data;
G all axes must be correctly mastered;
G no program may be selected;
G mode Single Step (T1) or Single Step (T2) is selected.

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Start--up

3.2 External kinematic calibration

3.2.1 Overview
The submenu “External kinematic” contains the following subprograms:

Program Calibration by...

Root point moving the distance between the robot and the external
kinematic system
Root point (numeric) manual entry of the distance the robot and the external
kinematic system
Offset moving the distance between the external kinematic system
and the workpiece
Offset (numeric) manual entry of the distance the external kinematic system
and the workpiece

Each of these calibration programs is assigned forms that guide you interactively through the
program.

3.2.2 Root point

φφφ Z

φφ

Y
Coordinate system φ = World coordinate system, which is identical to the Robot
coordinate system.
Coordinate system φφ = External kinematic coordinate system
Coordinate system φφφ = Workpiece coordinate system
The distance between coordinate system φφ and coordinate system φφφ is entered in the
machine data.
The distance between coordinate system φ and coordinate system φφ must be
manually entered or calibrated.

The menu item “Root point” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “External kinematic”.

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 3 Calibration -- External kinematics (continued)

The input window for selecting the kinematic system is opened:

Select the desired kinematic number (1...6) using the +/-- status key at the bottom right of
the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “ExtBase Ok” (at the bottom left of the display) in order to enter data for
this kinematic system.

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Start--up

The dialog window for entering the reference tool is then opened:

A reference tool is a tool which has already been calibrated and is used to calibrate the
external kinematic.

Use the +/-- status key to select the tool number (1...16).

...
Press the softkey “Tool Ok” in order to perform the calibration with this tool.

The next window is opened:

You are prompted to re--check the entry in the machine data for the distance between the
origin of the kinematic coordinate system φφφ and the reference mark.

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 3 Calibration -- External kinematics (continued)

If this distance is not correctly entered, the machine data must be corrected. Cancel the
calibration procedure, in this case, by pressing the “ESC” key. (The entries made up to this
point will not be saved.)

If the distance is correctly entered, confirm it by pressing the softkey “Point OK”.

You will then be prompted to move the axes of the external kinematic system and to position
the TCP (tool center point) of the reference tool to the reference mark in a number of different
positions. The following steps are necessary for this:

Step 1 -- Move the TCP to the reference mark

This can be done using either the traversing keys or the Space Mouse.

Reduce the traversing velocity in the vicinity of the reference mark in order to avoid
a collision.

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Start--up

To do so, repeatedly press the status key “HOV”, which is depicted here, and can be found
on the right of the display.

Step 2 -- Save the point

When the TCP is located exactly on the reference mark, save its position by pressing the
softkey “Point Ok”.

Step 3 -- Move the axis/axes of the external kinematic system

After the point has been accepted by the controller, you are prompted to define the root point
of the kinematic system by carrying out further measurements.

The external kinematic system is moved for this purpose.

Repeat steps 1 to 3 until the reference mark has been addressed in a total of four different
positions of the external kinematic system.

After all necessary measurements have been successfully completed, the dialog window for
saving the root data is opened:

Save the root data

At the end of the calibration procedure, you will be offered the softkey “Save” (at the bottom
of the display). Save the data of the kinematic system by pressing this softkey. The function
is then terminated.

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 3 Calibration -- External kinematics (continued)

3.3 Root point (numeric)

φφφ Z

φφ

The distance between coordinate φ

system φφ and coordinate system φφφ
is entered in the machine data.
The distance between coordinate Y
system φ and coordinate system φφ
must be manually entered or cali-
brated.

Using the menu key “Setup” (at the top of the display) open the menu “Measure” (“Calibrate”)
and “External kinematic” and there select the submenu “Root point (numeric)”.

The input window for selecting the kinematic system is opened:

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Start--up

Select the desired kinematic number (1...6) using the +/-- status key at the bottom right of
the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

Press the softkey “ExtBase OK” (at the bottom left of the display) in order to enter data for
this kinematic system. A window is opened for entering the root point data:

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 3 Calibration -- External kinematics (continued)

Now enter the values by means of the numeric keypad. You can move between the input
boxes using the “” or “” arrow keys.

The abbreviations in the dialog box have the following meaning:

X, Y, Z Distance between the root point of the kinematic system and the world1)
coordinate system.
1) In the basic setting, the world and robot coordinate systems coincide.
A, B, C Rotational offset of the kinematic coordinate system from the world1)
coordinate system.

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C
1) In the basic setting, the world and robot coordinate systems coincide.

When all entries have been made, confirm them by pressing the softkey “Data Ok”.

By pressing the softkey “Offset” on the bottom lefthand side of the display, it is possible to
switch directly to the input form with the same name. Further information can be found in
Sections 3.4 and 3.5.

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Start--up

Save the data of the kinematic system by pressing the softkey “Save” (at the bottom right
of the display). The function is then terminated.

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 3 Calibration -- External kinematics (continued)

3.4 Offset

IV

The distance between coordinate

φφφ system III and coordinate system
IV must be manually entered or
calibrated.

The menu item “Offset” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “External kinematic”.

The input window for selecting the kinematic system is opened:

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Start--up

Select the desired kinematic number (1...6) using the +/-- status key at the bottom right of
the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “ExtBase OK” (at the bottom left of the display) in order to enter data for
this kinematic system. A window is opened for entering the reference tool:

Select the reference tool to be used

Use the +/-- status key to select the tool number (1...16).

...
Press the softkey “Tool OK” in order to perform the calibration with this tool.
The following window is then opened:

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 3 Calibration -- External kinematics (continued)

You are prompted to position the TCP (Tool Center Point) to the future origin of the base coor-
dinate system (BASE). This can be done using either the traversing keys or the Space
Mouse.

Reduce the traversing velocity in the vicinity of the workpiece in order to avoid a
collision.

To do so, repeatedly press the +/-- status key “HOV” (on the right of the display).

When the TCP (tool center point) is located exactly at the desired origin of the base coordi-
nate system (BASE), save this position by pressing the softkey “Point Ok”.

The next dialog window is then opened:

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Start--up

You are prompted to show the controller the positive side of the X axis by positioning the TCP
to a specific point.
First move the tool away from the workpiece:

Reduce the traversing velocity in the vicinity of the workpiece in order to avoid a
collision.

To do so, repeatedly press the +/-- status key “HOV” again.

When the TCP (tool center point) is located exactly at the desired point, save this position
by pressing the softkey “Point OK”.

The status window changes:

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 3 Calibration -- External kinematics (continued)

You are prompted to show the controller the orientation of the XY plane by moving the tool
to a point with a positive Y value.
Here also, move the tool away from the workpiece first.

Reduce the traversing velocity in the vicinity of the workpiece in order to avoid a
collision.

To do so, repeatedly press the status key “HOV”.

When the TCP (tool center point) is located exactly at the point with a positive Y value on
the XY plane, save this position by pressing the softkey “Point OK”.

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Start--up

Save the offset data

At the end of the calibration procedure, you will again be offered the softkey “Save” situated
at the bottom of the display. Save the kinematic data by pressing this softkey. The function
is then terminated.

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 3 Calibration -- External kinematics (continued)

3.5 Offset (numeric)

IV

φφφ The distance between coordi-

nate system III and coordi-
nate system IV must be
manually entered or calibra-
ted.

The menu item “Offset (numeric)” is opened via the menu key “Setup”, the menu “Measure”
(“Calibrate”) and the submenu “External kinematic”.

The input window for selecting the kinematic system is opened:

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Start--up

Select the kinematic number (1...6) using the +/-- status key at the bottom right of the display.

You can use the arrow keys to access the input box “Name of the external axis” and there
enter a name for the axis.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
Press the softkey “ExtBase OK” in order to enter data for selected kinematic system.

The following dialog window for entering the offset data is then opened:

Enter the desired values by means of the numeric keypad.

You can move between the input boxes using the “” or “” arrow keys.
The abbreviations in the status window have the following meaning:

X, Y, Z Distance between the workpiece reference point (BASE), IV in the

illustration, and the kinematic coordinate system, III in the illustration.
A, B, C Rotational offset of the base coordinate system from the
kinematic coordinate system.

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 3 Calibration -- External kinematics (continued)

Z Z + --
Z

X + X
-- X
--
Y -- Y Y
1.) Rotation about Z 2.) Rotation about Y 3.) Rotation about X
Magnitude A Magnitude B Magnitude C

When all entries have been made, confirm them by pressing the softkey “Data OK” situated
at the bottom of the display.

Save the offset data by pressing the softkey “Save”. You will find this softkey at the bottom
right of the display. The function is thus completed.

3.6 Offset external kinematic

Further information on this can be found in the documentation [Start--up], chapter

[Fixed tool].

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 4 Software Update

4 Software Update
The user can load a new version of program using the control computer’s CD--ROM drive.
To do this, the CD with the newer program version is placed in the CD--ROM drive.
By pressing the menu key “Setup” and then selecting the “Software Update” --> “automatic”
function, the user can start the program update. The setup is then carried out according to
the specifications in the “SetupKRC.ini” file.

A request for confirmation is then generated in the message window.

Perform a Software Update ?

If you wish to carry out a software update, confirm this by pressing the “Yes” Softkey, other-
wise press “No” or “Cancel”.

If there is no CD currently in the drive, a corresponding error message is generated.

In the next stage the controller must be restarted.

You must now switch the controller off and wait until the computer unit has shut down com-
pletely (Power ON LED out). Only then may the controller be switched back on again.

The update CD must remain in the CD--ROM drive throughout the whole process.
Failure to do this will result in loss of data and incorrect installation.

First, a virus scanner is installed; this is then active every time the system is booted. Data
in the directories Init, Template, PowerOn (R1 and Steu) and MaDa are saved. The old
software version is then uninstalled and the new version installed. The User program is
upgraded, e.g. syntax changes, exchange of variables or new subprograms are updated.

If errors occur during the software update, you can view these in the display in the log file.
In the event of this happening, leave the log file displayed on the screen and call our service
department.
Once the upgrade is complete the computer is run back down again. (Only now may the CD
be removed from the drive.) The controller is then started automatically.

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 5 Robot name

5 Robot name
This option allows you to change the robot name, serial number and the validity of the
MADAs.
To do so, select the menu item “Configure” --> “Settings” --> “Robot name”. The following
status window is opened:

To achieve an unambiguous assignment of a KCP to a robot, the name of each robot can
be changed. The name can have a maximum length of 8 characters.
For positionally accurate robots, the serial number is important. The program can use it to
establish whether the robot (RDC component) or the controller (DSE component) has been
changed (e.g. use of the controller with another robot).

Specification of the serial number is particularly important for mastering (with or without
load), as the mastering offsets are assigned to the robot with the corresponding serial
number.
The serial number of the robot is stored in the directory “C:\Program Files\KRC\ir_spec”.

The option of saving the machine data is only displayed if the MADAs saved on the robot
(RDC) do not agree with those on the hard disk of the computer. In this case, the RDC data
are displayed under “Machine data until now” and those saved on the hard disk are displayed
under “Current machine data”. Selecting “Yes” replaces the robot MADAs (RDC) with the
current machine data.

The serial number of the robot and the validity of the machine data (MADAs) can only be
changed in the operating modes (T1) and (T2).

The entries are saved by pressing the softkey “Change”. The robot name is then displayed
in the status line.

Pressing the softkey “Close” closes the status window.

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Start--up

If the serial number has not been configured and if the valid machine data have not been
confirmed, the error message text “Wrong machine data for this robot type” is displayed
in the message window.

Information about saving the robot serial number in the RDC (Resolver--Digital Converter)
and checking the serial number for the purposes of the correct assignment of robot and
controller can be found in the documentation Diagnostic Functions, chapter [DSE--
RDW].

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 Index

Numbers F
3--Point, 65 FIRST_CALIBRATION_DIFFERENCE, 28
5D, 50, 85, 91 FIRST_ENCODER_VALUES, 28
6D, 55, 85, 91 Fixed tool, 77
Flange center point, 32
Frame, 33
A
Frontsight/rearsight marker, 6
A B C -- 2 Point, 36, 37, 45
A, B, C, 33, 60, 63, 96, 99, 113, 122
ABC--World, 36, 50 H
ABC--World (5D), 37 HOV, 117
ABC--World (6D), 37
All points in a line, 103 I
All points in one plane, 103
Indirect, 65, 70
Arrow keys, 42, 59, 113, 122
Introduction, 32
Axis traversing keys, 39

J
B
Jog--OV, 40
Base, 65, 117 JX, JY, JZ, 63, 100
Base coordinate system, 117

K
C
Kinematic number, 107
Coordinates, 100 KR_SERIALNO, 28
Coupling of the wrist axes, 27

M
D M, 63, 99
Data Ok, 113 MADA, 127
Default, 63, 99 Mastered, 6
Detailed information, 102 Mastering, 13
Determining the orientation, 36 Mastering with consideration of load, 12
Determining the position, 36 Mastering with the dial gauge, 7
Dial gauge, 5 Mastering with the EMT, 10
DSE, 127 Mastering without consideration of load, 12
Measurement error too big, 103
E Measurement Points, 100
Mechanical zero position reached, 6
EMERGENCY STOP, 6
Move the axis/axes of the external kinematic
EMT, 6
system, 110
Enabling switch, 16, 17, 19, 20, 23, 26
Move the TCP to the reference mark, 109
ENCODER_DIFFERENCE, 28
Error message, 49
Error treatment, 102 N
ExtBase Ok, 107 Numeric Input, 36, 37, 58, 65, 74, 77, 94
External kinematic, 100
External measuring device, 34 O
Offset, 106, 115
Offset (numeric), 106, 121

Index -- i
 Index

Offset external kinematic, 77, 88, 123 Tool load data, 36, 61
Operating mode, 127 Tool number, 39
Orientation, 33
Tool OK, 108
Overloaded, 61
Traversing velocity, 40
P
Point too near to origin point, 102
Point too near to other point, 102
Point too near to reference point, 102 U
Position, 32
Unmastered, 6
Pre--mastering position, 6, 13
Program start forwards, 16, 17, 19, 20, 23, Unmastering an axis, 27
26
Protective cap, 5

R V
RDC, 127
Reference point, 34 Variables, 28
Reference tool, 36, 108 Velocity, 40
Resolver, 32
Vernier, 5
Robot coordinate systems, 32
Robot flange coordinate, 32
Robot mastering, 5
Robot name, 127
Root point, 106 W
Root point (numeric), 106, 111
Weight difference, 12
Rotation about the X--axis, 33
Rotation about the Y--axis, 33 Working direction, 45
Rotation about the Z--axis, 33 Workpiece (TOOL), 77
WORLD coordinate system, 32
S
Save, 24
Save the point, 110
Serial number, 127 X
Software Update, 125
Space Mouse, 39 X Y Z -- 4 Point, 36, 38
Start key, 16, 17, 19, 20, 26
X Y Z -- Reference, 36, 40
Supplementary load data, 98
X, Y, Z, 33, 42, 59, 63, 96, 99, 113, 122

T X32, 6

TCP, 34, 38, 117

Test (T1), 15, 16, 18, 19, 22, 24
Test (T1/T2), 7
Tolerance limits, 101 Z
Tolerances, 101
Tool (BASE), 77, 83 Z--Y--X Euler angles, 33
Tool Center Point, 34, 117 Zero position, 5

Index -- ii
8 User Programming
SOFTWARE

KR C1

User Programming

Release 3.2

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 Program editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.3 Open (Edit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.4 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4.1 Current program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4.2 Logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Saving changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.6 Saving programs to diskette (Archive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.7 Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Editing a selected program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Cancel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Reset program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Working with the program editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.1 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.2 Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.3 Close editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Program commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Last command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.1 Point--to--point motions (PTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.2 Linear motions (LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.3 Circular motions (CIRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Motion parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.1 Wait functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.1.1 Time--dependent wait function (WAIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.1.2 Signal--dependent wait function (WAITFOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.2 Switching functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4.2.1 Simple switching function (OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4.2.2 Simple pulse function (PULSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.2.3 Path--dependent switching function (SYN OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.2.4 Path--dependent pulse function (SYN PULSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.3 Coupling and decoupling the INTERBUS segment (IBUS--Seg on/off) . . . . . . . . . . . . . . . . . 47
2.5 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.5.1 Static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.5.2 Dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6 Comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6.1 Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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2.6.2 Stamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6.3 ...changing comment lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.6.4 ...Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.7 KRL assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.7.1 KRL motion commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.7.1.1 Position specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.7.1.2 [PTP] Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.7.1.3 [LIN] Linear motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.7.1.4 [CIRC] Circular motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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 1 Program editing

1 Program editing
1.1 General
Before you create or modify a robot program for the first time, you should familiarize yourself
beforehand with the procedures required for managing and maintaining programs.
If you wish to create a new program, you must first create a so--called “skeleton program”.
If, on the other hand, you wish to modify an existing program, you simply need to select it
or load it in the editor.

More detailed information on using the file manager may be found in the documentation
[Operator Control], chapter [Navigator].

1.2 Programs
More detailed information about programs can be found in the documentation [Operator
Control], chapter [Navigator], section [“File” menu].
Block functions (e.g. Copy) are also available at expert level. More detailed information can
be found in the Programming Handbook in the documentation [Expert Programming].

1.2.1 New
With the Navigator active, press the softkey “New”.

If a program has been selected or there is a program in the editor, you must first toggle to
the file selection window, otherwise no new program can be created.

Enter the desired program name and the corresponding comment in the input line.

Program name Comment

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

1.2.2 Selecting
The softkey “Select” is available for the purposes of program execution.

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In this way the program can also to be tested at the same time as being created.
The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars changes at the same time, in order to make functions available
which are necessary for programming the robot.

1.2.3 Open (Edit)

If you wish to make modifications to an existing program, this can also be done using the
editor. While you are editing one program in the editor, another program can simultaneously
be executed. Programs can be opened using the command “Open” in the softkey bar.

If a program has already been selected, the option “Open” is no longer available in the
softkey bar.

Instead, use the menu command “File” --> “Open” --> “File/Folder”.

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

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 1 Program editing (continued)

1.2.4 Print
If you have connected a printer to your control computer or network, you can print out
program listings or the logbook. This is done using the command “File” --> “Print”.

The print function is only available if a printer has been configured in the operating system.
More detailed information on this can be found in the “Windows” online help file.

1.2.4.1 Current program

If you wish to print a selected program, you can, if you so desire, include the Folds. It is not
necessary to open the Folds first. The relevant request for confirmation is made in the mes-
sage window:

Do you want to print with opened Folds?

The printout contains opened Folds

The Folds are not printed

The action is cancelled; nothing is sent to the printer

Here is an example of a file without Folds:

File name KRC:\R1\TEST02.SRC

1 INI
2 PTP HOME Vel= 100 % DEFAULT
3 PTP P1 Vel= 100 % PDAT1 Tool[1] Base[0]
4 WAIT FOR IN 1 ’Freigabe’ State= TRUE
5 PTP P2 Vel= 100 % PDAT2 Too[1] Base[0]
6 WAIT FOR IN 2 ’Peripherie’ State= TRUE
7 PTP P3 Vel= 100 % PDAT3 Tool[1] Base[0]
8 PTP P4 Vel= 100 % PDAT4 Tool[1] Base[0]
9
10 PTP HOME Vel= 100 % DEFAULT

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1.2.4.2 Logbook
This function sends the logbook file, which can be viewed via the menu “Display” -->
“Diagnosis” --> “Logbook” --> “Display”, to the printer.

#1
-------------------------------------------------------------------
10:36:08’056 28.03.2000 Nr.:0: New Command: SN 63: WAIT FOR IN 2
’Periphery’ State= TRUE
Source: TP_KUKA

#2
-------------------------------------------------------------------
10:35:35’596 28.03.2000 Nr.:0: New Command: SN 51: WAIT FOR IN 1
’Enable’ State= TRUE
Source: TP_KUKA

#3
-------------------------------------------------------------------
10:35:20’386 28.03.2000 Nr.:0: Modification IO name: Input, 2, Input->
Enable
Source: ProjLangText
.
.

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

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 1 Program editing (continued)

1.2.5 Saving changes

You can deselect a selected program by using the menu command “Program” --> “Cancel
program”. A program in the editor can be closed using the command “Program” --> “Close”.
Alternatively, you can press the softkey “Close”. The changes are automatically saved, after
a request for confirmation where relevant.

Alternatively, in the Navigator, the option “deselect” is offered in the softkey bar. This
softkey is only available if no program window is open.

1.2.6 Saving programs to diskette (Archive)

This function allows you to save important data to floppy disk. All files are saved in
compressed form as Zip files.
Compressed data require much less storage space than the original data, but must be
decompressed before they can be read. This is carried out automatically in this case. With
Navigator, the user can see what is stored in the archives.

*1

*1 Not available below the user group “Expert”

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

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Completion of the operation is indicated in the message window:

The option “Current selection” is only available in the Navigator window. Furthermore, no
program may have been selected or loaded in the editor.

Information about saved files can be found in the documentation [Operator Control],
chapter [Navigator], section [”File” menu].

1.2.7 Duplicate
The option “Duplicate” creates a copy of a program.

Program name Comment

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).

1.2.8 Delete
If you want to delete a program, it must not be currently selected or being edited. You might
first have to deselect the program or close the editor. The program is permanently deleted
after a request for confirmation.

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 1 Program editing (continued)

1.3 Editing a selected program

1.3.1 Delete
Use the arrow keys to move the edit cursor to the line you want to delete.

Edit cursor

Press the menu key “Program” and select the option “Delete” from the menu that is opened.

Read the message displayed in the message window.

Press the softkey “Yes” if you are sure that you want to delete the selected line. Pressing this
softkey removes the line from the program.

Pressing the softkey “No” or “Cancel” cancels the action.

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1.3.2 Find
Here you can search through the program for a character string of your choice.
Press the menu key “Program” and select the option “Find...” from the menu that is opened.

Alternatively, you can use the keyboard shortcut “CTRL”+“F”.

This function searches through the program for a character string entered by the user. Once
the command has been selected, the search form is displayed in the program window:

This function searches through the program for a character string entered by the user. The
search is started by pressing the softkey “Find” or the Enter key and commences at the posi-
tion where the edit cursor is located.
If the search program finds the character string entered, the corresponding line is selected.

The character string entered remains displayed in the search form as a suggestion. You can
now search further through the program by pressing the softkey “Find” or the Enter key, or
search for a new string.

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 1 Program editing (continued)

If the term being searched for is not found, a corresponding text is displayed in the message
window:

Only the visible area of the program is searched.

The expert must switch the option “Detail view ” on if hidden Folds are also to be included
in the search.

Alternatively, you can terminate the search function by pressing the softkey “Cancel” or the
Escape key. The edit cursor is then located in the line in which the last character string was
found.

If the search function is called again, the last string to be entered is shown in the form as
a suggestion.

1.3.3 Cancel program

This command saves the changes made to the program and closes the program window.
Press the menu key “Program” and select the option “Cancel program” from the menu that
is opened.

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1.3.4 Reset program

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

The yellow block pointer then jumps to the first line of the indicated program. The selected
program can subsequently be restarted.

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 1 Program editing (continued)

1.4 Working with the program editor

1.4.1 Delete
Use the arrow keys to move the edit cursor to the line you want to delete.

Edit cursor
Press the menu key “Program” and select the option “Delete” from the menu that is opened.

Read the message displayed in the message window.

Press the softkey “Yes” if you are sure that you want to delete the selected line. Pressing this
softkey removes the line from the program.

Pressing the softkey “No” or “Cancel” cancels the action.

1.4.2 Find
Here you can search through the program for a character string of your choice.
Press the menu key “Program” and select the option “Find...” from the menu that is opened.

Alternatively, you can use the keyboard shortcut “CTRL”+“F”.

This function searches through the program for a character string entered by the user. Once
the command has been selected, the search form is displayed in the program window:

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This function searches through the program for a character string entered by the user. The
search is started by pressing the softkey “Find” or the Enter key and commences at the posi-
tion where the edit cursor is located.
If the search program finds the character string entered, the corresponding line is selected.

The character string entered remains displayed in the search form as a suggestion. You can
now search further through the program by pressing the softkey “Find” or the Enter key, or
search for a new string.
If the term being searched for is not found, a corresponding text is displayed in the message
window:

Only the visible area of the program is searched.

The expert must switch the option “Detail view ” on if hidden Folds are also to be included
in the search.

Alternatively, you can terminate the search function by pressing the softkey “Cancel” or the
Escape key. The edit cursor is then located in the line in which the last character string was
found.

If the search function is called again, the last string to be entered is shown in the form as
a suggestion.

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 1 Program editing (continued)

1.4.3 Close editor

This command saves the changes made in the editor and closes the program window.
Press the menu key “Program” and select the option “Close” from the menu that is opened.

The menu command “Close” is also available in the softkey bar if the editor is displayed
in the program window.

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 2 Program commands

2 Program commands
Overview
This chapter describes the functions provided in the KCP menu “Commands”.

G Last command Instruction for entering the last command executed;

G Motion Enables the programming of PTP, LIN and CIRC motions;
G Moveparams Torque monitoring function call;
G Logic Programming of logic commands and wait times,
path--dependent switching and pulse functions, setting
or polling inputs and outputs;
G Analog output Setting of analog outputs under program control;
G Comment Insertion of comments in program modules;
G KRL assistant Syntax--supported KRL programming of special functions.

The “Commands” menu is only available if a program has been selected or loaded in the
editor.

2.1 Last command

This instruction allows you to enter the last command executed, with suggested values
already entered in the input boxes.
Use the menu key “Commands” to open the menu and there select the menu item “Last
command”.

If the “GRIPPER Tech” option has been selected from the “Configure -- Status keys” menu,
the softkey “Last Cmd”, which has the same function, is available in the softkey bar.

This softkey is not available if “Configure -- Status keys -- ARC Tech 10” or “ARC Tech 20”
has been selected.

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User Programming

2.2 Motion

Moving the robot under program control requires the programming of a so--called motion
command. This instruction contains specifications for the type and velocity of the motion, the
definition of the start point and end point (for circular paths also an auxiliary point) and other
settings depending on the type of motion.
The individual parameters of the motion instruction are described in more detail in the follow-
ing sections.

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

Types of motion
The following types of motion are available for programming movements:

Standard motions

The tool is moved as quickly as possible along a curved path in

PTP (point--to--point)
space to a destination point
LIN (linear) The tool is guided at a defined velocity along a straight line
CIRC (circular) Motion of the tool at a defined velocity along a circular path

In sequences of motion instructions, there are two alternatives for selecting how movements
between individual points are executed:

Motion between the individual points

Exact positioning The motion stops exactly at the programmed point.

Approximate A smooth transition can be made from one motion to the next
positioning (Cont) without exact positioning at the destination point.

If you create or modify more than one point with the same name, and in so doing modify
Tool or Base, all program lines with this point name must be selected and updated by
means of the command “Change -- Cmd Ok”.
Programming

To program a motion command, you must select a program or load it in the editor. More
detailed information on creating and altering programs can be found in the chapter
[Program creation].

Please note the position of the edit

cursor. The next line you add to the
program will be inserted as a new line
after the cursor.

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 2 Program commands (continued)

Open the menu using the menu key “Commands”. From this menu select “Motion”. The
following submenu is displayed:

You can now make your selection from the motion instructions (PTP, LIN or CIRC) offered.

Infinitely rotating axes

All the robot axes (A1 ... A6) are defined by the manufacturer as finitely rotating axes (i.e.
with software limit switches). For certain applications, however, axes A4 and A6 can be
configured as infinitely rotating axes. The corresponding settings are made in the file
“$MACHINE.DAT”.

A4 and A6 also definable as infinitely

rotating axes [$MACHINE.DAT]

All other axes are

finitely rotating axes.

If the machine data have been altered to define the axes A4 and/or A6 as infinitely rotating
axes, please bear in mind that each rotation is executed along the shortest path.
This can cause problems if a tool with supply lines (for example, a welding gun) is
installed on the robot.

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User Programming

In the following example, two motion instructions (P1 -- P2 and P2 -- P3) are programmed
and the coordinates saved. Please refer to the following sketch.

The first motion instruction in this Tool P3 (220_)

example causes axis A6 to turn
120_ from P1 (0_) to P2. The sec-
ond motion command rotates A6 a P1 (0_) P1 (0_)
further 100_ from P2 (120_) to P3
(220_).
Robot flange P2 (120_)

With the third motion command is actual:

intended to move the tool 200_ in P3 (220_) 160_
P3 (220_)
the opposite direction from P2 to
P3, i.e. to the position 20_ from the
starting position P1. P1 (0_)
When the program is executed,
however, axis A6 will turn along the
P4 (380_)
shorter path from P3 (220_) to P4 P3 (120_)
(380_), covering just 160_. (desired: 200_)

This will inevitably result in any

supply lines from the robot to
the tool being “wound” round
the wrist.

It is therefore necessary for the

second (return) motion to be split
up into two motion instructions. P3 (220_)
In this example, two motions
(P3--P4 and P4--P5) have been
programmed, each with an angle 100_ P5 (20_)
of rotation of 100_. This ensures
that the tool moves to the destina-
tion point in the correct direction 100_
P4 (120_)
when the progam is executed.

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 2 Program commands (continued)

2.2.1 Point--to--point motions (PTP)

Here, the robot system is positioned using the quickest route between two points. Since the
motion starts and ends in all of the axes at the same time, the axes have to be synchronized.
The path taken by the robot cannot, therefore, be predicted exactly.

When this instruction is used, the path taken by the robot cannot be predicted exactly.
For this reason there is the risk of collision in the proximity of obstacles. The motion
characteristics of the robot near obstacles must be tested at reduced velocity!
Please note, in connection with this, that the path of a PTP motion is also dependent
on the traversing velocity!

PTP motions with exact positioning

In the case of PTP motions with exact positioning, the robot stops exactly at each destination
point.

Possible Possible
PTP path PTP path
P2

Exact positioning
P3
P1
Exact positioning

PTP motions with approximate positioning

During approximate positioning, the controller monitors a so--called approximate positioning

range around the destination point. This, in our example, is the point P2. When the TCP
enters this area, the robot motion immediately proceeds towards the destination point of the
next motion command.

Approximate
positioning range P2

P3

P1

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User Programming

Programming a PTP motion

After the option “PTP” is selected from the menu “Motion”, the inline form for entering the
values required for executing this instruction is opened in the program window.

Box name Function Range of values

PTP Type of motion PTP, LIN, CIRC
P1 Point name
Tool Tool number Nullframe, Tool_Data[1]...[16]
Nullframe, Base_Data[1]...[16],
Base Workpiece number
EX_AX_DATA[1]...[6]
external
Robot guides tool/workpiece True, False
TCP
CONT Approximate positioning ON “ ”, Cont
1 to 100% of the maximum value
Vel=100% Velocity
(default: 100%)
PDAT1 Motion parameters
Acceleration Acceleration 0 ... 100
Approximation Approximate positioning
0 ... 100
Distance *1 range
*1 Only available if “CONT” has been switched on

The assignment of the softkey bar changes at the same time, as follows:

It is possible to abort programming of the PTP motion at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the lefthand input box. The status key (at the bottom right of the display)
changes its assignment.
Using this status key, you can choose between the different types of motion again.

The type of motion can also be set using the softkey “LIN/CIRC”.
Move the cursor to the next input box on the right, here “P1”.

A status window is opened for entering data relating to the workpiece and tool. Activate this
status window using the “Window selection” key.

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 2 Program commands (continued)

Tool
Select here from the 16 available tools.
Base
Select here one of the 16 saved workpiece coordinate
systems (BASE).
external TCP
Tell the controller here whether the robot is guiding the
tool or the workpiece:
Robot guiding tool: external TCP = False
Robot guiding workpiece: external TCP = True

Now activate the program window again using the “Window selection” key.
If the softkey “Suggest” is pressed, the program finds the lowest standard point name avail-
able in the local data list and enters this name in the open inline form, i.e. if points P1 and
P3 are occupied, P2 will be suggested.
Then move the robot to the destination point you wish to program. There press the softkey
“Touch Up”. Read the messages displayed in the message window.

The softkey “Touch Up” allows you, at any moment, to save the current robot coordinates
for the program line in which the edit cursor is positioned. You thus have the possibility, for
example, to program a sequence of motion instructions and then define the exact destina-
tion point coordinates later.
The coordinates are saved in the program line in which the blinking edit cursor is located,
irrespective of where the (yellow) block pointer is currently positioned.

Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.
The approximate positioning function can be switched on or off using this status key.

Inline form Press the status key on Using the status key, Press the
“Exact the bottom righthand side. choose between “Exact Enter key
positioning”. The menu is opened positioning” and “Approxi- and the menu
in the inline form. mate positioning” (CONT). is closed.

Move the cursor to the box “Vel=”.

Here you can specify what percentage of the maximum possible velocity the robot should
use later when executing the motion. You can either enter the value using the keyboard or
alter it using the status key to the right of the display.
Move the cursor to the next input box on the right, here “PDAT2”.

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User Programming

A status window is opened, in which data must be entered characterizing the motion in
greater detail. Activate this status window using the “Window selection” key. You can either
enter the values in the input boxes using the keyboard or alter them using the status key to
the right of the display.

Acceleration
Here you can reduce the acceleration to be used in the
motion.
Depending on the length of the path, the degree of
acceleration and the approximation distance, it is
possible that the programmed velocity will not be
reached.
This is liable to happen when the wrist axes would have
to turn at an infinitely high speed when passing through
the extended position and would thus exceed the
maximum permissible values.
Therefore please be sure to use practically feasible
values.

Approximation Distance
Here you can reduce the approximate positioning range
to be used in the motion.

Please remember that a high payload/supplementary load, high acceleration and

short paths increase the loading of the drive motors unnecessarily!

Now press the softkey “Cmd Ok” or the Enter key. The motion function is now fully
programmed and saved.

If the position of the destination point has not yet been taught (Touch Up), the current
position of the robot is automatically saved.

You can use the softkey “Comment” at any time to insert a comment line into your program,
irrespective of the input box that is currently in focus.

Detailed information on comments in robot programs can be found in the section

[Comment].

You can use the softkey “Logic” at any time to insert a so--called logic command into your
program, irrespective of the input box that is currently in focus.

Detailed information on logic commands can be found in the section [Logic].

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 2 Program commands (continued)

2.2.2 Linear motions (LIN)

With a linear motion, the robot axes are coordinated in such a way that the TCP or workpiece
reference point is moved along a straight line to the destination point.
Linear motions are used if the robot has to follow an exact path to a point at a defined velocity
or if it has to move to points that cannot be reached using a PTP motion because of the risk
of collision.

Only the reference point follows the programmed path. The actual tool or workpiece is able
to change its orientation during the motion.

LIN motions with exact positioning

In the case of LIN motions with exact positioning, the robot stops exactly at each destination
point.

Exact positioning

P2
P3
P1
Exact positioning

LIN motions with approximate positioning

During approximate positioning, the controller monitors a so--called approximate positioning

range around the destination point. This, in our example, is the point P2. When the TCP
enters this area, the robot motion immediately proceeds towards the destination point of the
next motion command.

Approximate
positioning range P2

P3

P1

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User Programming

Programming a LIN motion

After the option “LIN” is selected from the menu “Motion”, the inline form for entering the
values required for executing this instruction is opened in the program window.

Box name Function Range of values

LIN Type of motion PTP, LIN, CIRC
P1 Point name
Tool Tool number Nullframe, Tool_Data[1]...[16]
Base Workpiece number Nullframe, Base_Data[1]...[16]
external
Robot guides tool/workpiece True, False
TCP
CONT Approximate positioning ON “ ”, Cont
Vel=2m/s Velocity 0.001 ... 2m/s (Default 2m/s)
CPDAT1 Motion parameters
Acceleration Acceleration 0 ... 100
Approximation Approximate positioning
0 ... 100
Distance *1 range
*1 Only available if “CONT” has been switched on

The assignment of the softkey bar changes at the same time, as follows:

It is possible to abort programming of the LIN motion at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the lefthand input box. The status key (at the bottom right of the display)
changes its assignment.
Using this status key, you can choose between the different types of motion again.

The type of motion can also be set using the softkey “CIRC/PTP”.
Move the cursor to the next input box on the right, here “P1”.

If the softkey “Suggest” is pressed, the program finds the lowest standard point name avail-
able in the local data list and enters this name in the open inline form, i.e. if points P1 and
P3 are occupied, P2 will be suggested.
A status window is opened for entering data relating to the workpiece and tool. Activate this
status window using the “Window selection” key.

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 2 Program commands (continued)

Tool
Select here from the 16 available tools.
Base
Select here one of the 16 saved workpiece coordinate
systems (BASE).
external TCP
Tell the controller here whether the robot is guiding the
tool or the workpiece:
Robot guiding tool: external TCP = False
Robot guiding workpiece: external TCP = True

Now activate the program window again using the “Window selection” key.
Then move the robot to the destination point you wish to program. There press the softkey
“Touch Up”. Read the messages displayed in the message window.

The softkey “Touch Up” allows you, at any moment, to save the current robot coordinates
for the program line in which the edit cursor is positioned. You thus have the possibility, for
example, to program a sequence of motion instructions and then define the exact destina-
tion point coordinates later.
The coordinates are saved in the program line in which the blinking edit cursor is located,
irrespective of where the (yellow) block pointer is currently positioned.

Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.
The approximate positioning function can be switched on or off using this status key.

Inline form Press the status key on Using the status key, Press the
“Exact the bottom righthand side. choose between “Exact Enter key
positioning”. The menu is opened positioning” and “Approxi- and the menu
in the inline form. mate positioning” (CONT). is closed.

Move the cursor to the box “Vel=”.

Here you can specify the velocity at which the robot should execute the motion. You can
either enter the value using the keyboard or alter it using the status key to the right of the
display.
Move the cursor to the next input box on the right, here “CPDAT1”.

A status window is opened, in which data must be entered characterizing the motion in
greater detail. Activate this status window using the “Window selection” key. You can either
enter the values in the input boxes using the keyboard or alter them using the status key to
the right of the display.

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User Programming

Acceleration
Here you can reduce the acceleration to be used in the
motion.
Depending on the length of the path, the degree of
acceleration and the approximation distance, it is
possible that the programmed velocity will not be
reached.
This is liable to happen when the wrist axes would have
to turn at an infinitely high speed when passing through
the extended position and would thus exceed the
maximum permissible values.
Therefore please be sure to use practically feasible
values.

Approximation Distance
Here you can reduce the approximate positioning range
to be used in the motion.

Please remember that a high payload/supplementary load, high acceleration and

short paths increase the loading of the drive motors unnecessarily!

Now press the softkey “Cmd Ok” or the Enter key. The motion function is now fully
programmed and saved.

If the position of the destination point has not yet been taught (Touch Up), the current posi-
tion of the robot is automatically saved.

You can use the softkey “Comment” at any time to insert a comment line into your program,
irrespective of the input box that is currently in focus.

Detailed information on comments in robot programs can be found in the section

[Comment].

You can use the softkey “Logic” at any time to insert a so--called logic command into your
program, irrespective of the input box that is currently in focus.

Detailed information on logic commands can be found in the section [Logic].

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 2 Program commands (continued)

2.2.3 Circular motions (CIRC)

Here, the TCP or workpiece reference point moves to the target point along an arc. The path
is defined using start, auxiliary and end points. The destination point of a motion instruction
executed with exact positioning serves as the start point for the subsequent motion. The
orientation changes uniformly over the whole length of the path.
CIRC motions are used when processing operations are to be executed at a preset velocity
along a circular path.

The start, auxiliary and end points lie in a plane in space. In order for the controller to be
able to determine this plane as accurately as possible, these three points should be as far
apart as possible.
Only the reference point follows the programmed path. The actual tool is able to change
its orientation during the motion.

CIRC motions with exact positioning

In the case of CIRC motions with exact positioning, the robot stops exactly at each destina-
tion point.

Auxiliary point End point

Start
point
End point

Start
point
Auxiliary point
End point

CIRC motions with approximate positioning

During approximate positioning, the controller monitors a so--called approximate positioning
range around the destination point. When the TCP enters this area, the robot motion immedi-
ately proceeds towards the destination point of the next motion command.

Approximate
positioning
range

End point
Start
point
End point

Auxiliary point
Start Auxiliary point
point

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User Programming

Programming a CIRC motion

After the option “CIRC” is selected from the menu “Motion”, the inline form for entering the
values required for executing this instruction is opened in the program window.

Box name Function Range of values

CIRC Type of motion PTP, LIN, CIRC
P1 Auxiliary point name
P2 Point name
Tool Tool number Nullframe, Tool_Data[1]...[16]
Base Workpiece number Nullframe, Base_Data[1]...[16]
external
Robot guides tool/workpiece True, False
TCP
CONT Approximate positioning ON “ ”, Cont
Vel=2m/s Velocity 0.001 ... 2m/s (Default 2m/s)
PDAT1 Motion parameters
Acceleration Acceleration 0 ... 100
Approximation Approximate positioning
0 ... 100
Distance *1 range
*1 Only available if “CONT” has been switched on

The assignment of the softkey bar changes at the same time, as follows:

Teach Aux Teach End

It is possible to abort programming of the LIN motion at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the lefthand input box. The status key (at the bottom right of the display)
changes its assignment.
Using this status key, you can choose between the different types of motion again.

The type of motion can also be set using the softkey “PTP/LIN”.
Move the cursor to the next input box on the right, here “P1”.

If the softkey “Suggest” is pressed, the program finds the lowest standard point name avail-
able in the local data list and enters this name in the open inline form. i.e. if points P1 and
P3 are occupied, P2 will be suggested.

Teach Aux Now move the robot to the auxiliary point. There press the softkey “Teach Aux”. Read the
messages displayed in the message window.

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 2 Program commands (continued)

The coordinates of the auxiliary point must be saved manually before conclusion of the
motion command; they are not automatically saved. If you want to define the point
coordinates later, “Teach Aux” can be carried out first in any robot position.

Move the cursor to the next input box on the right, here “P2”.

A status window is opened for entering data relating to the workpiece and tool. Activate this
status window using the “Window selection” key.

Tool
Select here from the 16 available tools.
Base
Select here one of the 16 saved workpiece coordinate
systems (BASE).
external TCP
Tell the controller here whether the robot is guiding the
tool or the workpiece:
Robot guiding tool: external TCP = False
Robot guiding workpiece: external TCP = True

Now activate the program window again using the “Window selection” key.

Then move the robot to the end point you wish to program. There press the softkey “Touch
Teach End
Up”. Read the messages displayed in the message window.

The softkey “Touch Up” allows you, at any moment, to save the current robot coordinates
for the program line in which the edit cursor is positioned. You thus have the possibility, for
example, to program a sequence of motion instructions and then define the exact destina-
tion point coordinates later.
The coordinates are saved in the program line in which the blinking edit cursor is located,
irrespective of where the (yellow) block pointer is currently positioned.

Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.

The approximate positioning function can be switched on or off using this status key.

Inline form Press the status key on Using the status key, Press the
“Exact the bottom righthand side. choose between “Exact Enter key
positioning”. The menu is opened positioning” and “Approxi- and the menu
in the inline form. mate positioning” (CONT). is closed.

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User Programming

Move the cursor to the box “Vel=”.

Here you can specify the velocity at which the robot should execute the motion. You can
either enter the value using the keyboard or alter it using the status key to the right of the
display.
Move the cursor to the next input box on the right, here “CPDAT1”.

A status window is opened, in which data must be entered characterizing the motion in
greater detail. Activate this status window using the “Window selection” key. You can either
enter the values in the input boxes using the keyboard or alter them using the status key to
the right of the display.

Acceleration
Here you can reduce the acceleration to be used in the
motion.
Depending on the length of the path, the degree of
acceleration and the approximation distance, it is
possible that the programmed velocity will not be
reached.
This is liable to happen when the wrist axes would have
to turn at an infinitely high speed when passing through
the extended position and would thus exceed the
maximum permissible values.
Therefore please be sure to use practically feasible
values.

Approximation Distance
Here you can reduce the approximate positioning range
to be used in the motion.

Please remember that a high payload/supplementary load, high acceleration and

short paths increase the loading of the drive motors unnecessarily!

Now press the softkey “Cmd Ok” or the Enter key. The motion function is now fully
programmed and saved.

If the position of the destination point has not yet been taught (Touch Up), the current posi-
tion of the robot is automatically saved.

You can use the softkey “Comment” at any time to insert a comment line into your program,
irrespective of the input box that is currently in focus.

Detailed information on comments in robot programs can be found in the section

[Comment].

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 2 Program commands (continued)

You can use the softkey “Logic” at any time to insert a so--called logic command into your
program, irrespective of the input box that is currently in focus.

Detailed information on logic commands can be found in the section [Logic].

Please note:
A full circle must be made up of at least two segments to prevent the circle from tilting
in the plane.

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User Programming

2.3 Motion parameters

This function allows the monitoring tunnel for collision monitoring to be changed. The sensiti-
vity of the collision monitoring can be defined in this way.

Calling this command opens the following inline form:

The values defined in the file “C:\Program Files\KRC\MaDa\Steu\$custom.dat” are used as

default values.

Alternatively, the user can manually define the amount by which the command torque may
deviate from the actual torque. If this is exceeded the robot is stopped.

Example
In the inline form, axes A1...A6 have each been defined with a value of 50%. If the actual
torque deviates from the calculated command torque by more than ¦50% of the maximum
torque, the robot is stopped and a corresponding message is generated in the message
window.

MMax
+50% of MMax
Monitoring tunnel

Actual torque

--50% of MMax
Command torque
0

The monitoring function does not guarantee that the tool will not be damaged in the
event of a collision, but it does reduce the extent of the resulting damage.

More detailed information on collision monitoring can be found in the Programming Hand-
book in the documentation [Configuration], chapter [Configuring the system, expert].

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 2 Program commands (continued)

2.4 Logic
Inputs and outputs of the controller enable the robot system to communicate with its periph-
eral environment. Specific commands are provided for polling inputs and setting outputs.
It is also possible for wait times to be programmed in order to ensure that operations are
completed before the robot starts moving again.

Programming

To program a so--called logic command, you must select a program or load it in the editor.
More detailed information on creating and altering programs can be found in the chapter
[Program editing].

Pay attention to the position of the

edit cursor. The next program line
created by you will be inserted as a
new line after the cursor.

Open the menu using the menu key “Commands”. From this menu select “Logic”. The follow-
ing submenu is displayed:

You can now make your selection from the logic instructions offered.

2.4.1 Wait functions

2.4.1.1 Time--dependent wait function (WAIT)

After selecting the menu item “WAIT”, the inline form for entering the wait time is opened in
the programming window.

The assignment of the softkey bar changes at the same time, as follows:

It is possible to abort programming of the wait function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.

Pressing the softkey “Motion” switches immediately to motion instruction programming,

cancelling programming of the time--dependent wait function.

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Pressing the softkey “W_F/IBUS” switches immediately to programming of the signal--

dependent wait function, cancelling programming of the time--dependent wait function.
Pressing the softkey “Comment” switches immediately to the programming function for
comment lines, cancelling programming of the time--dependent wait function.
You can alter the default wait time in increments of 0.05 seconds using this status key. You
can also enter the desired value using the numeric keypad.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

2.4.1.2 Signal--dependent wait function (WAITFOR)

This function waits until the named input/output has assumed the defined state: True or
False.
After selecting the menu option “WAITFOR”, the inline form for entering the parameters that
are required for executing the signal--dependent wait function is opened in the programming
window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the wait function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.

If the programming window is in focus, the various input boxes can be selected using the “”
and “” arrow keys. The box that is currently selected is highlighted by a color background.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “Motion” switches immediately to motion instruction programming,
cancelling programming of the signal--dependent wait function.
Pressing the softkey “IBUS/WAIT” switches immediately to the function for coupling and
decoupling an INTERBUS segment under program control. Programming of the signal--
dependent wait function is thus cancelled.
Pressing the softkey “Comment” switches immediately to the programming function for
comment lines, cancelling programming of the signal--dependent wait function.
Move the cursor to the lefthand input box. The assignment of the status key at the bottom
right of the display changes accordingly. Here you can specify whether or not the system
should wait for an input or output signal.

Move the cursor to the next input box, here “1”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, specify the input or output
to be polled. It is also possible to change the value shown in the input box using the status
key (at the bottom right of the display).

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Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. Using this status key, you can specify the state at which the motion
program is to be resumed.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

2.4.2 Switching functions

After selecting the menu item “OUT”, a submenu with further options is opened:

This menu offers you various switching functions, which are described in detail below.

2.4.2.1 Simple switching function (OUT)

Sets an output to True or False.

After selecting the menu option “OUT”, the inline form for entering the parameters that are
required for executing the simple switching function is opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the switching function at any time by pressing the
softkey “Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.

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Pressing the softkey “PULSE” switches immediately to programming of the simple pulse
function, cancelling programming of the simple switching function.
Pressing the softkey “SYNOUT” switches immediately to programming of the path--
dependent switching function, canceling programming of the simple switching function.
Move the cursor to the input box “OUT”. The assignment of the status key at the bottom right
of the display changes. Using the numeric keypad, specify the output that is to be set. It is
also possible to change the value shown in the input box using the status key (at the bottom
right of the display).

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the state to which the selected
output is to be set.

Move the cursor to the input box “CONT”. The assignment of the status key at the bottom
right of the display changes. If you set “CONT”, the output is set with the advance run pointer.
If “CONT” is not selected, the output is set with the main run pointer, i.e. as soon as the
advance run pointer reaches this function, it is stopped until the main run pointer has also
reached this function.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

2.4.2.2 Simple pulse function (PULSE)

This function sets a selected output to TRUE/FALSE for the duration of a defined pulse time.
After selecting the menu option “PULSE”, the Inline form for entering the parameters that are
required for executing the simple switching function is opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the pulse function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.

If the programming window is in focus, the various input boxes can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.

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The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “OUT” switches immediately to programming of the simple switching
function, cancelling programming of the simple pulse function.
Pressing the softkey “SYNPULSE” switches immediately to programming of the path--
dependent pulse function, cancelling programming of the simple pulse function.
Move the cursor to the input box “PULSE”. The assignment of the status key at the bottom
right of the display changes. Using the numeric keypad, specify the output that is to be set.
It is also possible to change the value shown in the input box using the status key (at the
bottom right of the display).

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the state to which the selected
output is to be set.

Move the cursor to the input box “CONT”. The assignment of the status key at the bottom
right of the display changes. If you set “CONT”, the function is executed when reached by
the advance run pointer. If “CONT” is not selected, the function is executed when the main
run pointer arrives, i.e. as soon as the advance run pointer reaches this function, it is stopped
until the main run pointer has also reached this function.

Move the cursor to the input box “Time”. The assignment of the status key at the bottom right
of the display changes. Using this status key, you can set the length of the pulse between
0.1 and 3 seconds in increments of 0.1 seconds.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

2.4.2.3 Path--dependent switching function (SYN OUT)

After selecting the menu option “SYN OUT”, the Inline form for entering the parameters that
are required for executing the path--dependent switching function is opened in the program-
ming window.

The assignment of the softkey bar changes at the same time:

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It is possible to abort programming of the switching function at any time by pressing the
softkey “Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “SYNPULSE” switches immediately to programming of the path--
dependent pulse function. Programming of the path--dependent switching function is
cancelled first.
Pressing the softkey “OUT” switches immediately to programming of the simple switching
function. Programming of the path--dependent switching function is cancelled first.
Move the cursor to the input box “SYN OUT”. Using the numeric keypad, specify the output
that is to be set. It is also possible to change the value shown in the input box using the status
key (at the bottom right of the display).

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the state to which the selected
output is to be set.

Move the cursor to the input box “at”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the point of the path segment
at which the selected output is to be set.

Move the cursor to the input box “Delay”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can shift the time at which the selected out-
put is to be set, by any amount in increments of 1 ms between the start and end points of
the path segment. It is also possible to enter the value via the numeric keypad.

If, on the other hand, you want to set the output in relation to the path, you must select the
option “PATH” in the input box “at”.

An additional input box then appears in the inline form in which you can specify the distance
from the destination point at which the output should be set. If, for example, you want the
output to be set between the start point and the destination point, you must enter a value with
a negative sign.

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The current value of the variable $DIST_NEXT can be displayed and altered by means of
the menu function “Monitor” -- “Variable” -- “Single”

The motion commands (type: LIN) before and after the SYN OUT function are important for
determining locally the start and end points and the points along the path.

G Case 1: the start point and end point are exact positioning points

Program: Start
LIN P1 +
SYN OUT
LIN P2 P1 P2
--
END
PATH

G Case 2: the start point is approximated, the end point is an exact positioning point

Program: P2
P1
LIN P1
LIN P2 CONT
SYN OUT
LIN P3
Start

+ --

END
P3 PATH

G Case 3: the end point is approximated, the start point is an exact positioning point

Program: Start P1
LIN P1
SYN OUT
LIN P2 CONT +
LIN P3

END
-- PATH
P3
P2 +

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G Case 4: the start point and end point are approximated

Program: P2
LIN P2 CONT
SYN OUT P1
LIN P3 CONT
LIN P4 Start

END
-- PATH
P4
P3 +

Example:
Adhesive application:
An adhesive gun is to start applying adhesive at a certain point on the workpiece. For this
purpose the command SYN OUT is set. When output 1= TRUE, the adhesive gun is
activated. PATH=10 mm defines the point at which the adhesive application is to begin. The
adhesive gun itself, however, must be activated approximately 15 ms earlier, as a certain
advance time is required before the adhesive begins to flow. The delay time is thus set to
--15 ms.

’ Output ’

Extract from the illustration

relating to “case 4”
P2

Output 1 is set to TRUE

at this point

PATH
--15 ms

P4
P3
+10 mm
Adhesive application

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.4.2.4 Path--dependent pulse function (SYN PULSE)

After selecting the menu option “SYN PULSE”, the inline form for entering the parameters
that are required for executing the path--dependent pulse function is opened in the program-
ming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the pulse function at any time by pressing the softkey
“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “SYNOUT” switches immediately to programming of the path--
dependent switching function, cancelling programming of the path--dependent pulse
function.
Pressing the softkey “PULSE” switches immediately to programming of the simple pulse
function, cancelling programming of the path--dependent pulse function.
Move the cursor to the input box “SYN PULSE”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, specify the output that is to
be set. It is also possible to change the value shown in the input box using the status key (at
the bottom right of the display).

Move the cursor to the input box “State”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can switch between the states to which the
selected output can be set.

Move the cursor to the input box “Time”. The assignment of the status key at the bottom right
of the display changes. You can set the length of the pulse in increments of 0.1 seconds within
the range of 0.1 to 3 seconds using this status key. It is also possible to enter the value via
the numeric keypad.

Move the cursor to the input box “at”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can specify the point of the path segment
at which the selected output is to be set.

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Move the cursor to the input box “Delay”. The assignment of the status key at the bottom right
of the display changes. With this status key, you can shift the time at which the selected out-
put is to be set, by any amount in increments of 1 ms between the start and end points of
the path segment. It is also possible to enter the value via the numeric keypad.

If, on the other hand, you want to set the output in relation to the path, you must select the
option “PATH” in the input box “at”.

An additional input box then appears in the inline form in which you can specify the distance
from the destination point at which the output should be set. If, for example, you want the
output to be set between the start point and the destination point, you must enter a value with
a negative sign.
The motion commands (type: LIN) before and after the SYN PULSE function are important
for determining locally the start and end points and the points along the path. Compare cases
1 to 4 for the previous function SYN OUT!
Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.4.3 Coupling and decoupling the INTERBUS segment (IBUS--Seg on/off)

After selecting the menu option “IBUS--Seg. on/off”, the inline form for programming the
coupling and decoupling of the INTERBUS segment is opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of this function at any time by pressing the softkey “Cmd
Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input boxes can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the “Window selection”
key until the window is highlighted in color.
Pressing the softkey “Motion” switches immediately to motion instruction programming,
cancelling programming of the function.
Pressing the softkey “WAIT/W_F” switches immediately to programming of motion instruc-
tions, cancelling programming of the function.
Pressing the softkey “Comment” switches immediately to the programming function for
comment lines, cancelling programming of the function.
By pressing the status key “CMD”, you can switch between coupling and decoupling of the
INTERBUS.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.5 Analog output

The eight analog outputs of the robot controller are set under program control using this
function.

Programming

To program the analog output, you must select a program or load it in the editor. More
detailed information on creating and altering programs can be found in the chapter
[Program creation].

Pay attention to the position of the

edit cursor. The next program line
created by you will be inserted as a
new line after the cursor.

2.5.1 Static

This option is used to set an analog output with a fixed value. After selecting the menu option,
the inline form for entering the necessary values is opened in the program window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the function at any time by pressing the softkey “Cmd
Abort” or the ESC key. The command will not be saved in this case.
If the program window is in focus, the various input windows can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.

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Move the cursor to the lefthand input box. The assignment of the status key at the bottom
right of the display changes. Here you can specify which of the eight analog outputs you want
to set.

Move the cursor to the next input box, here “0”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter the value the analog
output should take. It is also possible to change the value shown in the input box using the
status key (at the bottom right of the display) in increments of 10 mV.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

2.5.2 Dynamic

This option is used to set an analog output depending on the velocity or technology. After
selecting the menu option, the inline form for entering the necessary values is opened in the
program window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the function at any time by pressing the softkey “Cmd
Abort” or the ESC key. The command will not be saved in this case.

If the program window is in focus, the various input windows can be selected using the “”
and “” arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The program window can be activated by repeatedly pressing the “Window selection” key
until the entire window is highlighted in color.
Move the cursor to the lefthand input box. The assignment of the status key at the bottom
right of the display changes. Here you can specify whether you wish to switch the analog
output on or off.

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Move the cursor to the next input box, here “Channel 1”. The assignment of the status key
at the bottom right of the display changes. Here you can specify which of the eight analog
outputs you want to set or reset.

Move the cursor to the next input box, here “1”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter the factor by which the
corresponding velocity/technology parameters are to be multiplied. It is also possible to
change the value shown in the input box using the status key (at the bottom right of the
display) in increments of 0.05.

Move the cursor to the next input box, here “VEL_ACT”. The assignment of the status key
at the bottom right of the display changes. Here you can specify the velocity/technology
parameters with which the selected analog output is to be combined.

Move the cursor to the next input box, here “Offset”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter the value of the offset
voltage for the selected analog output. It is also possible to change the value shown in the
input box using the status key (at the bottom right of the display) in increments of 100 mV.

Move the cursor to the next input box, here “Delay”. The assignment of the status key at the
bottom right of the display changes. Using the numeric keypad, enter a delay value. It is also
possible to change the value shown in the input box using the status key (at the bottom right
of the display) in increments of 1/100 second.

Now press the softkey “Cmd Ok” or the Enter key. The command is now fully programmed
and saved.

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2.6 Comment

For the purpose of giving your programs a clearer structure, comment lines should be
inserted containing texts explaining the program modules.
Place the edit cursor one line above the position where you want to insert the comment line.
Open the menu by means of the menu key “Commands” and from it select the submenu
“Comment”.

You can now select one of the comment types “Normal” or “Stamp”.

2.6.1 Normal

Using the command “Normal”, you can insert a comment line containing any text into your
program. A semicolon ( ; ) will automatically be inserted at the beginning of the comment line.

Any text
Press the softkey “Cmd Abort” to discard your entries and close the inline form without insert-
ing a comment line into the program listing.
You can switch to the inline form for the stamp directly by using the softkey “Stamp”.

If you would like to enter a different text, you can delete the entry by means of the softkey
“New text”.
Press the softkey “Cmd Ok” to discard your entries and close the inline form without entering
them into the program listing.

Any text

When the “Comment” command is selected again, the previously entered string will already
be offered as a default text in the inline form.

2.6.2 Stamp

You can also insert a stamp in your program, however. In this instance, it is a comment line
with the time and date added. A semicolon ( ; ) will automatically be inserted at the beginning
of the line in this case as well.

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Any text

Use this type of comment to document changes to programs.

You can enter your name in the first input box after NAME. Enter an abbreviation for the
change that has been made in the second box after CHANGES.

Press the softkey “Cmd Abort” to discard your entries and close the inline form without
inserting a comment line into the program listing.
You can switch to the inline form for a normal comment directly by using the softkey “Normal”.

The new system time and the system date are entered into the inline form by pressing the
softkey “New time”.
If you would like to enter a different name, the previous entry can be deleted by pressing the
softkey “New name”.
Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
If you want to enter something else after CHANGES, press the softkey “New text”. This
deletes the previous entry and a new text can now be entered.
Use the softkey “Cmd Ok” to save your entry, close the Inline form and insert the comment
line.

Any text

When the “Comment” command is selected again, the previously entered string will already
be offered as a default text in the inline form.

2.6.3 ...changing comment lines

Move the program cursor to the line that is to be altered and press the softkey “Change”. This
opens an inline form. The existing text is displayed as a suggestion in the input box. Depend-
ing on the type of comment, ’Normal’ or ’Stamp’, the softkey bar has one of these two assign-
ments:

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Now alter the text as desired.

Press the softkey “Cmd Abort” to discard your entries and close the inline form without carry-
ing out the change to the program.
You can switch to the inline form for the stamp directly by using the softkey “Stamp”.

You can switch to the inline form for a normal comment directly by using the softkey “Normal”.

The new system time and the system date are entered into the inline form by pressing the
softkey “New time”.
If you would like to enter a different name, the previous entry can be deleted by pressing the
softkey “New name”.

Name
G can have a maximum length of 24 characters,
G can consist of letters (A--Z), numbers (0--9) and the signs ‘_’ and ‘$’,
G must not begin with a number,
G must not be a keyword (see Appendix, Keywords).
If you would like to enter a different text, you can delete the entry by means of the softkey
“New text”.
Use the softkey “Cmd Ok” to terminate your entry, close the inline form and alter the comment
line accordingly.

2.6.4 ...Delete

Use the “” or “” arrow key to move the edit cursor to the line you want to delete.
Press the menu key “Program” and select the option “Delete” from the menu that is opened.

Read the message displayed in the message window.

Press the softkey “Yes” if you are sure that you want to delete the selected line. When you
press this softkey, the selected line will be removed from the program.

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Pressing the softkey “No” cancels the action.

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2.7 KRL assistant

The KUKA technology packages include the most important functions for normal robot
applications. The user can implement special functions going beyond this scope by program-
ming the robot system directly in “KRL”, the “KUKA Robot Language”.
In order to enable even users who do not use this programming language often to program
specific functions effectively, the “KRL assistant” has been integrated.
The KRL assistant offers its user a syntax--supported method of programming. After the
desired KRL command has been selected, command--specific suggestions are offered in
forms. The contents of these forms are accepted or changed. All of the contents can always
be changed again at a later point.

Operator control

To program a motion command, you must select a program or load it in the editor. More
detailed information on creating and altering programs can be found in the chapter
[Program editing].

Pay attention to the position of the

edit cursor. The program line created
by you will be inserted as a new line
under the cursor.

Open the menu using the menu key “Commands”. Select “KRL assistant”. The following
submenu is displayed:

You can now make your selection from the motion instructions offered.

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2.7.1 KRL motion commands

2.7.1.1 Position specifications

The placeholder “!”

The character “!” is a placeholder. It allows a motion program to be created without knowing
the exact position of the points that subsequently determine the path of the robot.
When the program is subsequently executed, it is stopped here and the point can be taught
using the procedure described below.

If, during subsequent execution of the program, the message “Instruction not allowed”
appears in the message window, delete it using the softkey “Ack”.

Instruction not allowed

Move the robot system to the desired position.

Then press the softkey “Touch Up”. Observe the information displayed in the message
window.
A message indicating that the position has been saved is displayed in the message
window.

Current position “{POS: X 1620, Y 0, Z 1910, A 0, B 90, C 0, S 2, T 2}” taught.

This message can then be deleted again by pressing the softkey “Ack”.

Position specification by means of variables

A valid variable name can also be used instead of the placeholder. A list of the keywords
reserved for KRL, which cannot be used here, can be found in the [KRL Reference Guide].

The robot system should already be moved into the desired position before this function
is programmed.

Information on moving the robot manually can be found in the documentation [Operator
Control], chapter [Manual traversing of the robot].

Should the name that has been given not yet be recognized in the system, the softkey “VAR”
appears in the softkey bar. This is used to prompt you to assign a data format to the name.
After it has been pressed, the softkey bar changes:

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After pressing one of the softkeys “E6POS”, “POS”, “FRAME”, “E6AXIS” or “AXIS”, the
current position of the robot system is saved in the selected data format. This is confirmed
by a message displayed in the message window.

Point KUKA01 touched with current coordinates

This message can then be deleted again by pressing the softkey “Ack”.

Using “Touch Up” to save the position

Before positions can be saved in a program by means of “Touch Up”, data on the position
of the valid robot coordinate system and valid tool/workpiece data must be communicated
to the controller.
To do so, the INI sequence in the program header must be executed.

The robot system should already be moved into the desired position before the function
is programmed.

Press the softkey “Touch Up”; the current position of the robot system is saved.

A message confirming that the position has been saved is displayed in the message window.

Current position “{POS: X 1620, Y 0, Z 1910, A 0, B 90, C 0, S 2, T 2}” taught.

This message can then be deleted again by pressing the softkey “Ack”.

Manual position specification

In addition to the possibility of saving positions that have already been executed, points in
space can also be specified manually.

To do so, press the softkey “{ ? }” after the inline form has been displayed. The assignment
of the softkey bar changes:

After a data format has been selected by pressing the appropriate softkey, the current posi-
tion is entered into the inline form.

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User Programming

These position specifications can now be altered as desired with the aid of the edit functions

The geometric operator “:”

The geometric operator “:” is used to logically combine position specifications of the types
POS and FRAME. This is required whenever the origin of a coordinate system has to be off-
set by a correction value, for example.

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 2 Program commands (continued)

2.7.1.2 [PTP] Positioning

Here, the robot system is positioned along the quickest path between two points in the work
envelope. As the motion of all of the axes starts and ends at the same time, it is necessary
to synchronize them. The path of the robot cannot be predicted exactly in this instance.

When using this command, the precise path of the robot cannot be predicted
exactly. There is therefore the risk of a collision near obstacles in the work
envelope. The motion characteristics of the robot near obstacles must be tested at
reduced velocity!

Placeholder for position

specification
Back

Geometric expressions for

position specification, car-
tesian

Geometric expressions for

position specification, axis--
related

Placeholder for position

specification

Switch between PTP, LIN and CIRC

Switch between PTP and PTP REL

Back

Approximate positioning
between two PTP motions
Approximate positioning
between PTP and LIN or
CIRC commands. Criteria:
distance (DIS), velocity
(VEL) and tool/workpiece
orientation (ORI)
Save current position

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User Programming

Placeholder for position

specification

Back

Geometric expressions for

position specification, carte-
sian

Geometric expressions for

position specification, axis--
related

Placeholder for position

specification

Switch between PTP REL and PTP

Back

Approximate positioning
between two PTP motions
Approximate positioning bet-
ween PTP and LIN or CIRC
commands. Criteria:
distance (DIS), velocity
(VEL) and tool/workpiece
orientation (ORI)

Save current position

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 2 Program commands (continued)

2.7.1.3 [LIN] Linear motion

Here, the robot system is positioned along the shortest path between two points in the work
envelope, i.e. on a straight line. The axes of the robot system are synchronized so that the
path velocity always remains the same on this straight line.

Placeholder for position

specification

Back

Geometric expressions for

position specification, carte-
sian

Placeholder for position

specification

Switch between LIN, CIRC and PTP

Switch between LIN and LIN REL

Back
Approximate positioning
between PTP and LIN or
CIRC commands. Criteria:
distance (DIS), velocity
(VEL) and tool/workpiece
orientation (ORI)

Save current position

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User Programming

Placeholder for position

specification
Back

Geometric expressions for

position specification, car-
tesian

Placeholder for position

specification

Switch between LIN REL and LIN

Back

Approximate positioning
between PTP and LIN or
CIRC commands. Criteria:
distance (DIS), velocity
(VEL) and tool/workpiece
orientation (ORI)

Save current position

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 2 Program commands (continued)

2.7.1.4 [CIRC] Circular motion

Here, the robot system is positioned along a circular path in the work envelope, this path
being defined by a start point, an auxiliary point and an end point. The axes of the robot sys-
tem are synchronized so that the path velocity always remains the same on this circular path.

Placeholder for position

specification
Back

Geometric expressions for

position specification, car-
tesian

Placeholder for position

specification

Switch between CIRC, PTP and LIN

Switch between CIRC and CIRC REL

Specification of the angle that is to be executed;

priority higher than that of the destination point

Back
Approximate positioning
between PTP and LIN or
CIRC commands. Criteria:
distance (DIS), velocity
(VEL) and tool/workpiece
orientation (ORI)

Save current position

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User Programming

Placeholder for position

specification

Back

Geometric expressions for

position specification, car-
tesian

Placeholder for position

specification

Switch between CIRC and CIRC REL

Specification of the angle that is to be executed;

priority higher than that of the end point

Back
Approximate positioning
between PTP and LIN or
CIRC commands. Criteria:
distance (DIS), velocity
(VEL) and tool/workpiece
orientation (ORI)

Save current position

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 2 Program commands (continued)

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 Index

Symbols Edit cursor, 20, 25, 29, 33, 37, 48, 55

!, 56 Exact positioning, 20, 27, 31
?, 57
:, 58 F
Find, 12, 15
A FRAME, 57
Full circle, 35
Acceleration, 24, 26, 28, 30, 32, 34
Analog output, 48
Approximate positioning, 20, 27, 31 G
Approximation Distance, 24, 28, 32 Geometric operator ”:”, 58
at, 42, 45
AXIS, 57 I
IBUS--Seg on/off, 47
B IBUS/WAIT, 38
Block pointer, 25, 29, 33 Infinitely rotating axes, 21

C K
KRL assistant, 55
C_DIS, 59
KRL motion commands, 56
C_ORI, 59
KUKA Robot Language, 55
C_PTP, 59
C_VEL, 59
Changing comment lines, 52 L
CIRC, 20, 31, 63 Last command, 19
CIRC REL, 63 LIN, 20, 27, 61
Circular motions, 31 LIN REL, 61
Close editor, 17 Linear motions, 27
CMD, 47 Loading and saving programs, 9
Comment, 38, 47, 51 Logic, 37
CONT, 20, 24, 25, 28, 29, 32, 33, 40, 41
CPDAT1, 28 M
Managing programs, 5
D Manual position specification, 57
Delay, 42, 46 Motion, 20, 38, 47
Delay value, 50 Motion command, 20
Delete, 15, 53 Motion parameters, 36
Deleting comment lines, 53
Deleting programs, 10 N
Depending on the technology, 49 New, 5
Depending on the velocity, 49 New name, 52
Duplicate, 10 New text, 52
New time, 52
E Normal, 51, 52, 53

E6AXIS, 57
E6POS, 57 O
Edit, 6 Offset voltage, 50

Index -- i
 Index

Open, 6 V
Orientation, 27, 31
VAR, 56
OUT, 39, 40, 41, 42
Vel, 24, 28, 32
P Velocity parameters, 50
PATH, 42, 46
PDAT1, 24, 32 W
Placeholder, 56
Point--to--point motions, 23 W_F/IBUS, 38
POS, 57 WAIT, 37
Program editing, 5 Wait functions, 37
Program editor, 15 WAIT/W_F, 47
Programmed velocity, 26, 30, 34 WAITFOR, 38
Programming, 37, 48
Programming a LIN motion, 28
Programming a PTP motion, 24
Z
Programming movements, 20 Zip file, 9
Programs, 5
PTP, 20, 23, 59
PTP motions with approximate positioning, 23
PTP motions with exact positioning, 23
PTP REL, 59
PULSE, 40, 41, 45

R
Robot coordinates, 25, 29, 33

S
Save, 26, 30, 34
Save the current robot coordinates, 25, 29,
33
Select/open/save a program, 5
Stamp, 51
Standard motions, 20
State, 39, 40, 41, 42, 45
SYN OUT, 41, 42
SYN PULSE, 45
SYNOUT, 40, 45
SYNPULSE, 41, 42

T
Technology parameters, 50
Time, 41, 45
Touch Up, 25, 29, 33, 57
Types of motion, 20

Index -- ii
SOFTWARE

KR C...

Error messages / troubleshooting

KUKA System Software (KSS)

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Message groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Message time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Message number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Originator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Message text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 List of error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Error messages / troubleshooting

1 Error messages / troubleshooting

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

Message group
Message time
Message number
Originator
Message text

COMMAND ACCELERATION EXCEEDED A2

ACTIVE COMMANDS INHIBITED

1.1 Message groups

Hint messages
provide the operator with explanatory information, for example, if an illegal key has been
pressed.

Operational messages
signal the status of the system that has led to a control reaction, e.g. Emergency Stop. The
message is cleared once its cause has been eliminated. In some cases, a secondary signal
that has to be acknowledged is set for reasons of safety.

Acknowledgement messages
indicate a situation that must in all instances be recognized and acknowledged with the
acknowledge key. They are often a consequence of a status (operational) message. An
acknowledgement message stops a movement or prevents further operation.

Dialog messages
require confirmation by the operator (“Yes” or “No” softkeys). The message is cleared after
it has been confirmed.

1.2 Message time

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

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 1 Error messages / troubleshooting (continued)

1.3 Message number

With the aid of the message number, the corresponding cause, effect and remedy can quickly
be located in the list of error messages.

1.4 Originator
The origin of the error is indicated in this field.

1.5 Message text

The text of the error message is shown here.

1.6 List of error messages

To make it easier to find error messages in the following list, the message number is shown
first, unlike on the display. By referring to this message number, it is possible to obtain further
information on an error and the appropriate remedial action. This information is subdivided
into:
Message text
is the actual text of the error message as displayed.

Cause
gives a detailed description of the cause of the error.

Monitor
indicates when the conditions for generation of the message are checked.

Effect
describes how the controller reacts to the error.

Remedy
describes what action the user can take to eliminate the error.

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Error messages / troubleshooting

1 Message text EMERGENCY STOP

Cause -- Emergency Stop pushbutton pressed.

-- Emergency Stop initiated by the software.
Monitor -- Cyclic.
Effect -- Path--maintaining stop.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton and Emergency Stop circuit.
-- Release the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.
2 Message text Internal error

Cause -- Internal KRL software test.

Monitor -- Within the KRL software.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
3 Message text MESSAGE BUFFER OVERFLOW

Cause -- The message buffer, which contains the currently active messages
(acknowledgement and status messages), is full up to a specific limit.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Rectify and acknowledge the signalled faults.
4 Message text BUFFER BATTERY VOLTAGE LOW xx

Cause -- Voltage of the backup battery too low.

Monitor -- At “Power off”.
-- Cyclic.
Effect -- The battery voltage is checked when the power is switched off. When
the message is displayed, it is necessary to wait until the battery has
recharged. Only then may the controller be switched off.
-- Cyclic --> none.
Remedy -- Change the battery.
-- After the battery has been charged, the message “Ackn. batt. voltage”
is displayed --> acknowledge.
5 Message text Malfunction <HPU or RCP>

Cause -- KCP defective.

Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace KCP.

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 1 Error messages / troubleshooting (continued)

6 Message text Transmission error <HPU or RCP>

Cause -- Fault in KCP connection.

Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the KCP cable.
7 Message text TPBASIS

Cause -- The point could not be created

8 Message text System time invalid

Cause -- The system time is invalid after TIME_HW_FAILURE and has been
set to the initial value.
Monitor -- When the controller is booted.
Effect -- The system time is initialized with 01.01.93 00:00:00,00.
Remedy -- Update the system time with the form “systime”.
9 Message text MFC overtemperature

Cause -- The temperature sensor on the MFC has been triggered.

Monitor -- Cyclic.
Effect -- Path--maintaining braking.
Remedy -- Check fan. Exchange MFC if necessary.
10 Message text ERROR DIGITAL OUTPUTS @P1@

Cause -- Short circuit at outputs 1--8 or 9--16.

Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy --
11 Message text PROGRAM STACK OVERFLOW

Cause -- KRL program contains too many nested structures or too many recur-
sive subprogram calls! The C--stack of the R--INT would otherwise
overflow.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Change the structure of the program.
12 Message text TOO MANY MESSAGES

Cause -- Too many messages have been cyclically generated.

Monitor -- When a message is generated.
Effect -- All active commands are cancelled and cannot be restarted.
Remedy -- The KRC has to be booted.

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Error messages / troubleshooting

13 Message text ERROR SAFETY LOOP

Cause -- A channel has failed or more than one enabling switch has been
pressed.
Monitor -- Cyclic.
Effect -- Path--maintaining braking, active commands inhibited.
Remedy --
14 Message text SOFTPLC: @P1@

Cause --
Monitor --
Effect --
Remedy --
15 Message text OUTPUT MONITORING DC BUS VOLTAGE KPS: @P1@

Cause -- DC bus voltage of a KPS overloaded.

Monitor --
Effect --
Remedy --
16 Message text Error while reading “O file”

Cause -- Error during loading/reading of “ident_vx.o”: memory or file not found.

Monitor -- In the write function “w_ident_state”.
Effect -- Jump to the end in load data program.
Remedy -- Copy the file “ident_vx.o” to the directory “/ir_spec/l_ident”,
or increase memory by changing the value “VxWinRAM” in the registry.
17 Message text WRONG/UNKNOWN HARDWARE FOUND

Cause -- During setup, the wrong control hardware (KR C1, KR C1A, KR C2)
was selected or the hardware configuration is invalid.
Monitor --
Effect -- The controller is inoperable.
-- Robot traversing not possible.
Remedy -- Carry out setup again or make appropriate changes to
hardware configuration.
18 Message text Servobus DSE--No. %1 participant No. %2 unknown

Cause -- An unknown device which cannot be supported has been inserted in

Interbus
Monitor -- DSE ID, device ID
Effect -- The robot can no longer be traversed
Remedy -- Remove unknown device from servo bus

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 1 Error messages / troubleshooting (continued)

19 Message text FAILURE OF MOTOR PHASE <axis>

Cause -- Power module, intermediate circuit voltage discharged.

Monitor -- Cyclic.
Effect -- Dynamic braking.
-- All active commands inhibited.
Remedy -- Switch on drives.
-- Check power module, DSE.
20 Message text EXTERNAL EMERGENCY STOP PRESSED

Cause -- Emergency Stop button pressed.

-- Emergency braking triggered by software.
Monitor -- Cyclic.
Effect -- Path--maintaining braking.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.

21 Message text Second motorcable not connected

Cause -- Second motor cable is not connected or is incorrectly connected; the

additional cable contains two wires which are connected to the robot;
the return signal is connected to the KPS X114, pin 7
Monitor -- Cyclic.
Effect -- The robot cannot be traversed
Remedy -- Check second motor cable and return signal at KPS X114, pin 7

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Error messages / troubleshooting

100 Message text RDW ** BOOT UP FAILURE

Cause -- The resolver/digital converter (RDW) could not be initialized when

the controller was booted.
Monitor -- At runup.
Effect --
Remedy -- Replace RDW, DSE or cable between RDW and DSE.
101 Message text DSE ** BOOT UP FAILURE

Cause -- The DSE could not be initialized when the controller was booted.
Monitor -- At runup.
Effect -- Maximum braking (dynamic braking).
Remedy -- Replace DSE, MFC or motherboard.
102 Message text ENCODER CABLE FAILURE **

Cause -- Cable defective (e.g. loose connection).

-- RDW defective.
-- Encoder defective.
Monitor -- Cyclic.
Effect -- Maximum braking (dynamic braking).
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check encoder cable.
-- Check motor, resolver.
-- Possibly replace RDW.
103 Message text WATCHDOG INTERPOLATION CYCLE **

Cause -- DSE has not triggered software watchdog in the DP--RAM.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Software error.
104 Message text SYNCHRONIZATION ERROR WITH DSE **

Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Error in the DSE or PC area.
-- Software error.

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 1 Error messages / troubleshooting (continued)

105 Message text TRANSMISSION ERROR DSE -- RDW **

Cause -- Open--circuit between RDW and DSE.

-- Transmission malfunctions.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
106 Message text PERFORM MASTERING ** !

Cause -- Position actual value difference after restart too great and sensor
mastering not possible because sensor location run has not been
performed.
Monitor -- At “Power on”.
-- During mastering.
Effect -- All active commands inhibited.
Remedy -- Perform mastering.
107 Message text EMERGENCY STOP DUE TO DIAL ADJUSTMENT

Cause -- Softkeys for dial adjustment pressed.

-- Value assignment “$TURN = 1”.
-- Encoder setting, absolute or incremental.
Monitor -- When “$TURN” instruction is executed.
Effect -- Dynamic braking.
-- 0 signal at “$ALARM_STOP” output
-- All active commands inhibited.
Remedy -- Leave the mastering menu by pressing the Recall key twice.
108 Message text DYNAMIC BRAKING ACTIVE

Cause -- If the controller detects a request for maximum (dynamic) braking, it

geneates the status (operational) message “DYNAMIC BRAKING
ACTIVE”, which remains active until all axies have stopped.
Monitor -- Cyclic.
Remedy -- The status message “DYNAMIC BRAKING ACTIVE” is reset by the
controller when the robot is at standstill without a secondary message
being generated.
109 Message text CLEAR FAST MEASURING INPUT @P1@

Cause -- Rapid gauging has been switched on.

Monitor -- During rapid gauging.
Effect -- Rapid gauging becomes active when measuring tool has been
moved free.
Remedy -- Move measuring tool free.

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Error messages / troubleshooting

110 Message text ADVANCED PATH PROFILE NOT POSSIBLE WITH LINKED EXTER-
NAL AXES
Cause -- Coupling of external axes in higher motion profile.
Monitor -- During command and program execution.
Effect --
Remedy --
111 Message text TEPRO INACTIVE

Cause -- SBC no longer sending a signal to KRC.

Monitor -- Cyclic.
Effect -- SBC interface inoperable.
Remedy -- Re--initialize SBC program.
112 Message text INVALID $TOOL: WORKING ENVELOPE SURVEILLANCE NOT
POSSIBLE
Cause -- “$TOOL” invalid when working envelope monitoring is activated.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Assign “$TOOL” or switch off working envelope monitoring.
113 Message text RANGE OVERFLOW ** **

Cause -- Overflow of the actual value of an endless axis: actual value > +/--
90*10E15 increments or --99999000 < $REVO_NUM < 999999000
Monitor -- Cyclic in the interpolation cycle.
Effect -- Path--maintaining Emergency Stop.
Remedy -- Turn back or remaster the axis concerned.
114 Message text WORKING ENVELOPE NO. @P1@ VIOLATED

Cause -- TCP is inside a working envelope with MODE INSIDE STOP or outside
a working envelope with MODE OUTSIDE STOP.
Monitor -- Cyclic.
Effect -- Path--maintaining braking;
-- All active commands inhibited.
Remedy -- Switch off working envelope or use key on the KCP to override work
envelope monitoring, move free in T1 mode.
115 Message text DRIVE FREE WORK ENVELOPE %1

Cause -- TCP is inside a working envelope with

MODE INSIDE STOP or outside a working envelope with MODE
OUTSIDE STOP and the working envelope monitoring is overridden.
Monitor -- Cyclic.
Effect --
Remedy -- Free work envelope.

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 1 Error messages / troubleshooting (continued)

116 Message text DSE WATCHDOG COMMAND **

Cause -- DSE has not executed a command.

Monitor
Effect -- Ramp--down braking.
Remedy -- Check hardware in the DSE, MFC area.
117 Message text TORQUE EXCEEDED AXIS @P1@

Cause
Monitor
Effect
Remedy
118 Message text HEAT SINK TEMPERATURE **

Cause -- Thermostatic switch on the heat sinks of the servo output stage is
tripped due to overheating of the output stage transistors.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Clean the heat sinks.
119 Message text MOTOR TEMPERATURE **

Cause -- PTC thermistor (measuring shunt) in the motor winding has been
tripped (motor temperature too high).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Program more movement breaks.
120 Message text ACKN. MOTOR BLOCKED **

Cause -- As soon as the torque command value supplied by the speed controller
exceeds 30% of the max. torque command value, integration is
started, and when the value of i*t reaches approx. 0.75 [(torque
command value / max. torque command value) * sec] the control is
switched off (i*t -- monitoring).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Check that the axis is moving freely.
121 Message text OVERCURRENT **

Cause -- The current of each axis is monitored and the amplifier--internal current
protection is tripped if the power consumption is too high.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.

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Error messages / troubleshooting

Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
122 Message text BRAKE FAULT **

Cause -- The brake cable is monitored for short--circuit, overload and cable
break.
-- With the PM6, all axes are supplied from one brake driver.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
123 Meldungstext UNDERVOLTAGE <axis number>

Cause -- The internal operating voltage (+15V) of the servo output stage is
monitored. Undervoltage results in power failure.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
124 Message text OVERVOLTAGE <power module number>

Cause -- The intermediate--circuit voltage is too high. Possible causes are a de-
fective ballast (feedback) resistor or ballast fuse, a defective power
module, brake ramp too steep etc.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
125 Message text i2--t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string1> AFTER <string2> s EXCEEDED 100%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
126 Message text REGULATOR LIMIT EXCEEDED <axis number>

Cause -- Following error too great. The axis does not follow the command value.
Monitor -- Cyclic in the position controller.
Effect -- Maximum braking.
Remedy -- Check the axis.
127 Message text <axis number> DETACHED EXTERNAL AXIS

Cause -- Auxiliary (external) axis is operated as an asynchronous axis.

Monitor -- Cyclic.
Effect

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 1 Error messages / troubleshooting (continued)

Remedy
128 Message text SOFTWARE LIMIT SWITCH OF DETACHED EXTERNAL AXIS
<motion direction> <axis number>
Cause -- Asynchronous axis has tripped the pos. or neg. software limit
switch.
Monitor -- The software limit switch is checked cyclically if the axis is operated
as an asynchronous axis.
Effect
Remedy
129 Message text i2--t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string1> AFTER <string2> s EXCEEDED 95%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
130 Message text K1 CONTACT FAIL TO OPEN <KPS number>

Cause -- The K1 contact is welded.

Monitor --
Effect -- The energy supply system is not interrupted.
Remedy -- Exchange contactor, KPS.
131 Message text BUS VOLTAGE CHARGING UNIT IS DEFECTIVE <KPS number>

Cause -- The optocoupler on the KPS is not registering current flow.

Monitor --
Effect -- Intermediate circuit cannot be loaded.
Remedy -- Exchange KPS.
132 Message text BRAKE DEFECTIVE <axis ...>

Cause -- Wear on brakes, defective brake.

Monitor --
Effect -- Axis moves in an uncontrolled manner.
Remedy -- Exchange motor.
133 Message text MONITORING OF THE ACTUAL VELOCITY @P1@

Cause -- Fault in control loop:

-- motor cables of two axes interchanged;
-- error in the axis assignment;
-- power module defective;
-- resolver unmastered.
Monitor -- Cyclic.
Effect -- Robot remains motionless.
Remedy -- Rectify the corresponding error in the control loop.

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Error messages / troubleshooting

134 Message text DN CH ... WRONG FASTWRITE MACID IN INI FILE

Cause --
Monitor --
Effect --
Remedy --
135 Message text DN CH ... MODULE ERROR ...

Cause --
Monitor --
Effect --
Remedy --
136 Message text DN CH ... SLAVE ERROR ...

Cause --
Monitor --
Effect --
Remedy -- Exchange contactor, KPS.
137 Message text DN CH ... FIRMWARE ERROR

Cause --
Monitor --
Effect --
Remedy --
138 Message text DN CH ... HARDWARE ERROR

Cause --
Monitor --
Effect --
Remedy -- Exchange contactor, KPS.
139 Message text DN CH ... BUS ERROR ...

Cause --
Monitor --
Effect --
Remedy --
140 Message text DN CH ... WATCHDOG ERROR

Cause --
Monitor --
Effect --
Remedy --

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 1 Error messages / troubleshooting (continued)

141 Message text DN CH ... USER ERROR ...

Cause --
Monitor --
Effect --
Remedy --
142 Message text DN CH ... CONFIGURATION MODE ENABLED

Cause --
Monitor --
Effect --
Remedy --
143 Message text Ixt servo drive %1 exceed value %2 %%

Cause -- If the defined Ixt monitoring warning value of a drive servo is exceeded,
the robot must be brought to a standstill; otherwise, the drive servo is
deactivated when the maximum value of 100% is exceeded
Monitor -- Cyclic, the warning bit on the drive servo
Effect -- The robot is stopped in a controlled manner.
Remedy -- Verify load data
-- If necessary, reduce the load cycle (wait time)
-- Use stronger robot

146 Message text Wrong amplifier %1

Cause -- Drive module of a slave axis does not correspond to drive module on
the associated master axis
Monitor -- Cyclic.
Effect -- Traversing not possible
Remedy -- Shut down controller, exchange drive module for one corresponding to
the master axis and reboot controller

147 Message text DRIVE FREE AXIS WORK ENVELOPE NO. %1

Cause -- The robot is inside a working envelope with MODE INSIDE STOP or
outside a working envelope with MODE INSIDE STOP and the working
envelope monitoring is overridden.
Monitor -- Cyclic.
Effect --
Remedy -- Free axis work envelope

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Error messages / troubleshooting

148 Message text Axis work envelope No. %1 violated

Cause -- The robot is inside a working envelope with MODE INSIDE STOP or
outside a working envelope with MODE OUTSIDE STOP
Monitor -- Cyclic.
Effect -- Path--maintaining braking, all active commands inhibited
Remedy -- Switch off axis working envelope or override work envelope monitoring
in T1 mode and move free

155 Message text <axis> DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
200 Message text DRIVES CONTACTOR OFF

Cause -- Power module, intermediate--circuit voltage discharged.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Switch drives on.
-- Check power module, check DSE.
-- Emergency Stop is active, drives circuit is interrupted.
201 Message text KCP DEADMAN SWITCH

Cause -- The safety (deadman) switch has been released during an active
function (motion of an axis) in mode T1 or T2.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Press safety switch.
-- Check KCP, safety logic.
202 Message text I/O RECONFIGURATION

Cause -- An I/O reload command has been transmitted via the KCP.
Monitor --
Effect -- Path--maintaining braking.
Remedy -- After successful reconfiguration, the normal operating state is
automatically restored.

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 1 Error messages / troubleshooting (continued)

203 Message text GENERAL MOTION ENABLE

Cause -- Low signal at $MOVE_ENABLE input.

Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the input.
204 Message text HARDWARE LIMIT SWITCH / +24V MISSING

Cause -- The hardware limit switch has been tripped.

Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Shunt out the hardware limit switch and move axis off limit switch.
205 Message text SOFTWARE LIMIT SWITCH <motion direction> <axis number>

Cause -- The software limit switch of the axis indicated has been tripped in the
direction indicated. (The message is effective only after “Robot
synchronized”).
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Movement in the direction indicated is inhibited.
Remedy -- Move the axis in the opposite direction (no change to the robot--specific
coordinate system takes place).
206 Message text SERVO PARAMETERS <axis> LINE <integer> INCORRECT

Cause -- The parameters in the servo file are incorrect.

Monitor -- While loading machine data.
Effect --
Remedy -- Correct the parameters.
207 Message text OPERATOR SAFETY / GATE OPEN

Cause -- Operator safety has been tripped in the AUTOMATIC or EXTERNAL

mode (input at the peripheral interface).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch to mode T1 or T2 (in these modes the robot can be moved
when the signal is low).
-- Close the safety gate.
-- Check the input.
208 Message text FAILURE IN ESC SAFETY LOOP

Cause -- Emergency Stop button pressed.

-- Emergency braking triggered by software.
Monitor -- Cyclic.

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Error messages / troubleshooting

Effect -- Path--maintaining braking.

-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton;
-- Rectify and acknowledge the signalled fault.
209 Message text PASSIVE STOP <RCP or teach pendant>

Cause -- Stop from a passive operator control unit (the message is displayed
only if an active process has been stopped).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge the message “Passive Stop”.
210 Message text STOP KEY <RCP or teach pendant>

Cause -- The start key or a traversing key has been actuated while the stop
key is depressed.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the stop key.
211 Message text CHECK SAFETY LOGIC. DRIVES OFF TIMEOUT DURING EMER-
GENCY STOP OCCURRED
Cause --
Monitor --
Effect --
--
Remedy --
212 Message text ERROR WRITING TO PERCEPTRON

Cause --
Monitor --
Effect --
--
Remedy --
213 Message text ERROR WRITING TO BOSCH

Cause --
Monitor --
Effect --
--
Remedy --
214 Message text COMMON DRIVES ERROR <axis number>

Cause --
Monitor --

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 1 Error messages / troubleshooting (continued)

Effect --
--
Remedy --
215 Message text COMMON DRIVES ERROR <axis number>

Cause --
Monitor --
Effect --
--
Remedy --
216 Message text DRIVES ERROR ... NO.: ...

Cause -- The Start key or a direction key was activated while the Stop key
was pressed.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check Stop key.
217 Message text EMERGENCY STOP FROM KRC ( ALARM STOP )

Cause -- An alarm stop has been initiated by the KRL system software;
another serious error has occurred.
Monitor -- Cyclic.
Effect -- Maximum braking. All active commands inhibited.
Remedy -- Eliminate and acknowledge the signalled fault (serious error).

218 Message text FEEDBACK SWITCH TOO LONG ON **

Cause -- The energy of the axis to be braked was too high.

Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
219 Message text CABINET TEMPERATURE TOO HIGH **

Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.

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Error messages / troubleshooting

220 Message text DRIVES CONTACTOR OFF, INTERMEDIATE CIRCUIT LOADED !!!

Cause -- The drives contactor drops out. The energy in the intermediate circuit
is sufficient to ensure a path--maintaining stop. Caution: the
intermediate circuit is still charged! The intermediate circuit is
discharged after about 2 minutes. The message “DRIVES NOT
READY” is then displayed.
Monitor -- Cyclic.
Effect -- Path--maintaining Emergency Stop
Remedy -- Switch drives on again.
-- Check drives circuit for faults.
221 Message text MODE NOT ALLOWED

Cause -- E2 keyswitch in AUTO mode.

Monitor
Effect
Remedy
222 Message text PARITY ERROR POWERMODULE **

Cause -- A parity error has occurred more than five times in succession when
reading the power module register.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Too much interference at the power module interface, or power module
defective. Check cable, check shielding, replace power module.
223 Message text POWER MODULE AXIS ** NOT OR WRONGLY PLUGGED

Cause -- The axis is incorrectly plugged into the power module or not connected
at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect the axis correctly (high or low power).
224 Message text POWER FAIL

Cause -- The cabinet voltage has been switched off, the mains voltage is
interrupted.
Monitor
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.
225 Message text MOTOR CABLE **

Cause --
Monitor --
Effect --
Remedy --

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 1 Error messages / troubleshooting (continued)

226 Message text FAILURE OF HEAT SINK TEMPERATURE SENSOR **

Cause --
Monitor --
Effect --
Remedy --
227 Message text FAILURE OF CABINET INTERIOR TEMPERATURE SENSOR <AXIS
NUMBER>
Cause --
Monitor --
Effect --
Remedy --
228 Message text DRIVES PARAMETER DATA ** INVALID

Cause --
Monitor --
Effect --
Remedy --
229 Message text FAILURE OF MOTOR TEMPERATURE SENSOR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
230 Message text WRONG DRIVES PARAMETER <AXIS NUMBER> **

Cause --
Monitor --
Effect --
Remedy --
231 Message text ERROR SYNC. INPUT DRIVE <AXIS>

Cause --
Monitor --
Effect --
Remedy --
232 Message text SYNCHRONISATION ERROR DRIVE <AXIS>

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

233 Message text <AXIS> WITHOUT POWER

Cause --
Monitor --
Effect --
Remedy --
234 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
235 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
236 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
237 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
238 Message text COMMON DRIVES ERROR <AXIS NUMBER>

Cause --
Monitor --
Effect --
Remedy --
239 Message text LOADING ** SERVO PARAMETERS **

Cause -- Loading drive servo parameters

Monitor --
Effect --
Remedy --

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 1 Error messages / troubleshooting (continued)

240 Message text PLEASE SWITCH OFF THE CABINET

Cause -- The drive servo parameters have been loaded, but will not take effect
until the next reboot.
Monitor --
Effect --
Remedy --
241 Message text SERVOFILE CONFIGURATION ** DOES NOT FIT THE ** RELEASE
**
Cause -- The servo file configuration contains parameters for the drive servos
which are not supported by the firmware.
Monitor --
Effect --
Remedy -- Upgrade drive servo firmware or servo files.
242 Message text ** FIRMWARE RELEASE **

Cause -- Information about the firmware release of the axis in question.

Monitor --
Effect --
Remedy -- Upgrade drive servo firmware or servo files.
243 Message text SOFTWARE OF DSE ** DOES NOT FIT THE HARDWARE OR
DEFECTIVE DSE
Cause -- The wrong software was configured for the DSE
DSEAT and KR C1A/KR C2.
Monitor --
Effect --
Remedy -- Configure the correct software.
244 Message text ** SOFTWARE VERSION INCORRECT

Cause -- DSE software and kernel system do not work together.

Monitor --
Effect --
Remedy -- Configure the correct DSE software.
245 Message text SERVO BUS DISTURBANCE DSE **

Cause -- Defective bus cable.

Defective bus module.
Defective bus driver.
Monitor -- Rectify fault.
Effect --
Remedy --
246 Message text SERVO BUS DISTURBANCE DSE **, NO BUFFERING AND
AUTOMATIC DATA STORAGE POSSIBLE
Cause -- Buffering is activated via the servo bus on the KPS. If communication
with the KPS is faulty, the buffering cannot be activated and switch--off
takes place immediately.

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Error messages / troubleshooting

Monitor --
Effect --
Remedy -- Re--establish communication with the KPS.
247 Message text SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
248 Message text SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
249 Message text $MOVE_ENABLE INPUT (1025) NOT ALLOWED

Cause --
Monitor --
Effect --
Remedy --
250 Message text INCORRECT SERVO PARAMETER <AXIS>

Cause --
Monitor --
Effect --
Remedy --
251 Message text <variable> OVERLAPPING OUTPUT SIGNALS

Cause -- Interface unit outputs assigned twice.

Monitor -- At “Power On”.
After editing the machine data.
After loading the machine data.
Effect -- No RC Ready.
Remedy -- Value assignment.
252 Message text <variable> INTERFACE--I/O ASSIGNMENT ERROR <correct index>

Cause -- Double assignment of interface controller output.

Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the indicated machine datum.

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 1 Error messages / troubleshooting (continued)

253 Message text ERRONEOUS DSE AXIS ASSIGNMENT <axis number>

Cause -- Machine datum $IFACE_DRV[6] has been assigned twice to a drive

interface, or a non--existent interface has been addressed.
-- KTL encoders have been entered in IFACE_DRV[6] without connect-
ing APC interfaces, or ADAR axes have been entered in $ADAR_AXIS
without connecting ADAR interfaces.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the machine datum.
254 Message text DSE FILE <program name> NOT AVAILABLE

Cause -- The DSE program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter or alter the DSE program.
255 Message text <$ variable> INVALID VALUE

Cause -- The machine data loader has detected that a variable contains an
incorrect value:
a) Limit monitoring tripped.
b) Machine data not logically coherent.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the value assignment.
256 Message text CHECK MACHINE DATA !

Cause -- It cannot be assured that the machine data loaded during a cold
start are valid for the connected robot.
Monitor -- Generated at cold start.
Effect -- No RC ready.
-- Controller is in its initial state, i.e. tasks dependent on machine data
are not generated.
Remedy -- Either edit or copy the machine data or option data file.

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Error messages / troubleshooting

257 Message text ERRONEOUS USER DATA

Cause -- The user data loader has detected that a variable contains an incorrect
value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the user data.
-- After loading the user data (DEFDAT $CUSTOM PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
258 Message text ERRONEOUS OPTION DATA

Cause -- The option data loader has detected that a variable contains an incor-
rect value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the option data.
-- After loading the option data (DEFDAT $OPTION PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
259 Message text ** MACHINE DATA LOADER ABORTED

Cause -- The errors detected by the machine data loader exceed the capacity
of the message buffer.
Monitor -- At “POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
260 Message text USER DATA LOADER ABORTED

Cause -- The errors detected by the user data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the user data.
-- After loading the user data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.

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 1 Error messages / troubleshooting (continued)

261 Message text OPTION DATA LOADER ABORTED

Cause -- The errors detected by the option data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the option data.
-- After loading the option data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
262 Message text ERRONEOUS <path> MACHINE DATA

Cause -- The machine data loader has detected a variable with an illegal value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
263 Message text ERRONEOUS CORRECTION DATA

Cause -- The correction data loader has detected a variable with an illegal value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- POWER ON after editing the correction data, after loading the
correction data (DEFDAT $ROBCOR).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
264 Message text <path> CORRECTION DATA LOADER ABORTED

Cause -- The errors detected by the correction data loader exceed the capacity
of the message buffer.
Monitor -- At “POWER ON”.
-- After editing the correction data.
-- After loading the correction data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
265 Message text RDW FILE <program name> NOT AVAILABLE

Cause -- The RDW program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter the RDW program correctly in the INI file.

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Error messages / troubleshooting

266 Message text OVERTEMPERATURE FEEDBACK RESISTOR <power module no.>

OR FAN
Cause -- The ballast (feedback) resistor has overheated. In the motion program
the robot is cyclically accelerated and decelerated without a break.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.
267 Message text WATCHDOG POWER MODULE <power module number>

Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Dynamic braking.
Remedy -- Troubleshooting in the DSE and power module area.
268 Message text MEMORY TEST ERROR DSE <DSE number 1--4>

Cause -- The memory test on the DP--RAM of the DSE detected an error.
Monitor -- Runup.
Effect -- Active commands inhibited.
Remedy -- Replace DSE or MFC.
269 Message text DSE <DSE number 1--4> NOT AVAILABLE

Cause -- The bit on the MFC indicating whether a DSE is inserted is not set
although axes are allocated to this DSE.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Insert DSE, replace MFC or DSE.
270 Message text INCORRECT POWER MODULE SETTING <axis>

Cause -- Double assignment of $PMCHANNEL or incorrect channel.

Monitor -- When loading the robot machine data.
Effect -- Machine data loader aborted.
Remedy -- Correct $PMCHANNEL.
271 Message text ROBOT NO. ** DOES NOT CORRESPOND TO CALIBRATION FILE
**
Cause --
Monitor --
Effect --
Remedy --

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 1 Error messages / troubleshooting (continued)

272 Message text NO ROBOT NUMBER PROGRAMMED

Cause --
Monitor --
Effect --
Remedy --
273 Message text MORE THAN ONE CALIBRATION FILE AVAILABLE

Cause --
Monitor --
Effect --
Remedy --
274 Message text Check robot number

Cause --
Monitor --
Effect --
Remedy --
275 Message text SET ROBOT NUMBER – PROGRAM ROBOT NAME

Cause --
Monitor --
Effect --
Remedy --
276 Message text WRONG MACHINE DATA FOR THIS ROBOT TYPE

Cause -- The machine data do not correspond to the robot type stored in the
robot base.
Monitor -- Run--up.
Effect --
Remedy -- Load the correct machine data.
-- Reprogram the robot type.
277 Message text AUTOMATIC REPOSITIONING

Cause -- $MOT_STOP_OPT = TRUE. Robot not on path.

In EXTERN, $MOT_STOP (flag that the robot is not on path) has
been set by the user (via the GUI) to FALSE, so that the robot auto-
matically moves on path at process velocity.
Monitor --
Effect -- Only a message that the robot is moving on the path in EXTERN.
Remedy -- The message is deleted as soon as BCO is reached.

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Error messages / troubleshooting

286 Message text Warning: PC fan below nominal speed

Cause -- PC controller cooling is still sufficient, but could soon become critical
Monitor -- Cyclic.
Effect -- None
Remedy -- Check PC fan and exchange if necessary

287 Message text PC fan error

Cause -- PC controller cooling is no longer sufficient; continued operation

could cause damage to components
Monitor -- Cyclic.
Effect -- The robot is stopped and can no longer be traversed
Remedy -- Check PC fan immediately and exchange if necessary

288 Message text Over temperature feedback resistor %1

Cause -- The feedback resistor has got too hot

-- The robot is cyclically accelerated and braked in the motion program
without a pause
Monitor -- Cyclic.
Effect -- Ramp--down braking
Remedy -- Reduce acceleration, introduce wait times

289 Message text Overtemperature fan %1

Cause -- One of the two fans in the cabinet is defective

Monitor -- Cyclic.
Effect -- Ramp--down braking
Remedy -- Exchange the fan in question

300 Message text OPERATING MODE CHANGE

Cause -- The mode selector switch is set to an illegal position.

Monitor -- In command processing.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Set mode selector switch to a permissible position. The status
(operational) message is then reset.

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 1 Error messages / troubleshooting (continued)

301 Message text STOP WHILE MEASUREMENT ACTIVE -- MOVEMENT WILL BE

HANDLED AS TEST
Cause --
Monitor --
Effect --
Remedy --
302 Message text *<command name> ACTIVE

Cause -- OBJH command is being executed.

Monitor -- In command processing.
Effect -- None.
Remedy -- Wait until OBJH is free again.
303 Message text LIMIT <signal name>

Cause -- The value for the corresponding analog output lies outside the standard
range and has therefore been limited to the maximum or minimum
value.
Monitor -- Cyclic, when writing to analog outputs.
Effect -- None.
Remedy -- The message remains set until the value of the analog output
concerned lies within the standardized range and therefore no
limitation occurs.
304 Message text START UP

Cause -- Startup (setup) menu selected.

Monitor -- In command processing.
Effect -- Program processing not possible.
Remedy -- Quit the setup menu using the ESC key.
305 Message text COMPLETE COMPILATION ACTIVE

Cause --
Monitor --
Effect --
Remedy --
306 Message text SELECTION ACTIVE

Cause -- New selection requires deselection/linking.

Monitor -- Command processing (RUN command).
Effect -- None.
Remedy -- Wait until the linking procedure is finished, i.e. until the message
disappears.
307 Message text ERRORS AT COMPLETE COMPILATION -- ERR FILES EXIST

Cause --
Monitor --

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Error messages / troubleshooting

Effect --
Remedy --
308 Message text PALLETIZING MODE: MOVE AXIS <axis> <motion direction> INTO
POSITION
Cause -- Axes 4 and 5 have palletizing mode ( $PAL_MODE = TRUE ), but
not the right position, i.e. A4=0 degrees and A5=90 degrees.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Move axes into position in the specified direction.
309 Message text BLOCK SELECT : BCO REACHING IN T1/T2 REQUIRED

Cause --
Monitor --
Effect --
Remedy --
1000 Message text USER--MEMORY DELETED (**)

Cause --
Monitor --
Effect --
Remedy --
1001 Message text INTERNAL ERROR (DEFAULT MESSAGE)

Cause -- Internal; the message data have not been correctly set.
Monitor
Effect
Remedy
1002 Message text REBOOT AFTER POWERFAIL

Cause -- Controller is turned on again or voltage has returned.

Monitor --
Effect --
Remedy --
1003 Message text LEVEL OVERFLOW <IP,PCP>

Cause -- Computing time overload of CPU.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Increase basic cycle.
-- Increase interpolation cycle or position control cycle, depending on the
indicated parameter.

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 1 Error messages / troubleshooting (continued)

1004 Message text CAN CONTROLLER @P1@ FAILURE

Cause --
Monitor --
Effect --
Remedy --
1005 Message text NO MORE SYSTEM MEMORY AVAILABLE

Cause -- There is not enough memory available for the command “SHOW VAR”
or “SET INFO” to be executed (the control requires a certain amount
of memory for these commands, dependent on the length of the output
value.)
Monitor -- In form processing.
Effect -- Command is not executed.
Remedy -- Save and delete programs that are not required.
1006 Message text NO MORE USER MEMORY AVAILABLE

Cause -- No more memory is available for copying objects.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Delete objects that are not required.
1007 Message text CHANNEL <channel name> CANNOT BE ASSIGNED

Cause -- The selected channel cannot be assigned.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Free channel at another point (should occur only with printer channel).
1008 Message text CONTROLLER BOOTED

Cause -- Controller is booted for the first time (not reboot after power failure).
Monitor --
Effect --
Remedy --
1009 Message text POINT CONVERSION IMPOSSIBLE WITHOUT ABSOLUTE
ACCURACY MODEL
Cause -- $ABS_ACCUR = FALSE and $ABS_CONVERT = TRUE conversion
impossible without model. If $ABS_CONVERT is TRUE, then
$ABS_ACCUR must also be TRUE!
Monitor --
Effect --
Remedy -- $ABS_ACCUR = TRUE or $ABS_CONVERT = FALSE

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Error messages / troubleshooting

1010 Message text INTERNAL ERROR <system error number> (<task ID>, <status>)

Cause -- Internal test of KRC.

-- Software.
Monitor -- Within the KRC.
-- Software.
Effect -- RC Ready reset during processing.
Remedy -- Acknowledge message.
1011 Message text SYNTAX ERROR IN FILE <filename> IN ROW <contents of the line>

Cause -- Syntax error when interpreting the parameter file (absolutely accurate
robot).
Monitor -- When loading $OPTION.DAT or defining $LOAD or $LOAD_A3.

Effect --
Remedy -- Load file, boot controller.
1012 Message text GENERAL ERROR: <error no.> <function> <additional info>

Cause -- Unknown feedback from a function in the object.

Monitor -- In command processing.
Effect -- None.
Remedy -- Inform service department.
1013 Message text FILE <file name> NOT FOUND

Cause -- Parameter file for absolutely accurate robot is not available.

Monitor -- When loading $OPTION.DAT.
Effect --
Remedy -- Load file, boot controller.
1014 Message text UNKNOWN COMPILER ERROR: <error class>

Cause -- Compiler software has detected an error.

Monitor -- In command processing.
Effect -- None.
Remedy -- Inform service department.
1015 Message text OBJH ERROR: <localization>

Cause -- Internal error in the OBJH.

Monitor -- In command processing.
Effect -- None.
Remedy -- Inform service department.

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 1 Error messages / troubleshooting (continued)

1016 Message text HARDWARE LIMIT--SWITCH / +24V MISSING

Cause -- The interface module monitoring function has detected that a common
input for hardware limit switches has been set.
Monitor -- Cyclic in interface module monitoring.
Effect -- The roboter is stopped with maximum braking and the active
commands are inhibited until this message has been acknowledged.
Remedy -- Move robot off limit switch and acknowledge message.
!!!Caution!!! Moving the robot off the limit switch correctly is the
operator’s responsibility, since no axis--specific interlocks are set.
1017 Message text ABSOLUTE ACCURACY ROBOT: POINT CONVERSION ONLY POS-
SIBLE IN T1 MODE
Cause -- $ABS_CONVERT = TRUE and no T1 mode
Point conversion must be carried out carefully.
Monitor --
Effect -- Ramp--down braking.
Active commands inhibited.
Remedy -- Set variable $ABS_CONVERT in $CUSTOM.DAT to FALSE or select
T1 mode.
1018 Message text ERROR OCCURRED WHILE READING IDF FILE

Cause --
Monitor --
Effect --
Remedy --
1019 Message text PALLETIZING MODE NOT POSSIBLE WITH THIS ROBOT TYPE

Cause -- Palletizing is only possible with floor and ceiling--mounted robots. If

$ROBROOT A or B <> 0, palletizing is not possible.
Monitor -- Write function.
Effect -- Maximum braking.
Remedy -- Enter correct $ROBROOT or $PAL_MODE = FALSE.
1020 Message text INTERNAL ERROR <error number> (<task ID>, <return status>)

Cause -- Internal software error.

Monitor
Effect
Remedy
1021 Message text INTERNAL ERROR WHEN ACCESSING <object name>

Cause -- An internal error has occurred when accessing a file (acknowledge-

ment message already set). The action was not correctly carried out.
Monitor -- In object processing.
Effect
Remedy

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Error messages / troubleshooting

1022 Message text COMMUNICATION <operator control device> – KRC INTERRUPTED

Cause -- Communication between the active operator control unit and the KRC
has been interrupted while a motion was being executed in the test
mode.
Monitor -- In command processing.
Effect -- Maximum braking.
Remedy -- Re--establish the connection.
1023 Message text INPUT BUFFER OVERFLOW **

Cause --
Monitor --
Effect --
Remedy --
1024 Message text ERROR DURING READING OF INI FILE ** **

Cause -- Error in INI file.

Monitor -- At system start.
Effect -- All commands are inhibited.
Remedy -- Correct INI file.
1025 Message text CONFIGURATION ERROR I/O DRIVER <driver name>

Cause -- Error in the INI file.

Monitor -- In system runup.
Effect
Remedy -- Check io_int.ini.
1026 Message text ERROR DIGITAL INPUT READING PORT: **

Cause
Monitor
Effect
Remedy -- Check I/O components.
1027 Message text ERROR WRITE DIGITAL OUTPUTS PORT: **

Cause
Monitor
Effect -- Maximum braking.
Remedy -- Check the corresponding I/O hardware.
1028 Message text ERROR RESTART I/O <bus/driver name>

Cause -- Field bus error is still present.

Monitor
Effect -- Bus I/O still not available.
Remedy -- Eliminate field bus error (hardware).

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 1 Error messages / troubleshooting (continued)

1029 Message text SEN: <string> ** **

Cause -- Hint message of a sensor that does not require a stop.

Monitor
Effect
Remedy
1030 Message text SEN: <string> ** **

Cause -- Sensor error that requires ramp--down braking.

Monitor
Effect
Remedy -- Depends on sensor concerned.
1031 Message text SEN: <string> ** **

Cause -- Sensor error that requires ramp--down braking.

Monitor
Effect
Remedy
1032 Message text SEN: **

Cause -- Sensor error that requires ramp--down braking.

Monitor
Effect
Remedy
1033 Message text ERROR ON READING, DRIVER: ** **

Cause --
Monitor --
Effect --
Remedy --
1034 Message text ERROR ON WRITING, DRIVER: ** **

Cause --
Monitor --
Effect --
Remedy --
1035 Message text SINGULARITY--LESS MOTION: MAX. ORIENTATION ERROR

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

1036 Message text CHECK SAFETY LOGIC. DRIVES OFF TIMEOUT DURING EMER-
GENCY STOP
Cause --
Monitor --
Effect --
Remedy --
1037 Message text LOCAL EMERGENCY STOP BUTTON PRESSED

Cause --
Monitor --
Effect --
Remedy --
1038 Message text INVALID OPERATING MODE

Cause -- START MINUS was pressed in AUT or EXT. Only possible in T1 or

T2.
Monitor -- Command execution.
Effect --
Remedy --
1039 Message text BACKWARD MOTION EXECUTION NOT POSSIBLE: TRACE EMPTY

Cause -- All recorded motions have already been executed.

Monitor -- Command execution.
Effect --
Remedy -- Forward motion.
1040 Message text BACKWARD MOTION EXECUTION NOT POSSIBLE: NO TRACE

Cause -- No points were executed and recorded in the forwards direction, or

the traces were rejected.
Monitor -- Command execution.
Effect --
Remedy -- Forward motion.
1041 Message text SOFTPLC: **

Cause --
Monitor --
Effect --
Remedy --
1042 Message text ACKN K1 CONTACT FAIL TO OPEN <KPS number>

Cause -- The K1 contact is welded.

Monitor --
Effect -- The energy supply is not interrupted.
Remedy -- Exchange contactor, KPS.

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 1 Error messages / troubleshooting (continued)

1043 Message text ACKN BUS VOLTAGE CHARGING UNIT IS DEFECTIVE <KPS number>

Cause -- The optocoupler on the KPS is not registering current flow.

Monitor --
Effect -- Intermediate circuit cannot be loaded.
Remedy -- Exchange KPS.
1044 Message text ACKN BRAKE DEFECTIVE **

Cause -- Wear on brakes, defective brake.

Monitor --
Effect -- Axis moves in an uncontrolled manner.
Remedy -- Exchange motor.
1045 Message text SERVO INDEPENDENT COMMAND EXECUTION

Cause --
Monitor --
Effect --
Remedy --
1046 Message text BLOCKING OF OUTPUTS IN AUT/EXT IS ENABLED

Cause -- Variable $BLK_IO_AUT is set to TRUE (setting outputs in AUT/EXT

is blocked). The user nevertheless tries to set the outputs by hand.
Monitor --
Effect --
Remedy --
1047 Message text SERVO INDEPENDENT COMMAND EXECUTION ONLY POSSIBLE
IN TESTING MODE
Cause -- Robot simulation not allowed in operating modes #AUT or #EXT.
Monitor --
Effect -- No program execution/simulation possible.
Remedy -- Change operating mode.
1048 Message text ACKN. OUTPUT MONITORING DC BUS VOLTAGE KPS: **

Cause -- DC bus voltage of a KPS overloaded.

Monitor --
Effect --
Remedy --
1049 Message text PROFIBUS MASTER IS IN STATE AUTOCLEAR. PLEASE EXECUTE
RESET COMMAND
Cause -- Bus error in Profibus. Option AUTOCLEAR is set. This means that the
bus no longer starts again automatically. A Profibus reset is necessary.
Monitor --
Effect -- Indication that a bus reset is necessary since the bus does not start
again automatically (the corresponding option is not set).
Remedy -- Rectify bus error and carry out RESET via the menu.

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Error messages / troubleshooting

1050 Message text PROFIBUS : ERROR IN MASTER CIRCUIT ** **

Cause --
Monitor --
Effect --
Remedy --
1051 Message text PROFIBUS: ERROR IN SLAVE CIRCUIT

Cause --
Monitor --
Effect --
Remedy --
1052 Message text KCP: CAN BUS ERROR

Cause -- Transmission error in CAN BUS.

Monitor -- Teach pendant task.
Effect -- Path--maintaining braking.
Remedy -- Acknowledge.
1053 Message text CP VEL. REDUCTION POINT ** ** BY **

Cause --
Monitor --
Effect --
Remedy --
1054 Message text ACKN. DN CH ** TOO MANY MODULE ERRORS **

Cause --
Monitor --
Effect --
Remedy --
1055 Message text TRACE BUFFER EMPTY, START WITH BACKWARD SCAN

Cause -- Empty trace for backward motion, switching to SCAN method.

Monitor -- When START minus is pressed.
Effect -- Active commands inhibited.
Remedy -- Acknowledge.
1056 Message text ACKN. SERVOBUS DSE--NO.: <DSE no.> PARTICIPANT NO.: <IBS
device> UNKNOWN
Cause -- An unknown device which is not supported was inserted in Interbus.

Monitor -- DSE ID, device ID.

Effect --
Remedy -- Remove the device causing the fault from the bus system.

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 1 Error messages / troubleshooting (continued)

1057 Message text ACKN. FAILURE OF MOTOR PHASE <axis>

Cause -- Backup battery voltage low.

Monitor -- At “Power on”.
-- Cyclic.
Effect -- At “Power on” --> automatic general reset, and in addition the message
“User memory deleted” is displayed (machine data, user data, applica-
tion programs must be reloaded).
-- Cyclic --> none.
Remedy -- Exchange battery. After exchange, the message
“Ackn. check accumulator” appears --> acknowledge.
1058 Message text BCO MOTION: PRESS START PLUS

Cause -- An attempt was made to carry out BCO motion with START MINUS.
Monitor -- When START MINUS is pressed.
Effect -- The robot does not start.
Remedy -- Use START PLUS or set Implicit_BCO = TRUE in BACKWARD.INI.
1059 Message text FINISHED SUBROUTINE: SKIP MOTIONS

Cause -- During backward motion, the interpreter encounters a subprogram

which has already been completely executed.
Monitor -- Each time before backward motion is started.
Effect -- Active commands inhibited.
Remedy -- Acknowledge.
1060 Message text $BWDSTART NOT IN FOLD. NO TOOL AND BASE INFORMATION
FOUND
Cause -- Backward motion in SCAN method: a $BWDSTART assignment must
be programmed as the first instruction in a motion fold. From this line
onwards, all following instructions up to the motion are executed before
backward motion is carried out.
Monitor -- Each time before backward motion is started.
Effect -- Active commands inhibited.
Remedy -- Correct program or set the entry BACKWARDSTART = FALSE in
BACKWARD.INI. In this case, however, BASE and TOOL changes
cannot be carried out during backward motion.
1061 Message text Rapid EMERGENCY STOP with fixed braking ramps

Cause -- In the event of EMERGENCY STOP with dynamic model, the fixed
braking ramp strategy is used as this brakes the robot significantly
more quickly
Monitor -- In the event of EMERGENCY STOP with dynamic model
Effect -- EMERGENCY STOP brakes the robot more quickly than the strategy
based on the dynamic model
Remedy -- Verify load data and correct if necessary
-- Verify machine data

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Error messages / troubleshooting

1062 Message text Ackn. second motorcable not connected

Cause -- Second motor cable was not connected or was connected incorrectly
Monitor --
Effect --
Remedy -- Acknowledge message
1063 Message text Ackn. over temperature feedback resistor %1

Cause -- The feedback resistor has got too hot

-- The robot is cyclically accelerated and braked in the motion program
without a pause
Monitor -- Cyclic.
Effect --
Remedy -- Acknowledge message
1064 Message text Ackn.: over temperature fan %1

Cause -- One of the two fans in the cabinet is defective

Monitor -- Cyclic.
Effect -- Ramp--down braking
Remedy -- Acknowledge message
1065 Message text Ackn. mainboard overtemperature

Cause -- The cabinet fan has failed

-- The ambient temperature is too high
Monitor -- Cyclic.
Effect --
Remedy -- Acknowledge message
1066 Message text Mainboard temperature reached warning level

Cause -- PC controller cooling is still sufficient, but could soon become critical
Monitor -- Cyclic.
Effect -- None
Remedy -- Check fan
-- Exchange fan filter

1067 Message text Mainboard temperature check not available

Cause -- Motherboard does not support temperature monitoring

Monitor -- Once
Effect -- No monitoring
Remedy -- Exchange motherboard
-- Switch temperature monitoring off

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 1 Error messages / troubleshooting (continued)

1068 Message text INTERBUS: Watchdog Time expired!

Cause -- The Interbus driver read function was not called in the time defined
Monitor -- Cyclic.
Effect -- Inputs and outputs are not set
Remedy -- Terminate the Watchdog by reconfiguring the I/Os
-- De--energize controller board
-- Watchdog cycle time possibly set too low
-- Fault in the KRC system since the read function of the driver was not
called cyclically
1071 Message text MOTOR HOLDING TORQUE %1 EXCEEDED

Cause -- The motor holding torque of the axis is not sufficient to keep the robot
motion permanently stopped at a point.
Monitor -- Not cyclic, during path planning
Effect -- Interpreter stop
Remedy -- Correct or reduce load data
-- Verify machine data

1072 Message text BRAKE HOLDING TORQUE %1 EXCEEDED

Cause -- The brake holding torque on the axis is not sufficient to keep the robot
motion permanently stopped at a point.
Monitor -- Not cyclic, during path planning
Effect -- Interpreter stop
Remedy -- Correct or reduce load data
-- Verify machine data

1073 Message text COMMANDED GEAR TORQUE %1

Cause -- Permissible gear torque exceeded, dependent on dynamic data

$DYN_DAT()
Monitor -- Cyclic.
Effect -- Path--maintaining braking
-- Output ”$ALARM_STOP” 0 signal
-- Active commands inhibited.
Remedy -- Verify load data and reduce if necessary, reduce programmed accel-
eration, reduce programmed velocity; acknowledge message

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Error messages / troubleshooting

1074 Message text COMMANDED MOTOR TORQUE %1

Cause -- Permissible motor torque exceeded, dependent on dynamic data

$DYN_DAT()
Monitor -- Cyclic.
Effect -- Path--maintaining braking
-- Output ”$ALARM_STOP” 0 signal
-- Active commands inhibited.
Remedy -- Verify load data and reduce if necessary, reduce programmed accel-
eration, reduce programmed velocity; acknowledge message
1075 Message text MAXIMUM KINETIC ENERGY %1

Cause -- Permissible kinetic energy for crash exceeded, dependent on dynamic

data $DYN_DAT()
Monitor -- Cyclic.
Effect -- Path--maintaining braking
-- Output ”$ALARM_STOP” 0 signal
-- Active commands inhibited.
Remedy -- Verify load data and reduce if necessary, reduce programmed velocity;
acknowledge message
1078 Message text Ackn. servobus DSE--No. %1 participant No. %2 not available

Cause -- The device number in the servo bus was too low
Monitor --
Effect --
Remedy -- Acknowledge message
1079 Message text Ackn. servobus DSE--No. %1 participant No. %2 not available

Cause -- The device number in the servo bus was higher than the number
defined in the machine data
Monitor --
Effect --
Remedy -- Acknowledge message
1100 Message text STOPPED <axis number>

Cause -- Axis has beeen moved out of the standstill position according to the
machine data. Positioning window ($IN_POS_MA) times standstill
window minus factor ($IN_STILL_MA).
Monitor -- With robot “in position”.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check manipulator.
-- Check output stage, check motor brake.
-- Acknowledge message.

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 1 Error messages / troubleshooting (continued)

1101 Message text COMMAND ACCELERATION EXCEEDED <axis number>

Cause -- Permissible command acceleration exceeded; e.g. because robot

has been moved through singularity in cartesian mode.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check program for alpha5 transitions (singularity).
-- Reduce path velocity.
-- Reduce path acceleration.
-- Acknowledge message.
1102 Message text COMMAND VELOCITY EXCEEDED <axis number>

Cause -- Permissible command velocity exceeded; e.g. because robot has

been moved through singularity in cartesian mode.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Reduce path velocity.
-- Reduce path acceleration.
1103 Message text DATA EXCHANGE WITH TEPRO MISSING

Cause -- The SBC is not transmitting cyclic data on time (TEPRO =

Technological Process).
Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Re--initialize the SBC program or eliminate the error in the SBC program.
1104 Message text ACKN. REGULATOR LIMIT EXCEEDED <axis number>

Cause -- The set value of the machine datum $COM_VAL_MI has been exceed-
ed. The position controller output has gone into limitation. The axis
does not follow the command value.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check power module.
-- The brake control must be checked (LED on PM) if the error occurs on
more than one axis.
1105 Message text POSITIONING MONITOR <axis number>

Cause -- Positioning window $IN_POS_MA has not been reached within the
set positioning time $TIME_POS.
Monitor -- When positioning.

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Error messages / troubleshooting

Effect -- Maximum braking.

-- All active commands inhibited.
-- The axis has the status “in position” after the message has been
acknowledged.
Remedy -- Enlarge positioning window.
-- Lengthen positioning time.
-- Check power module.
-- Acknowledge message.
-- Check manipulator.
1106 Message text TOOL WEIGHT NOT YET LEARNT

Cause -- During EMT mastering a check run was carried out for a tool whose
weight has not yet been learnt.
Monitor -- During EMT mastering.
Effect --
Remedy -- “Learn” tool weight.
1107 Message text WORKING ENVELOPE SURVEILLANCE CAN ONLY BE OVERRIDDEN
IN T1 MODE
Cause -- An attempt was made to define the variable $WBOXDISABLE in
mode T2, AUT, EXT.
Monitor -- Cyclic.
Effect --
Remedy -- Change operating mode.
1108 Message text DYNAMIC BRAKING ERROR <axis number>

Cause -- Actual value does not decrease although braking ramp is predefined
in terms of command values.
Monitor -- Cyclic.
Effect -- Short--circuit braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
1109 Message text COMMUNICATION WITH TEPRO FAULTY

Cause -- The SBC is not collecting cyclic data on time.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Re--initialize the SBC program.
1110 Message text SENSOR LOCATION SEARCH FOR <axis>

Cause -- During the sensor location search, the sensor switching point was
detected.
Monitor -- Command execution.
Effect -- None.
Remedy -- None.
1111 Message text DRIFT COMPLETED

Cause -- Drift is completed.

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 1 Error messages / troubleshooting (continued)

Monitor --
Effect -- None.
Remedy -- None.
1112 Message text PERFORM SENSOR LOCATION SEARCH <axis number> !

Cause -- Sensor location search was not carried out or $ROBCOR.DAT not
available.
Monitor -- During command execution.
Effect -- None.
Remedy -- Notify customer support.
1113 Message text SENSOR LOCATION SEARCH INVALID <axis number>

Cause -- Command “Sensor location search”:

a) axis was not mastered
b) last mastering type was sensor adjustment
Monitor -- When command “ADJUST SENSOR”.
Effect -- Command is not executed.
Remedy -- Master axis with EMT or dial gauge.
-- Leave menu via Recall.
-- Acknowledge message.
1114 Message text INVALID MASTERING SEQUENCE

Cause -- Mastering sequence defined in machine datum $SEQ_CAL has not

been observed.
Monitor -- In mastering.
Effect
Remedy -- Master axis with EMT probe or depth gauge.
-- Press ESC to quit menu.
-- Acknowledge message.
1115 Message text SERVO PARAMETERS NOT TRANSFERRED!

Cause -- Servo parameters were not sent to DSE.

Monitor -- When defining the structure $SERVOPARA.
Effect --
Remedy -- Define $SERVOPARA correctly.
1116 Message text SENSOR ADJUSTMENT INVALID <axis number>

Cause -- When selecting sensor adjustment for an axis with incremental or

absolute encoder.
Monitor -- During sensor adjustment.
Effect -- Command is not executed.
Remedy -- Set axis with DIAL or TURN.
1117 Message text ACYCLIC DATA NOT RELEASED BY TEPRO

Cause -- Semaphore is inhibiting access to acyclic data.

Monitor -- In acyclic data transfer.
Effect -- Ramp--down braking; interruption of the SBC interface.

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Error messages / troubleshooting

Remedy -- Eliminate the error in the SBC program.

1118 Message text CYCLIC DATA NOT RELEASED BY TEPRO

Cause -- Semaphore is inhibiting access to acyclic data.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1119 Message text WRONG DATA TYPE FROM TEPRO

Cause -- SBC is cyclically sending incorrect data.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1120 Message text INCOMPLETE INSTRUCTION

Cause -- The interface with the SBC is not initialized.

Monitor -- In KRL interface instruction.
Effect -- None.
Remedy -- Initialize the interface.
1121 Message text DATA EXCHANGE

Cause -- The SBC stops data exchange because of an error.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1122 Message text ANALOG OUTPUT : DELAY REDUCTION

Cause -- The memory provided internally for the output function with a delay
is not adequate for the programmed delay.
Monitor
Effect -- The programmmed delay is automatically reduced.
Remedy -- Program a shorter delay.
1123 Message text APPROXIMATION NOT POSSIBLE

Cause -- Approximation (approximate positioning) is not possible for computing

time reasons.
Monitor -- When the approximate positioning criterion is reached in the interpolator.
Effect -- None.
Remedy -- Program $ADVANCE > 0.
-- Switch off axis simulation.
1124 Message text WRONG START POSITION

Cause -- 1. EMT mastering starts in the groove rather than before it.
-- 2. Cable for EMT mastering connected during sensor location run or
sensor mastering.
Monitor -- In command processing.

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 1 Error messages / troubleshooting (continued)

Effect -- Command aborted.

Remedy -- 1. Move axis to correct starting position.
-- 2. Disconnect cable for EMT mastering.
1125 Message text EMT SENSOR FAULTY

Cause -- Sensor supplies a zero signal because it is not properly tightened.

Monitor -- In command processing.
Effect -- Command aborted.
Remedy -- Check screwed connection of sensor.
-- Check robot--EMT connection.
-- Check A3/DSE module.
1126 Message text STOP COMMAND IGNORED

Cause -- Axis does not stop within a certain time after a stop command.
Monitor -- After command processing.
Effect -- Command aborted.
Remedy --
1127 Message text MASTERING PERFORMED <axis number>

Cause -- Attempt to remaster an axis that has already been mastered.

Monitor -- After command processing.
Effect -- Ramp--down braking.
Remedy -- Press ESC to cancel.
-- Repeat measurement.
1128 Message text STOP, APPROXIMATION NOT POSSIBLE

Cause -- Approximation not possible for reasons of planning or time. Robot

stops because $STOP_NOUES = TRUE is set and operating mode
= T1 or T2.
Monitor --
Effect -- Ramp--down braking.
Remedy -- Reduce the velocity and/or acceleration in the instruction until approxi-
mation is possible.
1129 Message text TOO MANY ASYPTP COMMANDS

Cause --
Monitor -- During program execution of ASYPTP commands.
Effect -- Program execution is stopped.
Remedy -- Fewer ASYPTP commands.
1130 Message text ACKN. MOTOR TEMPERATURE <axis number>

Cause -- A motor temperature fault is signalled by the DSE board if the tem-
perature exceeds 155 degrees.
Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.

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Error messages / troubleshooting

1131 Message text ACKN. TORQUE EXCEEDED <axis>

Cause -- The motor torque is not located in the specified monitoring tunnel.
Monitor -- Cyclic in interpolation cycle.
Effect -- Motion is stopped.
Remedy -- Verify load data, increase size of tunnel.
1132 Message text REFPO DETERMINES AXIS <axis>

Cause -- Output after reference point for axes 1--6 has been calculated.
Monitor -- In program mode.
Effect -- None.
Remedy -- None.
1133 Message text GEAR TORQUE EXCEEDED AXIS <axis>

Cause -- The calculated gear torque is larger than the maximum permissible
gear torque.
Monitor -- Cyclic in interpolation cycle.
Effect -- Motion and program are stopped.
Remedy -- Reteach points.
1134 Message text ACKNOWLEDGE ERROR 6SC620 <axis number>

Cause -- Malfunction/error in drive module or on processor module in Simodrive

6SC620 acknowledgement.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Acknowledge message.
1135 Message text TORQUE MODE VELOCITY LIMIT EXCEEDED <axis>

Cause -- Velocity limit exceeded in torque mode.

Monitor -- In torque mode.
Effect -- Short--circuit braking.
Remedy --
1136 Message text ACKN. HEATSINK TEMPERATURE <axis number: AX>

Cause -- A heat sink temperature fault is signalled by the DSE board if the
temperature exceeds 80 degrees.
Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
-- Clean heat sink.
1137 Message text EMT MASTERING DISTANCE EXCEEDED

Cause -- Groove not located, axis position not before groove prior to start.
Monitor
Effect -- Axis stops.
Remedy -- Move axis into mastering position; check EMT and groove.

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 1 Error messages / troubleshooting (continued)

1138 Message text DYNAMIC BRAKING

Cause -- If during an activated Emergency Stop a fault occurs that permits only
maximum (dynamic) braking, this message is additionally displayed.
Monitor -- With the following messages: 100, 101, 102, 103, 104, 105, 110,
111, 114, 200, 202, 206, 1100, 1108.
Effect -- Maximum braking.
Remedy -- Acknowledge message.
1139 Message text SYNACT NOT POSSIBLE <block number>

Cause -- The programming of synchronous actions with the variable $M_TIME

or $M_TIME_APO causes the message to be output when the
program is resumed after ramp--down braking, a path--maintaining
Emergency Stop ramp or maximum braking.
1140 Message text BLOCK CHANGE AT STOP

Cause -- Maximum braking or a path--maintaining stop and a simultaneous

block change which makes calculation of $POS_RET and the system
time impossible, with the result that the system time and $POS_RET
are determined by the beginning of a new block.
Monitor -- (e.g. cyclic; in command processing; in mastering).
Effect -- (e.g. ramp--down braking; program processing stopped; etc.).
Remedy -- (e.g. eliminate fault, correct operator action).
1141 Message text TTS NOT EXISTING

Cause -- The X--axis of the tool coordinate system and the path tangent are
parallel. (TTS = tool--based technological system).
Monitor -- Cyclic in the interpolation cycle when calculating the path correction.
Effect -- Maximum braking.
Remedy -- Reprogram the movement. Correct the point.
1142 Message text DEVIATION AT TARGET POINT

Cause -- An exact stop point has been approached with a deviation.

Monitor -- Function generator becomes active during positioning.
Effect -- Ramp--down braking.
Remedy -- SCALE_IN must be corrected.
1143 Message text REFERENCE OFFSET NOT VALID

Cause -- Mastering is not possible by transferring the reference offset as this

is not valid in $ROBCOR.DAT.
Monitor
Effect
Remedy

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Error messages / troubleshooting

1144 Message text V--GROOVE HAS WRONG PROFILE

Cause -- The mastering groove for EGP adjustment does not have a V or U
profile.
Monitor -- In EMT mastering.
Effect -- Ramp--down braking; mastering procedure is aborted.
Remedy -- Replace EMT groove.
-- Clean EMT.
1145 Message text STOP DUE TO VALUE OUT OF RANGE OVERFLOW, <motion direc-
tion> <axis number>
Cause -- Overflow of the actual value of an endless axis.
Monitor -- Cyclic in the interpolation cycle.
Effect -- The motion is stopped by a path--maintaining Emergency Stop.
Remedy -- Remaster the axis concerned.
1146 Message text ACKN. MOTOR BLOCKED <axis number>

Cause -- I*t monitoring is signalled by a DSE.

Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
1147 Message text PERFORM INITIAL MASTERING <axis number>

Cause -- An attempt was made to carry out a sensor location search for an axis
on which initial mastering has not yet been performed.
Monitor -- When selecting the function “dat_ueb” for the corresponding axis.
Effect -- The sensor location search is not carried out.
Remedy -- Perform initial mastering (e.g. dial gauge or EMT mastering) for the
corresponding axis.
1148 Message text INVALID AXIS COUPLING RATIO <axis number>

Cause -- An attempt was made to carry out “Extended sensor adjustment” for
an axis when the coupling axes are not in the same position as was
reported in the data transfer.
Monitor -- When selecting the function “Extended sensor adjustment” for the
corresponding axis.
Effect -- The function “Extended sensor adjustment” is not carried out.
Remedy -- Move coupling axes to the same position as in the data transfer.
1149 Message text ADJUSTMENT PROCEDURE NOT POSSIBLE <axis number>

Cause -- An attempt is made to carry out sensor adjustment or the axis is not
equipped with a KTL encoder and DSE.
Monitor -- When selecting the function “Extended sensor adjustment” for the
corresponding axis.
Effect -- The sensor adjustment is not carried out.
Remedy -- Cancel via Recall or master axis with EMT / dial gauge.
1150 Message text DATA TRANSFER INVALID <axis number>

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 1 Error messages / troubleshooting (continued)

Cause -- An attempt is made to carry out a sensor location search for an axis
which is not equipped with a KTL encoder and DSE.
Monitor -- When selecting the sensor location search function for the correspond-
ing axis.
Effect -- The sensor location search for the axis is not carried out.
Remedy -- Cancel via Recall.
1151 Message text PERFORM DATA TRANSFER <axis number>

Cause -- An attempt was made to carry out sensor adjustment for an axis on
which no sensor location search has been performed.
Monitor -- When selecting the function “Extended sensor adjustment” for the
corresponding axis.
Effect -- The function “Sensor location search” is not carried out.
Remedy -- Carry out sensor location search for the corresponding axis.
1152 Message text DATA TRANSFER PERFORMED <axis number>

Cause -- The sensor location search has been properly carried out.
Monitor -- When the function “Sensor location search” for the corresponding
axis is selected and the Enter key is pressed.
Effect -- None.
Remedy --
1153 Message text DEVIATION IN THE START POINT

Cause -- A PTP motion is to be executed with a sensor offset value.

Monitor -- Interpolator.
Effect -- Ramp--down braking.
Remedy -- Sensor offset must be eliminated before a PTP block is executed.
1154 Message text SBC ERROR: <Watchd.,Transf.,Corr>

Cause -- Error in communication between SBC and KRC32.

Monitor -- Cyclic in the TEP task.
Effect -- Maximum braking.
Remedy -- Check SBC (SW, HW).
1155 Message text APPROXIMATION NOT POSSIBLE, TORQUE TOO HIGH

Cause -- For an approximate positioning block to be executed, the velocity must

already be reduced in the preceding block. However, this block is not
long enough to allow that.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter.
Remedy -- Increase the length of the individual block by:
decreasing the approximate positioning radius at the end point of the
current motion block or, if the start point is approximated, by decreas-
ing this approximate positioning radius.
Decreasing the velocity and acceleration of the individual block.

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Error messages / troubleshooting

1156 Message text APPROX. NOT POSSIBLE INTERNAL ERROR IN PTP MOTION
PLAN
Cause -- Error in planning of the approximate positioning block.
Monitor -- Not cyclic, in motion planning.
Effect -- Approximate positioning is not executed; exact stop.
Remedy -- Modify profile data (rounding factor, velocity, acceleration). Please
consult KUKA.
1157 Message text OVERLOAD OF GEAR TORQUE <axis number> BY <percentage
value>
Cause -- The max. gear torque of the axis is statically exceeded by ....%.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Check load data (mass, center of gravity, moments of inertia).
1158 Message text STATIC MOTOR TORQUE OVERLOAD <axis number> BY <percentage
value>
Cause -- The max. motor torque of the axis is statically exceeded by ....%.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Check load data (mass, center of gravity, moments of inertia).
1159 Message text INTERNAL ERROR IN PTP MOTION PLANNING <number>

Cause -- Error in planning of the PTP motion profile.

Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Modify profile data (rounding factor, velocity, acceleration). Please
consult KUKA.
1160 Message text TRACE: RECORDING TIME IS TOO LONG

Cause -- The recording time in TRACE.DEF is too long. There is not enough
memory available for recording.
Monitor -- When starting the TRACE.
Effect -- TRACE is not recorded.
Remedy -- Shorten TRACE recording time or reduce the number of channels.
1161 Message text ACKN MONITORING OF THE ACTUAL VELOCITY **

Cause -- Fault in control loop:

-- motor cables of two axes interchanged;
-- error in the axis assignment;
-- power module defective;
-- resolver unmastered.
Monitor -- Cyclic.
Effect -- Robot remains motionless.
Remedy -- Rectify the corresponding error in the control loop.

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 1 Error messages / troubleshooting (continued)

1162 Message text SEPARATE BREAK CONTROL OF AUXILIARY AXIS NOT ENABLED

Cause --
Monitor --
Effect --
Remedy --
1163 Message text AXIS COUPLING NOT POSSIBLE (DSE/PM--CHANNEL ASSIGNMENT)

Cause --
Monitor --
Effect --
Remedy --
1164 Message text COUPLE PROCESS ACTIVE

Cause --
Monitor --
Effect --
Remedy --
1165 Message text ERROR ON AXIS COUPLING

Cause --
Monitor --
Effect --
Remedy --
1166 Message text ERROR ON AXIS DECOUPLING

Cause --
Monitor --
Effect --
Remedy --
1167 Message text <axis> DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
1168 Message text <axis> DECOUPLED AUXILIARY AXIS, MOVE NOT PERMITTED

Cause --
Monitor --
Effect --
Remedy --
1169 Message text <axis> DECOUPLED AUXILIARY AXIS, MASTERING NOT PERMITTED

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Error messages / troubleshooting

Cause --
Monitor --
Effect --
Remedy --
1170 Message text ASYPTP COMMAND INCLUDES DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
1171 Message text VALUE OF $ASYNC_AXIS CONTAINS DECOUPLED AUXILIARY AXIS

Cause --
Monitor --
Effect --
Remedy --
1172 Message text VALUE CANNOT BE CHANGED, PROGRAM IS SELECTED

Cause --
Monitor --
Effect --
Remedy --
1173 Message text Ackn. deviation warning master--slave %1

Cause -- Positional deviation between master and slave exceeds lower limit
value
Monitor -- Cyclic.
Effect -- None
Remedy -- Acknowledge message
1174 Message text Ackn. deviation alarm master--slave %1

Cause -- Positional deviation between master and slave exceeds middle limit value
Monitor -- Cyclic.
Effect -- Maximum braking
Remedy -- Acknowledge message; the drives synchronize themselves automati-
cally
1175 Message text Ackn. deviation critical master--slave %1

Cause -- Positional deviation between master and slave exceeds upper limit value
Monitor -- Cyclic.
Effect -- Maximum braking
-- Loss of mastering of the corresponding axis
Remedy -- Dial mastering of the axis

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 1 Error messages / troubleshooting (continued)

1176 Message text Ackn. speed deviation master--slave %1

Cause -- Speed deviation between master and slave exceeds limit value
Monitor -- Cyclic.
Effect -- Maximum braking
Remedy -- Acknowledge message
1200 Message text ACKN. EMERGENCY STOP

Cause -- Emergency Stop was active.

Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
1201 Message text BUFFER BATTERY VOLTAGE LOW **

Cause -- The battery voltage is too low for backup purposes. Do not switch
off until battery has recharged.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Acknowledge message.
1202 Message text ACKN. RDW <axis number> BOOT UP FAILURE

Cause -- Secondary message following the status (operational) message

“RDW BOOT UP FAILURE”.
Monitor
Effect
Remedy -- Acknowledge message.
1203 Message text ACKN. DSE <DSE number> BOOT UP FAILURE

Cause -- Secondary message following the status (operational) message

“DSE BOOT UP FAILURE”.
Monitor -- Runup.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace encoder.
-- Acknowledge message.
1204 Message text ACKN. ENCODER CABLE FAILURE <axis number>

Cause -- Secondary message following the status (operational) message

“ENCODER CABLE FAILURE”.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Acknowledge message.

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Error messages / troubleshooting

1205 Message text ACKN. WATCHDOG INTERPOLATION CYCLE <DSE number>

Cause -- Secondary message following the status (operational) message

“WATCHDOG INTERPOLATION CYCLE”.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Acknowledge message.
1206 Message text ACKN. SYNCHRONIZATION ERROR WITH DSE <axis number>

Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect
Remedy -- Acknowledge message.
1207 Message text ACKN. TRANSMISSION ERROR DSE -- RDW <DSE number>

Cause -- Open--circuit between RDW and DSE.

-- Transmission malfunction
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
-- Acknowledge message.
1208 Message text ACKN. MASTERING PERFORMED <axis number>

Cause -- Follow--up message for status message “PERFORM MASTERING”

Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Perform mastering
-- Acknowledge message.
1209 Message text ACKN. GENERAL SERVO ENABLE

Cause -- There was a low signal at $SERVO_RDY input.

Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
1210 Message text ACKN. GENERAL MOTION ENABLE

Cause -- There was a low signal at $MOVE_ENABLE input.

Monitor -- Cyclic.
Effect -- All active commands inhibited.

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 1 Error messages / troubleshooting (continued)

Remedy -- Acknowledge message.

1211 Message text STOP DUE TO SOFTWARE LIMIT SWITCH <motion direction> <axis
number>
Cause -- Overrun of a sofware limit switch (command value) has been detected.
Monitor -- Cyclic, not with axis--specific manual traversing.
Effect -- Maximum braking.
Remedy -- If necessary acknowledge message, move robot in the opposite
direction.
1212 Message text ACKN. OPERATOR SAFETY

Cause -- Operator safety has been tripped in the AUTOMATIC or EXTERNAL

mode.
Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message. (The robot can then be started in the AUTO-
MATIC or EXTERNAL mode again.)
1213 Message text ACKN. PASSIVE STOP <RCP or teach pendant>

Cause -- The originator of the passive stop has acknowledged the message.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message. (Acknowledgement possible only on active
unit.)
1214 Message text POWER FAILURE

Cause -- The cabinet voltage has been switched off, the mains voltage is
interrupted.
Monitor --
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.
1215 Message text <command name> <action>

Cause -- OBJH command finished.

Monitor -- Command processing.
Effect -- None.
Remedy -- None.
1216 Message text ACKN. DRIVES ERROR <axis number> NO.: **

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

1217 Message text ACKN. SBX--HPU CONNECTED INPUT

Cause -- Safety box has detected a fault in signal input “teach pendant
plugged in”.
Monitor -- Cyclic.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Acknowledge message.
1218 Message text ACKN. SBX--HPU DEPOSITED INPUT

Cause -- Safety box has detected a fault in the input unit of the permanently
installed input.
Monitor -- Cyclic.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Acknowledge message.
1219 Message text ACKN. SBX--HPU CONNECTED

Cause -- The software has detected that in the dual--channel evaluation of the
signal “Teach pendant plugged in” the two channels (MPC interface
and safety box) have different statuses.

Monitor -- Cyclic.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Acknowledge message.
1220 Message text ACKN. EMERGENCY STOP DUE TO DIAL MASTERING

Cause -- Softkeys for dial mastering pressed.

Monitor -- When $TURN instruction is executed.
Effect -- Dynamic braking.
-- All active commands inhibited.
-- Low signal at “$ALARM_STOP 0” output; ramp--down braking.
Remedy -- Press the Recall key twice.
1221 Message text ACKN. POWER MODULE AXIS <axis number> NOT /OR INCOR-
RECTLY CONNECTED
Cause -- The axis is incorrectly plugged into the power module or not connected
at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect axis correctly.
-- Acknowledge message.
1222 Message text ACKN. BRAKE ERROR <axis number>

Cause --
Monitor --
Effect --
Remedy --
1223 Message text ACKN. UNDERVOLTAGE <power module>

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 1 Error messages / troubleshooting (continued)

Cause --
Monitor --
Effect --
Remedy --
1224 Message text ACKN. OVERVOLTAGE <power module>

Cause --
Monitor --
Effect --
Remedy --
1225 Message text ACKN. OVERCURRENT <axis number>

Cause --
Monitor --
Effect --
Remedy --
1226 Message text ACKN. E<2 or 7 keyswitch> SWITCH CLOSED

Cause --
Monitor --
Effect --
Remedy --
1227 Message text ACKN. E<2 or 7 keyswitch> SWITCH OPEN

Cause --
Monitor --
Effect --
Remedy --
1228 Message text ACKN. FEEDBACK SWITCH ON TOO LONG **

Cause -- The energy of the axis to be braked was too high.

Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
1229 Message text ACKN. WATCHDOG POWER MODULE <number>

Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Troubleshooting in the DSE and power module area.
1230 Message text ACKN. OVERTEMPERATURE, BALLAST RESISTOR <number> OR
FAN
Cause -- The ballast (feedback) resistor has overheated. In the motion program
the robot is cyclically accelerated and decelerated without a break.

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Error messages / troubleshooting

Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.
1231 Message text ACKN. CABINET OVER TEMPERATURE **

Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.
1232 Message text ACKN. MOTOR CABLE **

Cause --
Monitor --
Effect --
Remedy --
1233 Message text ACKN. FAILURE OF HEAT SINK TEMPERATURE SENSOR <axis
number>
Cause --
Monitor --
Effect --
Remedy --
1234 Message text ACKN. CABINET INTERIOR TEMPERATURE SENSOR FAILURE
<axis number>
Cause --
Monitor --
Effect --
Remedy --
1235 Message text ACKN. DRIVES PARAMETER DATA <axis number> INVALID

Cause --
Monitor --
Effect --
Remedy --
1236 Message text ACKN. FAILURE OF MOTOR TEMPERATURE SENSOR <axis number>

Cause --
Monitor --
Effect --
Remedy --

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 1 Error messages / troubleshooting (continued)

1237 Message text ACKN. WRONG DRIVES PARAMETER <axis number> **

Cause --
Monitor --
Effect --
Remedy --
1238 Message text ACKN. ERROR SYNC. INPUT DRIVE <axis>

Cause --
Monitor --
Effect --
Remedy --
1239 Message text ACKN. SYNCHRONISATION ERROR DRIVE <axis>

Cause --
Monitor --
Effect --
Remedy --
1240 Message text ACKN. <axis> WITHOUT POWER

Cause --
Monitor --
Effect --
Remedy --
1241 Message text ACKN. i2 t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string> AFTER <string>s EXCEEDED 100%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
1242 Message text ACKN. i2 t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
** AFTER ** EXCEEDED 95%
Cause --
Monitor --
Effect --
Remedy --
1243 Message text LINE ** IN ** TOO LONG. LINE WAS CUT OFF.

Cause -- An excessively long program line was cut off in order to avoid deletion
of the rest of the program.
Monitor -- Triggered during line compilation.
Effect -- The line is cut off. The program is retained.
Remedy -- Modify the incorrect line in expert mode.

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Error messages / troubleshooting

1244 Message text SUCCESS LOADING ** SERVO PARAMETERS **

Cause -- Completed loading of servo parameters.

Monitor --
Effect --
Remedy --
1245 Message text ACKN SERVO BUS DISTURBANCE DSE **

Cause --
Monitor --
Effect --
Remedy --
1246 Message text ACKN SERVO BUS DISTURBANCE DSE **, NO BUFFERING AND
AUTOMATIC DATA STORAGE POSSIBLE
Cause --
Monitor --
Effect --
Remedy --
1247 Message text ACKN SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
1248 Message text ACKN SERVO BUS DISTURBANCE **

Cause --
Monitor --
Effect --
Remedy --
1254 Message text Ackn. PC fan error

Cause -- PC fan speed was below the alarm threshold and is now back in the
nominal range
Monitor -- Cyclic.
Effect -- None
Remedy -- Acknowledge message
1255 Message text Ackn. Ixt servo drive %1 exceed value of %2 %%

Cause -- If the defined Ixt monitoring warning value of a drive servo is exceeded,
the robot must be brought to a standstill; otherwise, the drive servo is
deactivated when the maximum value of 100% is exceeded
Monitor --
Effect --
Remedy -- Acknowledge message

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 1 Error messages / troubleshooting (continued)

1300 Message text PARITY ERROR

Cause -- Parity incorrectly set.

Monitor -- On transmission.
Effect -- None.
Remedy -- Check parity setting on controller and operator control unit (PC).
1301 Message text PROCEDURE ERROR

Cause -- Transmission error in LSV2 procedure which was not detected by

the parity monitor.
Monitor -- On transmission.
Effect -- None.
Remedy -- Repeat transmission.
-- Increase procedure repetition counter.
-- Check cable.
1302 Message text CHANNEL NOT AVAILABLE

Cause -- Procedure monitoring time elapsed.

Monitor -- On transmission.
Effect -- None.
Remedy -- Increase procedure monitoring time.
1303 Message text SCC OVERFLOW

Cause -- Baud rate set too high (SCC = Serial Communication Controller).
Monitor -- On transmission.
Effect -- None.
Remedy -- Reduce baud rate.
1304 Message text REFERENCING AXIS <axis number> INADMISSIBLE

Cause -- Attempt to reference a non--incremental axis.

Monitor -- During single--axis referencing.
Effect -- The specified axis is not referenced.
Remedy -- Master the axis.
1305 Message text RCP SWITCH POSITION INADMISSIBLE

Cause -- Too many transfer processes started (a maximum of 4 transfer pro-

cesses can be started.)
Monitor -- During transfer.
Effect -- None.
Remedy -- Wait until one process has been completed.
-- Stop one process.

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Error messages / troubleshooting

1306 Message text DEVICE NOT READY

Cause -- Cable defective or not connected.

-- Device switched off (e.g. printer).
Monitor -- During transfer.
Effect -- None.
Remedy -- Check cable and device.
1307 Message text FORMAT ERROR

Cause -- Hardware error of the interface on I--CPU.

Monitor -- During transfer.
Effect -- None.
Remedy -- If the error occurs repeatedly, change the board (interface CPU).
1308 Message text CHANNEL NOT ALLOWED IN COMMAND

Cause -- Command does not support any channels.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1309 Message text OBJECT IS NOT AVAILABLE

Cause -- Objects that are not available in the KRC cannot be addressed.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Wrong object selected.
1310 Message text TOO MANY OBJECTS ARE SELECTED

Cause -- Too many objects selected.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select only the permitted number of objects (approx. 150).
1311 Message text <object name> NOT CORRECTLY COPIED

Cause -- Errors have been detected in the line analysis.

Monitor -- In command processing.
Effect -- Error token in the object.
Remedy -- Correct object.

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 1 Error messages / troubleshooting (continued)

1312 Message text <object name> ASSIGNED

Cause -- Object cannot be processed in this state (object already assigned).

-- Module package cannot be linked since at least one of the objects
of the module package is assigned.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1313 Message text INVALID STATEMENT

Cause -- The source and target specifications do not conform to the convention
for “COPY”.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Specify the source and target correctly.
1314 Message text DATA NOT ALLOWED

Cause -- Extension not compatible.

-- copy *.* (copy *.* is possible into a directory only).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Specify extension correctly.
1315 Message text <module name> IS NOT A MODULE

Cause -- The name represents a directory.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Take a different module.
1316 Message text RUNTIME VALUES FOR TRIGGER IN SUBROUTINES INADMISSIBLE

Cause -- In a subroutine a trigger is defined which is possibly not activated until

the main program. If runtime values are used in trigger assignment,
they are not valid at the time of activation.
Monitor -- During program execution.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Alter program, use only global variables, acknowledge message.
1317 Message text DELETING OF SYSTEM FILES IS INADMISSIBLE

Cause --
Monitor --
Effect --
Remedy --

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Error messages / troubleshooting

1318 Message text FILE DESCRIPTION CANNOT BE PROCESSED

Cause -- Module information that cannot be evaluated has been received in a

COPY operation from an external source.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check interface software.
1319 Message text <object> CANNOT BE CORRECTED

Cause -- An invalid extension has been specified (only “DAT” is allowed).

-- An attempt has been made to transmit or edit a protected file.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select data list.
-- Set INIT switch on I--CPU to position 3.
1320 Message text EXTENSION NOT ALLOWED

Cause -- An extension has been specified in a command where it is not allowed

(e.g. analyse otto.src).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.
1321 Message text <path> IS NOT A DIRECTORY

Cause -- Command contains an invalid subdirectory (e.g. dir /R1/otto/abc,

/abc not allowed).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.
1322 Message text <module> NOT LINKED

Cause -- “UNLINK” has been applied to an object that is not a program.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1323 Message text <path> INVALID DATA MODULE NAME OR EXTENSION

Cause -- An invalid path, module name or extension has been specified.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.

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 1 Error messages / troubleshooting (continued)

1324 Message text <object> NOT AVAILABLE

Cause -- An object that is not available has been addressed.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Create the object.
1325 Message text <object> CANNOT BE PROCESSED

Cause -- An object that has already been assigned has been addressed.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Free the assignment (/R1/CONFIG>DAT).
1326 Message text <object> : <number of errors> COMPILATION ERROR

Cause -- The indicated number of errors have been detected in the indicated
object during total compilation.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct the errors.
1327 Message text <module> LINKING ERROR

Cause -- One or more errors have been detected in the indicated module
during linking.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Using the error list, correct the error(s).
1328 Message text FAULTY FILE

Cause -- Module is not correct for TTS calculation.

Monitor -- In command processing.
Effect -- None.
Remedy --
1329 Message text ACCESS TO IMPORTED VARIABLE IS NOT POSSIBLE

Cause -- The search path has not been extended to the external data list.
Monitor -- In command processing.
Effect -- Command has not been executed.
Remedy -- Extend the search path.
1330 Message text SOURCE AND TARGET OBJECT ARE IDENTICAL

Cause -- The source and target specifications define the same object.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Change target object.

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Error messages / troubleshooting

1331 Message text <module> NOT CORRECT

Cause -- An incorrect module has been selected in a linking operation.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct the error in the indicated module (perform ANALYSE).
1332 Message text Line selection not possible: too many Interrupts

Cause -- An attempt has been made to carry out a block selection in a local
subprogram that is not in the caller stack. At this point, the maximum
permissible number of interrupts that can be declared or activated was
exceeded.
Monitor --
Effect -- Block selection to the subprogram is not possible.
Remedy -- Reduce the number of KRL interrupts accordingly.
1333 Message text <object> CANNOT BE DELETED

Cause -- Object cannot be deleted because it is write--protected.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None.
1334 Message text MORE THAN 16 INTERRUPTS DEFINED

Cause -- Program instruction INTERRUPT ON can switch on a maximum of

16 defined interrupts but more than 16 are defined.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Reduce number.
1335 Message text <module> SELECTED

Cause -- Program cannot be unlinked; module is selected with “RUN”.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Terminate program run (CANCEL).
1336 Message text COR ARE FOR DATA LISTS ONLY

Cause -- COR is allowed for data lists only.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select a data list.
1337 Message text TOO COMPLEX

Cause -- Copying from one channel to another (not allowed in SWP1).

Monitor -- In command processing.
Effect -- Command is not executed.

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 1 Error messages / troubleshooting (continued)

Remedy -- None.
1338 Message text BLOCK CANNOT BE CORRECTED

Cause -- TTS or BASE calculation cannot be performed. (TTS = tool--based

technological system).
Monitor -- In command processing.
Effect -- None.
Remedy
1339 Message text UNKNOWN EXTERNAL MESSAGE (<external message number>)

Cause -- It has not been possible to convert an external message (e.g. from
the interface CPU, PSX) into an RCX message.
Monitor -- In command processing.
Effect -- None.
Remedy -- Acknowledge message.
1340 Message text NOT ALLOWED REFERENCE SYSTEM

Cause -- The reference system for manual motion is not possible for the kine-
matic system.
Monitor -- At start.
-- With traversing keys.
Effect --
Remedy -- Select a different reference system (TRANSSYS).
1341 Message text REFERENCE SYSTEM DEFINITION NOT COMPLETE

Cause -- At least one frame required for calculating the reference matrix has
not been assigned.
Monitor -- In cartesian motion commands (e.g. MOVE, PTP, LIN).
Effect
Remedy
1342 Message text WORK ENVELOPE EXCEEDED

Cause -- Working zone limit has been exceeded.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1343 Message text SYNC()--CALL NOT PROGRAMMED

Cause -- In IRSTOPMESS, the user has failed to respond to $Power--Fail by

calling the SYNC() function.
Monitor -- During power failure.
Effect -- None.
Remedy -- Correct the application program.
1344 Message text Robot system is not available

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Cause -- No second robot system activated in the machine data (command:

$HOME = “/R2”)
Monitor -- During command execution.
-- During program execution.
Effect -- In command execution
a) The command is not executed.

-- In program execution
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter machine data.
-- Acknowledge message.
1345 Message text CHANGE REFERENCE DIRECTION <axis number>

Cause -- During single--axis referencing the wrong direction key was pressed,
depending on machine datum $DIR_CAL.
-- All axes are mastered.
Monitor -- During referencing.
Effect -- Axis cannot be referenced in this direction.
Remedy -- Carry out referencing in the other direction.
1346 Message text INADMISSIBLE MASTERING SEQUENCE

Cause -- The mastering sequence was not adhered to (depending on machine

datum $SEQ_CAL).
Monitor -- During mastering.
Effect -- Axis cannot be mastered.
Remedy -- Observe mastering sequence.
1347 Message text ROBOT NOT MASTERED

Cause -- Selection of a program without the robot being mastered.

-- Start of a program without the robot being mastered.
Monitor -- In command processing.
-- In program processing.
Effect --
Remedy -- Master the robot.
-- Acknowledge message.
1348 Message text <axis number> AXIS SYNCHRONIZED

Cause -- In single--axis referencing, an attempt has been made to reference

an axis which has already been referenced.
Monitor -- During referencing.
Effect -- The axis is not referenced.
Remedy -- Select the next axis which has not been referenced.
1349 Message text ROBOT MASTERED

Cause -- All axes mastered.

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 1 Error messages / troubleshooting (continued)

Monitor -- In mastering.
Effect -- Robot is mastered.
Remedy --
1350 Message text BCO REACHED

Cause -- After the first position in the user program has been reached.
-- After repositioning ($POS_RET, $AXIS_RET, $POS_FOR,
$AXIS_FOR, etc.).
Monitor -- With BCO travel.
Effect -- Signalling that BCO has been achieved.
Remedy -- None.
1351 Message text DRIFT COMPENSATION ABORTED

Cause -- The drift compensation was interrupted by a stop (Stop key, message
triggering a stop).
Monitor -- Cyclic for the duration of drift compensation.
Effect -- Drift compensation failed (dynamic braking).
Remedy -- Repeat drift compensation.
1352 Message text AXIS <axis number> INHIBITED

Cause -- An attempt has been made to move an axis in the inhibited direction
(inhibited by software limit switch).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Move axis off limit switch in other direction.
1353 Message text KEY COMBINATION <KCP> INADMISSIBLE

Cause -- Simultaneous pressing of more than one key on the KCP.

Monitor -- Cyclic.
Effect -- KCP operation momentarily interrupted.
Remedy -- Release all keys on the KCP.
1355 Message text DEADMAN SWITCH REQUIRED

Cause -- The safety (deadman) switch has not been pressed while actuating
the start or traversing key in mode T1 or T2.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Press safety switch.
1356 Message text START KEY REQUIRED

Cause -- The “START” command has been entered textually.

-- Execution of the command requires the start key to be pressed.
Monitor -- In command processing.
Effect -- None.

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Error messages / troubleshooting

Remedy -- Press start key.

-- External computer: check job identification.
1357 Message text RESET REQUIRED

Cause -- RUN has been applied to a process in the end state.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- RESET program.
-- In program processing the message has to be acknowledged.
1358 Message text SELECTION REQUIRED

Cause -- Start key pressed without a program being selected.

-- “RUN” without path specification and no program is selected.
Monitor -- When start key is pressed.
-- At RUN command.
Effect -- Command is not executed.
Remedy -- Select program.
1359 Message text TTS CANNOT BE DETERMINED

Cause -- Termination of search for the path direction point. (TTS = tool--based
technological system).
Monitor -- In command processing.
Effect -- None.
Remedy --
1360 Message text SELECTION NOT ALLOWED

Cause -- Selected block does not exist in the program.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select correct block number.
1361 Message text STOP DUE TO NODE SWITCHOVER

Cause -- The node setting has been changed during actuation of a traversing
key or execution.
Monitor -- In command processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1362 Message text STOP DUE TO OPERATING MODE CHANGE

Cause -- Active processes are stopped if the mode is changed.

Monitor -- Cyclic.

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Effect -- Path--maintaining Emergency Stop.

Remedy -- Acknowledge message.
1363 Message text OPERATOR CONTROL UNIT DISABLED

Cause -- Command cannot be executed because the KCP settings do not

fulfil the conditions.
a) For RCP and stationary KCP the mode AUT is required.
b) For non--stationary KCP the mode T1 or T2 is required.
c) For host computers the mode EXT is required.
Monitor -- In command processing.
Effect -- Command cannot be executed.
Remedy -- Fulfil the “active” conditions.
1364 Message text OUT PARAMETERS INADMISSIBLE

Cause -- Trigger with subprogram call where reference parameters are trans-
ferred.
Monitor --
Effect --
Remedy -- Correct program, acknowledge.
1365 Message text PATH TRIGGER WITH PTP MOTION INADMISSIBLE

Cause -- Path triggers are not permissible with PTP motions.

Monitor --
Effect -- Program execution is stopped.
Remedy -- Correct program, acknowledge, reboot.
1366 Message text CARTESIAN TARGET NOT POSSIBLE

Cause -- When using a 5--axis robot ($DEF_A4FIX=TRUE) and palletizing

mode is deactivated ($PAL_MODE=FALSE), only PTP motions with
an axis--specific target may be carried out.
Monitor -- In the line interpreter.
Effect -- Path--maintaining braking.
Remedy --
1367 Message text ACTIVE STATUS REQUIRED

Cause -- The command entered may only be issued from an active operator
control unit (modes T1, T2, AUT).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to active status.
1368 Message text <operator control device> IS ACTIVE

Cause -- Indicated operator control unit is active.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch indicated operator control unit to passive status.

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1369 Message text ACTIVE ALLOWED IN <mode> ONLY

Cause -- For RCP and stationary KCP the mode AUT is required.
-- For non--stationary KCP the mode T1 or T2 is required.
-- For host computers the mode EXT is required.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set the correct mode.
1370 Message text PASSIVE STOP

Cause -- Stop from a passive operator control unit (the message is displayed
only if an active process has been stopped).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message (acknowledgement possible only on the
originating unit, even in passive status).
1371 Message text STOP DUE TO UNIT PASSIVE

Cause -- The operator control unit has been deactivated during actuation of
the start key or a traversing key in mode T1 or T2, or during the
BCO run.
Monitor -- In command processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch operator control unit to active status.
-- Acknowledge message.
1372 Message text PROCESS ACTIVE

Cause -- An attempt has been made to start an active command during an

active process.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Wait until end of processing.
-- Stop active processing.
-- In program processing the message has to be acknowledged.
1373 Message text PROCESS BUSY

Cause -- Program already selected.

Monitor -- In command processing.
-- In program processing.

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 1 Error messages / troubleshooting (continued)

Effect -- In command processing

-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Deselect program already selected.
-- In program processing the message has to be acknowledged.
1374 Message text PROCESS DISABLED

Cause -- All selected processes have the program mode “DISABLED” or a

non--disabled process is finished.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Alter program mode.
1375 Message text COMMAND NOT ALLOWED

Cause -- Impermissible or unknown command.

Monitor -- In command processing.
Effect -- None.
Remedy -- Enter command correctly.
1376 Message text ACTIVE COMMANDS INHIBITED

Cause -- A message which causes the active commands to be inhibited has

been set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Acknowledge active messages in the message window.
1377 Message text COMMAND EXECUTION NOT POSSIBLE

Cause -- A preceding command is still being processed.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Cancel command.
-- Wait until end of preceding command.
1378 Message text COMMAND NOT BEING PROCESSED

Cause -- The command that is to be cancelled has already been processed.

Monitor -- In command processing.
Effect -- None.
Remedy -- None.
1379 Message text COMMAND ABORTED

Cause -- The command has been cancelled.

-- During editing abort has been selected by the editor kernel before
the command concerned (ERASE,GET,FIND) is called.

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Error messages / troubleshooting

Monitor -- In command processing.

-- In editing.
Effect --
Remedy --
1380 Message text BACKGROUND PROCESS BUSY WITH <operator control device>

Cause -- The background is exclusively assigned to another operator.

Monitor -- In command processing.
Effect -- Background cannot be exclusively assigned.
Remedy -- Cancel the exclusive assignment of the indicated device.
-- Provide complete specifications in $OPTION.DAT.
1381 Message text BACKGROUND OCCUPIED

Cause -- A command is already being processed in the background.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Cancel command.
-- Wait until command has been executed.
1382 Message text ABORTED

Cause -- “BREAK” has been repeated.

Monitor -- In command processing.
Effect -- None.
Remedy -- None.
1383 Message text ** IS NOT A MEMORY DUMP

Cause -- When writing a data block (a file received from the controller or a
temporary file created by the server), it has been discovered that there
is not enough space available on the storage medium (hard disk).
Monitor
Effect -- The currently edited file is deleted.
Remedy -- Create space on the storage medium
(delete files that are no longer required).
1384 Message text PARAMETER NOT PROCESSED

Cause -- A RUN command with a parameter has been executed for a program
that is already selected.
Monitor -- In command processing.
Effect -- The parameter is not evaluated.
Remedy -- Cancel and reselect the program.
1385 Message text PROTOCOL ERROR

Cause -- Error in the protocol software of the operator control unit or output
device.
Monitor -- In command processing.
Effect -- The command is aborted.

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 1 Error messages / troubleshooting (continued)

Remedy -- Check protocol software.

1386 Message text INTERRUPT--UP: MAX. 10 ARGUMENTS ADMISSIBLE

Cause -- More than 10 arguments have been specified.

Monitor --
Effect --
Remedy -- Reduce the number of arguments to the maximum permissible number.
1387 Message text VARIABLE TOO LARGE

Cause -- The variable specified in SHOW VAR or SET INFO is too complex
or too large (e.g. field is larger than the display).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Subdivide the request into several sections.
1388 Message text <string> VARIABLE WRITE PROTECTED IN MODULE <string> LINE
<string>
Cause -- In a program module an attempt was made to change a write--
protected variable.
Monitor -- In program mode.
Effect --
Remedy --
1389 Message text OPTION <option name> MISSING

Cause -- The option has not been entered.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Enter the option.
1390 Message text CIRC ANGLE NOT ACCEPTED

Cause
Monitor
Effect -- None.
Remedy
1391 Message text Access to component not allowed

Cause -- Illegal access to a component of the program/motion trace

(e.g. SHOW VAR $PRO_TRACE[5].NAME[2]).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy
1392 Message text WRITE PROTECTION DUE TO PROCESS STATUS

Cause -- Write access to a “$” variable with an illegal process status

(active, not active, RC Ready).
Monitor -- In command processing.

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Effect -- Command is not executed.

Remedy -- Set a permissible process status.
1393 Message text WRITE PROTECTION DUE TO OPERATOR CONTROL UNIT
STATUS
Cause -- An attempt has been made to write a “$” variable with the operator
control unit status incorrectly set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to “active” status.
1394 Message text READ PROTECTION DUE TO PROCESS STATUS

Cause -- Reading of a “$” variable with an inadmissible process status

(active, not active, RC ready).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set a permissible process status.
1395 Message text READ PROTECTION DUE TO OPERATOR CONTROL UNIT STATUS

Cause -- Reading of a “$” variable with the operator control unit status incorrectly
set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to “active” status.
1396 Message text PROGRAM NOT LINKED

Cause -- Selection of a non--linked program.

Monitor -- At selection.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Link the program.
-- In program processing the message has to be acknowledged.
1397 Message text MEMORY REQUEST FOR PARAMETER LIST TOO LARGE

Cause -- The transfer parameters of the program require too much memory.
Monitor -- During command execution.
Effect --
Remedy -- Acknowledge message, correct program, reselect program.
1398 Message text Check rcp selector switch

Cause -- The selector switch on the RCP is not set to “RUN” in the case of
selection or start from another operator control unit.
Monitor -- In command processing.
Effect -- Command is not executed.

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 1 Error messages / troubleshooting (continued)

Remedy -- Turn the selector switch on the RCP to “RUN”.

1399 Message text MESSAGE CANNOT BE ACKNOWLEDGED

Cause -- Acknowledgement of a status (operational) message.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None. Read the message.
1400 Message text Message not available

Cause -- Textual acknowledgement of a message that is not available.

Monitor -- In command processing.
Effect -- Command cannot be executed.
Remedy --
1401 Message text Control structure next block <block number>

Cause -- Selection into a control structure.

Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
-- The control structure is exited when the end is identified.
Remedy -- Acknowledge message.
1402 Message text Select startup

Cause -- A command has been entered that is only allowed in the startup mode.
Monitor -- With all commands of the startup mode.
Effect -- Command is not executed.
Remedy -- Select the startup mode.
-- Acknowledge message.
1403 Message text Interrupt instruction aborted

Cause -- Motion instruction in the interrupt routine that is executed after an error
stop. The interrupt module that is called after an error stop may not
contain any motion instructions.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Modify interrupt module accordingly.
-- Acknowledge message.
1404 Message text Edit commands now allowed

Cause -- The user is in the mode “Editing without implicit block selection”, and
after completion of the current motion block has received an editor
enable. The object is write--protected.
Monitor -- During command execution.
Effect --
Remedy -- Note: editing is now possible.

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1405 Message text <object name> is write protected

Cause -- Object is write--protected.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check object status (e.g. unlink or deselect object).
1406 Message text Error in path

Cause -- Error in path specification e.g. /R5.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check and correct path specification.
1407 Message text Edit commands inadmissible, finish movement first

Cause -- The user tries to edit a program while in mode “Editing without implicit
block selection”. The user is still located in a motion instruction.
Monitor -- During command execution.
Effect -- Editing is not possible.
Remedy -- Press the Start key again until the message “Edit commands now
allowed” appears. Editing is then possible.
1408 Message text Line compilation or decompilation error

Cause -- Message will soon be deleted.

Monitor
Effect -- No effect.
Remedy
1409 Message text No trigger allowed in ISR or *.SUB

Cause -- Trigger was programmed in interrupt or SUB module.

Monitor -- Program execution.
Effect -- Program execution stopped, all active commands inhibited.
Remedy -- Correct program, acknowledge message.
1410 Message text Program line does not exist

Cause --
Monitor --
Effect --
Remedy --

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 1 Error messages / troubleshooting (continued)

1411 Message text Line selection beyond buffer: Next start deletes buffer.

Cause -- Line selection outside the trace.

Monitor -- During line selection.
Effect -- When the Start key is pressed, the buffer for backward motion is
deleted.
Remedy -- Before pressing the Start key, make another line selection within the
buffer. After that the backward motion can be carried out.
1412 Message text Axis <axis number> acceleration not programmed

Cause -- No value has been assigned to the program datum “$ACC_AXIS”.

Monitor -- When starting a PTP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1413 Message text Axis <axis number> velocity not programmed

Cause -- No value has been assigned to the program datum “$VEL_AXIS”.

Monitor -- When starting a PTP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1414 Message text Path acceleration not programmed

Cause -- No value has been assigned to the program datum “$ACC.CP”.

Monitor -- At the first CP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1415 Message text Path velocity not programmed

Cause -- No value has been assigned to the program datum “$VEL.CP”.

Monitor -- At the first CP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1416 Message text Orientation acceleration not programmed

Cause -- No value has been assigned to the program data “$ACC.ORI1” and
“$ACC.ORI2”.
Monitor -- At the first CP block.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1417 Message text Orientation velocity not programmed

Cause -- No value has been assigned to the program data “$VEL.ORI1” and
“$VEL.ORI2”.
Monitor -- At the first CP block.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1418 Message text <X,Y,Z,A,B,C> BASE not programmed

Cause -- No value has been assigned to the program datum “$BASE”.

-- in a user program
-- after overall reset of the control for a cartesian command.
Monitor -- With a cartesian motion.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- In command processing
-- Assign a value to “$BASE”.
-- In program processing
-- Alter the program accordingly
-- Acknowledge message.
1419 Message text <X,Y,Z,A,B,C> TOOL not programmed

Cause -- No value has been assigned to the program datum “$TOOL”

-- in a user program
-- after overall reset of the control for a cartesian command.
Monitor -- With a cartesian motion.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- In command processing
-- Assign a value to “$TOOL”.
-- In program processing
-- Alter the program accordingly
-- Acknowledge message.
1420 Message text Approximation not programmed <approximation criterion>

Cause -- No value has been assigned to the program data “$APO.VEL”,

“$APO.ROB”, “$APO.DIS”, and/or “$APO.ORI”.
Monitor -- When starting the first motion block with approximate positioning.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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 1 Error messages / troubleshooting (continued)

1421 Message text <file> : <number> compilation error

Cause -- Compilation error due to unrecognized data type can occur in the case
of global self--defined data types and ENUMs. This means that the GUI
must initiate a second download.
Monitor -- During command execution.
Effect -- When this error is caused by global types, it can be corrected by down-
loading the files twice.
Remedy -- The GUI filters out the error number and initiates the double download
for the file in question.
1422 Message text <$ variable> invalid value

Cause -- Read access to a variable that is not initialized or that has an invalid
value, e.g. reading of “$POS_INT” outside an interrupt routine.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1423 Message text Overflow

Cause -- Value is not compatible with the specified data type, e.g. value
assignment of a number >255 to the data type “char”.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter data type.
-- Acknowledge message in program processing.
1424 Message text PROGRAM STACK OVERFLOW

Cause -- The nesting depth for subprograms and functions has been
exceeded.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1425 Message text Instruction not allowed

Cause -- Program instruction that is not allowed as a command.

-- Program instruction that is only allowed in an interrupt routine.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1426 Message text Variable stack depth exceeded

Cause -- The nesting depth of the variable has been exceeded.

Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the variable accordingly.
-- Acknowledge message.
1427 Message text $OUT_C[N] IS NOT PERMISSIBLE IN INTERRUPT PROGRAMS

Cause -- Instruction not permissible here

Monitor --
Effect -- Interpreter stop
Remedy -- Revise SRC file and acknowledge message
1428 Message text Function value not defined

Cause -- RETURN instruction missing in the function module.

Monitor -- In the program.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Insert a RETURN instruction.
1429 Message text String too long

Cause -- In a value assignment to arrays, the string consists of more characters

than the existing array.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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 1 Error messages / troubleshooting (continued)

1430 Message text <Interrupt or Trigger> not defined

Cause -- An interrupt that has not been defined has been switched on.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Define interrupt.
-- Acknowledge message.
1431 Message text Selection not possible

Cause -- Selection of the editor is not possible.

The file may not exist or it may have the attribute “hidden”.
Monitor
Effect
Remedy -- Check whether the file exists (e.g. when attempting to open a file
in the view mode) or has the attribute “hidden”.
1432 Message text Max. no. of interrupts defined

Cause -- More than 32 interrupts have been defined.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program accordingly.
1433 Message text Max. no. of interrupts on

Cause -- More than 8 interrupts have been switched on.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program accordingly.

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1434 Message text Target point not reached

Cause -- The contour cannot be determined when selecting a CIRC block

with a circle angle. A LIN motion to the programmed target point is
executed when the robot is started.
Monitor -- In program processing.
Effect -- The next motion is also a BCO run.
Remedy -- None.
1435 Message text Read protection

Cause -- A “$” variable that is not admissible for the selected interpreter type
has been read.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- In program processing the message has to be acknowledged.
1436 Message text Disk write protected

Cause -- The write protection is activated.

Monitor
Effect -- It is not possible to save data on the floppy disk.
Remedy -- Remove the write protection.
1437 Message text Reposition

Cause -- BCO was not achieved on returning from the interrupt routine. The
robot must be repositioned to the interrupt point before the end of the
interrupt routine, e.g. with LIN $POS_RET.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1438 Message text Data storage device not ready: ...

Cause -- There is no disk inserted or the floppy disk drive is defective.

Monitor
Effect -- It is not possible to save to floppy disk.
Remedy -- Insert floppy disk into the disk drive in; check disk drive.

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 1 Error messages / troubleshooting (continued)

1439 Message text <variable name> argument inadmissible

Cause -- At least one argument in the function is inadmissible; e.g. SQRT

(negative value).
Monitor -- In interpretation of C functions.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1440 Message text Mailbox identification not allowed

Cause -- An incorrect MBX_ID is specified in the C function “MBX_REC”.

Monitor -- In interpretation of “MBX_REC”.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1441 Message text Interrupt priority not allowed

Cause -- Interrupt priority greater than 128 or less than 1

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program accordingly.
1442 Message text Approximation not allowed for instructions

Cause -- “DRIFT”, “$TOOL” or “$FILTER” is programmed between two motion

instructions.
Monitor -- In program processing.
Effect -- Approximate positioning is not performed for the motion instructions.
Remedy -- Alter the program accordingly.

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Error messages / troubleshooting

1443 Message text Start movement not allowed

Cause -- The first motion instruction in the program is relative.

-- The first motion instruction in the program is not programmed
completely, e.g. PTP [33.33].
Monitor -- In program processing.
Effect -- No program motion.
Remedy -- Alter the program.
-- Acknowledge message.
1444 Message text Array index inadmissible

Cause -- An attempt has been made to access an array element that does
not exist.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
Acknowledge message.
1445 Message text Angle status inadmissible

Cause -- After repositioning with LIN the angle status does not agree with the
status of the programmed block.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Perform repositioning with PTP.
1446 Message text Value assignment not allowed

Cause -- Inadmissible value assignment for predefined variables,

e.g. $SPEED.ORI1 <= 0.0 or > $SPEED_MA.ORI1.
-- Assigned $BASE or $TOOL not possible for the kinematic system.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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 1 Error messages / troubleshooting (continued)

1447 Message text Software limit <motion direction> <axis number> out of range

Cause -- Target point cannot be reached due to a software limit switch.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1448 Message text <Name> ambiguous

Cause -- The specified memory dump name contains wildcards. Expansion of

these wildcards has resulted in more than one valid file name. This is
not allowed however.
Monitor
Effect -- Data transfer is not carried out.
Remedy -- Specify an unambiguous name.
1449 Message text <$variable> variable write protected

Cause -- Write access to a write--protected variable e.g. “$POS_ACT”.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1450 Message text Transformation not configured

Cause -- $BASE or $TOOL has been assigned although no transformation is

configured.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.

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Error messages / troubleshooting

1451 Message text Division by 0

Cause -- An attempt has been made to divide a value by “0”.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
-- Command is not executed.
-- In program processing
-- Ramp--down braking
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1452 Message text Backward motions not active

Cause -- Backward motion is deactivated ($VW_BACKWARD = FALSE).

Monitor -- When START MINUS key is pressed.
Effect -- Command is rejected.
Remedy -- Set variable $VW_BACKWARD to TRUE.
1454 Message text Start continue not possible

Cause -- BSTEP
Monitor -- In command processing.
Effect -- None.
Remedy --
1455 Message text Inadmissible in this edit mode

Cause -- A command that would alter the object has been entered in the listing
mode of the editor.
-- An attempt has been made in the data correction mode to delete or
copy a range of blocks or to delete a block consisting of only one line.
Monitor -- In the editor.
Effect -- The attempted action is not executed.
Remedy -- Edit in full edit mode.
1456 Message text Start point equal to end point

Cause -- Distance between start point and end point is too small.
Monitor -- During preparation.
Effect -- Ramp--down braking.
-- Active commands inhibited.
Remedy -- Reprogram start point and/or end point.
-- Acknowledge message.

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 1 Error messages / troubleshooting (continued)

1457 Message text Start point equal to mid point

Cause -- Distance between start point and auxiliary point is too small.
Monitor -- During preparation.
Effect -- Ramp--down braking.
-- Active commands inhibited.
Remedy -- Reprogram start point and/or auxiliary point.
1458 Message text Mid point equal to end point

Cause -- Distance between auxiliary point and end point is too small.
Monitor -- During preparation.
Effect -- Ramp--down braking.
-- Active commands inhibited.
Remedy -- Reprogram auxiliary point and/or end point.
1459 Message text Backward motions not possible: finished subroutine

Cause -- An attempt was made to carry out backward a motion located inside
a subprogram which has already been executed.
Switching to forwards in this subprogram would not be possible.
Backward motion is thus also disabled.
Monitor -- When the “Start backwards” key is pressed.
Effect -- Command is not executed.
Remedy -- Forward motion.
1460 Message text Deleting Trace: no backward motions possible

Cause -- Editing was carried out or a block selection was made at a position
which causes the trace to be discarded.
From now on backward motion is no longer possible.
Monitor -- When the “Start backwards” key is pressed.
Effect -- Command is not executed.
Remedy -- Forward motion.
1462 Message text Command syntax error

Cause -- The command contains a syntax error.

Monitor -- In the editor.
Effect -- Command is not executed.
Remedy -- Correct the command.
1463 Message text Object not ready

Cause -- Program cannot be processed by the editor.

Monitor -- In the editor.
Effect -- Command is not executed.
Remedy -- Select program with “Edit”.

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Error messages / troubleshooting

1464 Message text $OUT_C[N] IS NOT PERMISSIBLE IN SUBMIT

Cause -- Instruction not permissible here

Monitor --
Effect -- Interpreter stop
Remedy -- Revise SRC file and acknowledge message
1465 Message text ONLY 8 $OUT_C[N] ASSIGNMENTS PER MOTION PERMISSIBLE

Cause -- Instruction not permissible here

Monitor --
Effect -- Interpreter stop
Remedy -- Revise SRC file and acknowledge message
1468 Message text Key not assigned

Cause -- An unassigned softkey or function key has been pressed during

prompted operation.
Monitor -- When a softkey is pressed.
-- When a function key is pressed.
Effect -- None.
Remedy -- None.
1472 Message text Key not allowed

Cause -- Impermissible key (e.g. softkey) pressed in textual operation.

-- Alphanumeric key pressed in prompted operation when no input field
is available.
Monitor -- When a key is pressed.
Effect -- Entry is ignored.
Remedy -- Acknowledge the message.
1474 Message text Change of direction not possible

Cause
Monitor -- In command processing.
Effect -- None.
Remedy
1477 Message text Main process not available

Cause -- Main run display (motion trace) selected but no main run block inter-
preted yet.
Monitor -- In command processing.
Effect -- None.
Remedy -- Start the program.

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 1 Error messages / troubleshooting (continued)

1478 Message text Pre process not available

Cause -- Advance run display (program trace) selected but no program is in the
STOP or END state.
Monitor -- In command processing.
Effect -- None.
Remedy -- Start the program.
1481 Message text No runtime data access

Cause -- Access to an invalid or non--existent object value memory or runtime

data area via the hierarchy table (search path).
Monitor -- In the interpreter (prim -- init).
Effect -- None.
Remedy -- Set the search path to the current interpreter environment.
1482 Message text Volume too small

Cause -- Monitoring of the dispensed volume has been triggered. Insufficient

adhesive has been dispensed.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1483 Message text Excessive volume

Cause -- Monitoring of the dispensed volume has been triggered. Too much
adhesive has been dispensed.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1484 Message text Wrong adhesive pressure

Cause -- The initial pressure of the adhesive is continuously monitored by the

PLC during dispensing. A pressure value outside the permissible
tolerance range has been detected. Possibly there are bubbles in the
adhesive supply line, or the outlet nozzle is clogged.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1485 Message text Oil filter dirty

Cause -- The hydraulic pressure is no longer adequate because the hydraulic

oil filter is dirty.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Clean or replace oil filter.

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Error messages / troubleshooting

1486 Message text Max. oil temperature exceeded

Cause -- The maximum permissible hydraulic oil temperature has been ex-
ceeded.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Wait until the hydraulic oil has cooled down.
-- If this situation occurs frequently, check the hydraulic unit.
1487 Message text General system air pressure

Cause -- The required air supply pressure for the pneumatic valves is not
available.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Ensure that the air pressure and quantity are sufficient.
1488 Message text Vacuum error

Cause -- Vacuum missing or insufficient.

In the application of adhesive to glass, the glass is held in position by
means of a vacuum. If this vacuum is not available, the glass cannot
be held in position after it has been centered.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the vacuum pump and hoses.
1489 Message text Centering error

Cause -- The workpiece is not correctly positioned or clamped. There is possibly

a fault in the feed equipment, or the fixture is defective.
Monitor -- From the PLC application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check fixture, feed equipment or workpiece position.
1490 Message text Component check error

Cause -- Component damaged or no longer clamped to the fixture.

-- In the application of adhesive to glass, the adhesive nozzle is pressed
onto the glass. If this pressure is missing during adhesive application,
the glass might be damaged or might no longer be clamped to the
fixture.
In this case, the robot motion and adhesive application must be
stopped immediately!
Monitor -- From the PLC application program (bonding technology).
Effect -- Maximum braking. All active commands inhibited. Emergency Stop.
Remedy -- Check the workpiece.

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 1 Error messages / troubleshooting (continued)

1491 Message text CP/PTP approximation not feasible

Cause -- In the CP block the traversing distance of an axis is greater than 180
degrees; S change in the CP block; software limit switch violated in
travel along “shortest path”.
Monitor
Effect
Remedy
1492 Message text Channel not compatible with protocol

Cause -- PLC protocol is set and channel declaration is not set to SER1.
Monitor -- In command processing.
Effect -- None.
Remedy -- Alter the channel declaration protocol.
1493 Message text Channel assigned to PLC

Cause -- An attempt has been made to access the channel that has already
been parameterized for the PLC link.
Monitor -- In command processing.
Effect -- None.
Remedy -- Reparameterize the channel. Close the channel and open it again.
1495 Message text Timeout during filling

Cause -- The maximum time for filling the dispenser with adhesive has been
exceeded.The time for filling the dispensing unit with adhesive is
monitored by the PLC. If the maximum time is exceeded, there is a
fault in the adhesive application hardware.
Monitor -- From the PLC application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware.
1496 Message text Adhesive level

Cause -- The adhesive drum is empty.

Monitor -- From the PLC application program (bonding technology).
Effect -- None.
Remedy -- Prepare a new adhesive drum or switch over to a filled drum.
1497 Message text All analog functions assigned

Cause -- More than 2 cyclic analog outputs have been switched on.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Set ANOUT OFF, or cancel the instruction.

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Error messages / troubleshooting

1498 Message text <Signal name> not an analog output

Cause -- Non--existent analog output signal or incorrect signal index accessed.

Monitor -- In command and program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1499 Message text Analog output already assigned

Cause -- A cyclic analog output is assigned a second time in the program,

e.g. SIGNAL SIG1 $ANOUT[1]; SIGNAL SIG2 $ANOUT[1]; ANOUT
ON SIG1 = ....; ANOUT ON SIG2 = ....
Monitor -- In the program.
Effect -- Ramp--down braking.
Remedy -- Switch off cyclic analog output: ANOUT OFSIG.
1504 Message text Invalid SYNACT variable <variable name> <block number>

Cause -- In logical comparison of value assignments during cyclic Synact moni-

toring, an error occurred when accessing a variable, e.g. variable
write--protected.
Monitor -- Cyclic.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Correct the data or the program.
-- Acknowledge the message.
1505 Message text Combination of variables not allowed <block number>

Cause -- In a synact instruction, variables for individual blocks and approximate

positioning blocks are combined in the logic comparison or value
assignment.
Monitor -- In program processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Program synact instruction differently.
1506 Message text CIRC parameter not allowed

Cause -- Distance between starting point and/or auxiliary point and/or end point
is too small, or all points lie on a straight line. Formation of a circle is
not possible.
Monitor -- In the individual CIRC block.
Effect -- CIRC block is not executed;
-- Ramp--down braking;
-- All active commands inhibited.
Remedy -- Program auxiliary point and/or end point correctly.

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 1 Error messages / troubleshooting (continued)

1507 Message text Hydraulic level

Cause -- The oil level in the hydraulic system has fallen below the minimum limit.
Monitor -- In PLC program processing.
Effect -- None.
Remedy -- Top up hydraulic oil and check hydraulic system for leaks.
1508 Message text No file available

Cause -- No file is available that meets the search criteria specified in the DIR
command.
Monitor -- In command processing.
Effect -- None.
Remedy -- Check specifications and spelling in the DIR command.
1509 Message text Program exec. mode inadmissible

Cause -- The selected program execution mode is not permissible.

Monitor -- In command processing.
Effect -- None.
Remedy -- Change program execution mode.
1510 Message text Error at format selection no. <number of incorrect format selection>

Cause -- Parameter inconsistent with format specification, or incorrect format

specification in CWRITE instruction.
Monitor -- Program processing in S_INT function CWRITE.
Effect -- Program execution is stopped.
Remedy -- Program the correct format specification.
1511 Message text Access denied

Cause --
Monitor --
Effect --
Remedy --
1513 Message text Range for <path> <axis number> exceeded

Cause -- 32--bit word is exceeded.

Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Alter the program accordingly.
1514 Message text Insert another disk

Cause -- Request for next floppy disk.

Monitor --
Effect --
Remedy -- Insert floppy disk in the disk drive.

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Error messages / troubleshooting

1515 Message text <object> copy refused (--S.)

Cause -- System file has been transmitted via an interface without the option
“--S” being set
“--S” is the code for the download command.
Monitor -- In command processing.
Effect -- File is not transmitted.
Remedy -- Set the option “--S”.
1516 Message text Reference system not programmed

Cause -- $BASE is programmed incompletely or not at all.

Monitor -- In program processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Program $BASE correctly.
1517 Message text BCO move to aux. point required

Remedy -- Carry out BCO run to end point.

1518 Message text Default parameter

Cause -- A default parameter or no parameter has been transferred to a pre-

defined C function.
Monitor -- In program processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Call the C function with a parameter.
1519 Message text Pressure sensor cable failure

Cause -- The current flow of the analog signal for pressure sensing has fallen
below the minimum limit (4 -- 20 mA interface).
Monitor -- In command processing.
Effect -- Ramp--down braking.
Remedy -- Check connecting cable, connectors and current source.
1520 Message text Volume actual value cable failure

Cause -- The current flow of the analog input channel for volume sensing has
fallen below the minimum limit (4 -- 20 mA interface).
Monitor -- In command processing.
Effect -- Ramp--down braking.
Remedy -- Check connecting cable, connectors and current source.
1521 Message text Change of segment is erroneous

1522 Message text Selected axis is not adjustable

Cause -- The axis selected for mastering is inactive.

Monitor -- In command processing.
Effect -- The command is aborted.
Remedy -- Master only active axes.

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 1 Error messages / troubleshooting (continued)

1523 Message text EXTFCTP instruction inadmissible

Cause -- An EXTFCTP instruction has been programmed in the program.

Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Delete the EXTFCTP instruction in the program.
1524 Message text Max. active triggers reached

Cause -- Too many Trigger commands programmed in a block.

Effect -- Command is not executed.
Remedy -- Reduce number of active Trigger commands in the program.
1525 Message text Invalid trigger -- “PRIO”

Cause -- An inadmissible value was entered for Trigger--PRIO.

Remedy -- Correct the value.
1526 Message text Max. triggers (50) defined

Cause -- The maximum number of Trigger commands has been defined.

Remedy -- Alter the program.
1527 Message text Sensor mastering inadmissible

Cause -- No sensor location run has been performed for the axis.
Monitor -- In command processing.
Effect -- Command is aborted.
Remedy -- Perform sensor location run for the axis.
1528 Message text Brakes open during mastering selection

Cause -- A brake is still open after the preceding motion.

Monitor -- In command processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Wait until all brakes are closed and the servos are disabled.
1529 Message text Segment exchange successful

1530 Message text Reduced velocity during sensor location search

Cause -- The velocity defined by the user for the sensor loction run in
$RED_JUS_UEB is greater than the possible maximum at which the
sensor can be detected. The controller automatically reduces the
velocity to allow the sensor to be detected.
Monitor -- In command processing.
Effect -- None.
Remedy -- Reduce the permissible velocity for manual traversing in the machine
data.

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Error messages / troubleshooting

1531 Message text Adjustment possible only in mode T1

Cause -- The operating mode of the controller is not set to mode T1.
Monitor -- In command processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Set the mode to T1. Perform mastering again.
1532 Message text CIRC is executed as LIN

Cause -- An attempt has been made to execute a CIRC motion as a BCO run.
Monitor -- In program processing.
Effect -- Program execution is stopped.
Remedy -- Acknowledge message, after the start the CIRC block is then executed
as a LIN motion.
1533 Message text Program line changed

Cause -- Message that the program line has been corrected.

Monitor --
Effect --
Remedy --
1534 Message text COR.dat check sum error

Cause -- The correction data have been altered.

Monitor -- In command processing.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Sensor location run/referencing, execution/archiving of the correction
data.
1535 Message text Delay <block number> inadmissible

Cause -- Neg. delay in the synact instruction has not been used in combination
with one of the 4 position trigger variables (M_SC_F, M_SC_B,
M_SCAPO_F, M_SCAPO_B).
Monitor -- In the program.
Effect -- Ramp--down braking, all active commands inhibited.
Remedy -- Change the logic condition of the synact instruction.
1536 Message text Array parameter inadmissible

Cause -- Undefined array parameter or complete “call--by--value” array in the list

of current parameters when function is called.
Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Do not use undefined array parameters and transfer complete arrays
as current parameters only on a “call--by--reference” basis.
1537 Message text Stop due to loading new custom data

Cause -- Loader for the file “$CUSTOM.DAT” has been called. No process may
be active at the same time since the system is fully occupied with the
loader.

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 1 Error messages / troubleshooting (continued)

Monitor -- In command processing.

Effect -- Maximum braking. All active commands inhibited.
Remedy -- Acknowledge message. Do not edit “$CUSTOM.DAT” during an
“active process”
1538 Message text Invalid “DISTANCE” value

Cause -- The value for “DISTANCE” is not permissible.

Remedy -- Acknowledge message; enter permissible value.
1539 Message text Invalid “DELAY” value

Cause -- The value for “DELAY” is not permissible.

Remedy -- Acknowledge message; enter permissible value.
1540 Message text Interrupt expression complexity exceeded

Cause -- In total more than 16 “slow” variables have been used in the logical
expressions of the INTERRUPT DECL instructions on the control and
robot levels.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Use fewer predefined variables.
1541 Message text Machine data error

Cause -- Machine data have not yet been checked.

Monitor -- With active commands.
Effect -- None.
Remedy -- Edit the machine data or copy the machine data or option data file.
1542 Message text Error in “UPCALL” token

1543 Message text No more dynamic analog inputs available

Cause -- A third dynamic analog input has been switched on in the program.
Monitor -- In program processing.
Effect -- Stop.
Remedy -- One of the dynamic analog inputs must first be switched off.
1544 Message text Digital input already assigned

Cause -- A digital input has been cyclically switched on in the program for a
second time.
Monitor -- In program processing.
Effect -- Stop.
Remedy -- Switch off the dynamic digital input.
1545 Message text All pulse outputs assigned

Cause -- More than 16 impulse outputs have been switched on.

Monitor -- In program processing.
Effect -- Ramp--down braking; program execution stopped.

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Error messages / troubleshooting

Remedy -- Alter program accordingly.

1546 Message text Invalid pulse duration

Cause -- The permissible range for the pulse duration extends from 0.05 to
3049. A value outside this range has been specified.
Monitor -- In program processing.
Effect -- Ramp--down braking; program execution stopped.
Remedy -- Program values in the permissible range.
1547 Message text Target variable must be of type REAL

Cause -- Incorrect data type of a target variable or wrong format in a CREAD or

SREAD instruction.
Monitor --
Effect --
Remedy -- Correct CREAD or SREAD instruction: change format specification
or use variable of type REAL.
1548 Message text <name of the displayed program> reselection not possible

Cause -- Program that must be linked for reselection causes linking error.
Monitor -- Command processing (RUN command).
Effect -- None.
Remedy -- Eliminate the error using the error list containing the linking errors.
1549 Message text Invalid handle

Cause -- An invalid HANDLE has been programmed into CWRITE or CREAD.

Monitor -- Program.
Effect -- Ramp--down braking.
Remedy -- Specify a valid HANDLE.
1550 Message text No more data/variables available

Cause -- With SREAD/CREAD there is no more text to be read or there are no

variables available for storing the values.
Monitor --
Effect --
Remedy --
1552 Message text Channel already open

Cause -- An attempt has been made to open a channel that is alraedy open.
Monitor -- In command processing.

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 1 Error messages / troubleshooting (continued)

1553 Message text Channel cannot be opened/closed

Cause -- The operator has attempted to open a SINEC H1 channel by means of

the OPEN command or to close it by means of the CLOSE command.
Monitor -- In command processing.
Effect -- None.
Remedy -- None; SINEC H1 channels are opened and closed automatically.
1554 Message text Wrong type of parameter variable

Cause -- The parameter variable for the channel is of the wrong type.
Monitor -- In command processing.
Effect -- None.
Remedy -- Correct CHANNEL declaration for the channel.
1555 Message text Channel parameters faulty or incomplete

Cause -- At least one channel parameter in the parameter variable of the

channel in “$CUSTOM.DAT” is faulty or not initialized.
Monitor -- In command processing.
Effect -- None.
Remedy -- Correct or initialize the parameter variable.
1556 Message text SINEC L2 bus channel not opened

Cause -- An attempt has been made to open a SINEC L2 connection without

the SINEC L2 bus channel being open.
Monitor -- In command processing.
Effect -- None.
Remedy -- Open SINEC L2 bus channel.
1557 Message text Channel already fully assigned

Cause -- The maximum number of jobs have already been assigned to the
channel.
Monitor -- In command processing.
Effect -- None.
Remedy -- Wait until at least one of the jobs is finished.
1558 Message text Channel has to be opened/closed

Cause -- The channel parameters used for assigning the channel do not
correspond to the current channel parameters.
Monitor -- In command processing.
Effect -- None.
Remedy -- Close the channel prior to assignment.

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Error messages / troubleshooting

1559 Message text Channel specification inadmissible

Cause -- An attempt has been made to transmit a productive command via

the SINEC L2 bus channel.
-- An attempt has been made to output the listing or the message
buffer through the SINEC H1 channel to a third station.
Monitor -- In command processing.
Effect -- None.
Remedy -- None.
1560 Message text Channel already closed

Cause -- An attempt has been made to close a channel that is already closed.
Monitor -- In command processing.
Effect -- None.
Remedy -- Abort.
1561 Message text SINEC L2 communication channels not closed

Cause -- An attempt has been made to close the SINEC L2 bus channel without
all the SINEC L2 communication channels being closed first.
Monitor -- In command processing.
Effect -- None.
Remedy -- Close all the SINEC L2 communication channels.
1562 Message text <SINEC L2, SINEC H1> board not available

Cause -- An attempt has been made to access a SINEC L2 or SINEC H1

channel without the corresponding board being installed.
Monitor -- In command processing.
Effect -- None.
Remedy -- Install the corresponding board.
1564 Message text Value range exceeded

Cause -- The wait time in the WAIT_SEC command, expressed in basic clock
rate cycles, exceeds the long range, i.e. is greater than 2147483647.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Enter shorter wait times.
1565 Message text SINEC L2 CONFIGURATION ERROR **

Cause -- The opening or closing of a SINEC L2 channel is refused on account

of a configuration error detected by the SINEC L2 module.
Monitor -- In command processing.
Effect -- None.
Remedy -- Check and correct the channel parameters (e.g. baud rate).

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 1 Error messages / troubleshooting (continued)

1566 Message text SINEC L2 TRANSMISSION ERROR <error no. SINEC L2--M>

Cause -- Data transmission via SINEC L2 is not possible on account of an error

detected by the SINEC L2 module.
Monitor -- In data transmission.
Effect -- None.
Remedy -- Check the transmission link and rectify the error.
1567 Message text NO CONNECTION TO SINEC L2 BOARD

Cause -- The connection of the IFC to the SINEC L2 board is faulty.

Monitor -- Cyclic
Effect -- None.
Remedy -- Carry out warm start;
-- If fault recurs, exchange board (IFC with SINEC L2 board).
1568 Message text Maximum no. of processes assigned to channel

Cause -- Too many processes are running through the serial interface.
Monitor --
Effect --
Remedy -- Wait until a process is finished.
1569 Message text Parameter change inadmissible, channel assigned

Cause -- An attempt has been made to allocate parameters differing from the
current ones to a channel that is already assigned.
Monitor --
Effect --
Remedy -- Correct the data used for the channel as required, or close the channel
and re--open it with the appropriate parameters.
1570 Message text Invalid parameter value

Cause -- The maximum value of a channel parameter has been exceeded.

Monitor --
Effect --
Remedy -- Correct the channel parameter.
1571 Message text Baud rate summation exceeded

Cause -- The aggregate baud rate of both channels has been exceeded (it is
limited to 19200 bauds).
Monitor --
Effect --
Remedy -- Alter the baud rate.

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Error messages / troubleshooting

1572 Message text Protocol timeout

Cause -- The defined protocol time has been exceeded.

Monitor --
Effect --
Remedy -- Check whether the physical connection to the periphery still exists.
Increase the timeout setting appropriately if it is too low.
1573 Message text IFC syntax error

Cause -- During an attempt to open or close a channel, a syntax error has

occurred in the interface CPU with regard to the command generated
by the control.
Monitor --
Effect --
Remedy -- Close and re--open the channel.
1574 Message text KRC system error <error number> <originator>

Cause -- KRC system error (core system, not acknowledgeable). “KRC system
error 0” indicates that a task has crashed.
Monitor --
Effect -- Maximum braking, all active commands inhibited.
Remedy -- Reboot the KRC controller.
1576 Message text BASE change inadmissible

Cause -- During conveyor operation an attempt has been made to change the
BASE.
Monitor --
Effect -- Maximum braking.
Remedy -- Alter the program accordingly.
1577 Message text <Name> already exists

Cause -- A SUB module cannot be created in the editor if an SCR module of

the same name already exists and vice versa.
Monitor -- Command processing.
Effect --
Remedy -- Change the name of the module.
1578 Message text <Value> inadmissible

Cause -- An inadmissible value has been entered.

Monitor -- Command processing.
Effect --
Remedy -- Enter an admissible value.

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 1 Error messages / troubleshooting (continued)

1579 Message text APS system error

Cause -- Internal error in APS detected by APS.

Monitor --
Effect --
Remedy -- Request confirmation from APS, reboot probably required.
1580 Message text Tech. function $TECH[<parameters 1--3>].FCT inadmissible

Cause -- The function parameters programmed in $TECH[i].FKT i=1..3, are

incompatible with the function definition.
Monitor -- The function parameters are checked by the interpreter in the advance
run.
Effect -- Ramp--down braking.
Remedy -- Correct the function parameters.
1581 Message text Tech mode inadmissible

Cause -- The “CYCLE” mode has been programmed for the technology cate-
gory “VEL”.
Monitor -- In the interpreter when changing CLASS or MODE.
Effect -- Ramp--down braking.
Remedy -- Alter the program.
1582 Message text Kinematic instruction inadmissible

Cause -- A non--existent external kinematic system has been assigned to the

system variable “$BASE” with the function EK.
Monitor --
Effect --
Remedy --
1583 Message text <SER_1> block size error

Cause -- The received data block is too large.

Monitor --
Effect --
Remedy -- Alter the buffer length in the external data storage device to the control--
internal size or smaller.
1584 Message text Program structure for resume inadmissible

Cause -- An interrupt has occurred in the program section where the interrupt
with RESUME was declared. The return is therefore executed to the
advance run pointer, which is not defined.
Monitor --
Effect -- Ramp--down braking.
Remedy -- RESUME may be used only in conjunction with the subprogram
technique. The interrupt must not be triggered on the level where the
interrupt was declared.

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1585 Message text CA parameter out of range

Cause -- Too large a value has been programmed for the parameter CA
(complete angle) in the CIRC block.
Monitor --
Effect --
Remedy -- Correct the value of the CA appropriately.
1586 Message text SINEC AP/TF ERROR <SINEC AP/TF--Fhlcode>

Cause -- See “SINEC AP Technological Functions, Part B”.

Monitor -- In command processing.
Effect --
Remedy -- See “SINEC AP Technological Functions, Part B”.
1587 Message text Application comm. interrupted (File server)

Cause -- The application communication with the file server has been inter-
rupted or disconnected.
Monitor -- In command processing.
Effect --
Remedy -- Check the transmission link between the ACR and the file server.
1588 Message text Path inadmissible

Cause -- The path specification for SINEC H1 contains “wildcards”.

Monitor -- In command processing.
Effect --
Remedy -- Copy just one file at a time.
1589 Message text ... closing channel inadmissible, channel active

Cause -- The channel concerned cannot be closed during transmission.

Monitor --
Effect --
Remedy -- Wait for the transmission to finish or abort the transmission.
1590 Message text ENUM not declared in $CONFIG

Cause -- A SET INFO is being applied to an ENUM variable from a user data list.
The search path extension has been altered again --> no access to
ENUM type information.
Monitor -- Command processing.
Effect --
Remedy -- Enter ENUM declaration and variable declaration in the
“$CONFIG.DAT” file.

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 1 Error messages / troubleshooting (continued)

1591 Message text MINIMUM MUST BE LESS THAN MAXIMUM

Cause -- The minimum value defined for an ANOUT command was greater
than the maximum
Monitor --
Effect -- Interpreter stop
Remedy -- Set minimum to a value less than the maximum
1595 Message text Load dependent ACC. adaption not possible for PTP <...>

Cause -- The simulation calculation of the integrated dynamic model exceeds

the given limit values of the continuous gear torque.
Monitor -- At every PTP preparation with activated load--dependent acceleration
adaptation.
Effect -- Operator information; no effect.
Remedy -- If allowed: increase the max. permissible continuous gear torque
“$DYN_DAT[50..]”.
-- Lower the optimization limit “$OPTEXCLUDE”.
1596 Message text Tacho balance only possible for one axis

Cause -- An attempt has been made to carry out a DSE tacho balance for
several axes at the same time.
Monitor -- On value assignment to “$PROG_EEPOT”.
Effect -- Value assignment is not carried out.
Remedy -- Carry out tacho balance for one axis only.
1597 Message text Not a DSE axis

Cause -- An attempt to carry out a tacho balance for an axis which is not present
on the DSE board.
Monitor -- On value assignment to “$TACH_CHANGE”.
Effect -- Value assignment is not carried out.
Remedy -- Carry out tacho balance for DSE axes only.
1598 Message text Load not programmed

Cause -- With the acceleration adaptation activated, the load has not been
completely programmed.
Monitor -- In every motion in the program or interrupt.
Effect -- Program stop.
Remedy -- Correctly program “$LOAD”.
1599 Message text No axis selected

Cause -- An attempt has been made to carry out a tacho balance even though
no axis has been selected.
Monitor -- On value assignment to “$TACH_CHANGE”.
Effect -- Value assignment is not carried out.
Remedy -- First select an axis, then carry out tacho balance.
1600 Message text CONTROL : **

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1601 Message text No block coincidence, step mode first

Cause -- No block coincidence when changing mode to AUTO.

Monitor --
Effect --
Remedy -- Achieve block coincidence in the SINGLE--STEP mode first.
1602 Message text BCO run in step mode required

1603 Message text Safety fence open

1604 Message text Error in trace definition

Cause -- The trace has been incorrectly defined in the “TRACE.DEF” file.
Monitor -- When starting a trace.
Effect --
Remedy -- Correct “TRACE.DEF”.
1605 Message text Error reading TRACE.DEF

Cause -- The “TRACE.DEF” file could not be read at the start of trace recording.
Monitor -- When starting a trace.
Effect --
Remedy -- Make “TRACE.DEF” available, start or check FTP server.
1606 Message text InterBus : bus error <segment, position>

Cause -- Error or malfunction in data transmission on the Interbus.

Monitor --
Effect -- Data transmission on the Interbus is stopped, outputs are reset.
Remedy -- Troubleshooting with CMD (Phoenix diagnostic tool).
1607 Message text InterBus : bus warning <segment, position>

Cause -- Malfunction in the bus module specified (Segment Position).

Monitor --
Effect -- Outputs are reset.
Remedy -- Eliminate the error in the specified module, diagnosis with CMD
software (Phoenix).
1608 Message text Assignment of function value to $CYCFLAG inadmissible

Cause -- Return value of a BOOL function has been assigned directly to a

$CYCFLAG.
Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Alter the program, acknowledge message.

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 1 Error messages / troubleshooting (continued)

1609 Message text Assignment of runtime value to $CYCFLAG inadmissible

Cause -- A $CYCFLAG has been assigned local runtime data.

Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Alter the program (use global variables only), acknowledge message.
1610 Message text ERROR IN CONFIGURATION FILE

1611 Message text MAC--ID IN USE

1612 Message text ERROR DURING TASK START

1613 Message text ERROR DURING ALLOCATE DEVICE **

1614 Message text ERROR DURING SCAN DEVICE **

1615 Message text “PRIO” 40--80 CLOSED

1616 Message text Start locked <string>

Cause -- Start is inhibited during insertion of one or more blocks in PROCOR.

1617 Message text InterBus: bus error in slave ring

Cause -- Bus error in the ring of the higher--level controller (PLC, etc.).
Monitor --
Effect -- Automatic External interface deactivated.
Remedy -- Rectify bus error in higher--level ring.
2000 Message text NEW BLOCK IS NOT A DECLARATION

2001 Message text BINARY OUTPUT SIGNAL EXPECTED

2002 Message text INCORRECT INITIALIZATION

2003 Message text FAULTY INITIALIZATION VALUE

2004 Message text “DEFDAT” EXPECTED

2005 Message text VARIABLE NOT INITIALIZED

2006 Message text “CA” EXPECTED

2007 Message text “DEF” OR “DEFFCT” EXPECTED

2008 Message text BLOCK CANNOT BE MODIFIED

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Error messages / troubleshooting

2009 Message text GLOBAL SR/FCT CANNOT BE RENAMED

2010 Message text DATA LIST CANNOT BE RENAMED

2011 Message text DIFFERENT TYPES WITH CHANGE OF INITIAL VALUE

2012 Message text SUB CANNOT BE LINKED TO SRC

2013 Message text VARIABLE CANNOT BE RENAMED

2014 Message text INDEX CANNOT BE CHANGED

2015 Message text NOT A SYSTEM SUBROUTINE

2016 Message text NOT A SYSTEM FUNCTION

2017 Message text SYNTAX ERROR IN P_PATH

2018 Message text UNUSED EXTERNALLY DECLARED SUBROUTINE

2019 Message text EXPECTED EXT. SUBROUTINE, FOUND FUNCTION

2020 Message text EXTERNAL FUNCTION EXPECTED, SUBROUTINE FOUND

2021 Message text DATA LIST NOT “PUBLIC”

2022 Message text IMPORTED VARIABLE NOT DECLARED IN DATA LIST

2023 Message text IMPORTED VARIABLE NOT DECLARED IN DATA LIST

2024 Message text IMPORTED VARIABLE TYPE/DIMENSION CONFLICT

2025 Message text EXTERNAL AND SR/FCT DECLARATIONS DO NOT MATCH

2026 Message text EXTERNAL AND SR/FCT DECLARATIONS DO NOT MATCH

2027 Message text IMPORT INTERFACE NOT CORRECT

2028 Message text EXT[FCT] AND DEF[FCT] PARAMETERS ARE INCOMPATIBLE

2029 Message text SYNTAX ERROR IN MODULE

2030 Message text MODULE USED BY ANOTHER PROCESS

2031 Message text MODULE PACKAGE NOT AVAILABLE

2032 Message text ILLEGAL COMMAND

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 1 Error messages / troubleshooting (continued)

2033 Message text END OF BLOCK OR COMMENT EXPECTED

2034 Message text INSERT BEFORE FIRST BLOCK NOT ALLOWED

2035 Message text INVALID BLOCK NUMBER

2036 Message text ONLY COMMENT MAY BE ENTERED AFTER “ENDDAT”

2037 Message text ILLEGAL OR UNKNOWN BLOCK

2038 Message text DECLARATION NOT IN DECLARATION SECTION

2039 Message text INSTRUCTION NOT IN INSTRUCTION SECTION

2040 Message text INITIAL VALUE BLOCK NOT INITIALIZATION SECTION

2041 Message text ERROR IN “DEFDAT”, INSERT NOT SUCCESSFUL

2042 Message text “DEFDAT” NOT ALLOWED

2043 Message text ERROR IN GLOBAL “DEF”/“DEFFCT”

2044 Message text “DEF”/“DEFFCT” NOT ALLOWED

2045 Message text “END”/“ENDFCT”/“ENDDAT” NOT ALLOWED HERE

2046 Message text “EXT”/“EXTFCT”/“IMPORT” NOT ALLOWED HERE

2047 Message text FILE NOT FOUND

2048 Message text ERROR ON ENTERING THE DATA LIST

2049 Message text INITIAL VALUE NOT ALLOWED HERE

2050 Message text INITIAL VALUE SYNTAX INCORRECT

2051 Message text NAME IN FIRST LINE MUST BE SAME AS MODULE NAME

2052 Message text ARRAY NAME ENTERED NOT ALLOWED HERE

2053 Message text INITIAL VALUE OF INDEX ALREADY EXISTS

2054 Message text ’=’ EXPECTED

2055 Message text REAL CONSTANT EXPECTED

2056 Message text ’{’ EXPECTED

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Error messages / troubleshooting

2057 Message text COMPONENT NOT PART OF VARIABLE TYPE

2058 Message text CONSTANT NAME NOT PART OF VARIABLE TYPE

2059 Message text STRING CONSTANT TOO LONG

2060 Message text ARRAY INDEX ENTERED INADMISSIBLE HERE

2061 Message text AGGREGATE COMPONENT INITIALIZED MORE THAN ONCE

2062 Message text INFORMATION LOSS POSSIBLE ON CHANGE OF TYPE

2063 Message text INTEGER, REAL OR CHARACTER CONSTANT EXPECTED

2064 Message text CHARACTER OR INTEGER CONSTANT EXPECTED

2065 Message text “TRUE” OR “FALSE” EXPECTED

2066 Message text ENUM CONSTANT TYPE DOES NOT MATCH ENUM VARIABLE

2067 Message text COMPONENT ARRAY SPEC. MULTIDIMENSIONAL

2068 Message text ARRAY SUBSCRIPT MISSING

2069 Message text COMPONENT IS NO ARRAY

2070 Message text ’#’ OR ENUM TYPE NAME EXPECTED

2071 Message text STRUCTURE TYPE NAME EXPECTED

2072 Message text TYPENAME INCOMPATIBLE WITH TEXT

2073 Message text COMPONENT NEITHER PART OF “FRAME” OR “POS”

2074 Message text ASCENDING INDICES EXPECTED

2075 Message text NUMBER TOO LOW

2076 Message text ’IS’ EXPECTED

2077 Message text INTEGER CONSTANT EXPECTED

2078 Message text IDENTICAL PREDEFINED SIGNAL NAMES EXPECTED

2079 Message text COMPONENT TYPE UNKNOWN

2080 Message text PROTOCOL VARIABLE DECLARED IMPLICITLY

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 1 Error messages / troubleshooting (continued)

2081 Message text “POS”, “FRAME”, OR “AXIS” EXPECTED

2082 Message text VARIABLE WITH STRUCTURE TYPE EXPECTED

2083 Message text PREDEFINED SIGNAL EXPECTED

2084 Message text PREDEFINED CHANNEL NAME EXPECTED

2085 Message text ’[’ EXPECTED

2086 Message text ARRAY LIMIT MISSING

2087 Message text ’,’ EXPECTED

2088 Message text SIGNAL INDEX TOO LARGE

2089 Message text ’..’ EXPECTED

2090 Message text ONE DIMENSIONAL CHAR FIELD EXPECTED

2091 Message text “IN” OR “OUT” EXPECTED

2092 Message text SYNTAX ERROR IN ARRAY SPECIFICATION

2093 Message text POS. INTEGER, “]” OR “,” EXPECTED

2094 Message text NO MORE THAN THREE DIMENSIONS ALLOWED

2095 Message text RELATIVE P_PATH NOT COMPATIBLE WITH NODE

2096 Message text “]” OR “,” EXPECTED

2097 Message text STRUCTURE TYPE VARIABLE NOT ALLOWED

2098 Message text VARIABLE NOT DECLARED IN DATA LIST

2099 Message text ARRAY INDEX EXCEEDS ARRAY LIMITS

2100 Message text POSITIVE INTEGER EXPECTED

2101 Message text ARRAY INDEX NOT COMPATIBLE WITH INDEX

2102 Message text ARRAY LIMIT EXCEEDED

2103 Message text NO VARIABLE EXISTS WITH THIS NAME

2104 Message text PARAMETER SPECIFICATION NOT ALLOWED IN DATA LIST

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Error messages / troubleshooting

2105 Message text LOCAL PARAMETER TYPE DEFINED LOCALLY

2106 Message text BLOCK CANNOT BE DELETED

2107 Message text DELETE MODULE BY MEANS OF DEDICATED FUNCTION

2108 Message text “ERROR” TOKEN IN I--CODE

2109 Message text END STATEMENT MISSING

2110 Message text INCORRECT END OF CONTROL STRUCTURE

2111 Message text SUBROUTINE/FUNCTION INCORRECTLY COMPLETED

2112 Message text IDENTIFIER NOT DECLARED

2113 Message text PROTOCOL VARIABLE MUST BE OF STRUCTURE TYPE

2114 Message text CORRECT TYPE ENTRY UNAVAILABLE

2115 Message text COMPONENT TYPE NOT DEFINED OR CORRECTLY DEFINED

2116 Message text TYPE OF A PARAMETER IS DEFINED LOCALLY

2117 Message text ENDDAT STATEMENT MISSING

2118 Message text TYPE CHANGE FOR INITIAL VALUE NOT POSSIBLE

2119 Message text COMPILE LOC. NOT COMPATIBLE WITH CALL LOCATION

2120 Message text OBJECT MUST BE DECLARED IN DATA LIST OR IMPLICITLY

2121 Message text INCORRECT DIMENSION

2122 Message text NAME NOT DECLARED AS ARRAY

2123 Message text NAME NOT DECLARED AS FUNCTION

2124 Message text VARIABLE NOT DECLARED IN DATA LIST

2125 Message text COMPONENT NOT PART OF TYPE

2126 Message text NO STRUCTURE DATA TYPE

2127 Message text FORMAL PARAMETER DECLARATION MISSING

2128 Message text MORE ACTUAL THAN FORMAL PARAMETERS SPECIFIED

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 1 Error messages / troubleshooting (continued)

2129 Message text FORMAL PARAMETER NOT DEFINED

2130 Message text NOT ALLOWED EXPRESSION AFTER RETURN INSTRUCTION

2131 Message text EXPRESSION AFTER RETURNING INSTRUCTION MISSING

2132 Message text NO INTERFACES ALLOWED

2133 Message text TYPE MUST BE “POS”,“FRAME”,“AXIS”

2134 Message text OBJECT TYPE NOT VALID

2135 Message text NAME NOT DECLARED AS SUBROUTINE

2136 Message text LOCAL SUBROUTINE NOT ALLOWED IN PROCESS COMMANDS

2137 Message text NAME NOT DECLARED AS SIMPLE VARIABLE

2138 Message text NO NAME OF SUCH A CONSTANT TYPE

2139 Message text SPECIFIED TYPE IS NOT ENUM TYPE

2140 Message text NO ENUM TYPE SPECIFIED

2141 Message text INDEXING OR [] NOT ALLOWED

2142 Message text INDEXING OR [] EXPECTED

2143 Message text END OF CONTROL STRUCTURE NOT ALLOWED HERE

2144 Message text “ENDLOOP” MISSING

2145 Message text “ENDWHILE” MISSING

2146 Message text “ENDFOR” MISSING

2147 Message text “UNTIL” MISSING

2148 Message text “ENDIF” MISSING

2149 Message text “ENDSWITCH” MISSING

2150 Message text “SWITCH” CONTAINS NO “CASE”

2151 Message text NO “CASE” AFTER “SWITCH”

2152 Message text “CASE”/“DEFAULT” AFTER “DEFAULT”

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Error messages / troubleshooting

2153 Message text “EXIT” NOT IN LOOP BODY

2154 Message text NAME NOT DECLARED AS CHANNEL

2155 Message text NAME NOT DECLARED AS LABEL

2156 Message text JUMP DESTINATION NOT DECLARED LOCALLY

2157 Message text JUMP DESTINATION NOT DECLARED GLOBALLY

2158 Message text JUMP TO LABEL NOT ALLOWED

2159 Message text THERE EXISTS AN INVALID JUMP TO THIS LABEL

2160 Message text “THEN” EXPECTED

2161 Message text “DO” EXPECTED

2162 Message text INVALID INPUT CHARACTER

2163 Message text COUNT EXCEEDED

2164 Message text NO “/” IN P_PATH

2165 Message text WILDCARD NOT ALLOWED

2166 Message text NO FILE NAME

2167 Message text NAME TOO LONG

2168 Message text INVALID EXTENSION

2169 Message text PATH INCORRECT

2170 Message text BLANK CHARACTER INVALID

2171 Message text EXTENSION NOT ALLOWED

2172 Message text CHANNEL HANDLE EXPECTED

2173 Message text ABSOLUTE PATH EXPECTED

2174 Message text ’TO’ EXPECTED

2175 Message text USER, DEVICE OR NODE TYPE NAME EXPECTED

2176 Message text “OBJ”, “NODE”, “USER”, “PERI” EXPECTED

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 1 Error messages / troubleshooting (continued)

2177 Message text “NODE”, “USER”, “PERI” EXPECTED

2178 Message text VALUE MISSING

2179 Message text “NODE” MUST FOLLOW

2180 Message text “BVS” OR “MSD” MUST FOLLOW

2181 Message text “DEV” MUST FOLLOW

2182 Message text CONSTANT OR VARIABLE EXPECTED

2183 Message text OPTION ENTERED TWICE

2184 Message text OPTION EXPECTED AFTER MINUS SIGN

2185 Message text BLOCK NUMBER EXPECTED

2186 Message text BLOCK NUMBER MUST BE POSITIVE

2187 Message text STRING EXPECTED

2188 Message text STRING EXPECTED

2189 Message text INITIAL BLOCK NUMBER > FINAL BLOCK NUMBER

2190 Message text ATTRIBUTE NAME MUST FOLLOW

2191 Message text CONSTANT FOR KEY MUST FOLLOW

2192 Message text EXTENSION MISSING

2193 Message text EXTENSION OR ’.*’ INVALID

2194 Message text “WHEN” EXPECTED

2195 Message text CHANNEL NAME EXPECTED

2196 Message text ABSOLUTE PATH AFTER DEVICE/CHANNEL NAME EXPECTED

2197 Message text “INFO” EXPECTED

2198 Message text “MESSAGE” EXPECTED

2199 Message text INTEGER CONSTNT EXPECTED

2200 Message text KI EXPECTED: 1<=I<=12

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Error messages / troubleshooting

2201 Message text “+” OR “--” EXPECTED

2202 Message text “VAR” EXPECTED

2203 Message text ONLY “I”, “B”, “H”, “V” ALLOWED AS OPTION ONLY

2204 Message text ERROR AT END OF BLOCK

2205 Message text “SEC”, “FOR” OR “CLOCK” EXPECTED

2206 Message text CHANNEL NAME MISSING

2207 Message text NAME NOT DECLARED AS CHANNEL

2208 Message text “DEL” MUST FOLLOW

2209 Message text TOO MUCH MEMORY REQUIRED FOR DYNAMIC VARIABLE

2210 Message text “,” EXPECTED

2211 Message text SYMBOL IS NOT AT BEGINNING OF EXPR./VALUE ASSIGNMENT

2212 Message text LABEL NOT DECLARED LOCALLY

2213 Message text “WAIT CLOCK” NOT AVAILABLE IN PACKAGE 1

2214 Message text ARRAY CONTAINS TOO MANY ELEMENTS

2215 Message text TYPE TOO LARGE

2216 Message text ENTRY IN SYMBOL TABLE IS NOT LABEL

2217 Message text “USER”, “ACCESS” OR “COMMENT” EXPECTED

2218 Message text NESTING DEPTH EXCEEDED

2219 Message text OPERAND OR EXPRESSION EXPECTED

2220 Message text “)” EXPECTED

2221 Message text NAME OF LOOP VARIABLE EXPECTED

2222 Message text EXPRESSION TYPE NOT EQUAL TO STAT_T

2223 Message text EXPRESSION TYPE NOT EQUAL TO INT, REAL, CHAR, BOOL,
ENUM
2224 Message text CONSTANT EXPECTED

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 1 Error messages / troubleshooting (continued)

2225 Message text POSITIVE INTEGER CONSTANT EXPECTED

2226 Message text INVALID SIGN

2227 Message text LEFT OPERAND NOT EQUAL TO INT, REAL

2228 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL

2229 Message text BOTH OPERANDS NOT EQUAL TO INT, REAL

2230 Message text LEFT OPERAND NOT EQUAL TO INT, CHAR

2231 Message text RIGHT OPERAND NOT EQUAL TO INT, CHAR

2232 Message text BOTH OPERANDS NOT EQUAL TO INT, CHAR

2233 Message text LEFT OPERAND NOT EQUAL TO BOOL

2234 Message text RIGHT OPERAND NOT EQUAL TO BOOL

2235 Message text BOTH OPERANDS NOT EQUAL TO BOOL

2236 Message text LEFT OPERAND NOT EQUAL TO INT, REAL, CHAR, ENUM

2237 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL, CHAR, ENUM

2238 Message text BOTH OPERANDS NOT EQUAL TO INT, REAL, CHAR, ENUM

2240 Message text LEFT OPERAND NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2241 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2242 Message text OPERANDS NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2243 Message text OPERAND TYPES NOT COMPARABLE

2244 Message text LEFT OPERAND NOT EQUAL TO POS, FRAME

2245 Message text RIGHT OPERAND NOT EQUAL TO POS, FRAME

2246 Message text OPERANDS NOT EQUAL TO POS, FRAME

2247 Message text BOTH SIDES OF THE VALUE ASSIGNMENT ARE NOT
COMPATIBLE
2248 Message text EXPRESSION NOT EQUAL TO INT, REAL

2249 Message text EXPRESSION NOT EQUAL TO INT

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Error messages / troubleshooting

2250 Message text EXPRESSION NOT EQUAL TO BOOL

2251 Message text EXPRESSION NOT EQUAL TO POS, FRAME

2252 Message text EXPRESSION NOT EQUAL TO POS, FRAME, AXIS

2253 Message text VARIABLE OR ARRAY ELEMENT EXPECTED

2254 Message text SELECTION INVALID HERE

2255 Message text EXPRESSION NOT EQUAL TO CHAR, INT, ENUM

2256 Message text OPERAND NOT EQUAL TO INT, REAL

2257 Message text OPERAND NOT EQUAL TO, CHAR

2258 Message text OPERAND NOT EQUAL TO BOOL

2259 Message text LEFT OPERAND: ARRAY OR PATH INVALID

2260 Message text RIGHT OPERAND: ARRAY INVALID

2261 Message text RIGHT OPERAND: ARRAY WITH DIMENSION > 1 INVALID

2262 Message text ARRAY AS OPERAND INVALID

2263 Message text TYPE OF LOOP VARIABLE NOT EQUAL TO INT

2264 Message text EXPRESSION TYPE NOT “MODUS_T”

2265 Message text COMMA OR “)” EXPECTED

2266 Message text TYPE COMPONENT INCOMPATIBLE WITH TYPE INITIAL VALUE

2267 Message text LEFT SIDE: ARRAY INVALID

2268 Message text RIGHT SIDE: ARRAY INVALID

2269 Message text RIGHT STRING CONSTANT => LEFT INDEXING

2270 Message text TYPE OF LEFT AND RIGHT HAND SIDE INCOMPATIBLE

2271 Message text PATH EXPRESSION REQUIRED! (ARRAY!)

2272 Message text PATH EXPRESSION INVALID

2273 Message text ARRAY INVALID

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2274 Message text TYPE ACTUAL/FORMAL PARAMETER INCOMPATIBLE

2275 Message text TYPE ACTUAL/FORMAL PARAMETER INCOMPATIBLE

2276 Message text DIMENSION INCOMPATIBLE

2277 Message text ARRAY DIMENSION GREATER THAN 1 NOT ALLOWED

2278 Message text RETURN VALUE: STRING CONSTANT ARRAY INVALID

2279 Message text TYPE RETURN VALUE INCOMPATIBLE WITH TYPE FUNCTION

2280 Message text RIGHT OPERAND: PARENTHESES INVALID IN PATH

EXPRESSIONS
2281 Message text PARENTHESES NOT ALLOWED FOR PATH EXPRESSIONS

2282 Message text FIRST CONSTANT INCOMPATIBLE WITH THIS CONSTANT

2283 Message text CONSTANT TYPE INCOMPATIBLE WITH EXPR. TYPE IN SWITCH

2284 Message text NO SELECTION OF ENTIRE ARRAYS

2285 Message text COMPONENT NAME EXPECTED

2286 Message text COMPONENT SPECIFIED TWICE

2287 Message text “,” OR “}” EXPECTED

2288 Message text “]” EXPECTED

2289 Message text INCORRECT RANGE SPECIFICATION

2290 Message text CONSTANT EXPECTED

2291 Message text NAME OF A STRUCTURE DATA TYPE EXPECTED

2292 Message text NO DATA TYPE NAME: CREATION NOT ALLOWED

2293 Message text COMPONENT NOT DECLARED AS ARRAY

2294 Message text “#”EXPECTED

2295 Message text ARRAY COMPONENTS CANNOT BE INDEXED

2296 Message text NOT A NAME OF A CONSTANT OF THIS TYPE

2297 Message text COMPONENT DECLARED AS ARRAY: INDEXING EXPECTED

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Error messages / troubleshooting

2298 Message text AGGREGATE TYPE (POS) INCOMPATIBLE WITH CONTEXT

2299 Message text EXPECTED CONSTANT TYPE UNKNOWN

2300 Message text NOT A NAME OF AN ENUM DATA TYPE

2301 Message text NOT AN AXIS COMPONENT

2302 Message text NOT A FRAME COMPONENT

2303 Message text NOT A POS COMPONENT

2304 Message text INCORRECT END OF PARAMETER LIST

2305 Message text NAME OF A SUBROUTINE EXPECTED

2306 Message text RELATIVE PATH INVALID

2307 Message text ANALOG INPUT EXPECTED

2308 Message text DIGITAL INPUT EXPECTED

2309 Message text “(”EXPECTED

2310 Message text DIGITAL INPUT NOT ALLOWED HERE

2311 Message text TYPE OF FORMAL PARAMETER INVALID

2312 Message text PROGRAM NOT AVAILABLE

2313 Message text NO ERROR

2314 Message text NO FILE NAME SPECIFIED

2315 Message text FILE NAME TOO LONG

2316 Message text FILE NAME MAY NOT CONTAIN “.”

2317 Message text HIERARCH. NO. NOT IN SEARCH PATH

2318 Message text PARAMETERS TO BE DECLARED IN MODULE

2319 Message text “ON”,“OFF”,“ENABLE”,“DISABLE”,“DECL” EXPECTED

2320 Message text SIGNAL NAME CANNOT BE CHANGED

2321 Message text PREDEFINED SIGNAL CANNOT BE CHANGED

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 1 Error messages / troubleshooting (continued)

2322 Message text SIGNAL TYPES ARE DIFFERENT

2323 Message text SIGNAL TYPE CANNOT BE CHANGED

2324 Message text DUAL DECLARATION

2325 Message text TYPE UNKNOWN

2326 Message text NAME EXPECTED

2327 Message text TYPE EXPNAME OF A SIGNAL EXPECTED

2328 Message text “:” EXPECTED

2329 Message text COMBINED ANALOG SIGNALS INADMISSIBLE

2330 Message text NAME OF A SIGNAL EXPECTED

2331 Message text ANALOG OUTPUT EXPECTED

2332 Message text ARRAY ELEMENT/VARIABLE NOT TYPE REAL

2333 Message text “*” EXPECTED

2334 Message text REAL CONSTANT, VARIABLE OR ARRAY ELEMENT EXPECTED

2335 Message text COMBINED SIGNAL MORE THAN 32 BITS

2336 Message text “ON” OR “OFF” EXPECTED

2337 Message text ARRAY LIMITS INVALID IN PARAMETER SPECIFICATION

2338 Message text ARRAY LIMITS INVALID IN PARAMETER SPECIFICATION

2339 Message text TEACH--IN FOR TYPE INVALID

2340 Message text RECOMPILE BLOCK

2341 Message text INT. CONSTANT NOT EQUAL 0 EXPECTED

2342 Message text NO MORE THAN 12 CHARACTERS

2343 Message text NO GLOBAL PROCEDURE AVAILABLE

2344 Message text “DISTANCE” EXPECTED

2345 Message text “DELAY” EXPECTED

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Error messages / troubleshooting

2346 Message text “PRIO” EXPECTED

2347 Message text “PRIO” BETWEEN 40 AND 80 NOT ALLOWED

2348 Message text “DISTANCE”: ONLY 1 OR 0 ALLOWED

2349 Message text ASSIGNMENT TO CONSTANT NOT PERMISSIBLE

2350 Message text RUNTIME DATA OF THE MAIN PROGRAM CANNOT BE USED

2351 Message text RUNTIME DATA CANNOT BE USED

2700 Message text <object name> BLOCK NOT AVAILABLE

2701 Message text <object name> BLOCK TOO LONG

2702 Message text <object name> BLOCK TOO LONG OR INCORRECTLY COMPLETED

2703 Message text TOO MANY ELEMENTS IN <object name> ARRAY

2704 Message text <object name> NO DYNAMIC MEMORY AVAILABLE

2705 Message text BLOCK <object name> CANNOT BE FORMATED

2706 Message text BLOCK <object name> CANNOT BE DECOMPILED

2707 Message text BLOCK <object name> UNAVAILABLE

2708 Message text STACKING DEPTH <object name> EXCEEDED

2709 Message text <object name> LINK LIST CANNOT BE EXTENDED

2710 Message text <object name> TOO MANY LOCAL SUBROUTINES

2711 Message text <object name> has reached maximum size

Cause -- When a module has reached the maximum size (65536 bytes) the
message “SRC HAS REACHED MAXIMUM SIZE AND CANNOT
BE ENLARGED”, for example, is displayed.
2712 Message text <object name> NOT ENOUGH MEMORY, FILE OPEN ERROR

2713 Message text <object name> NO FREE PHYSICAL MEMORY

2714 Message text <object name> NO FREE VIRTUAL MEMORY

2800 Message text INTERNAL COMPILER ERROR <object name>

2801 Message text <object name> ERROR IN MEMORY MANAGER <error number>

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 1 Error messages / troubleshooting (continued)

2803 Message text UNDEFINED SYNTAX ERROR

2821 Message text $ORI_TYPE implicitly set to #VAR

Cause -- The external TCP is activated for operating mode “T1” or “T2”
($IPO_MODE = TCP) and the orientation control $ORI_TYPE is set
to #JOINT. This combination is not permissible.
Monitor --
Effect -- $ORI_TYPE is implicitly set to #VAR.
Remedy -- Set $IPO_MODE to #BASE
-- Set $ORI_TYPE to #VAR or #CONSTANT
2822 Message text Blending $ORI_TYPE=#VAR/#CONSTANT to $ORI_TYPE=#JOINT
not possible
Cause -- Inconsistent axis angle in CP--CP approximation from $ORI_TYPE
= #VAR or #CONSTANT to $ORI_TYPE = #JOINT. This happens if
one of the wrist axis angles turns too greatly during a non--OriJoint
CP motion (see also message #1491).
Monitor --
Effect -- Exact stop
Remedy -- Avoid excessive rotation of the wrist axis angles during non--OriJoint
motions.
2829 Message text OriJoint not possible: Configuration of start and target position differs

Cause -- This occurs when the TCP is moved over the extension of the line
A 2 – A 3 (“elbow configuration”). This prevents the TCP from moving
with a different orientation to a programmed point.
Monitor --
Effect -- Ramp--down braking; the motion block cannot be executed with
$ORI_TYPE = #JOINT.
Remedy -- Set $ORI_TYPE to #VAR or “CONSTANT”
-- Change the orientation of the end point
4300 Message text <object name> COMPILE ?

4301 Message text <object name> COPY ?

4302 Message text <object name> OVERWRITE ?

Cause -- A file that is to be copied already exists.

Monitor -- In command processing.
4303 Message text <object> DELETE ?

4304 Message text <object> LINK ?

4305 Message text <object> UNLINK ?

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Error messages / troubleshooting

4307 Message text DELETE COMPLETE PROCEDURE ?

Cause -- DEF block is to be deleted. The DEF block can be deleted only
together with the complete procedure.
Monitor -- In command processing.
Effect -- None.
Remedy -- None.
4308 Message text DELETE COMPLETE INITIALIZATION ?

Cause -- An array declaration is to be deleted for which there is a subsequent

initialization (also subsequent blank lines). These have to be deleted too.
Monitor -- In command processing.
Effect -- None.
Remedy -- None.
4309 Message text <object name> PROGRAM, OVERWRITE ?

Cause -- The file already exists and the operator intends to recreate it (COPY).
Monitor -- None.
4310 Message text <object name> SELECTED, OVERWRITE ?

Cause -- The file already exists, is selected and the operator intends to recreate it.
Monitor -- Command processing (COPY command).
Effect -- None.
4311 Message text <object name> PROGRAM DELETE ?

Cause -- The file that is to be deleted is a program.

Monitor -- Command processing (DELETE command).
Effect -- None.
4312 Message text <object name> SELECTED, DELETE

Cause -- The file that is to be deleted is selected.

Monitor -- Command processing (DELETE command).
Effect -- None.
4314 Message text DIRECTORY NOT FOUND ! CREATE ?

Cause -- The destination directory has not yet been created on the PC.
Monitor --
Effect --
Remedy -- Create the directory.
4315 Message text <file name> ACTIVE : PROCESS STOP ?

Cause -- Reloading of machine data.

Monitor --
Effect -- Program processing is stopped.

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 1 Error messages / troubleshooting (continued)

Remedy -- The program must be restarted after the machine data have been
loaded.
9000 Message text ******

Cause -- User--programmable message.

Monitor --
Effect --
Remedy --

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13 Appendix
SOFTWARE

KR C1

Appendix

Release 3.2

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 Error messages / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Message groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Message time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Message number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Originator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Message text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 List of error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 A ............................................................................ 95
2.3 B ............................................................................ 96
2.4 C ............................................................................ 97
2.5 D ............................................................................ 98
2.6 E ............................................................................ 99
2.7 F ............................................................................ 100
2.8 G ............................................................................ 101
2.9 H ............................................................................ 101
2.10 I ............................................................................. 102
2.11 J............................................................................. 102
2.12 K ............................................................................ 102
2.13 L ............................................................................ 103
2.14 M ............................................................................ 103
2.15 N ............................................................................ 104
2.16 O ............................................................................ 105
2.17 P ............................................................................ 105
2.18 R ............................................................................ 107
2.19 S ............................................................................ 108
2.20 T ............................................................................ 109
2.21 U ............................................................................ 110
2.22 V ............................................................................ 111
2.23 W ............................................................................ 111
2.24 X ............................................................................ 112

3 System variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4 Keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5 History of Operating Handbook from V2.3 --> V3.2 . . . . . . . . . . . . . . . . . . 117

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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Appendix

5.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

5.3 Robot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4 Initial Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.5 Operator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.6 Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.7 Configuration --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.8 User Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.9 Expert Programming --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.10 Diagnostic Functions --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.11 Additional Functions --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.12 Applications --> see Programming Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

6 Overall index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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 1 Error messages / troubleshooting

1 Error messages / troubleshooting

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

COMMAND ACCELERATION EXCEEDED A2

ACTIVE COMMANDS INHIBITED

1.1 Message groups

Hint messages
provide the operator with explanatory information, for example, if an illegal key has been
pressed.

Operational messages
signal the status of the system that has led to a control reaction, e.g. Emergency Stop. The
message is cleared once its cause has been eliminated. In some cases, a secondary signal
that has to be acknowledged is set for reasons of safety.

Acknowledgement messages
indicate a situation that must in all instances be recognized and acknowledged with the
acknowledge key. They are often a consequence of a status (operational) message. An
acknowledgement message stops a movement or prevents further operation.

Dialog messages
require confirmation by the operator (”Yes” or “No” softkeys). The message is cleared after
it has been confirmed.

1.2 Message time

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

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Appendix

1.3 Message number

With the aid of the message number, the corresponding cause, effect and remedy can quickly
be located in the list of error messages.

1.4 Originator
The origin of the error is indicated in this field.

1.5 Message text

The text of the error message is shown here.

1.6 List of error messages

To make it easier to find error messages in the following list, the message number is shown
first, unlike on the display. By referring to this message number, it is possible to obtain further
information on an error and the appropriate remedial action. This information is subdivided
into:
Message text
is the actual text of the error message as displayed.

Cause
gives a detailed description of the cause of the error.

Monitor
indicates when the conditions for generation of the message are checked.

Effect
describes how the controller reacts to the error.

Remedy
describes what action the user can take to eliminate the error.

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 1 Error messages / troubleshooting (continued)

1 Message text EMERGENCY STOP

Cause -- Emergency Stop pushbutton pressed.

-- Emergency Stop initiated by the software.
Monitor -- Cyclic.
Effect -- Path--maintaining stop.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton and Emergency Stop circuit.
-- Release the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.
2 Message text INTERNAL ERROR @P1@ (**, **)

Cause -- Internal KRL software test.

Monitor -- Within the KRL Software.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
3 Message text MESSAGE BUFFER OVERFLOW

Cause -- The message buffer, which contains the currently active messages
(acknowledgement and status messages), is full up to a specific
limit.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Rectify and acknowledge the signalled faults.
4 Message text BUFFER BATTERY VOLTAGE LOW XX

Cause -- Voltage of the backup battery too low.

Monitor -- At “Power off”.
-- Cyclic.
Effect -- The battery voltage is checked when the power is switched off.
When the message is displayed, it is necessary to wait until the bat-
tery has recharged. Only then may the controller be switched off.
-- Cyclic --> none.
Remedy -- Change the battery.
-- After the battery has been charged, the message ”Ackn. batt. voltage“
is displayed --> acknowledge.
5 Message text MALFUNCTION XX

Cause -- KCP defective.

Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace KCP .

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Appendix

6 Message text TRANSMISSION ERROR **

Cause -- Fault in KCP connection.

Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the KCP cable.
7 Message text TP BASE

Cause -- The point could not be created.

8 Message text SYSTEM TIME INVALID

Cause -- The system time is invalid after TIME_HW_FAILURE and has been
set to the initial value.
Monitor -- When the controller is booted.
Effect -- The system time is initialized with 01.01.93 00:00:00,00.
Remedy -- Update the system time with the form “systime”.
11 Message text PROGRAM STACK OVERFLOW

Cause -- KRL program contains too many nested structures or too many re-
cursive subprogram calls! The C--stack of the R--INT would other-
wise overflow.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Change the structure of the program.
12 Message text TOO MANY MESSAGES

Cause -- Too many messages have been cyclically generated.

Monitor -- When a message is generated.
Effect -- All active commands are cancelled and cannot be restarted.
Remedy -- The KRC has to be booted.
100 Message text RDW ** BOOT UP FAILURE

Cause -- The resolver/digital converter (RDW) could not be initialized when

the controller was booted.
Monitor -- At runup.
Effect
Remedy -- Replace RDW, DSE or cable between RDW and DSE.
101 Message text DSE ** BOOT UP FAILURE

Cause -- The DSE could not be initialized when the controller was booted.
Monitor -- At runup.
Effect -- Maximum braking (dynamic braking).
Remedy -- Replace DSE, MFC or motherboard.

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 1 Error messages / troubleshooting (continued)

102 Message text ENCODER CABLE FAILURE **

Cause -- Cable defective (e.g. loose connection).

-- RDW defective.
-- Encoder defective.
Monitor -- Cyclic.
Effect -- Maximum braking (dynamic braking).
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check encoder cable.
-- Check motor, resolver.
-- Possibly replace RDW.
103 Message text WATCHDOG INTERPOLATION CYCLE **

Cause -- DSE has not triggered software watchdog in the DP--RAM.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Software error.
104 Message text SYNCHRONIZATION ERROR WITH DSE **

Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Error in the DSE or PC area.
-- Software error.
105 Message text TRANSMISSION ERROR DSE -- RDW **

Cause -- Open--circuit between RDW and DSE.

-- Transmission malfunctions.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.

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Appendix

106 Message text PERFORM MASTERING ** !

Cause -- Position actual value difference after restart too great and sensor
mastering not possible because sensor location run has not been
performed.
Monitor -- At ”Power on”.
-- During mastering.
Effect -- All active commands inhibited.
Remedy -- Perform adjustment.
108 Message text DYNAMIC BRAKING ACTIVE

Cause -- If the controller detects a request for maximum (dynamic) braking, it

geneates the status (operational) message ”DYNAMIC BRAKING
ACTIVE”, which remains active until all axies have stopped.
Monitor -- Cyclic.
Remedy -- The status message ”DYNAMIC BRAKING ACTIVE” is reset by the
controller when the robot is at standstill without a secondary message
being generated.
113 Message text RANGE OVERFLOW ** **

Cause -- Overflow of the actual value of an endless axis: actual value > +/--
90*10E15 increments or --99999000 < $REVO_NUM < 999999000
Monitor -- Cyclic in the interpolation cycle.
Effect -- The robot motion is stopped by a path--maintaining Emergency
Stop.
Remedy -- Turn back or remaster the axis concerned.
116 Message text DSE WATCHDOG COMMAND **

Cause -- DSE has not executed a command.

Monitor
Effect -- Ramp--down braking.
Remedy -- Check hardware in the DSE, MFC area.
118 Message text HEAT SINK TEMPERATURE **

Cause -- Thermostatic switch on the heat sinks of the servo output stage is
tripped due to overheating of the output stage transistors.
Monitor -- Cyclic
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Clean the heat sinks.

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 1 Error messages / troubleshooting (continued)

119 Message text MOTOR TEMPERATURE **

Cause -- PTC thermistor (measuring shunt) in the motor winding has been
tripped (motor temperature too high).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Program more movement breaks.
120 Message text ACKN. MOTOR BLOCKED **

Cause -- As soon as the torque command value supplied by the speed con-
troller exceeds 30% of the max. torque command value, integration
is started, and when the value of i*t reaches approx. 0.75 [(torque
command value / max. torque command value) * sec] the control is
switched off (i*t -- monitoring).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Check that the axis is moving freely.
121 Message text OVERCURRENT **

Cause -- The current of each axis is monitored and the amplifier--internal cur-
rent protection is tripped if the power consumption is too high.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
122 Message text BRAKE FAULT **

Cause -- The brake cable is monitored for short--circuit, overload and cable
break.
-- With the PM6, all axes are supplied from one brake driver.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
123 Message text UNDERVOLTAGE **

Cause -- The internal operating voltage (+15V) of the servo output stage is
monitored. Undervoltage results in power failure.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.

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124 Message text OVERVOLTAGE **

Cause -- The intermediate--circuit voltage is too high. Possible causes are a

defective ballast (feedback) resistor or ballast fuse, a defective
power module, brake ramp too steep etc.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
126 Message text COMMAND VALUE IS OUT OF RANGE **

Cause -- Following error too great. The axis does not follow the command
value.
Monitor -- Cyclic in the position controller.
Effect -- Maximum braking.
Remedy -- Check the axis.
127 Message text ** DETACHED AUXILIARY AXIS

Cause -- Auxiliary (external) axis is operated as an asynchronous axis.

Monitor -- Cyclic.
Effect
Remedy
128 Message text SOFTWARE LIMIT SWITCH OF DETACHED AUXILIARY AXIS ** **

Cause -- Asynchronous axis has tripped the pos. or neg. software limit
switch.
Monitor -- The software limit switch is checked cyclically if the axis is operated
as an asynchronous axis.
Effect
Remedy
200 Message text DRIVES CONTACTOR OFF

Cause -- Power module, intermediate--circuit voltage discharged.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Switch drives on.
-- Check power module, check DSE.
-- Emergency Stop is active, drives circuit is interrupted.

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 1 Error messages / troubleshooting (continued)

201 Message text KCP DEADMAN SWITCH

Cause -- The safety (deadman) switch has been released during an active
function (motion of an axis) in mode T1 or T2.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Press safety switch.
-- Check KCP, safety logic.
203 Message text GENERAL MOTION ENABLE

Cause -- Low signal at $MOVE_ENABLE input.

Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the input.
204 Message text HARDWARE LIMIT SWITCH / +24V MISSING

Cause -- The hardware limit switch has been tripped.

Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Shunt out the hardware limit switch and move axis off limit switch.
205 Message text SOFTWARE LIMIT SWITCH ** **

Cause -- The software limit switch of the axis indicated has been tripped in
the direction indicated. (The message is effective only after ”Robot
synchronized”).
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Movement in the direction indicated is inhibited.
Remedy -- Move the axis in the opposite direction (no change to the robot--specific
coordinate system takes place).
207 Message text OPERATOR SAFETY / GATE OPEN

Cause -- Operator safety has been tripped in the AUTOMATIC or EXTERNAL

mode (input at the peripheral interface).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch to mode T1 or T2 (in these modes the robot can be moved
when the signal is low).
-- Close the safety gate.
-- Check the input.

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209 Message text PASSIVE STOP **

Cause -- Stop from a passive operator control unit (the message is displayed
only if an active process has been stopped).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge the message ”Passive Stop”.
210 Message text STOP KEY **

Cause -- The start key or a traversing key has been actuated while the stop
key is depressed.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the stop key.
217 Message text EMERGENCY STOP FROM KRC ( ALARM STOP )

Cause -- An alarm stop has been initiated by the KRL system software;
another serious error has occurred.
Monitor -- Cyclic.
Effect -- Maximum braking. All active commands inhibited.
Remedy -- Eliminate and acknowledge the signalled fault (serious error).

218 Message text FEEDBACK SWITCH TOO LONG ON **

Cause -- The energy of the axis to be braked was too high.

Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
219 Message text CABINET TEMPERATURE TOO HIGH **

Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.

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220 Message text DRIVES CONTACTOR OFF, INTERMEDIATE CIRCUIT LOADED !!!

Cause -- The drives contactor drops out. The energy in the intermediate
circuit is sufficient to ensure a path--maintaining stop. Caution: the
intermediate circuit is still charged! The intermediate circuit is
discharged after about 2 minutes. The message ”DRIVES NOT
READY” is then displayed.
Monitor -- Cyclic.
Effect -- Path--maintaining Emergency Stop
Remedy -- Switch drives on again.
-- Check drives circuit for faults.
221 Message text MODE NOT ALLOWED

Cause -- E2 closure (keyswitch) in AUTO mode.

Monitor
Effect
Remedy
222 Message text PARITY ERROR POWERMODULE **

Cause -- A parity error has occurred more than five times in succession when
reading the power module register.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Too much interference at the power module interface, or power module
defective. Check cable, check shielding, replace power module.
223 Message text POWER MODULE AXIS ** NOT OR WRONGLY PLUGGED

Cause -- The axis is incorrectly plugged into the power module or not con-
nected at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect the axis correctly (high or low power).
224 Message text POWER FAIL

Cause -- The cabinet voltage has been switched off, the mains voltage is in-
terrupted.
Monitor
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.

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252 Message text XX INTERFACE CONTROLLER -- I/O ASSIGNMENT ERROR XX

Cause -- Double assignment of interface controller output.

Monitor -- At ”Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the indicated machine datum.
253 Message text DSE POSITION CONTROL ASSIGNMENT **

Cause -- With machine datum DSE CHANNEL[12] a drive interface has been
assigned twice, or a non--existent interface has been addressed.
-- DSE defective.
Monitor -- At ”Power on” .
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the machine datum.
254 Message text DSE FILE NOT AVAILABLE **

Cause -- The DSE program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter or alter the DSE program.
255 Message text ** INVALID VALUE

Cause -- The machine data loader has detected that a variable contains an
incorrect value:
a) Limit monitoring tripped.
b) Machine data not logically coherent.
Monitor -- At ”Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the value assignment.
256 Message text CHECK MACHINE DATA !

Cause -- It cannot be assured that the machine data loaded during a cold
start are valid for the connected robot.
Monitor -- Generated at cold start.
Effect -- No RC ready.
-- Controller is in its initial state, i.e. tasks dependent on machine data
are not generated.
Remedy -- Either edit or copy the machine data or option data file.

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257 Message text USER DATA NOT CORRECT

Cause -- The user data loader has detected that a variable contains an incor-
rect value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At ”POWER ON”.
-- After editing the user data.
-- After loading the user data (DEFDAT $CUSTOM PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
258 Message text OPTION DATA NOT CORRECT

Cause -- The option data loader has detected that a variable contains an in-
correct value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At ”POWER ON”.
-- After editing the option data.
-- After loading the option data (DEFDAT $OPTION PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
259 Message text ** MACHINE DATA LOADER ABORTED

Cause -- The errors detected by the machine data loader exceed the capacity
of the message buffer.
Monitor -- At ”POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
260 Message text USER DATA LOADER ABORTED

Cause -- The errors detected by the user data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At ”POWER ON”.
-- After editing the user data.
-- After loading the user data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.

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261 Message text OPTION DATA LOADER ABORTED

Cause -- The errors detected by the option data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At ”POWER ON”.
-- After editing the option data.
-- After loading the option data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
262 Message text ** MACHINE DATA INCORRECT

Cause -- The machine data loader has detected a variable with an illegal
value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At ”POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
263 Message text CORRECTION DATA FAULTY

Cause -- The correction data loader has detected a variable with an illegal
value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- POWER ON after editing the correction data, after loading the
correction data (DEFDAT $ROBCOR).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
264 Message text ** CORRECTION DATA LOADER ABORTED

Cause -- The errors detected by the correction data loader exceed the capac-
ity of the message buffer.
Monitor -- At ”POWER ON”.
-- After editing the correction data.
-- After loading the correction data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
265 Message text RDW FILE NOT AVAILABLE **

Cause -- The RDW program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter the RDW program correctly in the INI file.

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266 Message text OVERTEMPERATURE FEEDBACK RESISTOR **

Cause -- The ballast (feedback) resistor has overheated. In the motion pro-
gram the robot is cyclically accelerated and decelerated without a
break.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.
267 Message text WATCHDOG POWERMODULE **

Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Troubleshooting in the DSE and power module area.
268 Message text ERROR MEMORY TEST DSE **

Cause -- The memory test on the DP--RAM of the DSE detected an error.
Monitor -- Runup.
Effect -- Active commands inhibited.
Remedy -- Replace DSE or MFC.
269 Message text DSE ** NOT AVAILABLE

Cause -- The bit on the MFC indicating whether a DSE is inserted is not set
although axes are allocated to this DSE.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Insert DSE, replace MFC or DSE.
270 Message text WRONG POWERMODULE SETTING **

Cause -- Double assignment of $PMCHANNEL or incorrect channel.

Monitor -- When loading the robot machine data.
Effect -- Machine data loader aborted.
Remedy -- Correct $PMCHANNEL.
300 Message text OPERATING MODE CHANGE

Cause -- The mode selector switch is set to an illegal position.

Monitor -- In command processing.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Set mode selector switch to a permissible position. The status
(operational) message is then reset.

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302 Message text ** ACTIVE

Cause -- OBJH command is being executed.

Monitor -- In command processing.
Effect -- None
Remedy -- Wait until OBJH is free again.
303 Message text LIMIT **

Cause -- The value for the corresponding analog output lies outside the stan-
dard range and has therefore been limited to the maximum or mini-
mum value.
Monitor -- Cyclic, when writing to analog outputs.
Effect -- None
Remedy -- The message remains set until the value of the analog output con-
cerned lies within the standardized range and therefore no limitation
occurs.
304 Message text START UP

Cause -- Startup (setup) menu selected.

Monitor -- In command processing.
Effect -- Program processing not possible.
Remedy -- Quit the setup menu using the ESC key.
306 Message text SELECTION ACTIVE

Cause -- New selection requires deselection/linking.

Monitor -- Command processing (RUN command).
Effect -- None
Remedy -- Wait until the linking procedure is finished, i.e. until the message
disappears.
1000 Message text USER--MEMORY DELETED (**)

1001 Message text INTERNAL ERROR (DEFAULT MESSAGE)

Cause -- Internal; the message data have not been correctly set.
Monitor
Effect
Remedy

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1003 Message text LEVEL OVERFLOW **

Cause -- Computing time overload of CPU.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Increase basic cycle.
-- Increase interpolation cycle or position control cycle, depending on the
indicated parameter.
1005 Message text NO MORE SYSTEM MEMORY AVAILABLE

Cause -- There is not enough memory available for the command ”SHOW
VAR” or ”SET INFO” to be executed (the control requires a certain
amount of memory for these commands, dependent on the length of
the output value.)
Monitor -- In form processing.
Effect -- Command is not executed.
Remedy -- Save and delete programs that are not required.
1006 Message text NO MORE USER MEMORY AVAILABLE

Cause -- No more memory is available for copying objects.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Delete objects that are not required.
1007 Message text CHANNEL ** NOT ASSIGNABLE

Cause -- The selected channel cannot be assigned.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Free channel at another point (should occur only with printer channel).
1010 Message text INTERNAL ERROR ** (**, **)

Cause -- Internal test of KRC.

-- Software.
Monitor -- Within the KRC.
-- Software.
Effect -- RC ready reset during processing.
Remedy -- Acknowledge message.
1012 Message text GENERAL ERROR: ** ** **

Cause -- Unknown feedback from a function in the object.

Monitor -- In command processing.
Effect -- None
Remedy -- Inform service department.

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1014 Message text UNKNOWN COMPILER ERROR: **

Cause -- Compiler software has detected an error.

Monitor -- In command processing.
Effect -- None
Remedy -- Inform service department.
1015 Message text OBJH -- ERROR: **

Cause -- Internal error in the OBJH.

Monitor -- In command processing.
Effect -- None
Remedy -- Inform service department.
1016 Message text HARDWARE LIMIT--SWITCH / +24V MISSING

Cause -- The interface module monitoring function has detected that a com-
mon input for hardware limit switches has been set.
Monitor -- Cyclic in interface module monitoring.
Effect -- The roboter is stopped with maximum braking and the active com-
mands are inhibited until this message has been acknowledged.
Remedy -- Move robot off limit switch and acknowledge message.
!!!Caution!!! Moving the robot off the limit switch correctly is the
operator’s responsibility, since no axis--specific interlocks are set.
1020 Message text INTERNAL ERROR ** (**,**)

Cause -- Internal software error.

Monitor
Effect
Remedy
1021 Message text ** INTERNAL ERROR AT ACCESS

Cause -- An internal error has occurred when accessing a file (acknowledge-

ment message already set). The action was not correctly carried
out.
Monitor -- In object processing.
Effect
Remedy
1022 Message text COMMUNICATION ** -- KRC INTERRUPTED

Cause -- Communication between the active operator control unit and the
KCR has been interrupted while a motion was being executed in the
test mode.
Monitor -- In command processing.
Effect -- Maximum braking.
Remedy -- Re--establish the connection.
1023 Message text INPUT BUFFER OVERFLOW

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1024 Message text ERROR DURING READING OF INI FILE ** **

Cause -- Error in INI file.

Monitor -- At system start.
Effect -- All commands are inhibited.
Remedy -- Correct INI file.
1025 Message text ERROR CONFIGURATION I/O DRIVER **

Cause -- Error in the INI file.

Monitor -- In system runup.
Effect
Remedy -- Check io_int.ini.
1026 Message text ERROR DIGITAL INPUT READING PORT: **

Cause
Monitor
Effect
Remedy -- Check I/O components.
1027 Message text ERROR WRITE DIGITAL OUTPUTS PORT: **

Cause
Monitor
Effect -- Maximum braking.
Remedy -- Check the corresponding I/O hardware.
1028 Message text ERROR RESTART I/O **

Cause -- Field bus error is still present.

Monitor
Effect -- Bus I/O still not available.
Remedy -- Eliminate field bus error (hardware).
1029 Message text SEN: **

Cause -- Hint message of a sensor that does not require a stop.

Monitor
Effect
Remedy
1030 Message text SEN: **

Cause -- Sensor error that requires ramp--down braking.

Monitor
Effect
Remedy -- Depends on sensor concerned.

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1031 Message text SEN: **

Cause -- Sensor error that requires ramp--down braking.

Monitor
Effect
Remedy
1032 Message text SEN: **

Cause -- Sensor error that requires ramp--down braking.

Monitor
Effect
Remedy
1100 Message text STOPPED **

Cause -- Axis has beeen moved out of the standstill position according to the
machine data. Positioning window ($IN_POS_MA) times standstill
window minus factor ($IN_STILL_MA).
Monitor -- With robot ”in position”.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check manipulator.
-- Check output stage, check motor brake.
-- Acknowledge message.
1101 Message text COMMANDED ACCELERATION **

Cause -- Permissible command acceleration exceeded; e.g. because robot

has been moved through singularity in cartesian mode.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check program for alpha5 transitions (singularity).
-- Reduce path velocity.
-- Reduce path acceleration.
-- Acknowledge message.
1102 Message text COMMANDED VELOCITY **

Cause -- Permissible command velocity exceeded; e.g. because robot has

been moved through singularity in cartesian mode.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Reduce path velocity.
-- Reduce path acceleration.

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1103 Message text DATA EXCHANGE WITH TEPRO MISSING

Cause -- The SBC is not transmitting cyclic data on time (TEPRO =

Technological Process).
Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Re--initialize the SBC program or eliminate the error in the SBC
program.
1104 Message text ACKNOWLEDGE COMMAND VALUE **

Cause -- The set value of the machine datum $COM_VAL_MI has been ex-
ceeded. The position controller output has gone into limitation. The
axis does not follow the command value.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check power module.
-- The brake control must be checked (LED on PM) if the error occurs on
more than one axis.
1105 Message text POSITIONING MONITOR **

Cause -- Positioning window $IN_POS_MA has not been reached within the
set positioning time $TIME_POS.
Monitor -- When positioning.
Effect -- Maximum braking.
-- All active commands inhibited.
-- The axis has the status “in position“ after the message has been
acknowledged.
Remedy -- Enlarge positioning window.
-- Lengthen positioning time.
-- Check power module.
-- Acknowledge message.
-- Check manipulator.
1108 Message text ERROR AT DYNAMIC BRAKING **

Cause -- Actual value does not decrease although braking ramp is predefined
in terms of command values.
Monitor -- Cyclic.
Effect -- Short--circuit braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
1109 Message text COMMUNICATION WITH TEPRO FAULTY

Cause -- The SBC is not collecting cyclic data on time.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Re--initialize the SBC program.

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1114 Message text INVALID MASTERING SEQUENCE

Cause -- Mastering sequence defined in machine datum $SEQ_CAL has not

been observed.
Monitor -- In mastering.
Effect
Remedy -- Master axis with EMT probe or depth gauge.
-- Press ESC to quit menu.
-- Acknowledge message.
1117 Message text ACYCL. DATA NOT RELEASED BY TEPRO

Cause -- Semaphore is inhibiting access to acyclic data.

Monitor -- In acyclic data transfer.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1118 Message text CYCL. DATA NOT RELEASED BY TEPRO

Cause -- Semaphore is inhibiting access to acyclic data.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1119 Message text WRONG DATA TYPE FROM TEPRO

Cause -- SBC is cyclically sending incorrect data.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.
1120 Message text INSTRUCTION NOT COMPLETE

Cause -- The interface with the SBC is not initialized.

Monitor -- In KRL interface instruction.
Effect -- None
Remedy -- Initialize the interface.
1121 Message text DATA EXCHANGE

Cause -- The SBC stops data exchange because of an error.

Monitor -- Cyclic by transfer task.
Effect -- Ramp--down braking; interruption of the SBC interface.
Remedy -- Eliminate the error in the SBC program.

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1122 Message text ANALOG OUTPUT : DELAY REDUCTION

Cause -- The memory provided internally for the output function with a delay
is not adequate for the programmed delay.
Monitor
Effect -- The programmmed delay is automatically reduced.
Remedy -- Program a shorter delay.
1123 Message text APPROXIMATION NOT POSSIBLE

Cause -- Approximation (approximate positioning) is not possible for comput-

ing time reasons.
Monitor -- When the approximate positioning criterion is reached in the interpo-
lator.
Effect -- None
Remedy -- Program $ADVANCE > 0.
-- Switch off axis simulation.
1124 Message text WRONG START POSITION

Cause -- 1. EMT mastering starts in the groove rather than before it.
-- 2. Cable for EMT mastering connected during sensor location run or
sensor mastering.
Monitor -- In command processing.
Effect -- Command aborted.
Remedy -- 1. Move axis to correct starting position.
-- 2. Disconnect cable for EMT mastering.
1125 Message text EMT SENSOR FAULTY

Cause -- Sensor supplies a zero signal because it is not properly tightened.

Monitor -- In command processing.
Effect -- Command aborted.
Remedy -- Check screwed connection of sensor.
-- Check robot--EMT connection.
-- Check A3/DSE module.
1126 Message text STOP COMMAND IGNORED

Cause -- Axis does not stop within a certain time after a stop command.
Monitor -- After command processing.
Effect -- Command aborted.
1127 Message text MASTERING PERFORMED **

Cause -- Attempt to remaster an axis that has already been mastered.

Monitor -- After command processing.
Effect -- Ramp--down braking.
Remedy -- Press ESC to cancel.
-- Repeat measurement.

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1130 Message text ACKN. MOTOR TEMPERATURE **

Cause -- A motor temperature fault is signalled by the DSE board if the tem-
perature exceeds 155 degrees.
Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
1132 Message text REFPO DETERMINES AXIS **

Cause -- Output after reference point for axes 1--6 has been calculated.
Monitor -- In program mode.
Effect -- None
Remedy -- None
1136 Message text ACKN. HEATSINK TEMPERATURE **

Cause -- A heat sink temperature fault is signalled by the DSE board if the
temperature exceeds 80 degrees.
Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
-- Clean heat sink.
1137 Message text EMT MASTERING DISTANCE EXCEEDED

Cause -- Groove not located, axis position not before groove prior to start.
Monitor
Effect -- Axis stops.
Remedy -- Move axis into mastering position; check EMT and groove.
1138 Message text DYNAMIC BRAKING

Cause -- If during an activated Emergency Stop a fault occurs that permits

only maximum (dynamic) braking, this message is additionally dis-
played.
Monitor -- With the following messages: 100, 101, 102, 103, 104, 105, 110,
111, 114, 200, 202, 206, 1100, 1108.
Effect -- Maximum braking.
Remedy -- Acknowledge message.
1139 Message text SYNACT NOT POSSIBLE **

Cause -- The programming of synchronous actions with the variable

$M_TIME or $M_TIME_APO causes the message to be output
when the program is resumed after ramp--down braking, a path--
maintaining Emergency Stop ramp or maximum braking.

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1140 Message text BLOCK CHANGE AT STOP

Cause -- Maximum braking or a path--maintaining stop and a simultaneous

block change which makes calculation of $POS_RET and the sys-
tem time impossible, with the result that the system time and
$POS_RET are determined by the beginning of a new block.
Monitor -- (e.g. cyclic; in command processing; in mastering).
Effect -- (e.g. ramp--down braking; program processing stopped; etc.).
Remedy -- (e.g. eliminate fault, correct operator action).
1141 Message text TTS NOT EXISTING

Cause -- The X--axis of the tool coordinate system and the path tangent are
parallel. (TTS = tool--based technological system).
Monitor -- Cyclic in the interpolation cycle when calculating the path correction.
Effect -- Maximum braking.
Remedy -- Reprogram the movement. Correct the point.
1142 Message text DEVIATION AT TARGET POINT

Cause -- An exact stop point has been approached with a deviation.

Monitor -- Function generator becomes active during positioning.
Effect -- Ramp--down braking
Remedy -- SCALE_IN must be corrected.
1143 Message text REFERENCE OFFSET NOT VALID

Cause -- Mastering is not possible by transferring the reference offset as this

is not valid in $ROBCOR.DAT.
Monitor
Effect
Remedy
1144 Message text V--GROOVE HAS WRONG PROFILE

Cause -- The mastering groove for EGP adjustment does not have a V or U
profile.
Monitor -- In EMT mastering.
Effect -- Ramp--down braking; mastering procedure is aborted.
Remedy -- Replace EMT groove.
-- Clean EMT.
1145 Message text ACKN. RANGE OVERFLOW ** **

Cause -- Overflow of the actual value of an endless axis.

Monitor -- Cyclic in the interpolation cycle.
Effect -- The motion is stopped by a path--maintaining Emergency Stop.
Remedy -- Remaster the axis concerned.

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1146 Message text ACKN. MOTOR BLOCKED **

Cause -- I*t monitoring is signalled by a DSE.

Monitor -- Cyclic in the interpolation cycle.
Effect
Remedy -- Acknowledge message.
1153 Message text DEVIATION IN THE START POINT

Cause -- A PTP motion is to be executed with a sensor offset value.

Monitor -- Interpolator.
Effect -- Ramp--down braking.
Remedy -- Sensor offset must be eliminated before a PTP block is executed.
1154 Message text ERROR SBC : **

Cause -- Error in communication between SBC and KRC32.

Monitor -- Cyclic in the TEP task.
Effect -- Maximum braking.
Remedy -- Check SBC (SW, HW).
1155 Message text APPROXIMATION NOT POSSIBLE, TORQUE TOO HIGH

Cause -- For an approximate positioning block to be executed, the velocity

must already be reduced in the preceding block. However, this block
is not long enough to allow that.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter.
Remedy -- Increase the length of the individual block by:
decreasing the approximate positioning radius at the end point of the
current motion block or, if the start point is approximated, by decreas-
ing this approximate positioning radius.
Decreasing the velocity and acceleration of the individual block.
1156 Message text APPROX. NOT POSSIBLE INTERNAL ERROR IN PTP MOTION
PLAN
Cause -- Error in planning of the approximate positioning block.
Monitor -- Not cyclic, in motion planning.
Effect -- Approximate positioning is not executed; exact stop.
Remedy -- Modify profile data (rounding factor, velocity, acceleration). Please
consult KUKA.
1157 Message text OVERLOAD OF GEAR TORQUE ** BY **

Cause -- The max. gear torque of the axis is statically exceeded by ....%.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Check load data (mass, center of gravity, moments of inertia).

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1158 Message text OVERLOAD OF MOTOR TORQUE ** BY **

Cause -- The max. motor torque of the axis is statically exceeded by ....%.
Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Check load data (mass, center of gravity, moments of inertia).
1159 Message text INTERNAL ERROR IN PTP MOTION PLANNING **

Cause -- Error in planning of the PTP motion profile.

Monitor -- Not cyclic, in motion planning.
Effect -- Interpreter stop.
Remedy -- Modify profile data (rounding factor, velocity, acceleration). Please
consult KUKA.
1160 Message text TRACE: RECORDING TIME IS TOO LONG

Cause -- The recording time in TRACE.DEF is too long. There is not enough
memory available for recording.
Monitor -- When starting the TRACE.
Effect -- TRACE is not recorded.
Remedy -- Shorten TRACE recording time or reduce the number of channels.
1200 Message text ACKN. EMERGENCY STOP

Cause -- Emergency Stop was active.

Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
1201 Message text BUFFER BATTERY VOLTAGE LOW **

Cause -- The battery voltage is too low for backup purposes. Do not switch
off until battery has recharged.
Monitor -- Cyclic.
Effect -- None
Remedy -- Acknowledge message.
1202 Message text ACKN. RDW ** BOOT UP FAILURE

Cause -- Secondary message following the status (operational) message

”RDW BOOT UP FAILURE”.
Monitor
Effect
Remedy -- Acknowledge message.

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1203 Message text ACKN. DSE ** BOOT UP FAILURE

Cause -- Secondary message following the status (operational) message

“DSE BOOT UP FAILURE”.
Monitor -- Runup.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace encoder.
-- Acknowledge message.
1204 Message text ACKN. ENCODER CABLE FAILURE **

Cause -- Secondary message following the status (operational) message

”ENCODER CABLE FAILURE”.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1205 Message text ACKN. WATCHDOG INTERPOLATION CYCLE **

Cause -- Secondary message following the status (operational) message

“WATCHDOG INTERPOLATION CYCLE”.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Acknowledge message.
1206 Message text ACKN. SYNCHRONIZATION ERROR WITH DSE **

Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect
Remedy -- Acknowledge message.
1207 Message text ACKN. TRANSMISSION ERROR DSE -- RDW **

Cause -- Open--circuit between RDW and DSE.

-- Transmission malfunction
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at ”$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
-- Acknowledge message.

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1210 Message text ACKN. GENERAL MOTION ENABLE

Cause -- There was a low signal at $MOVE_ENABLE input.

Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
1211 Message text ACKN. SOFTWARE LIMIT SWITCH ** **

Cause -- Tripping of software limit switch has been detected.

Monitor -- Cyclic.
Effect -- Movement in the direction indicated is inhibited.
Remedy -- Acknowledge message.
1212 Message text ACKN. OPERATOR SAFETY

Cause -- Operator safety has been tripped in the AUTOMATIC or EXTERNAL

mode.
Monitor -- Cyclic.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message. (The robot can then be started in the AUTO-
MATIC or EXTERNAL mode again.)
1213 Message text ACKN. PASSIVE STOP **

Cause -- The originator of the passive stop has acknowledged the message.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message. (Acknowledgement possible only on active
unit.)
1214 Message text POWER FAILURE

Cause -- The cabinet voltage has been switched off, the mains voltage is in-
terrupted.
Monitor
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.
1215 Message text ** **

Cause -- OBJH command finished.

Monitor -- Command processing.
Effect -- None
Remedy -- None

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1221 Message text ACKN. POWER MODULE AXIS ** NOT/OR INCORRECTLY

CONNECTED
Cause -- The axis is incorrectly plugged into the power module or not con-
nected at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect axis correctly.
-- Acknowledge message.
1222 Message text ACKN. BRAKE ERROR **

1223 Message text ACKN. UNDER VOLTAGE **

1224 Message text ACKN. OVER VOLTAGE **

1225 Message text ACKN. OVER CURRENT **

1226 Message text ACKN. E** -- SWITCH CLOSED

1227 Message text ACKN. E** -- SWITCH OPEN

1228 Message text ACKN. FEEDBACK SWITCH ON TOO LONG **

Cause -- The energy of the axis to be braked was too high.

Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
1229 Message text ACKN. WATCHDOG POWER MODULE **

Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Troubleshooting in the DSE and power module area.
1230 Message text ACKN. OVER TEMPERATURE ON FEEDBACK RESISTOR **

Cause -- The ballast (feedback) resistor has overheated. In the motion pro-
gram the robot is cyclically accelerated and decelerated without a
break.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.

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1231 Message text ACKN. CABINET OVER TEMPERATURE **

Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.
1300 Message text PARITY ERROR

Cause -- Parity incorrectly set.

Monitor -- On transmission.
Effect -- None
Remedy -- Check parity setting on controller and operator control unit (PC).
1301 Message text PROCEDURE ERROR

Cause -- Transmission error in LSV2 procedure which was not detected by

the parity monitor.
Monitor -- On transmission.
Effect -- None
Remedy -- Repeat transmission.
-- Increase procedure repetition counter.
-- Check cable.
1302 Message text CHANNEL NOT AVAILABLE

Cause -- Procedure monitoring time elapsed.

Monitor -- On transmission.
Effect -- None
Remedy -- Increase procedure monitoring time.
1303 Message text SCC OVERFLOW

Cause -- Baud rate set too high (SCC = Serial Communication Controller).
Monitor -- On transmission.
Effect -- None
Remedy -- Reduce baud rate.
1306 Message text DEVICE NOT READY

Cause -- Cable defective or not connected.

-- Device switched off (e.g. printer).
Monitor -- On transmission.
Effect -- None
Remedy -- Check cable and device.

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1307 Message text FORMAT ERROR

Cause -- Hardware error of the interface on I--CPU.

Monitor -- On transmission.
Effect -- None
Remedy -- If the error occurs repeatedly, change the board (interface CPU).
1308 Message text CHANNEL NOT ALLOWED IN COMMAND

Cause -- Command does not support any channels.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None
1309 Message text OBJECT IS NOT AVAILABLE

Cause -- Objects that are not available in the KRC cannot be addressed.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Wrong object selected.
1310 Message text TOO MANY OBJECTS ARE SELECTED

Cause -- Too many objects selected.

Monitor -- In command processing.
Effect -- Command is not executed
Remedy -- Select only the permitted number of objects (approx. 150).
1311 Message text ** NOT CORRECTLY COPIED

Cause -- Errors have been detected in the line analysis.

Monitor -- In command processing.
Effect -- Error token in the object.
Remedy -- Correct object.
1312 Message text ** ASSIGNED

Cause -- Object cannot be processed in this state (object already assigned).

-- Module package cannot be linked since at least one of the objects
of the module package is assigned.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None

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1313 Message text INVALID STATEMENT

Cause -- The source and target specifications do not conform to the conven-
tion for “COPY”.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Specify the source and target correctly.
1314 Message text DATA NOT ALLOWED

Cause -- Extension not compatible.

-- copy *.* (copy *.* is possible into a directory only).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Specify extension correctly.
1315 Message text ** IS NOT A MODULE

Cause -- The name represents a directory.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Take a different module.
1318 Message text FILE DESCRIPTION CANNOT BE PROCESSED

Cause -- Module information that cannot be evaluated has been received in a

COPY operation from an external source.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check interface software.
1319 Message text ** CANNOT BE CORRECTED

Cause -- An invalid extension has been specified (only ”DAT” is allowed).

-- An attempt has been made to transmit or edit a protected file.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select data list.
-- Set INIT switch on I--CPU to position 3.
1320 Message text EXTENSION NOT ALLOWED

Cause -- An extension has been specified in a command where it is not al-

lowed (e.g. analyse otto.src).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.

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1321 Message text ** IS NOT A DIRECTORY

Cause -- Command contains an invalid subdirectory (e.g. dir /R1/otto/abc,

/abc not allowed).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.
1322 Message text ** NOT LINKED

Cause -- ”UNLINK” has been applied to an object that is not a program.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None
1323 Message text ** INVALID DATA MODULE NAME OR EXTENSION

Cause -- An invalid path, module name or extension has been specified.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct command.
1324 Message text ** NOT AVAILABLE

Cause -- An object that is not available has been addressed.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Create the object.
1325 Message text ** CANNOT BE PROCESSED

Cause -- An object that has already been assigned has been addressed.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Free the assignment (/R1/CONFIG>DAT).
1326 Message text ** : ** COMPILATION ERROR

Cause -- The indicated number of errors have been detected in the indicated
object during total compilation.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct the errors.
1327 Message text ** LINKING ERROR

Cause -- An error has been detected in the indicated module during linking.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Look at the error list of the indicated module and correct the indicated
errors

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1328 Message text FAULTY FILE

Cause -- Module is not correct for TTS calculation.

Monitor -- In command processing.
Effect -- None
Remedy
1329 Message text ACCESS TO IMPORTED VARIABLE IS NOT POSSIBLE

Cause -- The search path has not been extended to the external data list.
Monitor -- In command processing.
Effect -- Command has not been executed.
Remedy -- Extend the search path.
1330 Message text SOURCE AND TARGET OBJECT ARE IDENTICAL

Cause -- The source and target specifications define the same object.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None
1331 Message text ** NOT CORRECT

Cause -- An incorrect module has been selected in a linking operation.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Correct the error in the indicated module (perform ANALYSE).
1332 Message text RESET REQUIRED FOR BLOCK SELECT

Cause -- Block selection in an interrupt routine.

Monitor -- In program processing when exiting from an interrupt.
Effect
Remedy -- Reset.
1333 Message text ** CANNOT BE DELETED

Cause -- Object cannot be deleted because it is write--protected.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None
1334 Message text MORE THAN 16 INTERRUPTS DEFINED

Cause -- Program instruction INTERRUPT ON can switch on a maximum of 8

defined interrupts but more than 8 are defined.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Switch on individual interrupts.

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1335 Message text ** SELECTED

Cause -- Program cannot be unlinked; module is selected with ”RUN”.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Terminate program run (CANCEL)
1336 Message text COR ARE FOR DATA LISTS ONLY

Cause -- COR is allowed for data lists only.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select a data list.
1337 Message text TOO COMPLEX

Cause -- Copying from one channel to another (not allowed in SWP1).

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None
1338 Message text BLOCK CANNOT BE CORRECTED

Cause -- TTS or BASE calculation cannot be performed. (TTS = tool--based

technological system).
Monitor -- In command processing.
Effect -- None
Remedy
1339 Message text UNKNOWN EXTERNAL MESSAGE (**)

Cause -- It has not been possible to convert an external message (e.g. from
the interface CPU, PSX) into an RCX message.
Monitor -- In command processing.
Effect -- None
Remedy -- Acknowledge message.
1340 Message text NOT ALLOWED REFERENCE SYSTEM

Cause -- The reference system for manual motion is not possible for the kine-
matic system.
Monitor -- At start.
-- With traversing keys.
Effect
Remedy -- Select a different reference system (TRANSSYS).

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1341 Message text REFERENCE SYSTEM DEFINITION NOT COMPLETE

Cause -- At least one frame required for calculating the reference matrix has
not been assigned.
Monitor -- In cartesian motion commands (e.g. MOVE, PTP, LIN).
Effect
Remedy
1342 Message text WORK ENVELOPE EXCEEDED

Cause -- Working zone limit has been exceeded.

Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1347 Message text ROBOT NOT MASTERED

Cause -- Selection of a program without the robot being mastered (hint mes-
sage).
-- Start of a program without the robot being mastered.
Monitor -- In command processing.
-- In program processing.
Effect
Remedy -- Master the robot.
-- In program processing the message has to be acknowledged.
1349 Message text ROBOT MASTERED

Cause -- All axes mastered.

Monitor -- In mastering.
Effect -- Robot is mastered.
Remedy -- Cyclic.
1350 Message text BCO REACHED

Cause -- After the first position in the user program has been reached.
-- After repositioning ($POS_RET, $AXIS_RET, $POS_FOR,
$AXIS_FOR, etc.).
Monitor -- With BCO travel.
Effect -- Signalling that BCO has been achieved.
Remedy -- None
1352 Message text ** AXIS INHIBITED

Cause -- An attempt has been made to move an axis in the inhibited direction
(inhibited by software limit switch).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Move axis off limit switch in other direction.

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1353 Message text KEY COMBINATION ** NOT ALLOWED

Cause -- Simultaneous pressing of more than one key on the KCP.

Monitor -- Cyclic.
Effect -- KCP operation momentarily interrupted.
Remedy -- Release all keys on the KCP.
1355 Message text DEADMAN SWITCH REQUIRED

Cause -- The safety (deadman) switch has not been pressed while actuating
the start or traversing key in mode T1 or T2.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Press safety switch.
1356 Message text START KEY REQUIRED

Cause -- The ”START” command has been entered textually.

-- Execution of the command requires the start key to be pressed.
Monitor -- In command processing.
Effect -- None
Remedy -- Press start key.
-- External computer: check job identification.
1357 Message text RESET REQUIRED

Cause -- RUN has been applied to a process in the end state.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- RESET program.
-- In program processing the message has to be acknowledged.
1358 Message text SELECTION REQUIRED

Cause -- Start key pressed without a program being selected.

-- ”RUN” without path specification and no program is selected.
Monitor -- When start key is pressed.
-- At RUN command.
Effect -- Command is not executed.
Remedy -- Select program.

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1359 Message text TTS CANNOT BE DETERMINED

Cause -- Termination of search for the path direction point. (TTS = tool--based
technological system).
Monitor -- In command processing.
Effect -- None
Remedy
1360 Message text SELECTION NOT ALLOWED

Cause -- Selected block does not exist in the program.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Select correct block number.
1361 Message text STOP DUE TO NODE SWITCHOVER

Cause -- The node setting has been changed during actuation of a traversing
key or execution.
Monitor -- In command processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1362 Message text STOP DUE TO OPERATING MODE CHANGE

Cause -- Active processes are stopped if the mode is changed.

Monitor -- Cyclic.
Effect -- Path--maintaining Emergency Stop.
Remedy -- Acknowledge message.
1363 Message text OPERATOR CONTROL UNIT DISABLED

Cause -- Command cannot be executed because the operator control unit

does not fulfil the “active” conditions.
a) For RCP and stationary KCP the mode AUT is required.
b) For non--stationary KCP the mode T1 or T2 is required.
c) For host computers the mode EXT is required.
Monitor -- In command processing.
Effect -- Command cannot be executed.
Remedy -- Fulfil the “active” conditions.
1367 Message text ACTIVE STATUS REQUIRED

Cause -- The command entered may only be issued from an active operator
control unit (modes T1, T2, AUT).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to active status.

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1368 Message text ** IS ACTIVE

Cause -- Indicated operator control unit is active.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch indicated operator control unit to passive status.
1369 Message text ACTIVE ALLOWED IN ** ONLY

Cause -- For RST and stationary KCP the mode AUT is required.
-- For non--stationary KCP the mode T1 or T2 is required.
-- For host computers the mode EXT is required.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set the correct mode.
1370 Message text PASSIVE STOP

Cause -- Stop from a passive operator control unit (the message is displayed
only if an active process has been stopped).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message (acknowledgement possible only on the
originating unit, even in passive status).
1371 Message text STOP DUE TO UNIT PASSIVE

Cause -- The operator control unit has been switched to passive status during
actuation of the start key or a traversing key in mode T1 or T2, like-
wise during the BCO run.
Monitor -- In command processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch operator control unit to active status.
-- Acknowledge message.
1372 Message text PROCESS ACTIVE

Cause -- An attempt has been made to start an active command during an

active process.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Wait until end of processing.
-- Stop active processing.
-- In program processing the message has to be acknowledged.

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1373 Message text PROCESS BUSY

Cause -- Program already selected.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Delete program already selected.
-- In program processing the message has to be acknowledged.
1374 Message text PROCESS DISABLED

Cause -- All selected processes have the program mode ”DISABLED” or a

non--disabled process is finished.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Alter program mode.
1375 Message text COMMAND NOT ALLOWED

Cause -- Unknown command.

Monitor -- In command processing.
Effect -- None
Remedy -- Enter correct command.
1376 Message text ACTIVE COMMANDS INHIBITED

Cause -- A message which causes the active commands to be inhibited has

been set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Acknowledge active messages.
1377 Message text COMMAND EXECUTION NOT POSSIBLE

Cause -- Preceding command is still being processed.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Cancel command.
-- Wait until end of command.
1378 Message text COMMAND NOT BEING PROCESSED

Cause -- The command that is to be cancelled has already been processed.

Monitor -- In command processing.
Effect -- None
Remedy -- None

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1379 Message text COMMAND ABORTED

Cause -- The command has been cancelled.

-- During editing abort has been selected by the editor kernel before
the command concerned (ERASE,GET,FIND) is called.
Monitor -- In command processing.
-- In editing.
Effect
Remedy
1380 Message text BACKGROUND PROCESS BUSY WITH **

Cause -- The background is exclusively assigned to another operator.

Monitor -- In command processing.
Effect -- In command processing.
Remedy -- Cancel the exclusive assignment on the indicated device.
-- $OPTION>DAT with incomplete specifications.
1381 Message text BACKGROUND OCCUPIED

Cause -- A command is already being processed in the background.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Cancel command.
-- Wait until end of command.
1382 Message text ABORTED

Cause -- ”BREAK” has been repeated.

Monitor -- In command processing.
Effect -- None
Remedy -- None
1383 Message text ** IS NOT A MEMORY DUMP

Cause -- When writing a data block (a file received from the controller or a
temporary file created by the server), it has been discovered that
there is not enough space available on the storage medium. The
currently edited file is deleted.
Monitor
Effect
Remedy -- Create more space!
1384 Message text PARAMETER NOT PROCESSED

Cause -- A RUN command with a parameter has been executed for a pro-
gram that is already selected.
Monitor -- In command processing.
Effect -- The parameter is not evaluated.
Remedy -- Cancel and reselect the program.

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1385 Message text PROTOCOL ERROR

Cause -- Error in the protocol software of the operator control unit or output
device.
Monitor -- In command processing.
Effect -- The command is aborted.
Remedy -- Check protocol software.
1387 Message text VARIABLE TOO LARGE

Cause -- The variable specified in SHOW VAR or SET INFO is too complex
or too large (e.g. field is larger than the display).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Subdivide the request into several sections.
1389 Message text OPTION ** MISSING

Cause -- An option is missing.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Order the option.
1390 Message text CIRC ANGLE NOT ACCEPTED

Cause
Monitor
Effect -- None
Remedy
1391 Message text ACCESS TO COMPONENT NOT ALLOWED

Cause -- Illegal access to a component of the program/motion trace (e.g.

SHOW VAR $PRO_TRACE[5].NAME[2]).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy
1392 Message text WRITE PROTECTION DUE TO PROCESS STATUS

Cause -- Write access to a ”$” variable with an illegal process status (active,
not active, RC Ready).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set a permissible process status.

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1393 Message text WRITE PROTECTION DUE TO OPERATOR CONTROL UNIT

STATUS
Cause -- An attempt has been made to write a ”$” variable with the operator
control unit status incorrectly set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to ”active” status.
1394 Message text READ PROTECTION DUE TO PROCESS STATUS

Cause -- Reading of a ”$” variable with an inadmissible process status

(active, not active, RC ready).
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Set a permissible process status.
1395 Message text READ PROTECTION DUE TO OPERATOR CONTROL UNIT STATUS

Cause -- Reading of a ”$” variable with the operator control unit status incor-
rectly set.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Switch operator control unit to ”active” status.
1396 Message text PROGRAM NOT LINKED

Cause -- Selection of a non--linked program.

Monitor -- At selection.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Link the program.
-- In program processing the message has to be acknowledged.
1398 Message text CHECK RCP SELECTOR SWITCH !

Cause -- The selector switch on the RCP is not set to ”RUN” in the case of
selection or start from another operator control unit.
Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Turn the selector switch on the RCP to ”RUN” .
1399 Message text MESSAGE CANNOT BE ACKNOWLEDGED

Cause -- Acknowledgement of a status (operational) message.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Look at the message display.

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1400 Message text MESSAGE NOT AVAILABLE

Cause -- Textual acknowledgement of a message that is not available.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- None
1401 Message text CONTROL STRUCTURE NEXT BLOCK **

Cause -- Selection into a control structure.

Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
-- The control structure is exited when the end is identified.
Remedy -- Acknowledge message.
1402 Message text SELECT START UP !

Cause -- A command has been entered that is only allowed in the startup
mode.
Monitor -- With all commands of the startup mode.
Effect -- Command is not executed.
Remedy -- Select the startup mode.
-- Acknowledge message.
1403 Message text INTERRUPT INSTRUCTION ABORTED

Cause -- Motion instruction in the interrupt routine that is executed after an

error stop.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- The interrupt module that is called after an error stop may not contain
any motion instructions.
1405 Message text ** IS WRITE PROTECTED

Cause -- Object is write--protected.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check object status (e.g. unlink or deselect object).
1406 Message text ERROR IN PATH

Cause -- Error in path specification e.g. /R5.

Monitor -- In command processing.
Effect -- Command is not executed.
Remedy -- Check path specification.

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1408 Message text LINE COMPILATION OR DECOMPILATION ERROR

Cause -- Message will soon be deleted.

Monitor
Effect
Remedy
1412 Message text AXIS ** ACCELERATION NOT PROGRAMMED

Cause -- No value has been assigned to the program datum $ACC_AXIS.

Monitor -- When starting a PTP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1413 Message text AXIS ** VELOCITY NOT PROGRAMMED

Cause -- No value has been assigned to the program datum $VEL_AXIS.

Monitor -- When starting a PTP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1414 Message text PATH ACCELERATION NOT PROGRAMMED

Cause -- No value has been assigned to the program datum $ACC.CP.

Monitor -- At the first CP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1415 Message text PATH VELOCITY NOT PROGRAMMED

Cause -- No value has been assigned to the program datum $VEL.CP.

Monitor -- At the first CP block.
Effect -- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1416 Message text ORIENTATION ACCELERATION NOT PROGRAMMED

Cause -- No value has been assigned to the program data $ACC.ORI1 and
$ACC.ORI2.
Monitor -- At the first CP block.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1417 Message text ORIENTATION VELOCITY NOT PROGRAMMED

Cause -- No value has been assigned to the program data $VEL.ORI1 and
$VEL.ORI2.
Monitor -- At the first CP block.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.
1418 Message text ** BASE NOT PROGRAMMED

Cause -- No value has been assigned to the program datum $BASE.

a) in a user program
b) after overall reset of the control for a cartesian command.
Monitor -- With a cartesian motion.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- In command processing
a) Assign a value to $BASE.
-- In program processing
a) Alter the program accordingly
b) Acknowledge message.
1419 Message text ** TOOL NOT PROGRAMMED

Cause -- No value has been assigned to the program datum $TOOL

a) in a user program
b) after overall reset of the control for a cartesian command.
Monitor -- With a cartesian motion.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- In command processing
a) Assign a value to $TOOL.
-- In program processing
a) Alter the program accordingly
b) Acknowledge message.
1420 Message text APPROXIMATION NOT PROGRAMMED **

Cause -- No value has been assigned to the program data $APO.VEL,

$APO.ROB, $APO.DIS, $APO.ORI.
Monitor -- When starting the first motion block with approximate positioning.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program accordingly.
-- Acknowledge message.

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1422 Message text ** INVALID VALUE

Cause -- Read access to a variable that is not initialized or that has an invalid
value, e.g. reading of $POS_INT outside an interrupt routine.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1423 Message text OVERFLOW

Cause -- Value is not compatible with the specified data type, e.g. value
assignment of a number >255 to the data type ”char”.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter data type.
-- Acknowledge message in program processing.
1424 Message text PROGRAM STACK OVERFLOW

Cause -- The nesting depth for subprograms and functions has been
exceeded.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1425 Message text INSTRUCTION NOT ALLOWED

Cause -- Program instruction that is not allowed as a command.

-- Program instruction that is only allowed in an interrupt routine.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.

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1426 Message text VARIABLE STACK DEPTH EXCEEDED

Cause -- The nesting depth of the variable has been exceeded.

Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the variable.
-- Acknowledge message.
1428 Message text FUNCTION VALUE NOT DEFINED

Cause -- No RETURN instruction in the function module.

Monitor -- In the program.
Effect -- Ramp--down braking (all active commands inhibited).
Remedy -- Insert a RETURN value.
1429 Message text STRING TOO LONG

Cause -- In a value assignment to arrays, the string consists of more charac-

ters than the existing array.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1430 Message text INTERRUPT NOT DEFINED

Cause -- An interrupt that has not been defined has been switched on.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Define interrupt.
-- Acknowledge message.
1431 Message text SELECTION NOT POSSIBLE

Cause -- Selection of the editor is not possible.

Monitor
Effect
Remedy -- Check whether the file exists (e.g. when attempting to open a file in the
view mode). File is ’hidden’.

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1432 Message text MAX. NO. OF INTERRUPTS DEFINED

Cause -- More than 32 interrupts have been defined.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program.
1433 Message text MAX. NO. OF INTERRUPTS ON

Cause -- More than 8 interrupts have been switched on.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program.
1434 Message text TARGET POINT NOT REACHED

Cause -- The contour cannot be determined when selecting a CIRC block

with a circle angle. A LIN motion to the programmed target point is
executed when the robot is started.
Monitor -- In program processing.
Effect -- The next motion is also a BCO run.
Remedy -- None
1435 Message text READ PROTECTION

Cause -- A ”$” variable that is not admissible for the selected interpreter type
has been read.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- In program processing the message has to be acknowledged.

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1436 Message text DISK WRITE PROTECTED

Cause -- The write protection is activated.

Monitor
Effect
Remedy -- Remove the write protection.
1437 Message text REPOSITION !

Cause -- BCO has not been achieved in returning from the interrupt routine,
i.e. the robot must be repositioned to the interrupt point before the
end of the interrupt routine (e.g. with LIN $POS_RET).
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1438 Message text DATA STORAGE DEVICE NOT READY : **

Cause -- There is no disk inserted or the floppy disk drive is defective.

Monitor
Effect
Remedy -- Check the above--mentioned items.
1439 Message text ** ARGUMENT NOT ALLOWED

Cause -- At least one argument in the function is inadmissible; e.g. SQRT

(negative value).
Monitor -- In interpretation of C functions.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1440 Message text MAILBOX IDENTIFICATION NOT ALLOWED

Cause -- An incorrect MBX_ID is specified in the C function MBX_REC.

Monitor -- In interpretation of MBX_REC.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.

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1441 Message text INTERRUPT PRIORITY NOT ALLOWED

Cause -- Interrupt priority greater than 128 or less than 1

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Acknowledge message.
-- Alter the program.
1442 Message text APPROXIMATION NOT ALLOWED FOR INSTRUCTIONS

Cause -- ”DRIFT”, $TOOL or $FILTER is programmed between two motion

instructions.
Monitor -- In program processing.
Effect -- Approximate positioning is not performed for the motion instructions.
Remedy -- Alter the program.
1443 Message text START MOVEMENT NOT ALLOWED

Cause -- The first motion instruction in the program is relative.

-- The first motion instruction in the program is not programmed com-
pletely, e.g. PTP [e.g. 33.33].
Monitor -- In program processing.
Effect -- No program motion.
Remedy -- Alter the program.
-- Acknowledge message.
1444 Message text ARRAY INDEX NOT ALLOWED

Cause -- An attempt has been made to access an array element that does
not exist.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Acknowledge message.

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 1 Error messages / troubleshooting (continued)

1445 Message text ANGLE STATUS NOT ALLOWED

Cause -- After repositioning with LIN the angle status does not agree with the
status of the programmed block.
Monitor -- In program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
-- Perform repositioning with PTP.
1446 Message text VALUE ASSIGNMENT NOT ALLOWED

Cause -- Inadmissible value assignment for predefined variables, e.g.

$SPEED.ORI1 <= 0.0 or > $SPEED_MA.ORI1.
-- Assigned $BASE or $TOOL not possible for the kinematic system.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1447 Message text SOFTWARE LIMIT **** OUT OF RANGE

Cause -- Target point cannot be reached due to a software limit switch.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1448 Message text ** AMBIGUOUS

Cause -- The specified memory dump name contains wildcards. Expansion of

these wildcards has resulted in more than one valid file name. This
is not allowed however (see above).
Monitor
Effect -- Data transfer is not carried out.
Remedy -- Specify an unambiguous name.

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1449 Message text ** VARIABLE WRITE PROTECTED

Cause -- Write access to a write--protected variable e.g. $POS_ACT.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1450 Message text TRANSFORMATION NOT CONFIGURED

Cause -- $BASE or $TOOL has been assigned although no transformation is

configured.
Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1451 Message text DIVISION BY 0

Cause -- An attempt has been made to divide a value by ”0”.

Monitor -- In command processing.
-- In program processing.
Effect -- In command processing
a) Command is not executed.
-- In program processing
a) Ramp--down braking
b) All active commands inhibited.
Remedy -- Alter the program.
-- Acknowledge message.
1454 Message text START CONTINUE NOT POSSIBLE

Cause -- BSTEP
Monitor -- In command processing.
Effect -- None
Remedy

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1455 Message text NOT ALLOWED IN THIS EDIT MODE

Cause -- A command that would alter the object has been entered in the list-
ing mode of the editor. An attempt has been made in the data
correction mode to delete or copy a range of blocks or to delete a
block consisting of only one line.
Monitor -- In the editor.
Effect -- The attempted action is not executed.
Remedy -- Edit with the full scope of editor functions.
1462 Message text COMMAND SYNTAX ERROR

Cause -- The command contains a syntax error.

Monitor -- In the editor.
Effect -- Command is not executed.
Remedy -- Correct the command.
1463 Message text OBJECT NOT READY

Cause -- Program cannot be processed by the editor.

Monitor -- In the editor.
Effect -- Command is not executed.
Remedy -- Select program with ”edit”.
1468 Message text KEY NOT ASSIGNED

Cause -- An unassigned softkey or function key has been pressed during

prompted operation.
Monitor -- When a softkey is pressed.
-- When a function key is pressed.
Effect -- None
Remedy -- None
1472 Message text KEY NOT ALLOWED

Cause -- Pressing a softkey in textual operation.

-- Pressing an alphanumeric key in prompted operation when no input
field is available.
Monitor -- When a key is pressed.
Effect -- Key is ignored.
Remedy -- None
1474 Message text CHANGE OF DIRECTION NOT POSSIBLE

Cause
Monitor -- In command processing.
Effect -- None
Remedy

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1477 Message text MAIN PROCESS NOT AVAILABLE

Cause -- Main run display (motion trace) is selected but no main run block
has been interpreted yet.
Monitor -- In command processing.
Effect -- None
Remedy -- Start the program.
1478 Message text PRE PROCESS NOT AVAILABLE

Cause -- Advance run display (program trace) is selected but no program is

in the STOP or END state.
Monitor -- In command processing.
Effect
Remedy -- Start the program.
1481 Message text NO RUNTIME DATA ACCESS

Cause -- Access to an invalid (non--existent) object value memory or runtime

data area via the hierarchy table (search path).
Monitor -- In the interpreter (prim -- init).
Effect -- None
Remedy -- Set the search path to the current interpreter environment.
1482 Message text VOLUME TOO SMALL

Cause -- Monitoring of the dispensed volume has been triggered. Insufficient

adhesive has been dispensed.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1483 Message text EXCESSIVE VOLUME

Cause -- Monitoring of the dispensed volume has been triggered. Too much
adhesive has been dispensed.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.
1484 Message text WRONG ADHESIVE PRESSURE

Cause -- The initial pressure of the adhesive is continuously monitored by the

PLC during dispensing. A pressure value outside the permissible
tolerance range has been detected. Possibly there are bubbles in
the adhesive supply line, or the outlet nozzle is clogged.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Check the adhesive application hardware, purge it if necessary.

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1485 Message text OIL FILTER DIRTY

Cause -- The hydraulic pressure is no longer adequate because the hydraulic

oil filter is dirty.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Clean or replace the filter.
1486 Message text MAX. OIL TEMPERATURE EXCEEDED

Cause -- The maximum permissible hydraulic oil temperature has been ex-
ceeded.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Wait until the hydraulic oil has cooled down, possibly check the
hydraulic unit.
1487 Message text GENERAL SYSTEM AIR PRESSURE

Cause -- The required air supply pressure for the pneumatic valves is not
available.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Ensure that the air pressure is high enough.
1488 Message text VACUUM ERROR

Cause -- In the application of adhesive to glass, the glass is held in position

by means of a vacuum. If this vacuum is not available, the glass
cannot be held in position after it has been centered.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the vacuum pump.
1489 Message text CENTERING ERROR

Cause -- The workpiece is not correctly positioned or clamped. There is pos-

sibly a fault in the feed equipment, or the fixture is defective.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check fixture, feed equipment or workpiece position.
1490 Message text COMPONENT CHECK ERROR

Cause -- In the application of adhesive to glass, the adhesive nozzle is

pressed onto the glass. If this pressure is missing during adhesive
application, the glass might be broken or might no longer be
clamped to the fixture. The robot motion and adhesive application
must be stopped immediately.
Monitor -- From the PCL application program (bonding technology).
Effect -- Maximum braking. All active commands inhibited. Emergency Stop.
Remedy -- Check the workpiece.

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1491 Message text CP/PTP APPROXIMATION NOT FEASIBLE

Cause -- In the CP block the traversing distance of an axis is greater than

180 degrees; S change in the CP block; software limit switch vio-
lated in travel along ”shortest path”.
Monitor
Effect
Remedy
1492 Message text CHANNEL NOT COMPATIBLE WITH PROTOCOL

Cause -- PLC protocol is set and channel declaration is not set to SER1.
Monitor -- In command processing.
Effect -- None
Remedy -- Alter the channel declarartion protocol.
1493 Message text CHANNEL ASSIGNED TO PLC

Cause -- An attempt has been made to access the channel that has already
been parameterized for the PLC link.
Monitor -- In command processing.
Effect -- None
Remedy -- Reparameterize the channel. Close the channel and open it again.
1495 Message text TIMEOUT DURING FILLING

Cause -- The time for filling the dispensing unit with adhesive is monitored by
the PLC. If the maximum time is exceeded, there is a fault in the
adhesive application hardware.
Monitor -- From the PCL application program (bonding technology).
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Check the adhesive application hardware.
1496 Message text ADHESIVE LEVEL

Cause -- The adhesive drum is empty.

Monitor -- From the PLC user program (bonding technology).
Effect -- None
Remedy -- Prepare a new adhesive drum or switch over to a new drum.
1497 Message text ALL ANALOG FUNCTIONS ASSIGNED

Cause -- More than 2 cyclic analog outputs have been switched on.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Possibly ANOUT OFF, or cancel the instruction.

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1498 Message text ** NOT AN ANALOG OUTPUT

Cause -- When accessing a non--existent analog output signal, incorrect sig-

nal index.
Monitor -- In command and program processing.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Acknowledge message.
1499 Message text ANALOG OUTPUT ALREADY ASSIGNED

Cause -- A cyclic analog output is assigned a second time in the program

e.g. SIGNAL SIG1 $ANOUT[1]
SIGNAL SIG2 $ANOUT[1]
ANOUT ON SIG1 = ....
ANOUT ON SIG2 = ....
Monitor -- In the program.
Effect -- Ramp--down braking.
Remedy -- Switch off cyclic analog output ANOUT OFSIG.
1505 Message text COMBINATION OF VARIABLES NOT ALLOWED **

Cause -- In a synact instruction, variables for individual blocks and approxi-

mate positioning blocks are combined in the logic comparison or
value assignment.
Monitor -- In program processing.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Program synact instruction differently.
1506 Message text CIRC PARAMETER NOT ALLOWED

Cause -- Distance between starting point and/or auxiliary point and/or target
point is too small, or all points lie on a straight line. Formation of a
circle is not possible.
Monitor -- In the individual CIRC block. Presentation.
Effect -- Ramp--down braking, interface inhibited.
-- CIRC block is not executed.
Remedy -- Reprogram auxiliary point and/or target point.
1507 Message text HYDRAULIC LEVEL

Cause -- The oil level in the hydraulic system has fallen below the minimum
limit.
Monitor -- In PLC program processing.
Effect -- None
Remedy -- Top up hydraulic oil and check hydraulic system for leaks.

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1508 Message text NO FILE AVAILABLE

Cause -- No file is available that meets the search criteria specified in the DIR
command.
Monitor -- In command processing.
Effect -- None
Remedy -- None necessary.
1509 Message text PROGRAM EXEC. MODE NOT ALLOWED

Cause
Monitor -- In command processing.
Effect -- None
Remedy
1510 Message text ERROR AT FORMAT SELECTION NO. **

Cause -- Parameter inconsistent with format specification, or incorrect format

specification in CWRITE instruction.
Monitor -- Program processing in S_INT function CWRITE.
Effect -- Program execution is stopped.
Remedy -- Program the correct format specification.
1511 Message text ACCESS NOT ALLOWED

Cause
Monitor
Effect
Remedy
1513 Message text RANGE FOR ** ** EXCEEDED

Cause -- 32--bit word is exceeded.

Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy
1514 Message text INSERT ANOTHER DISK

Cause -- Floppy server.

Monitor
Effect
Remedy

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1515 Message text ** COPY REFUSED (--S!)

Cause -- System file has been transmitted via an interface without the option
--S being set (--S = code for download command).
Monitor -- In command processing.
Effect -- File is not transmitted.
Remedy -- Set the option --S.
1516 Message text REFERENCE SYSTEM NOT PROGRAMMED

Cause -- $BASE is programmed incompletely or not at all.

Monitor -- In program processing.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Program $BASE.
1517 Message text BCO MOVE TO AUX. POINT REQUIRED

1518 Message text DEFAULT PARAMETER

Cause -- A default parameter or no parameter has been transferred to a pre-

defined C function.
Monitor -- In program processing.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Call the C function with a parameter.
1519 Message text PRESSURE SENSOR CABLE FAILURE

Cause -- The current flow of the analog signal for pressure sensing has fallen
below the minimum limit (4 -- 20 mA interface).
Monitor -- In command processing.
Effect -- Ramp--down braking.
Remedy -- Check connecting cable, connectors and current source.
1520 Message text VOLUME ACTUAL VALUE CABLE FAILURE

Cause -- The current flow of the analog input channel for volume sensing has
fallen below the minimum limit (4 -- 20 mA interface).
Monitor -- In command processing.
Effect -- Ramp--down braking.
Remedy -- Check connecting cable, connectors and current source.
1521 Message text CHANGE OF SEGMENT IS ERRONEOUS

1522 Message text SELECTED AXIS IS NOT ADJUSTABLE

Cause -- The axis to be mastered is inactive.

Monitor -- In command processing.
Effect -- The command is aborted.
Remedy -- Master only active axes.

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1523 Message text EXTFCTP INSTRUCTION IS NOT ALLOWED

Cause -- An EXTFCTP instruction has been programmed in the program.

Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Delete the EXTFCTP instruction.
1524 Message text MAX. NO. OF ACTIVE TRIGGERS

1525 Message text INVALID TRIGGER -- PRIO

1526 Message text MAX. TRIGGERS (50) DEFINED

1527 Message text SENSOR MASTERING NOT ALLOWED

Cause -- No sensor location run has been performed for the axis.
Monitor -- In command processing.
Effect -- Command is aborted.
Remedy -- Perform sensor location run for the axis.
1528 Message text BRAKES OPEN DURING MASTERING SELECTION

Cause -- A brake is still open after the preceding motion.

Monitor -- In command processing.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Wait until all brakes are closed and the servos are disabled.
1529 Message text SEGMENT EXCHANGE SUCCESSFUL

1530 Message text REDUCED VELOCITY DURING SENSOR LOCATION SEARCH

Cause -- The velocity defined by the user for the sensor loction run in
$RED_JUS_UEB is greater than the possible maximum at which the
sensor can be detected. The controller automatically reduces the
velocity to allow the sensor to be detected.
Monitor -- In command processing.
Effect -- None
Remedy -- Reduce the permissible velocity for manual traversing in the machine
data.
1531 Message text ADJUSTMENT POSSIBLE ONLY IN MODE T1

Cause -- The operating mode of the controller is not set to mode T1.
Monitor -- In command processing.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Set the mode to T1. Perform mastering again.

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1532 Message text CIRC IS EXECUTED AS LIN

Cause -- An attempt has been made to execute a CIRC motion as a BCO

run.
Monitor -- In program processing.
Effect -- Program execution is stopped.
Remedy -- Acknowledge message, after the start the CIRC block is then executed
as a LIN motion.
1534 Message text COR.DAT CHECK SUM WRONG

Cause -- The correction data have been altered.

Monitor -- In command processing.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Sensor location run/referencing, execution/archiving of the correction
data.
1535 Message text DELAY ** NOT ALLOWED

Cause -- Neg. delay in the synact instruction has not been used in combina-
tion with one of the 4 position trigger variables (M_SC_F, M_SC_B,
M_SCAPO_F, M_SCAPO_B).
Monitor -- In the program.
Effect -- Ramp--down braking, All active commands inhibited.
Remedy -- Change the logic condition of the synact instruction.
1536 Message text ARRAY PARAMETER NOT ALLOWED

Cause -- Undefined array parameter or complete call--by--value array in the

list of current parameters when function is called.
Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Do not use undefined array parameters and transfer complete arrays
as current parameters only on a call--by--reference basis.
1537 Message text STOP DUE TO LOADING NEW CUSTOM DATA

Cause -- Loader for the file /$CUSTOM.DAT has been called. No process
mnay be active at the same time since the system is fully occupied
with the loader.
Monitor -- In command processing.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message. Do not edit /$CUSTOM.DAT during an
”active process”
1538 Message text INVALID “DISTANCE” VALUE

1539 Message text INVALID “DELAY” VALUE

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1540 Message text INTERRUPT EXPRESSION COMPLEXITY EXCEEDED

Cause -- In total more than 16 ”slow” variables have been used in the logical
expressions of the INTERRUPT DECL instructions on the control
and robot levels.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Do not use so many predefined variables.
1541 Message text MACHINE DATA ERROR

Cause -- Machine data have not yet been checked.

Monitor -- With active commands.
Effect -- None
Remedy -- Edit the machine data or copy the machine data or option data file.
1542 Message text ERROR IN “UPCALL” TOKEN

1543 Message text NO MORE DYNAMIC ANALOG INPUTS AVAILABLE

Cause -- A third dynamic analog input has been switched on in the program.
Monitor -- In program processing.
Effect -- Stop.
Remedy -- One of the dynamic analog inputs must first be switched off.
1544 Message text DIGITAL INPUT ALREADY ASSIGNED

Cause -- A digital input has been cyclically switched on in the program for a
second time.
Monitor -- In program processing.
Effect -- Stop.
Remedy -- The dynamic digital input must first be switched off.
1545 Message text ALL PULSE OUTPUTS ASSIGNED

Cause -- More than 16 impulse outputs have been switched on.

Monitor -- (e.g. cyclic; in command processing; in mastering etc.)
In program processing.
Effect -- (e.g. ramp--down braking; program execution stopped; etc.)
ramp--down braking; program execution stopped.
Remedy -- (e.g. eliminate fault; correct operator action; etc.)
alter program.
1546 Message text INVALID PULSE DURATION

Cause -- The possible range for the pulse duration extends from 0.05 to
3049. A value outside this range has been specified.
Monitor -- (e.g. cyclic; in command processing; in mastering etc.)
Program processing.
Effect -- (e.g. ramp--down braking; program execution stopped; etc.)
ramp--down braking; program execution stopped.
Remedy -- (e.g. eliminate fault; correct operator action; etc.)
program admissible values only.

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 1 Error messages / troubleshooting (continued)

1547 Message text TARGET VARIABLE MUST BE OF TYPE REAL

Cause -- Incorrect data type of a target variable or wrong format in a CREAD

or SREAD instruction.
Monitor
Effect
Remedy -- Correct CREAD or SREAD instruction: change format specification
or use variable of type REAL.
1548 Message text ** RESELECTION NOT POSSIBLE

Cause -- Program must be linked for reselection, but this results in an error.
Monitor -- Command processing (RUN command).
Effect -- None
Remedy -- Error list contains the linking errors. Look at this list and eliminate the
errors.
1549 Message text INVALID HANDLE

Cause -- An invalid HANDLE has been programmed into CWRITE or

CREAD.
Monitor -- Program.
Effect -- Ramp--down braking.
Remedy -- Specify a valid HANDLE.
1550 Message text NO MORE DATA/VARIABLES AVAILABLE

Cause -- With SREAD/CREAD there is no more text to be read or there are

no variables available for storing the values.
Monitor
Effect
Remedy
1552 Message text CHANNEL ALREADY OPEN

Cause -- An attempt has been made to open a channel that is alraedy open.
Monitor -- In command processing.
1553 Message text CHANNEL CANNOT BE OPENED/CLOSED

Cause -- The operator has attempted to open a SINEC H1 channel by means

of the OPEN command or to close it by means of the CLOSE com-
mand.
Monitor -- In command processing.
Effect -- None
Remedy -- None; SINEC H1 channels are opened and closed automatically.

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1554 Message text WRONG TYPE OF PARAMETER VARIABLE

Cause -- The parameter variable for the channel is of the wrong type.
Monitor -- In command processing.
Effect -- None
Remedy -- Correct CHANNEL declaration for the channel.
1555 Message text CHANNEL PARAMETERS FAULTY OR INCOMPLETE

Cause -- At least one channel parameter in the parameter variable of the

channel in /$CUSTOM.DAT is faulty or not initialized.
Monitor -- In command processing.
Effect -- None
Remedy -- Correct the initialization of the parameter variable.
1556 Message text SINEC L2 BUS CHANNEL NOT OPENED

Cause -- An attempt has been made to open a SINEC L2 connection without

the SINEC L2 bus channel being open.
Monitor -- In command processing.
Effect -- None
Remedy -- Open SINEC L2 bus channel.
1557 Message text CHANNEL ALREADY FULLY ASSIGNED

Cause -- The maximum number of jobs have already been assigned to the
channel.
Monitor -- In command processing.
Effect -- None
Remedy -- Wait until at least one of the jobs is finished.
1558 Message text CHANNEL HAS TO BE OPENED/CLOSED

Cause -- The channel parameters used for assigning the channel do not cor-
respond to the current channel parameters.
Monitor -- In command processing.
Effect -- None
Remedy -- Close the channel prior to assignment.
1559 Message text CHANNEL SPECIFICATION NOT ALLOWED

Cause -- An attempt has been made to transmit a productive command via

the SINEC L2 bus channel.
-- An attempt has been made to output the listing or the message
buffer through the SINEC H1 channel to a third station.
Monitor -- In command processing.
Effect -- None
Remedy -- None

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 1 Error messages / troubleshooting (continued)

1560 Message text CHANNEL ALREADY CLOSED

Cause -- An attempt has been made to close a channel that is already

closed.
Monitor -- In command processing.
Effect -- None
Remedy -- Abort.
1561 Message text SINEC L2 COMMUNICATION CHANNELS NOT CLOSED

Cause -- An attempt has been made to close the SINEC L2 bus channel with-
out all the SINEC L2 communication channels being closed first.
Monitor -- In command processing.
Effect -- None
Remedy -- Close all the SINEC L2 communication channels.
1562 Message text ** BOARD NOT AVAILABLE

Cause -- An attempt has been made to access a SINEC L2 or SINEC H1

channel without the corresponding board being installed.
Monitor -- In command processing.
Effect -- None
Remedy -- Install the corresponding board.
1564 Message text VALUE RANGE EXCEEDED

Cause -- The wait time in the WAIT_SEC command, expressed in basic clock
rate cycles, exceeds the long range, i.e. is greater than
2147483647.
Monitor -- Program processing.
Effect -- Ramp--down braking.
Remedy -- Enter shorter wait times.
1565 Message text SINEC L2 CONFIGURATION ERROR **

Cause -- The opening or closing of a SINEC L2 channel is refused on ac-

count of a configuration error detected by the SINEC L2 module.
Monitor -- In command processing.
Effect -- None
Remedy -- Check and correct the channel parameters (e.g. baud rate).
1566 Message text SINEC L2 TRANSMISSION ERROR **

Cause -- Data transmission via SINEC L2 is not possible on account of an

error detected by the SINEC L2 module.
Monitor -- In data transmission.
Effect -- None
Remedy -- Check the transmission link and rectify the error.

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1567 Message text NO CONNECTION TO SINEC L2 BOARD

Cause -- The connection of the IFC to the SINEC L2 board is faulty.

Monitor -- Cyclic
Effect -- None
Remedy -- Warm start, possibly replace the board (IFC with SINEC L2 board).
1568 Message text MAX. NO. OF PROCESSES ASSIGNED TO CHANNEL

Cause -- Too many processes are running through a serial interface.

Monitor
Effect
Remedy -- Wait until a process is finished.
1569 Message text PARAMETER CHANGE NOT ALLOWED, CHANNEL ASSIGNED

Cause -- An attempt has been made to allocate parameters differing from the
current ones to a channel that is already assigned.
Monitor
Effect
Remedy -- Correct the data used for the channel as required, or close the channel
and re--open it with the appropriate parameters.
1570 Message text INVALID PARAMETER VALUE

Cause -- The maximum value of a channel parameter has been exceeded.

Monitor
Effect
Remedy -- Correct the channel parameter.
1571 Message text BAUD RATE SUMMATION EXCEEDED

Cause -- The aggregate baud rate of both channels has been exceeded (it is
limited to 19200 bauds).
Monitor
Effect
Remedy -- Alter the baud rate.
1572 Message text PROTOCOL TIMEOUT

Cause
Monitor
Effect
Remedy -- Check whether the physical connection to the periphery still exists.
Increase the timeout setting appropriately if it is too low.

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1573 Message text IFC SYNTAX ERROR

Cause -- During an attempt to open or close a channel, a syntax error has

occurred in the interface CPU with regard to the command gener-
ated by the control.
Monitor
Effect
Remedy -- Close and re--open the channel.
1574 Message text KRC SYSTEM ERROR **

Cause -- KRC system error (core system, not acknowledgeable). “KRC SYS-
TEM ERROR 0” indicates that a task has crashed.
Monitor
Effect -- Maximum braking, All active commands inhibited.
Remedy -- Reboot the controller.
1576 Message text BASE CHANGE INADMISSIBLE

Cause -- During conveyor operation an attempt has been made to change the
BASE.
Monitor
Effect -- Maximum braking.
Remedy -- Alter the program.
1577 Message text ** ALREADY EXISTS

Cause -- A SUB module cannot be created in the editor if an SCR module of

the same name already exists and vice versa.
Monitor -- Command processing.
Effect
Remedy -- Change the name.
1578 Message text ** NOT ALLOWED

Cause -- An inadmissible value has been entered.

Monitor -- Command processing.
Effect
Remedy -- Enter an admissible value.
1580 Message text TECH FCT $TECH[**].FCT NOT ALLOWED

Cause -- The function parameters programmed in $TECH[i].FKT i=1..3, are

incompatible with the function definition.
Monitor -- The function parameters are checked by the interpreter in the ad-
vance run.
Effect -- Ramp--down braking.
Remedy -- Correct the function parameters.

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1581 Message text TECH MODE NOT ALLOWED

Cause -- The CYCLE mode has been programmed for the technology cate-
gory VEL.
Monitor -- In the interpreter when changing CLASS or MODE.
Effect -- Ramp--down braking.
Remedy -- Alter the program.
1582 Message text KINEMATIC INSTRUCTION NOT ALLOWED

Cause -- A non--existent external kinematic system has been assigned to the

system variable $BASE with the function EK.
Monitor
Effect
Remedy
1583 Message text ** BLOCK SIZE ERROR

Cause -- The received data block is too large.

Monitor
Effect
Remedy -- Alter the buffer length in the external data storage device to the control--
internal size or smaller.
1584 Message text PROGRAM STRUCTURE FOR RESUME NOT ALLOWED

Cause -- The interrupt occurs in the program section where the interrupt with
RESUME was declared. The return is therefore executed to the ad-
vance run pointer, which is not defined.
Monitor
Effect -- Ramp--down braking.
Remedy -- RESUME may be used only in conjunction with the subprogram
technique. The interrupt must not be triggered on the level where the
interrupt was declared.
1585 Message text CA PARAMETER OUT OF RANGE

Cause -- Too large a value has been programmed for the parameter CA
(complete angle) in the CIRC block.
Monitor
Effect
Remedy -- Correct the value of the CA appropriately.
1586 Message text SINEC AP/TF ERROR **

Cause -- See “SINEC AP Technological Functions, Part B”.

Monitor -- In command processing.
Effect
Remedy -- See “SINEC AP Technological Functions, Part B”.

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1587 Message text APPLICATION COMM. INTERRUPTED (FILE SERVER)

Cause -- The application communication with the file server has been inter-
rupted or disconnected.
Monitor -- In command processing.
Effect
Remedy -- Check the transmission link between the ACR and the file server.
1588 Message text PATH NOT ALLOWED

Cause -- The path specification for SINEC H1 contains wildcards.

Monitor -- In command processing.
Effect
Remedy -- Copy just one file at a time.
1589 Message text ** CLOSING CHANNEL NOT ALLOWED, CHANNEL ACTIVE

Cause -- The channel concerned cannot be closed during transmission.

Monitor
Effect
Remedy -- Wait for the transmission to finish or abort the transmission.
1590 Message text ENUM NOT DECLARED IN $CONFIG

Cause -- A SET INFO is being applied to an ENUM variable from a user data
list. The search path extension has been altered again --> no access
to ENUM type information.
Monitor -- Command processing.
Effect
Remedy -- Enter ENUM declaration and variable declaration into $CONFIG.DAT.
1594 Message text TECH_MAX VALUE EXCEEDED

Cause -- The number of the programmed function generator is greater than

the maximum number of function generators configured in the ro-
bot--specific machine data (TECH_MAX).
Monitor
Effect -- Ramp--down braking.
Remedy -- Alter the program.
1595 Message text LOAD DEPENDENT ACC. ADAPTATION NOT POSSIBLE
FOR PTP **
Cause -- The simulation calculation of the integrated dynamic model exceeds
the given limit values of the continuous gear torque.
Monitor -- At every PTP preparation with activated load--dependent accelera-
tion adaptation.
Effect -- Operator information; no effect.
Remedy -- If allowed: increase the max. permissible continuous gear torque
$DYN_DAT[50..].
-- Lower the optimization limit $OPTEXCLUDE.

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1598 Message text LOAD NOT PROGRAMMED

Cause -- With the acceleration adaptation activated, the load has not been
completely programmed.
Monitor -- In every motion in the program or interrupt.
Effect -- Program stop.
Remedy -- Correctly program $LOAD.
1600 Message text CONTROL : **

1601 Message text NO BLOCK COINCIDENCE, STEP MODE FIRST

Cause -- No block coincidence when changing mode to AUTO.

Monitor
Effect
Remedy -- Achieve block coincidence in the SINGLE--STEP mode first.
1602 Message text BCO RUN IN STEP MODE REQUIRED

1603 Message text SAFETY FENCE OPEN

1604 Message text ERROR IN TRACE DEFINITION

Cause -- The trace has been incorrectly defined in the TRACE.DEF file.
Monitor -- When starting a trace.
Effect
Remedy -- Correct TRACE.DEF.
1605 Message text ERROR READING TRACE.DEF

Cause -- The TRACE.DEF file could not be read at the start of trace recor-
ding.
Monitor -- When starting a trace.
Effect
Remedy -- Make TRACE.DEF available, start or check FTP server.
1606 Message text INTERBUS : BUS ERROR **

Cause -- Error or malfunction in data transmission on the Interbus.

Monitor
Effect -- Data transmission on the Interbus is stopped, outputs are reset.
Remedy -- Troubleshooting with CMD (Phoenix diagnostic tool).
1607 Message text INTERBUS : BUS WARNING **

Cause -- Malfunction in the bus module specified (Segment Position).

Monitor
Effect -- Outputs are reset.
Remedy -- Eliminate the error in the specified module, diagnosis with CMD
software (Phoenix).

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 1 Error messages / troubleshooting (continued)

1608 Message text ASSIGNMENT OF FUNCTION VALUE TO $CYCFLAG

NOT ALLOWED
Cause -- Return value of a BOOL function has been assigned directly to a
$CYCFLAG.
Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Alter the program, acknowledge message.
1609 Message text ASSIGNMENT OF RUNTIME VALUE TO $CYCFLAG NOT ALLOWED

Cause -- A $CYCFLAG has been assigned local runtime data.

Monitor -- In program processing.
Effect -- Ramp--down braking. All active commands inhibited.
Remedy -- Alter the program (use global variables only), acknowledge message.
1610 Message text ERROR IN CONFIGURATION FILE

1611 Message text MAC--ID IN USE

1612 Message text ERROR DURING TASK START

1613 Message text ERROR DURING ALLOCATE DEVICE **

1614 Message text ERROR DURING SCAN DEVICE **

1615 Message text “PRIO” 40--80 CLOSED

1616 Message text START LOCKED : **

Cause -- Start is inhibited during insertion of one or more blocks in PROCOR.

2000 Message text NEW BLOCK IS NOT A DECLARATION

2001 Message text BINARY OUTPUT SIGNAL EXPECTED

2002 Message text INCORRECT INITIALIZATION

2003 Message text FAULTY INITIALIZATION VALUE

2004 Message text “DEFDAT” EXPECTED

2005 Message text VARIABLE NOT INITIALIZED

2006 Message text “CA” EXPECTED

2007 Message text “DEF” OR “DEFECT” EXPECTED

2008 Message text BLOCK CANNOT BE MODIFIED

2009 Message text GLOBAL SR/FCT CANNOT BE RENAMED

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2010 Message text DATA LIST CANNOT BE RENAMED

2011 Message text DIFFERENT TYPES WITH CHANGE OF INITIAL VALUE

2012 Message text SUB CANNOT BE LINKED TO SRC

2013 Message text VARIABLE CANNOT BE RENAMED

2014 Message text INDEX CANNOT BE CHANGED

2015 Message text NOT A SYSTEM SUBROUTINE

2016 Message text NOT A SYSTEM FUNCTION

2017 Message text SYNTAX ERROR IN P_PATH

2018 Message text UNUSED EXTERNALLY DECLARED SUBROUTINE

2019 Message text EXPECTED EXT. SUBROUTINE, FOUND FUNCTION

2020 Message text EXTERNAL FUNCTION EXPECTED, SUBROUTINE FOUND

2021 Message text DATA LIST NOT “PUBLIC”

2022 Message text IMPORTED VARIABLE NOT DECLARED IN DATA LIST

2023 Message text IMPORTED VARIABLE NOT DECLARED IN DATA LIST

2024 Message text IMPORTED VARIABLE TYPE/DIMENSION CONFLICT

2025 Message text EXTERNAL AND SR/FCT DECLARATIONS DO NOT MATCH

2026 Message text EXTERNAL AND SR/FCT DECLARATIONS DO NOT MATCH

2027 Message text IMPORT INTERFACE NOT CORRECT

2028 Message text EXT[FCT] AND DEF[FCT] PARAMETERS ARE INCOMPATIBLE

2029 Message text SYNTAX ERROR IN MODULE

2030 Message text MODULE USED BY ANOTHER PROCESS

2031 Message text MODULE PACKAGE NOT AVAILABLE

2032 Message text ILLEGAL COMMAND

2033 Message text END OF BLOCK OR COMMENT EXPECTED

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 1 Error messages / troubleshooting (continued)

2034 Message text INSERT BEFORE FIRST BLOCK NOT ALLOWED

2035 Message text INVALID BLOCK NUMBER

2036 Message text ONLY COMMENT MAY BE ENTERED AFTER “ENDDAT”

2037 Message text ILLEGAL OR UNKNOWN BLOCK

2038 Message text DECLARATION NOT IN DECLARATION SECTION

2039 Message text INSTRUCTION NOT IN INSTRUCTION SECTION

2040 Message text INITIAL VALUE BLOCK NOT INITIALIZATION SECTION

2041 Message text ERROR IN “DEFDAT”, INSERT NOT SUCCESSFUL

2042 Message text “DEFDAT” NOT ALLOWED

2043 Message text ERROR IN GLOBAL “DEF”/”DEFFCT”

2044 Message text “DEF”/”DEFFCT” NOT ALLOWED

2045 Message text “END”/”ENDFCT”/”ENDDAT” NOT ALLOWED HERE

2046 Message text “EXT”/”EXTFCT”/”IMPORT” NOT ALLOWED HERE

2047 Message text FILE NOT FOUND

2048 Message text ERROR ON ENTERING THE DATA LIST

2049 Message text INITIAL VALUE NOT ALLOWED HERE

2050 Message text INITIAL VALUE SYNTAX INCORRECT

2051 Message text NAME IN FIRST LINE MUST BE SAME AS MODULE NAME

2052 Message text ARRAY NAME ENTERED NOT ALLOWED HERE

2053 Message text INITIAL VALUE OF INDEX ALREADY EXISTS

2054 Message text ’=’ EXPECTED

2055 Message text REAL CONSTANT EXPECTED

2056 Message text ’{’ EXPECTED

2057 Message text COMPONENT NOT PART OF VARIABLE TYPE

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2058 Message text CONSTANT NAME NOT PART OF VARIABLE TYPE

2059 Message text STRING CONSTANT TOO LONG

2060 Message text ARRAY INDEX ENTERED INADMISSIBLE HERE

2061 Message text AGGREGATE COMPONENT INITIALIZED MORE THAN ONCE

2062 Message text INFORMATION LOSS POSSIBLE ON CHANGE OF TYPE

2063 Message text INTEGER, REAL OR CHARACTER CONSTANT EXPECTED

2064 Message text CHARACTER OR INTEGER CONSTANT EXPECTED

2065 Message text “TRUE” OR “FALSE” EXPECTED

2066 Message text ENUM CONSTANT TYPE DOES NOT MATCH ENUM VARIABLE

2067 Message text COMPONENT ARRAY SPEC. MULTIDIMENSIONAL

2068 Message text ARRAY SUBSCRIPT MISSING

2069 Message text COMPONENT IS NO ARRAY

2070 Message text ’#’ OR ENUM TYPE NAME EXPECTED

2071 Message text STRUCTURE TYPE NAME EXPECTED

2072 Message text TYPENAME INCOMPATIBLE WITH TEXT

2073 Message text COMPONENT NEITHER PART OF “FRAME” OR “POS”

2074 Message text ASCENDING INDICES EXPECTED

2075 Message text NUMBER TOO LOW

2076 Message text ’IS’ EXPECTED

2077 Message text INTEGER CONSTANT EXPECTED

2078 Message text IDENTICAL PREDEFINED SIGNAL NAMES EXPECTED

2079 Message text COMPONENT TYPE UNKNOWN

2080 Message text PROTOCOL VARIABLE DECLARED IMPLICITLY

2081 Message text “POS”, “FRAME”, OR “AXIS” EXPECTED

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2082 Message text VARIABLE WITH STRUCTURE TYPE EXPECTED

2083 Message text PREDEFINED SIGNAL EXPECTED

2084 Message text PREDEFINED CHANNEL NAME EXPECTED

2085 Message text ’[’ EXPECTED

2086 Message text ARRAY LIMIT MISSING

2087 Message text ’,’ EXPECTED

2088 Message text SIGNAL INDEX TOO LARGE

2089 Message text ’..’ EXPECTED

2090 Message text ONE DIMENSIONAL CHAR FIELD EXPECTED

2091 Message text “IN” OR “OUT” EXPECTED

2092 Message text SYNTAX ERROR IN ARRAY SPECIFICATION

2093 Message text POS. INTEGER, “]” OR “,” EXPECTED

2094 Message text NO MORE THAN THREE DIMENSIONS ALLOWED

2095 Message text RELATIVE P_PATH NOT COMPATIBLE WITH NODE

2096 Message text “]” OR “,” EXPECTED

2097 Message text STRUCTURE TYPE VARIABLE NOT ALLOWED

2098 Message text VARIABLE NOT DECLARED IN DATA LIST

2099 Message text ARRAY INDEX EXCEEDS ARRAY LIMITS

2100 Message text POSITIVE INTEGER EXPECTED

2101 Message text ARRAY INDEX NOT COMPATIBLE WITH INDEX

2102 Message text ARRAY LIMIT EXCEEDED

2103 Message text NO VARIABLE EXISTS WITH THIS NAME

2104 Message text PARAMETER SPECIFICATION NOT ALLOWED IN DATA LIST

2105 Message text LOCAL PARAMETER TYPE DEFINED LOCALLY

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2106 Message text BLOCK CANNOT BE DELETED

2107 Message text DELETE MODULE BY MEANS OF DEDICATED FUNCTION

2108 Message text “ERROR” TOKEN IN I--CODE

2109 Message text END STATEMENT MISSING

2110 Message text INCORRECT END OF CONTROL STRUCTURE

2111 Message text SUBROUTINE/FUNCTION INCORRECTLY COMPLETED

2112 Message text IDENTIFIER NOT DECLARED

2113 Message text PROTOCOL VARIABLE MUST BE OF STRUCTURE TYPE

2114 Message text CORRECT TYPE ENTRY UNAVAILABLE

2115 Message text COMPONENT TYPE NOT DEFINED OR CORRECTLY DEFINED

2116 Message text TYPE OF A PARAMETER IS DEFINED LOCALLY

2117 Message text ENDDAT STATEMENT MISSING

2118 Message text TYPE CHANGE FOR INITIAL VALUE NOT POSSIBLE

2119 Message text COMPILE LOC. NOT COMPATIBLE WITH CALL LOCATION

2120 Message text OBJECT MUST BE DECLARED IN DATA LIST OR IMPLICITLY

2121 Message text INCORRECT DIMENSION

2122 Message text NAME NOT DECLARED AS ARRAY

2123 Message text NAME NOT DECLARED AS FUNCTION

2124 Message text VARIABLE NOT DECLARED IN DATA LIST

2125 Message text COMPONENT NOT PART OF TYPE

2126 Message text NO STRUCTURE DATA TYPE

2127 Message text FORMAL PARAMETER DECLARATION MISSING

2128 Message text MORE ACTUAL THAN FORMAL PARAMETERS SPECIFIED

2129 Message text FORMAL PARAMETER NOT DEFINED

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 1 Error messages / troubleshooting (continued)

2130 Message text NOT ALLOWED EXPRESSION AFTER RETURN INSTRUCTION

2131 Message text EXPRESSION AFTER RETURNING INSTRUCTION MISSING

2132 Message text NO INTERFACES ALLOWED

2133 Message text TYPE MUST BE “POS”,”FRAME”,”AXIS”

2134 Message text OBJECT TYPE NOT VALID

2135 Message text NAME NOT DECLARED AS SUBROUTINE

2136 Message text LOCAL SUBROUTINE NOT ALLOWED IN PROCESS COMMANDS

2137 Message text NAME NOT DECLARED AS SIMPLE VARIABLE

2138 Message text NO NAME OF SUCH A CONSTANT TYPE

2139 Message text SPECIFIED TYPE IS NOT ENUM TYPE

2140 Message text NO ENUM TYPE SPECIFIED

2141 Message text INDEXING OR [] NOT ALLOWED

2142 Message text INDEXING OR [] EXPECTED

2143 Message text END OF CONTROL STRUCTURE NOT ALLOWED HERE

2144 Message text “ENDLOOP” MISSING

2145 Message text “ENDWHILE” MISSING

2146 Message text “ENDFOR” MISSING

2147 Message text “UNTIL” MISSING

2148 Message text “ENDIF” MISSING

2149 Message text “ENDSWITCH” MISSING

2150 Message text “SWITCH” CONTAINS NO “CASE”

2151 Message text NO “CASE” AFTER “SWITCH”

2152 Message text “CASE”/”DEFAULT” AFTER “DEFAULT”

2153 Message text “EXIT” NOT IN LOOP BODY

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2154 Message text NAME NOT DECLARED AS CHANNEL

2155 Message text NAME NOT DECLARED AS LABEL

2156 Message text JUMP DESTINATION NOT DECLARED LOCALLY

2157 Message text JUMP DESTINATION NOT DECLARED GLOBALLY

2158 Message text JUMP TO LABEL NOT ALLOWED

2159 Message text THERE EXISTS AN INVALID JUMP TO THIS LABEL

2160 Message text “THEN” EXPECTED

2161 Message text “DO” EXPECTED

2162 Message text INVALID INPUT CHARACTER

2163 Message text COUNT EXCEEDED

2164 Message text NO “/” IN P_PATH

2165 Message text WILDCARD NOT ALLOWED

2166 Message text NO FILE NAME

2167 Message text NAME TOO LONG

2168 Message text INVALID EXTENSION

2169 Message text PATH INCORRECT

2170 Message text BLANK CHARACTER INVALID

2171 Message text EXTENSION NOT ALLOWED

2172 Message text CHANNEL HANDLE EXPECTED

2173 Message text ABSOLUTE PATH EXPECTED

2174 Message text ’TO’ EXPECTED

2175 Message text USER, DEVICE OR NODE TYPE NAME EXPECTED

2176 Message text “OBJ”, “NODE”, “USER”, “PERI” EXPECTED

2177 Message text “NODE”, “USER”, “PERI” EXPECTED

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2178 Message text VALUE MISSING

2179 Message text “NODE” MUST FOLLOW

2180 Message text “BVS” OR “MSD” MUST FOLLOW

2181 Message text “DEV” MUST FOLLOW

2182 Message text CONSTANT OR VARIABLE EXPECTED

2183 Message text OPTION ENTERED TWICE

2184 Message text OPTION EXPECTED AFTER MINUS SIGN

2185 Message text BLOCK NUMBER EXPECTED

2186 Message text BLOCK NUMBER MUST BE POSITIVE

2187 Message text STRING EXPECTED

2188 Message text STRING EXPECTED

2189 Message text INITIAL BLOCK NUMBER > FINAL BLOCK NUMBER

2190 Message text ATTRIBUTE NAME MUST FOLLOW

2191 Message text CONSTANT FOR KEY MUST FOLLOW

2192 Message text EXTENSION MISSING

2193 Message text EXTENSION OR ’.*’ INVALID

2194 Message text “WHEN” EXPECTED

2195 Message text CHANNEL NAME EXPECTED

2196 Message text ABSOLUTE PATH AFTER DEVICE/CHANNEL NAME EXPECTED

2197 Message text “INFO” EXPECTED

2198 Message text “MESSAGE” EXPECTED

2199 Message text INTEGER CONSTNT EXPECTED

2200 Message text KI EXPECTED: 1<=I<=12

2201 Message text “+” OR “--” EXPECTED

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2202 Message text “VAR” EXPECTED

2203 Message text ONLY “I”, “B”, “H”, “V” ALLOWED AS OPTION ONLY

2204 Message text ERROR AT END OF BLOCK

2205 Message text “SEC”, “FOR” OR “CLOCK” EXPECTED

2206 Message text CHANNEL NAME MISSING

2207 Message text NAME NOT DECLARED AS CHANNEL

2208 Message text “DEL” MUST FOLLOW

2209 Message text TOO MUCH MEMORY REQUIRED FOR DYNAMIC VARIABLE

2210 Message text “,” EXPECTED

2211 Message text SYMBOL IS NOT AT BEGINNING OF EXPR./VALUE ASSIGNMENT

2212 Message text LABEL NOT DECLARED LOCALLY

2213 Message text “WAIT CLOCK” NOT AVAILABLE IN PACKAGE 1

2214 Message text ARRAY CONTAINS TOO MANY ELEMENTS

2215 Message text TYPE TOO LARGE

2216 Message text ENTRY IN SYMBOL TABLE IS NOT LABEL

2217 Message text “USER”, “ACCESS” OR “COMMENT” EXPECTED

2218 Message text NESTING DEPTH EXCEEDED

2219 Message text OPERAND OR EXPRESSION EXPECTED

2220 Message text “)” EXPECTED

2221 Message text NAME OF LOOP VARIABLE EXPECTED

2222 Message text EXPRESSION TYPE NOT EQUAL TO STAT_T

2223 Message text EXPRESSION TYPE NOT EQUAL TO INT, REAL, CHAR, BOOL,
ENUM
2224 Message text CONSTANT EXPECTED

2225 Message text POSITIVE INTEGER CONSTANT EXPECTED

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2226 Message text INVALID SIGN

2227 Message text LEFT OPERAND NOT EQUAL TO INT, REAL

2228 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL

2229 Message text BOTH OPERANDS NOT EQUAL TO INT, REAL

2230 Message text LEFT OPERAND NOT EQUAL TO INT, CHAR

2231 Message text RIGHT OPERAND NOT EQUAL TO INT, CHAR

2232 Message text BOTH OPERANDS NOT EQUAL TO INT, CHAR

2233 Message text LEFT OPERAND NOT EQUAL TO BOOL

2234 Message text RIGHT OPERAND NOT EQUAL TO BOOL

2235 Message text BOTH OPERANDS NOT EQUAL TO BOOL

2236 Message text LEFT OPERAND NOT EQUAL TO INT, REAL, CHAR, ENUM

2237 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL, CHAR, ENUM

2238 Message text BOTH OPERANDS NOT EQUAL TO INT, REAL, CHAR, ENUM

2240 Message text LEFT OPERAND NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2241 Message text RIGHT OPERAND NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2242 Message text OPERANDS NOT EQUAL TO INT, REAL, BOOL, CHAR, ENUM

2243 Message text OPERAND TYPES NOT COMPARABLE

2244 Message text LEFT OPERAND NOT EQUAL TO POS, FRAME

2245 Message text RIGHT OPERAND NOT EQUAL TO POS, FRAME

2246 Message text OPERANDS NOT EQUAL TO POS, FRAME

2247 Message text BOTH SIDES OF THE VALUE ASSIGNMENT ARE NOT
COMPATIBLE
2248 Message text EXPRESSION NOT EQUAL TO INT, REAL

2249 Message text EXPRESSION NOT EQUAL TO INT

2250 Message text EXPRESSION NOT EQUAL TO BOOL

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2251 Message text EXPRESSION NOT EQUAL TO POS, FRAME

2252 Message text EXPRESSION NOT EQUAL TO POS, FRAME, AXIS

2253 Message text VARIABLE OR ARRAY ELEMENT EXPECTED

2254 Message text SELECTION INVALID HERE

2255 Message text EXPRESSION NOT EQUAL TO CHAR, INT, ENUM

2256 Message text OPERAND NOT EQUAL TO INT, REAL

2257 Message text OPERAND NOT EQUAL TO, CHAR

2258 Message text OPERAND NOT EQUAL TO BOOL

2259 Message text LEFT OPERAND: ARRAY OR PATH INVALID

2260 Message text RIGHT OPERAND: ARRAY INVALID

2261 Message text RIGHT OPERAND: ARRAY WITH DIMENSION > 1 INVALID

2262 Message text ARRAY AS OPERAND INVALID

2263 Message text TYPE OF LOOP VARIABLE NOT EQUAL TO INT

2264 Message text EXPRESSION TYPE NOT “MODUS_T”

2265 Message text COMMA OR “)” EXPECTED

2266 Message text TYPE COMPONENT INCOMPATIBLE WITH TYPE INITIAL VALUE

2267 Message text LEFT SIDE: ARRAY INVALID

2268 Message text RIGHT SIDE: ARRAY INVALID

2269 Message text RIGHT STRING CONSTANT => LEFT INDEXING

2270 Message text TYPE OF LEFT AND RIGHT HAND SIDE INCOMPATIBLE

2271 Message text PATH EXPRESSION REQUIRED! (ARRAY!)

2272 Message text PATH EXPRESSION INVALID

2273 Message text ARRAY INVALID

2274 Message text TYPE ACTUAL/FORMAL PARAMETER INCOMPATIBLE

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2275 Message text TYPE ACTUAL/FORMAL PARAMETER INCOMPATIBLE

2276 Message text DIMENSION INCOMPATIBLE

2277 Message text ARRAY DIMENSION GREATER THAN 1 NOT ALLOWED

2278 Message text RETURN VALUE: STRING CONSTANT ARRAY INVALID

2279 Message text TYPE RETURN VALUE INCOMPATIBLE WITH TYPE FUNCTION

2280 Message text RIGHT OPERAND: PARENTHESES INVALID IN PATH

EXPRESSIONS
2281 Message text PARENTHESES NOT ALLOWED FOR PATH EXPRESSIONS

2282 Message text FIRST CONSTANT INCOMPATIBLE WITH THIS CONSTANT

2283 Message text CONSTANT TYPE INCOMPATIBLE WITH EXPR. TYPE IN SWITCH

2284 Message text NO SELECTION OF ENTIRE ARRAYS

2285 Message text COMPONENT NAME EXPECTED

2286 Message text COMPONENT SPECIFIED TWICE

2287 Message text “,” OR “}” EXPECTED

2288 Message text “]” EXPECTED

2289 Message text INCORRECT RANGE SPECIFICATION

2290 Message text CONSTANT EXPECTED

2291 Message text NAME OF A STRUCTURE DATA TYPE EXPECTED

2292 Message text NO DATA TYPE NAME: CREATION NOT ALLOWED

2293 Message text COMPONENT NOT DECLARED AS ARRAY

2294 Message text “#”EXPECTED

2295 Message text ARRAY COMPONENTS CANNOT BE INDEXED

2296 Message text NOT A NAME OF A CONSTANT OF THIS TYPE

2297 Message text COMPONENT DECLARED AS ARRAY: INDEXING EXPECTED

2298 Message text AGGREGATE TYPE (POS) INCOMPATIBLE WITH CONTEXT

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2300 Message text NOT A NAME OF AN ENUM DATA TYPE

2301 Message text NOT AN AXIS COMPONENT

2302 Message text NOT A FRAME COMPONENT

2303 Message text NOT A POS COMPONENT

2304 Message text INCORRECT END OF PARAMETER LIST

2305 Message text NAME OF A SUBROUTINE EXPECTED

2306 Message text RELATIVE PATH INVALID

2307 Message text ANALOG INPUT EXPECTED

2308 Message text DIGITAL INPUT EXPECTED

2309 Message text “(”EXPECTED

2310 Message text DIGITAL INPUT NOT ALLOWED HERE

2311 Message text TYPE OF FORMAL PARAMETER INVALID

2312 Message text PROGRAM NOT AVAILABLE

2313 Message text NO ERROR

2314 Message text NO FILE NAME SPECIFIED

2315 Message text FILE NAME TOO LONG

2316 Message text FILE NAME MAY NOT CONTAIN “.”

2317 Message text HIERARCH. NO. NOT IN SEARCH PATH

2318 Message text PARAMETERS TO BE DECLARED IN MODULE

2319 Message text “ON”,“OFF”,“ENABLE”,“DISABLE”,“DECL ”EXPECTED

2320 Message text SIGNAL NAME CANNOT BE CHANGED

2321 Message text PREDEFINED SIGNAL CANNOT BE CHANGED

2322 Message text SIGNAL TYPES ARE DIFFERENT

2323 Message text SIGNAL TYPE CANNOT BE CHANGED

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2324 Message text DUAL DECLARATION

2325 Message text TYPE UNKNOWN

2326 Message text NAME EXPECTED

2327 Message text TYPE EXPNAME OF A SIGNAL EXPECTED

2328 Message text “:” EXPECTED

2329 Message text COMBINED ANALOG SIGNALS INADMISSIBLE

2330 Message text NAME OF A SIGNAL EXPECTED

2331 Message text ANALOG OUTPUT EXPECTED

2332 Message text ARRAY ELEMENT/VARIABLE NOT TYPE REAL

2333 Message text “*” EXPECTED

2334 Message text REAL CONSTANT, VARIABLE OR ARRAY ELEMENT EXPECTED

2335 Message text COMBINED SIGNAL MORE THAN 32 BITS

2336 Message text “ON” OR “OFF” EXPECTED

2337 Message text ARRAY LIMITS INVALID IN PARAMETER SPECIFICATION

2338 Message text ARRAY LIMITS INVALID IN PARAMETER SPECIFICATION

2339 Message text TEACH--IN FOR TYPE INVALID

2340 Message text RECOMPILE BLOCK

2341 Message text INT. CONSTANT NOT EQUAL 0 EXPECTED

2342 Message text NO MORE THAN 12 CHARACTERS

2343 Message text NO GLOBAL PROCEDURE AVAILABLE

2344 Message text “DISTANCE” EXPECTED

2345 Message text “DELAY” EXPECTED

2346 Message text “PRIO” EXPECTED

2347 Message text “PRIO” BETWEEN 40 AND 80 NOT ALLOWED

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2700 Message text ** BLOCK NOT AVAILABLE

2701 Message text ** BLOCK TOO LONG

2702 Message text ** BLOCK TOO LONG OR INCORRECTLY COMPLETED

2703 Message text TOO MANY ELEMENTS IN ** ARRAY

2704 Message text ** NO FREE DYNAMIC MEMORY

2705 Message text BLOCK ** CANNOT BE FORMATED

2706 Message text BLOCK ** CANNOT BE DECOMPILED

2707 Message text NO BLOCK **

2708 Message text STACKING DEPTH ** EXCEEDED

2709 Message text ** LINK LIST CANNOT BE EXTENDED

2710 Message text ** TOO MANY LOCAL SUBROUTINES

2711 Message text ** HAS REACHED MAXIMUM SIZE

Cause -- When a module has reached the maximum size (65536 bytes) the
message ”SRC HAS REACHED MAXIMUM SIZE AND CANNOT
BE ENLARGED”, for example, is displayed.
2712 Message text ** NOT ENOUGH MEMORY, FILE OPEN ERROR

2713 Message text ** NO FREE PHYSICAL MEMORY

2714 Message text ** NO FREE VIRTUAL MEMORY

2800 Message text INTERNAL COMPILER ERROR **

2801 Message text ** ERROR IN MEMORY MANAGER **

2803 Message text UNDEFINED SYNTAX ERROR

4300 Message text ** COMPILE ?

4301 Message text ** COPY ?

4302 Message text ** OVERWRITE ?

Cause -- A file that is to be copied already exists

Monitor -- In command processing
4303 Message text ** DELETE ?

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4304 Message text ** LINK ?

4305 Message text ** UNLINK ?

4307 Message text DELETE COMPLETE PROCEDURE ?

Cause -- DEF block is to be deleted. The DEF block can be deleted only
together with the complete procedure.
Monitor -- In command processing.
Effect -- None
Remedy -- None
4308 Message text DELETE COMPLETE INITIALIZATION ?

Cause -- An array declaration is to be deleted for which there is a subsequent

initialization (also subsequent blank lines). These have to be deleted
too.
Monitor -- In command processing.
Effect -- None
Remedy -- None
4309 Message text ** PROGRAM, OVERWRITE ?

Cause -- The file already exists and the operator intends to recreate it
(COPY).
Monitor -- None
4310 Message text ** SELECTED, OVERWRITE ?

Cause -- The file already exists, is selected and the operator intends to
recreate it.
Monitor -- Command processing (COPY command).
Effect -- None
4311 Message text ** PROGRAM DELETE ?

Cause -- The file that is to be deleted is a program.

Monitor -- Command processing (DELETE command).
Effect -- None
4312 Message text ** SELECTED, DELETE

Cause -- The file that is to be deleted is selected.

Monitor -- Command processing (DELETE command).
Effect -- None
4314 Message text DIRECTORY NOT FOUND ! CREATE ?

Cause -- The destination directory has not yet been created on the PC.
Monitor
Effect
Remedy -- Create the directory.

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4315 Message text ** ACTIVE : PROCESS STOP ?

Cause -- Reloading of machine data.

Monitor
Effect -- Program processing is stopped.
Remedy -- The program must be restarted after the machine data have been
loaded.
9000 Message text ******

Cause -- User--programmable message.

Monitor
Effect
Remedy

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2 Glossary
KUKA--specific terms from the software documentation are briefly explained in this section.

2.1 Symbols
$...
More detailed information on this can be found in the chapter [Appendix] under
“System variables”
#...
Variables of the enumeration type “Enum”
*
Placeholder, e.g. *.src – valid for all files with the ending “.src”

2.2 A
A B C -- 2 Point
Tool calibration program which first determines the working direction of the tool and
then a point in the XY plane
A B C -- World
Tool calibration program in which the coordinate system of the tool is aligned parallel
to the world coordinate system
ACC (Acceleration)
Specifies how quickly the corresponding axes reach their maximum set velocity
Acknowledgment message
Information in the status window, e.g. EMERGENCY STOP, which must be
acknowledged
Actual position
-->Cartesian, -->Joint or -->Incremental display
Advance run stop
Certain instructions stop the advance run until the arrival of the main run (e.g. setting
an output)
Air conditioner
Special -->Control cabinet with additional cooling for special applications
Alt key
Used for entering certain control functions
Analog input
Can be connected to a voltage between +10 V and –10 V
Analog output
Output with variable output voltage (e.g. from 0...9999mV)
Approximate positioning (VE)
The robot moves, for example, from P1 to P3 via P2 without -->Exact positioning at
P2; the robot takes a shortcut, so to speak, in that it only approaches the point in
question before moving on to the next point

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Archive
Saves data to floppy disk
Array
Grouping of objects of the same data type to form a data object
Attributes display
Window in the Navigator with additional information regarding a selected file
Automatic External mode
Control of the robot is taken over by a PLC
Automatic mode
In this operating mode, the robot executes its program automatically
Axis acceleration
The acceleration of an axis given as a percentage of the maximum value defined in
the machine data
Axis--specific (joint) coordinate system
Here, the linear offsets (for translational axes) or the rotational offsets (for rotational
axes) are specified for each robot axis
Axis--specific (joint) display
Rotation of each individual axis relative to its mechanical zero position determined
during -->Mastering
Axis velocity
The velocity at which an axis is moved given as a percentage of the maximum value
defined in the machine data

2.3 B
Base coordinate system
This is used as the reference system to define the position of the workpiece. It has the
world coordinate system as its reference coordinate system
Base--related interpolation
When interpolating the motion path, the robot controller calculates the current position
($POS_ACT) in relation to the $BASE coordinate system
BCO (block coincidence)
Correspondence between the robot position and the coordinates of the motion block
Binary output
Binary coded output
Block functions
Editing operations to -->Cut, -->Copy, -->Paste and -->Delete
Block pointer
Colored marker in the program window indicating the block currently selected in the
program
BS A/F
-->Time--distance function for setting outputs or -->Flags

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BS bin/ana
-->Time--distance function for the output of binary or analog signals

2.4 C
Calibration
The dimensions of a tool or workpiece are entered into the robot controller
Caller Stack
Display of the statuses of the advance run and main run pointers
Cartesian coordinate system
Rectangular coordinate system with an X, Y and Z axis
Cartesian display
Difference between the tool center point and the world coordinate system
CD--ROM drive
Drive for reading data from compact disks
CellProj
External program which allows easy modification of the file “Cell.src”
Check
Checks the -->Mastering of a tool mounted on the robot
CIRC (Circular)
Motion command for circular motions
Clipboard
An area in the main memory of a computer which other programs may access under
certain conditions
Cold start
Switches the computer system off and back on again
COM1
Connection for an external computer mouse
Comment
Additional information allowing easier recognition of program contents by the operator
Compiler
Translates the program code, legible to humans, into machine code and carries out
a syntax check
Computer advance run
The computer can process ahead of the motion command currently being executed
in order to eliminate the computing time at the end of the motion command which
would otherwise be required for execution of the next motion command
Configuration
Miscellaneous system settings affecting inputs/outputs, I/O drivers, language, etc.
Continuous--path motions
The start point and end point are specified here. The TCP moves along a linear or
circular path between these points

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Control cabinet
Houses the components necessary for controlling the robot, such as -->Processor unit
and -->Power module
Control ON
LED underneath the flap on the control cabinet displaying the status of the computer
Coordinate system
The robot motions are always executed relative to the system currently set; e.g. joint,
world, etc.
Coordinate transformation
Axis--specific (joint) coordinates are transformed to Cartesian coordinates and vice
versa
Copy
Data are copied to the -->Clipboard
Counter
Incrementation function with a settable start value
Crash
Collision between the robot and a tool, workpiece or device which makes -->Mastering
necessary
Cross
The “Kuka--Cross” program which runs in the background
Cross logbook
Displays the data from the Kuka--Cross program which runs in the background
CTRL key
Control key for program--specific commands
Cursor key
Operator control element allowing movement of the edit cursor or the focus in the
display
Cut
A selected area of text is deleted from the current position and copied to the
-->Clipboard

2.5 D
Data list
The “DAT” file (item list) belonging to a program
DAT file
Data list which can be seen at expert level
Degrees of freedom
Limitation of the number of axes which can be moved simultaneously using the Space
Mouse
Delay
Delay of certain commands, e.g. for adhesive applications

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Delete
A selected area or file is permanently removed
DEL key
Deletes the character to the right of the -->Edit cursor
Diagnosis
Functions for checking the statuses of the system
Dial gage
Tool for robot -->Mastering
Dialog message
Safety query generated by the system which must be answered
Directory
A kind of “Drawer” for organizing files
Directory list
Display of directories in the -->Navigator window
Directory structure
Window for displaying -->Drives and -->Directories in the -->Navigator
Display
The graphic user interface which is displayed on the LCD screen of the (V)KCP
Dominant axis
Movement of just one axis using the Space Mouse
Drive
Data storage medium for loading and saving data
Driver
Program for the correct control of hardware components
Drives ON / OFF
Buttons for activating or deactivating the drives
DSEAT (Digital servo--electronics)
This is plugged onto the -->MFC in the control cabinet’s processor unit and is
responsible for the digital control of up to 8 axes and the servo -->Power module
Duplicate
A copy is made of a selected area or file

2.6 E
Edit cursor
The cursor located in the position at which characters can be entered or deleted and
which indicates the current position in the program
Editor
Program section for editing text or program lines
EMERGENCY STOP
Immediate stoppage of the robot if the red EMERGENCY STOP button is pressed or
a safety gate is opened during operation

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EMT
Electronic measuring tool necessary for -->Mastering the robot
Enabling switch
Button on the back of the -->(V)KCP which must be pressed in order to carry out certain
actions, e.g. manual traversing or program start
End key
This is situated in the numeric keypad and moves the -->Edit cursor to the last
character in the program line
End stop
Buffer which reduces the impact of a robot axis
Enter key
Operator control element for completing inputs or confirming queries, etc.
Error display
Display in a -->Status window of the errors that have occurred in a program
Error list
-->Softkey which calls the error display
Escape key
Operator control element used to cancel an action
Exact positioning
The robot moves exactly to the point
Expert level
-->User group
Extension
-->File extension
External axes
Additional axes, e.g. axis 7 for movement of the entire robot
External kinematics
e.g. a turntable, which moves while the robot works on a part clamped on it
External tool
A tool which is not mounted on the robot

2.7 F
FALSE
Corresponds to the state “false” or bit “0” set
File
A program or data created by a program
File extension (e.g. Test.SRC)
Generally the last three characters of a file, which are used by a program in order to
identify its own data
File list
Display of files in the -->Navigator window

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Filter
Limits the display to files of certain kinds; only available at expert level
First Mastery
-->Mastering of the robot without load or additional load
Flag
A status (comparable to a switch) which can be switched on or off via the “Monitor”
menu or during program execution; it is evaluated the moment it is assigned
Focus
Colored marking which can be used for selecting -->Drives, -->Directories, -->Files,
-->Menu entries and input boxes -->Inline forms
Folge
Program comprising a -->SRC file and a -->DAT file
Format
Delete the contents of a drive
Format floppy
Completely delete the contents of a floppy disk
Forward transformation
Conversion from axis--specific to Cartesian coordinates

2.8 G
Gage cartridge
This is used to hold a -->Dial gage or -->EMT for -->Mastering the robot
Go
-->Program run mode
Graphic user interface
Graphic display of the KUKA software on the LCD screen of the (V)KCP
GUI (Graphic User Interface)
The (V)KCP display contains the menu and softkey bars, the status key bars, the
program window, the inline forms, the status and message windows and a status line

2.9 H
Hand programming unit
-->(V)KCP
Header
The bar at the top of the -->Navigator
Hexadecimal system
Base 16 system: digits 0--9 and A--F
Home key
This is situated in the numeric keypad and moves the -->Edit cursor to the first
character in the current program line

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Home run
The first motion instruction in a program

2.10 I
I--Step
-->Program run mode
Icon
Graphic representation of operational steps, hints, warnings, etc.
Incremental display
Values for the angular momentum delivered by the axis drives are displayed
Inline form
Input mask for program commands
Input box
Area in which text can be entered
Insert mode
When characters are entered, the text at the edit cursor position is shifted to the right
INS key
Switches to insert mode in which characters already present in a text are shifted to
the right
Interface
Connection between hardware and other hardware or software
Interrupt
Program interrupt caused by the operator, error messages, safety devices, etc.

2.11 J
Jog mode
-->Operating mode

2.12 K
KCIRC
Special motion command for circular motions in adhesive applications
Key CD
CD--ROM which must be situated in the CD--ROM drive in order to access expert level
Keyboard
Entry of letters, control functions and special characters
KLIN
Linear motion command for adhesive applications
KRL (KUKA Robot Language)
Programming language developed especially for robot controllers

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KUKA VGA card

Standard VGA card with interface for (V)KCP color display

2.13 L
LDEL key
Deletes the line in which the -->Edit cursor is positioned
Learn Tool
-->Mastering of the robot with a tool or -->Additional load
Left--arrow key
The character to the left of the -->Edit cursor is deleted
LIN
Linear motion command for the shortest distance between two points at a defined
velocity
Linear motion
Motion in a straight line from one point to another
Linkage editor
Internal program which checks for modules containing errors
Logbook
Output of operator actions to a window on the -->GUI or to the -->Printer
Logic operators
These are used for logic operations (AND, OR, etc.) with boolean variables, constants
and simple logic expressions
Long text
Additional comment for inputs and outputs making identification easier
Loop
A program section which is continuously repeated
LPT1
Interface for connecting an external printer

2.14 M
Macro
Combination of frequently--used -->PLC commands
Main axes
Axes A1, A2 and A3 of the robot
Main switch
Operator control element on the front of the control cabinet for switching the robot
system on or off
Manual override (HOV)
Manual traversing velocity can be reduced
Manual/test mode
The operating modes T1 and T2 allow manual/test traversing of the robot with reduced
velocity or process velocity

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Mastering
The robot axes are moved to the mechanical zero position
Mechanical zero position
This position represents an assignment to the axis drive angle and is defined by a ref-
erence notch or mark
Menu
Collection of commands grouped together
Menu bar
Row of keys at the top of the (V)KCP display for selecting menus
Menu key
One of the keys in the menu bar which is pressed in order to access the programs
belonging it
Merker (notices)
Links between -->PLC commands which are cyclically evaluated
Message window
Display of notification, error and status messages, etc.
MFC (Multi--function card)
This is situated in the processor unit of the -->Control cabinet and contains an Ethernet
connection and a Device--Net/Can bus connection; it constitutes the interface
between the -->PC and the -->(V)KCP and can hold up to two -->DSEATs
Mirror
Here, programmed points in the path are mirrored in the X--Z plane of the robot
coordinate system
Module
Program at -->User level comprising a *.src file and a *.dat file

2.15 N
Navigator
Directory/file manager for program management and creation which is active by
default after the controller has run up
Notification message
Display of information in the message window, e.g. information regarding operator
actions or programming errors
Numeric input
Tool calibration program in which tool data are entered manually via the (V)KCP or an
external keyboard
Numeric keypad
Used for numeric input or -->Cursor control functions
Num key
Used for switching the numeric keypad between numeric input and -->Cursor control
functions

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2.16 O
Office--GUI
Symbols in the (V)KCP display which can be switched on in order to be able to operate
control elements such as the enabling switch or start key using the mouse
Offline
The system is not ready for operation
Offset external kinematic
Calibration program for moving the distance between the origin of the external
kinematic system to the tool located on the external kinematic system
Offset numeric
Manual entry of -->Offset external kinematic
Online
The system is ready for operation
Operating mode
The robot is traversed in test/manual mode (T1 or T2), “Automatic” or “Automatic
External” mode
Oscilloscope
Recording and display of motion data and signal states
Overhead area
If the x--value of the wrist root point, expressed in the A1 coordinate system, is
negative, the robot is in the overhead area
Override
See -->Manual override and -->Program override
Overwrite mode
When text is entered at the edit cursor position, the existing text already there is
deleted

2.17 P
Parameter
Additional information transferred to a program when it is started
Parameter list
Configuration window in some inline form boxes
Passive stop
The -->Stop key was pressed while a program was running
Paste
Data from the -->Clipboard are inserted at the current cursor position
Path velocity (VB)
The velocity with which the robot, or the tool or workpiece, moves along the
programmed path
Periphery
Additional hardware, e.g. Interbus module

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PGDN key
Scrolls a page further down the window, where possible
PGUP key
Scrolls a page back up the window, where possible
PLC instructions
Programmable Logic Controller instructions
Power module
The actual power unit for robot operation, comprising the supply module, the servo
output stages and the logic module
Power unit
-->Power module
Pre--mastering position
Position indicated by markings to which the robot axes are moved before -->Mastering

Processor unit
Standard personal computer with KUKA--specific equipment, housed in the -->Control
cabinet
ProgrammMaker
External utility program for the creation and modification of existing application
programs
Program override (POV)
The process velocity can be reduced
Program pointer
Colored pointer in the program window which indicates where the robot is or where
it should be moved to
Program run mode
Specifies how a program should be executed in manual mode. The options “Single
Step” (step by step), “I--Step” (line by line), “Go” (continuous) and “Backwards” are
available for selection
Program start backwards
Operator control element for starting a selected program in the reverse direction
Program start forwards
Operator control element for starting a selected program in the normal direction
Program window
Displays the program that is selected and can be modified
PTP
Motion command for point--to--point motion by the quickest route
Pulse outputs
Outputs can be set or reset for a specified period

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2.18 R
Rapid gauging
The DSEAT inputs, canals 1 -- 4 (125 ←s cycle), are used here
Rating plate
Sticker with the serial number of the controller or robot
RDW (Resolver Digital Converter -- RDC)
Located in the base of the robot and connected to the -->DSE ; it is responsible for
resolver power supply, R/D conversion and monitoring of the motor temperature
Reference point
Known reference point for -->Calibration
Relational operators
These operators (equal to, not equal to, greater than, ...) can be used to form logical
expressions. The result of a comparison is therefore always of the data type BOOL,
since a comparison can only ever be (TRUE) or (FALSE)
Rename
Change the name of a file
Reset
-->Reset program
Reset program
The selected program is reset ready for restarting, i.e. returned to the state it had
directly after it was selected
Resolver
Reads the motor pulses and sends them to the -->RDW
Restore
Data are written back onto the hard drive having previously been saved to floppy with
the command -->Archive
Restore
-->Mastering of the robot with any load
Return key
-->Enter key
Reverse transformation
Conversion from Cartesian to axis--specific coordinates
Reverse traversing
Execution of the program towards the start of the program
Robot coordinate system
This is located in the base of the robot and serves as the reference coordinate system
for the mechanical construction of the robot. It, in turn, is derived from the -->World
coordinate system
Robot mastering
-->Mastering
Robot name
Name given to the robot in a system

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Root point
Distance from the world coordinate system to the origin of an external kinematic
system
Root point numeric
Manual entry of the -->Root point

2.19 S
Select
A program is loaded into the main memory and displayed in the -->Editor ready for
editing
Selection list
-->Filter
Selection window
Input line in which a preset value can be selected
Serial number
Number used by manufacturers to identify their products
Serial number
The -->Serial number of the -->Control cabinet or robot
Shift key
For switching between upper and lower case characters
Simple data types
These types are Integer, Real, Bool and Character
Single Step
-->Program run mode
Softkey
One of the keys in the softkey bar which is pressed in order to trigger the function
assigned to it
Softkey bar
The softkey bar is formed by the lower softkeys
Software limit switch
When a certain axis angle is reached the axis affected is immediately deactivated
Software--Update
Install current program version
Space Mouse
Operator control element for moving up to 6 robot axes simultaneously
SRC file
Program file which can be seen at expert level
SStep(T1) and SStep(T2)
-->Operating mode
Stand--by device
Spare device that can be quickly brought into operation if another device fails

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Status LED
-->Control ON
Status key
One of the keys in the status key bar which is pressed in order to execute the function
assigned to it
Status key bar
Row of keys on the left and right--hand sides of the (V)KCP display for triggering
certain actions
Status line
Display of important system information such as operating mode, program status and
program name
Status message
Information in the status window, e.g. EMERGENCY STOP
Status window
Display of coordinates, assignment of inputs and outputs, etc., in a separate window
Stop key
Operator control element for stopping a program in “Automatic” or “Automatic
External” mode
Structures
Using the declaration statement STRUC, different data types which have been
previously defined or are predefined data types are combined to form a new composite
data type
SUBMIT interpreter
A program which runs cyclically in the background
Subprogram
Part of a program which (to save time and space) can be repeated more than once
Supplementary load
Additional weight on axis 3
Sym key
For entering special characters via the keyboard of the -->(V)KCP
System variables
Certain variables which cannot be modified by the user

2.20 T
Tab key
Tabulation
TCP (Tool Center Point)
The reference point of the tool that has been set (e.g. the tip of the tool)
Technologies
Combination of additional software and hardware, for example “ArcTech10”
Test/manual mode
The robot can be moved manually or a program can be executed step by step

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Three--dimensional array
Corresponds to several two--dimensional matrices situated one behind the other
Time--distance functions
Functions for binary/analog outputs and for setting outputs and -->Flags
Timer
This function can be compared with a stopwatch for which the start value can be
altered
Tool
-->TOOL
Tool center point
-->TCP
Tool coordinate system
This has its origin at the tip of the tool (Tool Center Point: TCP). If the tool center point
is moved, the tool coordinate system is moved with it. It has the world coordinate
system as its reference coordinate system
TOOL coordinate system
The robot moves in the -->Coordinate system of the mounted tool
Tool load data
Manual entry of the mass, the center of mass, the orientation and the moments of
inertia of a tool
Top--mounted cabinet
An additional -->Control cabinet which can be installed on top of another one
Transport position
Configuration of the axes which allows the robot to be transported safely – varies
according to the robot type. The robot must be brought into the transport position
before the mounting base bolts are slackened
Traversing keys
Operator control element for the manual traversing of each individual robot axis
Traversing mode
Determines whether the robot can be moved using the -->Space Mouse or the
-->Traversing keys or whether -->Manual traversing is not possible at all
Trigger
Activation of -->Time--distance functions at a determined distance or a given amount
of time before the target point is reached
TRUE
Corresponds to the state “true” or bit “1” set

2.21 U
Unmastering
The -->Mastering of the robot is deleted in order to be able to carry out a new mastering
procedure
USER
-->KRL function call with parameter transfer

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 2 Glossary (continued)

User group
Depending on the operator (e.g. “User”, “Expert”), different funtions are available on
the KUKA program interface
User level
-->User group

2.22 V
VB
-->Path velocity
VE
-->Approximate positioning
Vernier
Scale on the axes of certain robot models enabling -->Mastering to be carried out
without a -->Dial gage or -->EMT
Version number
Number used by manufacturers to identify their programs; the higher the number, the
more up to date the program in question
(V)KCP (VW KUKA Control Panel)
Hand--held unit and interface for operation and control of the robot
VK--Editor
External utility program for loading, displaying and editing files
(V)KR C1
Robot controller comprising the -->Control cabinet and the -->(V)KCP

2.23 W
Waiting condition
The program waits until the corresponding states have been reached (e.g. input
present, output set, etc.)
Wait message
Output in the message window if a waiting condition is executed while a program is
running
Warm restart
The computer is reset by pressing Reset on the processor or via the keyboard
Weave
Superpositioning of a path motion with one of the weave patterns available for
selection, e.g. triangle, trapezoid, etc.
Window selection key
Operator control element for toggling between different windows
Workpiece
-->BASE
World coordinate system
This is a fixed coordinate system, which serves as the underlying coordinate system
for a robot system (robot, component support or tool). It represents the reference
system for the robot system and the peripheral equipment of the cell

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Wrist axes
Axes A4, A5 and A6 of the robot
Wrist root point
Intersection of the -->Wrist axes

2.24 X
X Y Z -- 4 Point
Tool calibration program in which a reference point is addressed by a tool from four
different directions
X Y Z -- Reference
Tool calibration program in which a known reference point is addressed first by a
calibrated tool and then by an uncalibrated tool

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 3 System variables

3 System variables

The system variables can be found in the Programming Handbook in the [Appendix],
chapter [System variables].

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 4 Keywords

4 Keywords
The keywords used are listed below and may not be used as point, variable or program
names. Nor should they be placed at the start of identifiers.

Keyword Keyword Keyword Keyword

ADJUST DO IMPORT SHOW
ANALYSE DOWNLOAD INSERT SHOW_ATT
AND DRIFT INSTALL SIGNAL
ANOUT EDIT INT START
AXIS ELSE INTERRUPT START_OFF
BOOL END LIN STOP
BRAKE ENDDAT LIN_REL STRUCT
B_AND ENDFCT LIST SWITCH
B_EXOR ENDFOR LOOP THEN
B_NOT ENDIF MESSAGE TO
B_OR ENDINST MOVE TRIGGER
CALIBRATE ENDLOOP MOVEOFF TRUE
CANCEL ENDSWITCH NOT UNLINK
CASE ENDWHILE OPEN UNTIL
CHANGE_ATT ENUM OR UPLOAD
CHANNEL ERASE PASSWD WAIT
CHAR EXIT POINT WHEN
CIRC EXOR PRINT WHILE
CIRC_REL EXT PTP WRITE
CLOSE EXTFCT PTP_REL XCHANGE
CONFIRM EXTFCTP PULSE
CONTINUE EXTP READ
COPY FALSE RENAME
CREATE FIND REPEAT
DECL FOR RESET
DEF FORMAT RESUME
DEFAULT FRAME RETURN
DEFDAT GET RSYS
DEFFCT GOTO RUN
DELAY HALT SAVE
DIRDO IF SET

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 5 History of Operating Handbook from V2.3 --> V3.2

5 History of Operating Handbook from V2.3 --> V3.2

5.1 Introduction
KUKA Roboter GmbH
G Addresses updated

About this documentation

Service

5.2 Safety
Liability

Safety symbols

Safety

Planning and construction

G Additions to “Operation in potentially explosive areas of Explosion protection zone 2”

Installation, operation and other work

5.3 Robot System

Manipulator

Control system

Software concept
G Adapted to software modifications

Jumpers for stand--alone operation X11

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5.4 Initial Start--up

5.5 Operator Control

Running up / shutting down the controller
G Subsequent connection of mouse without rebooting the controller

The KUKA Control Panel KCP

G The meaning of the CAPS Lock display in the status line and its activation are explained
here

Coordinate systems

Manual traversing of the robot

G Section “Selecting the kinematic system” inserted, explaining the selection of external
axes and external kinematic systems
G New function “Mouse position”
G Procedure for defining the “Space Mouse’s degrees of freedom” changed
G Procedure for defining the “dominant axis of the Space Mouse” changed

Navigator
G New section added describing the new file manager

Executing, stopping and resetting a program

G New section “Symbols in the program window” explains the icons that appear in the
program window
G New section “Program status line” explains the symbols and messages relevant to the
program
G Additions to program run mode
G New function “Program start backwards”

Monitor
G Inputs/outputs updated
G “SIM” (simulated inputs) option explained
G Additions to Actual position
G Description of logbook function improvements
G Section “Caller Stack” expanded
G New section “Interrupts”
G “Refresh display” and “Window”
G Help menu with expanded information display and on--line help

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 5 History of Operating Handbook from V2.3 --> V3.2 (continued)

Menu structure
G Adapted to current graphic user interface

5.6 Start--up
Robot mastering / unmastering
G General section revised
G Section “Mastering with the EMT” substantially expanded and adapted to the current
menu structure
G Modification of the variables for EMT mastering

Calibration -- Tools and workpieces

G Names for the tool, base system and external axis can be entered in the status window
G Section “Offset external kinematic” integrated, originally under “Calibration -- External
kinematics”
G Supplementary load can now also be defined for axes A1 and A2

Calibration -- Externer kinematics

G Names for the tool and external axis can be given in the status window

Software Update

Robot name
G Section originally located in “Configuration”, adapted to new menu structure

5.7 Configuration --> see Programming Handbook

5.8 User Programming

Program editing
G Completely reworked, divided into subject areas “Program” and “Editor”

Program commands
G Description of the new softkey “Suggest”
G Explanation of the command “SynOut” and insertion of examples

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Appendix

5.9 Expert Programming --> see Programming Handbook

5.10 Diagnostic Functions --> see Programming Handbook

5.11 Additional Functions --> see Programming Handbook

5.12 Applications --> see Programming Handbook

5.13 Appendix
Error messages, troubleshooting

Glossary
G Additions made

History
G The file you are currently reading

Overall index
G Regenerated

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 6 Overall index

6 Overall index

Symbols
!: User Programming 56
?: User Programming 57
:: User Programming 58
$PERI_RDY: Operator Control 13
$PhgBright: Operator Control 29
$PhgCont: Operator Control 29
$POS_ACT: Appendix 96
$POWER_FAIL: Operator Control 13
$PRO_IP: Operator Control 157, 181
$STOPMESS: Operator Control 13
*.DAT: Operator Control 169

Numbers
3--Point: Operator Control 183; Start--up 65
5D: Start--up 50, 85, 91
6D: Start--up 55, 85, 91

A
A B C -- 2 Point: Operator Control 183; Start--up 36, 37, 45
A B C -- World: Operator Control 183
A, B, C: Start--up 33, 60, 63, 96, 99, 113, 122
A10 Online Optimizing: Operator Control 174
ABC--World: Start--up 36, 50
ABC--World (5D): Start--up 37
ABC--World (6D): Start--up 37
About this documentation: Introduction 11
Acceleration: User Programming 24, 26, 28, 30, 32, 34
All points in a line: Start--up 103
All points in one plane: Start--up 103
ALT key: Operator Control 27
Alt--Escape: Operator Control 37
Alt--Tab: Operator Control 36
Analog output: Operator Control 187; User Programming 48
Analog Outputs: Operator Control 134, 180
Approximate positioning: User Programming 20, 27, 31
Approximation Distance: User Programming 24, 28, 32
ARC Tech 10: Operator Control 189
ARC Tech 20: Operator Control 189
Archive: Operator Control 90, 169
Arm: Robot System 7, 13
Arrow keys: Operator Control 23; Start--up 42, 59, 113, 122
at: User Programming 42, 45
Attributes: Operator Control 74, 98, 171

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Attributes display: Operator Control 64, 68

Aut: Operator Control 35
Automatic: Operator Control 44, 132
Automatic External: Operator Control 44, 137, 178
Automatic external: Operator Control 180
Automatic program execution: Operator Control 127
AXIS: User Programming 57
Axis specific: Operator Control 180
Axis traversing keys: Start--up 39
Axis--specific (joint) display: Operator Control 138

B
Backspace key: Operator Control 26
Backwards key: Operator Control 23
BASE: Operator Control 39, 42
Base: Operator Control 183; Start--up 65, 117
Base coordinate system: Start--up 117
Base frame: Robot System 11, 13
Base type: Operator Control 179, 183
BCO run: Operator Control 121, 127
Block coincidence: Operator Control 121
Block diagram of the KR C1: Robot System 17
Block pointer: Operator Control 30, 34, 114; User Programming 25, 29, 33
Braking ramp: Operator Control 118
Brightness: Operator Control 29

C
C_DIS: User Programming 59
C_ORI: User Programming 59
C_PTP: User Programming 59
C_VEL: User Programming 59
Cabinet lock: Operator Control 8
Calibration: Operator Control 167
Caller Stack: Operator Control 157, 181
Cancel: Operator Control 173
Cancel Info: Operator Control 147
Cancel program: Operator Control 173, 174
Caps Lock: Operator Control 27
Cartesian: Operator Control 180
Cartesian display: Operator Control 138
CD--ROM drive: Operator Control 8
Change: Operator Control 134, 140, 141, 142
Change password: Operator Control 179
Changing comment lines: User Programming 52
Chapter: Introduction 12
Check Gripper: Operator Control 190
Check mastering: Operator Control 184

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 6 Overall index (continued)

CIRC: Operator Control 186, 187; User Programming 20, 31, 63

CIRC REL: User Programming 63
CIRC_REL: Operator Control 187
Circular motions: User Programming 31
Cleaning: Robot System 27
Close: Operator Control 176
Close editor: User Programming 17
CMD: User Programming 47
Collision protection: Safety 19
COM1: Operator Control 8
Commands: Operator Control 167, 186
Comment: Operator Control 84, 102, 187; User Programming 38, 47, 51
Computer drives: Operator Control 8
Computer unit: Robot System 17
ConfigMon.ini: Operator Control 145
Configuration files: Operator Control 11
Configure: Operator Control 167, 177
Connection conditions: Safety 21
CONT: User Programming 20, 24, 25, 28, 29, 32, 33, 40, 41
Continuing a program: Operator Control 127
Contrast: Operator Control 29
Control cabinet: Robot System 5; Operator Control 7
Control ON: Operator Control 8
Control system: Robot System 17
Control--Escape: Operator Control 37
Controller switched back on: Operator Control 12
Cooling the control cabinet: Robot System 26
Coordinate system: Operator Control 39, 48
Coordinate systems TOOL, BASE, WORLD: Operator Control 60
Coordinates: Start--up 100
Copy: Operator Control 100, 172, 175
Counter: Operator Control 181
Counterbalancing system: Safety 12; Robot System 14
Counters: Operator Control 167
Counterweight: Robot System 7
Coupling of the wrist axes: Start--up 27
CPDAT1: User Programming 28
CROSS Log book: Operator Control 148, 154, 181
CROSS.EXE: Robot System 30
CROSS--Log symbols: Operator Control 155
Cross--reference: Introduction 12
CTRL key: Operator Control 26, 27
CTRL--Escape: Operator Control 37
Cur. tool/base: Operator Control 179
Current selection: Operator Control 169
Current value: Operator Control 144, 145
Cut: Operator Control 101, 172, 175
Cyclic Flags: Operator Control 180

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Appendix

D
Data list: Operator Control 80
Data Ok: Start--up 113
Deadman function: Safety 12
Def--line: Operator Control 179
Default: Start--up 63, 99
Degrees of freedom of the Space Mouse: Operator Control 54
DEL key: Operator Control 26
Delay: User Programming 42, 46
Delay value: User Programming 50
Delete: Operator Control 80, 101, 172, 174, 176; User Programming 15, 53
Deleting comment lines: User Programming 53
Deleting programs: User Programming 10
Depending on the technology: User Programming 49
Depending on the velocity: User Programming 49
Deselecting a program: Operator Control 129
Designated use: Safety 6
Detail view: Operator Control 66
Detail view on/off: Operator Control 179
Detailed information: Start--up 102
Details: Operator Control 139
Determining the orientation: Start--up 36
Determining the position: Start--up 36
Diagnosis: Operator Control 92, 181
Dial: Operator Control 184
Dial gauge: Start--up 5
Digital Inputs: Operator Control 180
Digital Outputs: Operator Control 180
Digital servo--electronics: Robot System 20
Digital Signal Processor: Robot System 21
Direction indicator: Operator Control 115
Directory list: Operator Control 64, 72
Directory structure: Operator Control 64, 67
Disable PowerOff Delay: Operator Control 179
Display: Operator Control 167
Documentation: Introduction 12
Dominant axis: Operator Control 57
Dominant axis activated: Operator Control 58
Dominant axis not activated: Operator Control 58
Drive concept: Robot System 17
Driver Reset: Operator Control 178
Drivers: Operator Control 167
Drives: Operator Control 64
Drives off: Operator Control 20, 127
Drives on: Operator Control 20
DSE: Start--up 127
DSE -- RDW: Operator Control 184
DSEAT: Robot System 20

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 6 Overall index (continued)

DSP: Robot System 21

Duplicate: Operator Control 102, 172; User Programming 10
Dynamic: Operator Control 187
Dynamic braking: Operator Control 119

E
E--Mail: Introduction 6
E6AXIS: User Programming 57
E6POS: User Programming 57
EC low voltage directive: Safety 5
EC machinery directives: Safety 5
Edit: Operator Control 80, 86, 169; User Programming 6
Edit Config.: Operator Control 178
Edit cursor: Operator Control 115; User Programming 20, 25, 29, 33, 37, 48, 55
Editor: Operator Control 181
Electromagnetic compatibility: Safety 5
EMERGENCY STOP: Start--up 6
EMERGENCY STOP button: Operator Control 20
EMERGENCY STOP circuit: Safety 19
EMT: Operator Control 184; Start--up 6
Enabling switch: Operator Control 23, 28; Start--up 16, 17, 19, 20, 23, 26
Enabling switches: Operator Control 51
ENCODER_DIFFERENCE: Start--up 28
END key: Operator Control 26
Enter key: Operator Control 23, 102
Error diagnosis: Operator Control 76
Error display: Operator Control 76
Error list: Operator Control 76
Error message: Start--up 49
Error treatment: Start--up 102
Errorlist: Operator Control 169
Escape key: Operator Control 22
Exact positioning: User Programming 20, 27, 31
Example: Introduction 12
Executing program lines: Operator Control 123
Executing, stopping and resetting a program: Operator Control 112
Existing directory structure: Robot System 31
Expert level: Operator Control 67
Expert user group: Operator Control 148
Explosion protection zone 2: Safety 17
Ext: Operator Control 35
ExtBase Ok: Start--up 107
External axes: Robot System 25; Operator Control 47
External Axis: Operator Control 179, 183
External Editor: Operator Control 184
External kinematic: Operator Control 42, 183; Start--up 100
External kinematic systems: Operator Control 47

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Appendix

External measuring device: Start--up 34

F
Fax: Introduction 6
File: Operator Control 81, 167, 168
File attributes: Operator Control 74
File list: Operator Control 64, 72
File manager: Operator Control 63
”File” menu: Operator Control 81
File name: Operator Control 74
File operations: Operator Control 167
File/Folder: Operator Control 169
Filter: Operator Control 66, 70, 98, 171
Filter mats: Robot System 26
Find: User Programming 12, 15
Find...: Operator Control 174, 176
First mastering: Operator Control 184
FIRST_CALIBRATION_DIFFERENCE: Start--up 28
FIRST_ENCODER_VALUES: Start--up 28
Fixed tool: Operator Control 183; Start--up 77
Flags: Operator Control 180
Flange center point: Start--up 32
Floppy disk drive: Operator Control 8
FOLD: Operator Control 174, 175
Force cold Startup: Operator Control 179
Format floppy disk: Operator Control 97, 170
FRAME: User Programming 57
Frame: Start--up 33
Frontsight/rearsight marker: Start--up 6
Full circle: User Programming 35

G
Geometric operator ”:”: User Programming 58
Glossary: Appendix 95
Go: Operator Control 120
Graphic user interface: Operator Control 64
Gripper: Operator Control 136, 178, 180, 190
GRIPPER Tech: Operator Control 190
Gripper+: Operator Control 136
Gripper--: Operator Control 136
GUI: Operator Control 29

H
Header: Operator Control 64, 66
Help: Operator Control 161, 167, 191
History of Operating Handbook: Appendix 117

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 6 Overall index (continued)

HOME key: Operator Control 26

Homepage: Introduction 6
HOV: Operator Control 35; Start--up 117
Hydropneumatic counterbalancing system: Robot System 14

I
I--Step: Operator Control 120
I/I Driver: Operator Control 178
I/O: Operator Control 178, 180
I/O Reconfigure: Operator Control 178
IBUS--Seg on/off: User Programming 47
IBUS--Seg.: Operator Control 187
IBUS/WAIT: User Programming 38
Icon: Operator Control 116
Icons: Operator Control 64
Identification plate: Introduction 15
In--line wrist: Robot System 6
Incremental: Operator Control 180
Incremental display: Operator Control 138
Incremental manual traversing: Operator Control 61
Incremental Step: Operator Control 120
Indirect: Operator Control 183; Start--up 65, 70
Industrial robot: Safety 5
Infinitely rotating axes: User Programming 21
Info: Operator Control 163, 191
Information: Introduction 11, 12
Inline form: Operator Control 31
Input mark: Operator Control 115
Inputs: Operator Control 132
Inputs/outputs: Operator Control 130, 167
INS key: Operator Control 26
Installation: Safety 21
Interpolation cycle rate: Robot System 18
Interrupts: Operator Control 181
Introduction: Start--up 32

J
Jog mode: Safety 12; Operator Control 35, 44, 120
Jog OV steps: Operator Control 50
Jog override: Operator Control 35, 50, 178
Jog--OV: Start--up 40
Jogging: Operator Control 178
Joint: Operator Control 39
Joint coordinate system: Operator Control 59
jump to: Operator Control 77
Jumpers for stand--alone operation X11: Robot System 33
JX, JY, JZ: Start--up 63, 100

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Appendix

K
K--VGA: Robot System 21
KCP: Robot System 22; Operator Control 19
KCP front: Operator Control 19
KCP rear: Operator Control 28
Keyboard: Robot System 22; Operator Control 27
Kinematic number: Start--up 107
KR_SERIALNO: Start--up 28
KRL assistant: Operator Control 187; User Programming 55
KRL motion commands: User Programming 56
KUKA CONTROL PANEL: Robot System 22
KUKA Robot Language: User Programming 55
KUKA Roboter GmbH: Introduction 5
KUKA VGA Card: Robot System 21
KUKA--Cross: Operator Control 154
KukaBof.EXE: Robot System 30
KukaDB.EXE: Robot System 30

L
Language: Operator Control 179
Last command: Operator Control 186; User Programming 19
LDEL key: Operator Control 26
Liability: Safety 5
LIN: Operator Control 186, 187; User Programming 20, 27, 61
LIN REL: User Programming 61
LIN_REL: Operator Control 187
Line breaks: Operator Control 115
Line/column: Operator Control 116
Linear motions: User Programming 27
Link arm: Robot System 7, 9, 13
Load correction: Operator Control 184
Load data determination: Operator Control 184
Load limitation: Safety 12
Load moment of axis: Robot System 14
Loading and saving programs: User Programming 9
Locations: Introduction 5
Log book: Operator Control 92, 148, 149, 169, 181
Logic: Operator Control 187; User Programming 37
Logic commands: Operator Control 167
Long text: Operator Control 178
LPT1: Operator Control 8

M
M: Start--up 63, 99
MADA: Start--up 127
Main axes: Operator Control 55
Main axis motor unit: Robot System 7, 10

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 6 Overall index (continued)

Main chapters: Introduction 12

Main switch: Operator Control 7
Maintenance of the control cabinet: Robot System 27
Managing programs: User Programming 5
Manipulator: Robot System 5
Manual gripper operation: Operator Control 136
Manual mode: Operator Control 35
Manual position specification: User Programming 57
Manual program execution: Operator Control 120
Manual traversing: Operator Control 39, 46
Manual traversing of the robot: Operator Control 44
Mark all: Operator Control 172
Master: Operator Control 184
Master load: Operator Control 184
Mastered: Start--up 6
Mastering: Operator Control 167; Start--up 13
Mastering with consideration of load: Start--up 12
Mastering with the dial gauge: Start--up 7
Mastering with the EMT: Start--up 10
Mastering without consideration of load: Start--up 12
Maximum braking: Operator Control 118
Meaning of symbols, words and icons: Introduction 11
Measure: Operator Control 183
Measurement error too big: Start--up 103
Measurement Points: Operator Control 183; Start--up 100
Mechanical limit stops: Robot System 7, 9, 11
Mechanical zero position reached: Start--up 6
Menu: Operator Control 166
Menu bar: Operator Control 29, 166
Menu key: Operator Control 166
Menu keys: Operator Control 24
Merker: Operator Control 139, 180
Message window: Operator Control 31
Messages in the status bar: Operator Control 34
MFC: Robot System 20
Miscellaneous: Operator Control 179
Mode selector switch: Operator Control 21, 44
Modul info: Operator Control 69
Module: Operator Control 145
Modules: Operator Control 66
Monitor: Operator Control 106, 130, 167, 180
”Monitor” menu: Operator Control 106
Motion: Operator Control 186; User Programming 20, 38, 47
Motion command: User Programming 20
Motion commands: Operator Control 167
Motion parameters: User Programming 36
Motor monitoring: Safety 12
Mouse configuration: Operator Control 178

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Mouse position: Operator Control 52, 178

Move the axis/axes of the external kinematic system: Start--up 110
Move the TCP to the reference mark: Start--up 109
Moveparams: Operator Control 186
Multi--function card: Robot System 20

N
Name: Operator Control 102, 144
Navigator: Operator Control 63, 181
New: Operator Control 71, 82, 169; User Programming 5
New name: User Programming 52
New text: User Programming 52
New time: User Programming 52
New Value: Operator Control 145
Normal: Operator Control 187; User Programming 51, 52, 53
NOTE: Introduction 11
NUM: Operator Control 34, 68
NUM key: Operator Control 26
Numeric Input: Operator Control 183; Start--up 36, 37, 58, 65, 74, 77, 94
Numeric keypad: Operator Control 26

O
Office GUI on/off: Operator Control 179
Offset: Operator Control 183; Start--up 106, 115
Offset (numeric): Start--up 106, 121
Offset external kinematic: Operator Control 183; Start--up 77, 88, 123
Offset voltage: User Programming 50
On/Off options: Operator Control 179
Online help: Operator Control 161, 191
Open: User Programming 6
Operating mode: Operator Control 35; Start--up 127
Operator control elements: Operator Control 7, 20
Orientation: Start--up 33; User Programming 27, 31
Oscilloscope: Operator Control 148, 181
OUT: Operator Control 187; User Programming 39, 40, 41, 42
Outputs: Operator Control 131
Overheat: Robot System 26
Overloaded: Start--up 61

P
Page +: Operator Control 151
Page --: Operator Control 151
Parameters: Operator Control 103
Particular safety measures: Safety 10
Pass over monitoring working envelope: Operator Control 179
Paste: Operator Control 100, 172, 175

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PATH: User Programming 42, 46

Path--maintaining braking in event of operator safety violation: Operator Control 119
Path--maintaining Emergency Stop: Operator Control 118
Payload data: Operator Control 183
PDAT1: User Programming 24, 32
PGDN key: Operator Control 26
PGUP key: Operator Control 26
Phone number: Introduction 6
Placeholder: User Programming 56
Planning and construction: Safety 15
Point too near to origin point: Start--up 102
Point too near to other point: Start--up 102
Point too near to reference point: Start--up 102
Point--to--point motions: User Programming 23
POS: User Programming 57
Position: Operator Control 167; Start--up 32
Potentially explosive areas: Safety 17
POV: Operator Control 35
Power failure: Operator Control 12
Power OFF function: Operator Control 11
POWER ON procedure: Robot System 29
Power unit: Robot System 17, 23
Pre--mastering position: Start--up 6, 13
Presetting of outputs: Safety 19
Print: Operator Control 88, 169
Process pointer: Operator Control 157
Processor unit: Robot System 19
Program: Operator Control 99, 167, 172, 181
Program creation: Operator Control 167
Program editing: User Programming 5
Program editor: User Programming 15
”Program” menu: Operator Control 99
Program name: Operator Control 116
Program OV steps: Operator Control 117
Program override: Operator Control 35, 117, 178
Program pointer: Operator Control 114
Program run mode: Operator Control 120
Program start backwards: Operator Control 120, 124
Program start backwards key: Operator Control 23
Program start forwards: Start--up 16, 17, 19, 20, 23, 26
Program start forwards key: Operator Control 22, 28
Program stop key: Operator Control 22
Program window: Operator Control 30, 114
Programmed velocity: User Programming 26, 30, 34
Programming: User Programming 37, 48
Programming a LIN motion: User Programming 28
Programming a PTP motion: User Programming 24
Programming movements: User Programming 20

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Programs: User Programming 5

Protection from dirt: Safety 21
Protection from dirt and UV radiation: Safety 21
Protective cap: Start--up 5
PTP: Operator Control 186, 187; User Programming 20, 23, 59
PTP motions with approximate positioning: User Programming 23
PTP motions with exact positioning: User Programming 23
PTP REL: User Programming 59
PTP_REL: Operator Control 187
PULSE: Operator Control 187; User Programming 40, 41, 45

R
Ramp--down braking: Operator Control 118
RDC: Robot System 20, 21; Start--up 127
Reduced velocity: Operator Control 136
Reference coordinate system: Operator Control 48
Reference point: Start--up 34
Reference tool: Start--up 36, 108
Refresh: Operator Control 151
Refresh display: Operator Control 181
Release device for robot axes: Safety 13
Releasing EMERGENCY STOP: Operator Control 20
Rename: Operator Control 96, 170
Replace: Operator Control 176
Reset: Operator Control 125, 173
Reset program: Operator Control 173, 174
Resetting a program: Operator Control 125
Resolver: Start--up 32
Resolver/digital converter: Robot System 21
Restore: Operator Control 93, 170
Return key: Operator Control 23
Reverse traversing: Operator Control 120
Rob. Position: Operator Control 138, 180
Robot: Robot System 5
Robot coordinate systems: Start--up 32
Robot coordinates: User Programming 25, 29, 33
Robot flange coordinate: Start--up 32
Robot mastering: Start--up 5
Robot name: Operator Control 185; Start--up 127
Robot system: Safety 5; Robot System 5
Root point: Operator Control 183; Start--up 106
Root point (numeric): Start--up 106, 111
Rotating column: Robot System 11, 13
Rotation about the X--axis: Start--up 33
Rotation about the Y--axis: Start--up 33
Rotation about the Z--axis: Start--up 33
Running up the controller: Operator Control 7, 9

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S
Safety: Safety 9
Safety (exclusion) zones and working zones: Safety 15
Safety features: Safety 12
Safety instruction: Safety 22
Safety instructions: Introduction 11; Operator Control 119
Safety labelling: Safety 25
Safety mats: Safety 19
Safety regulations: Safety 19
Safety switch: Operator Control 136
Safety symbols: Safety 7
Save: Start--up 24; User Programming 26, 30, 34
Save the current robot coordinates: User Programming 25, 29, 33
Save the point: Start--up 110
Section: Introduction 12
Select: Operator Control 103, 112, 172
Select/open/save a program: User Programming 5
Selecting the kinematic system: Operator Control 47
Selection list: Operator Control 64, 70
Serial number: Introduction 15; Start--up 127
Service: Introduction 15; Operator Control 167, 184
Service center: Introduction 16
Servo module: Robot System 24
Set mastering: Operator Control 184
Settings: Operator Control 167
Setup: Operator Control 167, 182
Shift key: Operator Control 27
Short--circuit braking: Operator Control 119
Shutting down the controller: Operator Control 7, 11
Signal states: Operator Control 130, 132
Simultaneous motion: Operator Control 40
Single Step: Operator Control 120
Skeleton program: Operator Control 84, 86, 104
Softkey bar: Operator Control 30
Softkeys: Operator Control 25, 136
Software concept: Robot System 29
Software limit switches: Robot System 7, 9, 11; Operator Control 44
Software Update: Operator Control 184; Start--up 125
Space Mouse: Operator Control 24, 39, 46, 51; Start--up 39
SPOT Tech: Operator Control 189
Stamp: Operator Control 187; User Programming 51
Standard motions: User Programming 20
START key: Operator Control 22
Start key: Start--up 16, 17, 19, 20, 26
Start/Stop: Operator Control 142
State: User Programming 39, 40, 41, 42, 45
Static: Operator Control 187
Status bar: Operator Control 32, 34

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Status key bar: Operator Control 30

Status keys: Operator Control 24, 136
Status LED: Operator Control 8, 10
Status line: Operator Control 32, 44, 64, 75, 116
Status window: Operator Control 31, 46, 48, 136
Statuskeys: Operator Control 178
STOP key: Operator Control 22
Stopping program execution: Operator Control 125, 127
SUBMIT Interpreter: Operator Control 178
Superposed motion: Operator Control 58
Supplementary load data: Operator Control 183; Start--up 98
Swivel range: Robot System 7, 9
SYM key: Operator Control 27
Symbols: Introduction 11; Operator Control 64
Symbols in the program window: Operator Control 114
SYN OUT: Operator Control 187; User Programming 41, 42
SYN PULSE: Operator Control 187; User Programming 45
SYNOUT: User Programming 40, 45
SYNPULSE: User Programming 41, 42
System time: Operator Control 35

T
T1: Operator Control 35, 44
T2: Operator Control 35, 44
TAB key: Operator Control 26
TCP: Start--up 34, 38, 117
Teach offset: Operator Control 184
Technology: Operator Control 167, 188
Technology commands: Operator Control 167
Technology parameters: User Programming 50
Technology selection: Operator Control 179
Temperature monitoring: Safety 12
Templates: Operator Control 71
Test (T1): Start--up 15, 16, 18, 19, 22, 24
Test (T1/T2): Start--up 7
Time: User Programming 41, 45
Timer: Operator Control 142, 181
Tip: Introduction 11
Toggling to the Windows interface: Operator Control 36
Tolerance limits: Start--up 101
Tolerances: Operator Control 183; Start--up 101
TOOL: Operator Control 39
Tool: Operator Control 43, 183
Tool (BASE): Start--up 77, 83
Tool Center Point: Start--up 34, 117
Tool change: Safety 19
Tool definition: Operator Control 179

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Tool load data: Start--up 36, 61

Tool number: Start--up 39
Tool OK: Start--up 108
Tool type: Operator Control 179, 183
Torquemon: Operator Control 186
Touch Up: User Programming 25, 29, 33, 57
TOUCHSENSE: Operator Control 190
Transportation: Safety 21
Traversing keys: Operator Control 39, 46, 59
Traversing mode: Operator Control 29, 39, 46
Traversing velocity: Start--up 40
Types of motion: User Programming 20

U
UNDO key: Operator Control 26
UnMaster: Operator Control 184
Unmastered: Start--up 6
Unmastering an axis: Start--up 27
UPVXWIN.EXE: Robot System 30
User data: Operator Control 69
User group: Operator Control 154, 157, 159, 178
User levels: Operator Control 178
USER Tech: Operator Control 190
USER Tech reininitialize: Operator Control 179

V
VAR: User Programming 56
Variable: Operator Control 145, 181
Variables: Operator Control 167; Start--up 28
Vel: User Programming 24, 28, 32
Velocity: Start--up 40
Velocity parameters: User Programming 50
Vernier: Start--up 5
Version information: Operator Control 167
Virus protection: Operator Control 15
Voltage monitoring: Safety 12
VxWorks: Robot System 20, 29

W
W_F/IBUS: User Programming 38
WAIT: User Programming 37
Wait functions: User Programming 37
WAIT/W_F: User Programming 47
WAITFOR: User Programming 38
Warning and safety instructions: Operator Control 119
Weight difference: Start--up 12

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WIN95: Robot System 29

Window selection key: Operator Control 22, 82
Windows: Operator Control 181
Windows interface: Operator Control 36
With offset: Operator Control 184
Without offset: Operator Control 184
Work cell: Operator Control 41
Working direction: Start--up 45
Working range limitation: Robot System 16
Working range monitoring: Robot System 16
Working space limitation: Safety 12
Workpiece: Operator Control 183
Workpiece (TOOL): Start--up 77
WORLD: Operator Control 39
WORLD coordinate system: Start--up 32
Wrist: Robot System 6, 13
Wrist axis motor units: Robot System 8

X
X axis: Operator Control 43
X Y Z -- 4 Point: Operator Control 183; Start--up 36, 38
X Y Z -- Reference: Operator Control 183; Start--up 36, 40
X, Y, Z: Start--up 33, 42, 59, 63, 96, 99, 113, 122
X32: Start--up 6

Z
Z--Y--X Euler angles: Start--up 33
Zero position: Start--up 5
Zip file: Operator Control 90; User Programming 9
1

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