KUKA System Technology

KUKA.ServoGun Basic 3.0

For KUKA System Software 8.5

Issued: 04.04.2019
KST ServoGun Basic 3.0 V2
KUKA Deutschland GmbH
KUKA.ServoGun Basic 3.0

© Copyright 2019
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user
has no claims 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 soft-
ware 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 regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation

Publication: Pub KST ServoGun Basic 3.0 (PDF) en

PB9872

Book structure: KST ServoGun Basic 3.0 V2.8

BS9207

Version: KST ServoGun Basic 3.0 V2

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Contents

1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Industrial robot documentation.............................................................................. 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8
1.5 Licenses................................................................................................................. 9

2 Product description................................................................................. 11
2.1 KUKA.ServoGun Basic – overview....................................................................... 11
2.2 Constant motion speed......................................................................................... 13
2.3 Overview of connecting cables............................................................................. 14
2.4 KUKA CFS10 (force gauge)................................................................................. 15
2.5 Intended use of the technology package............................................................. 16

3 Safety......................................................................................................... 17

4 Installation................................................................................................ 19
4.1 System requirements............................................................................................. 19
4.2 Installing or updating KUKA.ServoGun Basic 3.0................................................ 20
4.3 Uninstalling KUKA.ServoGun Basic 3.0............................................................... 20

5 Operation.................................................................................................. 23
5.1 Displaying status keys........................................................................................... 23
5.2 Manually opening/closing the gun........................................................................ 24
5.3 Manually coupling / decoupling the gun (in the software)................................... 25
5.4 Manually activating gun compensation................................................................. 25
5.5 Displaying electrode shank wear / resetting wear after a shank change........... 26
5.6 Displaying user rights............................................................................................ 27

6 Start-up and configuration..................................................................... 29

6.1 Start-up and configuration – overview.................................................................. 29
6.2 Inserting a weld timer into the project.................................................................. 31
6.2.1 Catalog elements for weld timers......................................................................... 31
6.3 Configuring options and inputs/outputs for the weld timer in WorkVisual........... 32
6.3.1 Weld timer options................................................................................................ 32
6.3.2 “Weld timer inputs/outputs” area........................................................................... 37
6.4 Configuring the gun motor.................................................................................... 38
6.5 Calling the ServoGun editor in WorkVisual.......................................................... 39
6.6 Configuring options and inputs/outputs for the gun in WorkVisual...................... 40
6.6.1 “Gun settings” area............................................................................................... 40
6.6.2 PLC input and output ranges................................................................................ 43
6.7 Configuring the KUKA CFS10 (force gauge)....................................................... 45
6.8 Adapting the velocity monitoring of the gun for T1............................................. 47
6.9 Temporarily canceling axis coupling in the drive configuration............................ 47
6.10 Exporting/importing the weld timer and gun configuration................................... 48
6.10.1 Exporting and importing the WorkVisual configuration........................................ 48
6.10.2 Exporting and importing the configuration on the robot controller...................... 49
6.11 Checking the sign of the gear ratio of the gun.................................................... 49

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6.12 TCP calibration and tool direction........................................................................ 50

6.13 Calling the start-up wizard on the robot controller............................................... 51
6.14 Gun mastering....................................................................................................... 53
6.15 Determining the gear ratio of the gun.................................................................. 54
6.16 Setting the software limit switches....................................................................... 55
6.16.1 Setting the limit switch for opening of the gun.................................................... 55
6.16.2 Setting the limit switch for closing of the gun...................................................... 56
6.17 Determining the thickness of the force gauge..................................................... 56
6.18 Calibration – overview........................................................................................... 58
6.18.1 Precalibration – determining the calibration positions.......................................... 58
6.18.2 Description of coarse calibration........................................................................... 59
6.18.3 Performing coarse calibration............................................................................... 60
6.18.4 Performing fine calibration (recalibration)............................................................. 62
6.18.5 Carrying out a force test....................................................................................... 63
6.19 Determining and compensating for the asymmetrical flexion of X guns............. 66
6.20 Determining and compensating for the sliding effect with X guns...................... 67
6.21 Tip initialization – overview................................................................................... 68
6.21.1 First initialization via status key............................................................................ 69
6.21.2 Cyclical initialization via status key....................................................................... 69
6.22 Having dialog messages answered by the PLC.................................................. 70
6.23 Linking error messages to outputs....................................................................... 70
6.24 Hybrid mode – re-application of pressure in the case of air gaps, incorrectly
positioned point, etc.............................................................................................. 72
6.25 Controller parameters – overview......................................................................... 72
6.25.1 ServoGun configuration window – SGControlView.............................................. 74
6.25.2 Optimizing the parameters for the speed and position controllers...................... 75
6.25.3 Optimizing the parameters for the force controller.............................................. 76

7 Programming............................................................................................ 79
7.1 Inline forms – overview......................................................................................... 79
7.2 Instructions for programming................................................................................ 79
7.2.1 Instructions for use of stationary guns................................................................. 79
7.3 Programming a weld spot..................................................................................... 80
7.3.1 Inline form “SPOT”................................................................................................ 80
7.4 Programming tip initialization................................................................................ 82
7.4.1 Programming first initialization (Ratio in % option).............................................. 82
7.4.2 Programming cyclical initialization (Ratio in % option)........................................ 83
7.4.3 Inline form “INIT” (Ratio in % option)................................................................... 84
7.4.4 Programming first initialization (Individual measurement option)......................... 85
7.4.5 Programming cyclical initialization (Individual measurement option)................... 86
7.4.6 Inline form “INIT” (Individual measurement option).............................................. 88
7.5 Inline form COUPLE and DECOUPLE................................................................. 89
7.6 Programming tip dressing..................................................................................... 89
7.6.1 Determining the thickness of the tip dresser....................................................... 91
7.6.2 Inline form “TippDress”.......................................................................................... 91
7.7 Closing the gun..................................................................................................... 92
7.7.1 Inline form Close gun............................................................................................ 93
7.8 Option window “Frames”....................................................................................... 93
7.9 Option window “Parameter”.................................................................................. 94

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7.10 Option window “Motion parameters”..................................................................... 95

7.11 Option window “Servo gun parameters”............................................................... 95
7.12 Using Teach mode/correcting weld spots............................................................. 96
7.13 Adaptable subprograms........................................................................................ 97

8 Background welding and tip dressing.................................................. 101

8.1 Functionality of background processes................................................................ 101
8.2 Configuring background processes – weld timer and gun.................................. 101
8.3 Configuring background processes – PLC inputs/outputs................................... 101
8.4 Programming background processes................................................................... 103
8.5 Inline form Background tip dressing and Background welding............................ 103
8.6 Sequence of background processes.................................................................... 104
8.7 Adaptable subprograms for background processes............................................. 104

9 Diagnosis.................................................................................................. 107
9.1 Displaying I/O states............................................................................................. 107
9.2 Displaying detailed information about weld spots................................................ 107
9.3 Configuring program selection for Overview tab (detailed information).............. 109

10 Messages.................................................................................................. 111
10.1 Information about the messages.......................................................................... 111
10.2 Information on dialog messages after a welding error........................................ 111
10.3 System messages from module: ServoGunMessages........................................ 111
10.3.1 ServoGunMessages 00101................................................................................... 111
10.3.2 ServoGunMessages 00103................................................................................... 112
10.3.3 ServoGunMessages 00104................................................................................... 114
10.3.4 ServoGunMessages 00105................................................................................... 116
10.3.5 ServoGunMessages 00106................................................................................... 116
10.3.6 ServoGunMessages 00107................................................................................... 117
10.3.7 ServoGunMessages 00108................................................................................... 118
10.3.8 ServoGunMessages 00109................................................................................... 119
10.3.9 ServoGunMessages 00110................................................................................... 120
10.3.10 ServoGunMessages 00111.................................................................................... 121
10.3.11 ServoGunMessages 00112................................................................................... 122
10.3.12 ServoGunMessages 00113................................................................................... 125
10.3.13 ServoGunMessages 00114................................................................................... 126
10.3.14 ServoGunMessages 00115................................................................................... 128
10.3.15 ServoGunMessages 00116................................................................................... 129
10.3.16 ServoGunMessages 00117................................................................................... 129
10.3.17 ServoGunMessages 00119................................................................................... 131
10.3.18 ServoGunMessages 00120................................................................................... 132
10.3.19 ServoGunMessages 00121................................................................................... 133
10.3.20 ServoGunMessages 00122................................................................................... 134
10.3.21 ServoGunMessages 00123................................................................................... 135
10.3.22 ServoGunMessages 00124................................................................................... 137
10.3.23 ServoGunMessages 00125................................................................................... 138
10.3.24 ServoGunMessages 00128................................................................................... 139
10.3.25 ServoGunMessages 00129................................................................................... 140
10.3.26 ServoGunMessages 00135................................................................................... 142
10.3.27 ServoGunMessages 00149................................................................................... 143

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10.3.28 ServoGunMessages 00153................................................................................... 146

10.3.29 ServoGunMessages 00154................................................................................... 148
10.3.30 ServoGunMessages 00155................................................................................... 150
10.3.31 ServoGunMessages 00156................................................................................... 151
10.3.32 ServoGunMessages 00158................................................................................... 152
10.3.33 ServoGunMessages 00160................................................................................... 154
10.3.34 ServoGunMessages 00163................................................................................... 155
10.3.35 ServoGunMessages 00164................................................................................... 156
10.3.36 ServoGunMessages 00167................................................................................... 157
10.3.37 ServoGunMessages 00206................................................................................... 158
10.3.38 ServoGunMessages 00210................................................................................... 159
10.3.39 ServoGunMessages 00212................................................................................... 160
10.3.40 ServoGunMessages 00214................................................................................... 161
10.3.41 ServoGunMessages 00215................................................................................... 163
10.3.42 ServoGunMessages 00352................................................................................... 164
10.3.43 ServoGunMessages 00303................................................................................... 166
10.3.44 ServoGunMessages 00304................................................................................... 168
10.3.45 ServoGunMessages 00305................................................................................... 170
10.3.46 ServoGunMessages 00306................................................................................... 171
10.3.47 ServoGunMessages 00307................................................................................... 172
10.3.48 ServoGunMessages 00308................................................................................... 174
10.3.49 ServoGunMessages 00212................................................................................... 175
10.3.50 ServoGunMessages 00301................................................................................... 176
10.3.51 ServoGunMessages 00353................................................................................... 178
10.3.52 ServoGunMessages 00354................................................................................... 178
10.3.53 ServoGunMessages 00355................................................................................... 179
10.3.54 ServoGunMessages 00356................................................................................... 180
10.3.55 ServoGunMessages 00357................................................................................... 181
10.3.56 ServoGunMessages 00358................................................................................... 183
10.3.57 ServoGunMessages 00359................................................................................... 184
10.3.58 ServoGunMessages 00360................................................................................... 185
10.3.59 ServoGunMessages 00361................................................................................... 187
10.3.60 ServoGunMessages 00368................................................................................... 187
10.3.61 ServoGunMessages 00369................................................................................... 188
10.3.62 ServoGunMessages 00371................................................................................... 189
10.3.63 ServoGunMessages 00372................................................................................... 190
10.3.64 ServoGunMessages 00373................................................................................... 190
10.3.65 ServoGunMessages 00374................................................................................... 192
10.3.66 ServoGunMessages 00375................................................................................... 193
10.3.67 ServoGunMessages 00376................................................................................... 195
10.3.68 ServoGunMessages 00377................................................................................... 197
10.3.69 ServoGunMessages 00378................................................................................... 198

11 KUKA Service........................................................................................... 201

11.1 Requesting support............................................................................................... 201
11.2 KUKA Customer Support...................................................................................... 201

Index 209

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 KUKA.ServoGun Basic 3.0

Introduction
1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and

skills:
• Advanced KRL programming skills
• Advanced knowledge of the robot controller system
• Advanced knowledge of WorkVisual
• Knowledge of field bus interfaces
• Knowledge of spot welding
• For determining and optimizing the controller parameters:
Expert knowledge in the start-up of guns

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about the
training program can be found at www.kuka.com or can be obtained di-
rectly from our subsidiaries.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts in KUKA.Xpert
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety

These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.

WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.

CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.

NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.

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Introduction KUKA.ServoGun Basic 3.0

These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:
SAFETY INSTRUCTION
The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

Notices

These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.

1.4 Terms used

Term Description
Burn-off (tip Wear or deformation of the electrode tips caused by
wear) the welding process or by tip dressing
Compensation Pneumatic compensation cylinder for compensating
(equalizing) the position of the gun:

• Compensation activated: “soft” gun position

• Compensation deactivated: “exact” gun position
Robot compen- Gun without pneumatic compensation cylinder
sator (compen-
sation-free gun)
First initialization Pressing in the new electrode tips and remeasuring
the tip burn-off
Mastering Definition of the zero point (closed position) of the
weld gun
Calibration Calibration is carried out by determining the force for
a defined flexion of the gun.
Tip dressing Restoring the profile of the electrode tips by cutting
(TipDress)
Force build-up Generation of the closing force during gun closure
Force gauge Instrument for measuring the closing force of the
weld gun
KSS KUKA System Software
Weld timer (= weld controller)
Device for controlling weld parameters, such as the
welding force and current, part thickness, etc.
Servo gun Weld gun with servomotor drive
VSS VW System Software

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Introduction
Term Description
Water monitor Monitoring unit in the cooling water circuit of the weld
gun. The water monitor monitors the cooling water
volume at the input and output of the cooling water
circuit.
Exchangeable Weld gun which is installed and removed on the ro-
gun bot flange via an automatic tool changing system.
Gun flexion Deformation of the weld gun caused by the action of
the closing force
Gear ratio of Ratio between the motor stroke and gun opening
gun
Cyclical initiali- Determination of the current electrode burn-off and
zation adaptation of the closing position to the burn-off.

1.5 Licenses

The KUKA license conditions and the license conditions of the open-
source software used can be found in the following folders:
• Under .\LICENSE on the data storage medium with the installation
files of the KUKA software
• Under D:\KUKA_OPT\Option package name\LICENSE after installation
on the robot controller
• In the license folder under the name of the option package in the Op-
tions catalog after installation in WorkVisual

Further information about open-source licenses can be requested from

the following address: opensource@kuka.com

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 KUKA.ServoGun Basic 3.0

Product description
2 Product description

2.1 KUKA.ServoGun Basic – overview

Functions

KUKA.ServoGun Basic is an add-on option package for sensorless force-

controlled electric motor-driven spot welding. It offers the following func-
tionalities and characteristics:
• Defined build-up of gun force through constant motion and sensorless
force control
• Control of up to 6 electric motor-driven weld guns
Any number of exchangeable guns and/or stationary guns, taking into
consideration the total number of possible axes and the controller var-
iant (KR C4, KR C4 extended)
• Force accuracy: the difference between the programmed setpoint force
and the actual force is generally between 3 and 7%.
• Particularly suitable for guns with a flexion in excess of 0.3 mm/
1,000 N (without compensation)
• Compensation:
‒ Pneumatic compensation of the gun position on the workpiece
possible
‒ Or: Compensation of the gun position on the workpiece through ro-
bot motion
• Start-up wizard
• Force calibration of the gun:
‒ Possible in T1 and with limitations in T2/AUT.
• Selection of the weld program: can be selected via the point name or
separately via the program number
• For many weld parameters, it is possible to select whether they are to
be obtained from the weld timer or defined via inline forms.
• “Background” mode for stationary guns:
The gun can be moved asynchronously for tip dressing or welding. At
the same time, the robot axes can carry out handling tasks independ-
ently of the gun, e.g. fetching a new workpiece.
• For X guns: asymmetrical flexion can be compensated.
• For X guns: the sliding effect due to oblique electrode shanks can be
compensated.
• Automatic correction for compensating the electrode burn-off
• Automatic correction for compensating the electrode shank wear
• Monitoring of various parameters
• Welding and deactivation of welding are possible in all operating
modes.
• For guns with pneumatic compensation: the gun can also be closed
with process force using the status keys in T1.
• “Hybrid mode”: welding can also be carried out successfully with gaps,
incorrectly positioned points, etc.
• “Maintain force at weld spot”: welding can also be carried out success-
fully if melting material could lead to a reduction in force.
• “Custom Timer”: KUKA.ServoGun Basic provides a catalog object for
weld timers without predefined communication. The communication be-
tween the timer and the robot controller can be programmed.

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 KUKA.ServoGun Basic 3.0

The servo gun is implemented as an external axis. Every taught point

Product description

contains the positions of the 6 robot axes and the opening width of the
gun.

Gear ratio

Both servo guns with a positive gear ratio and servo guns with a negative
gear ratio may be operated using KUKA.ServoGun Basic.

WorkVisual

The following software is required for configuring the servo guns:

• WorkVisual
The number of the required version must be taken from the file Release-
Notes_[…].txt. The file is located on the data storage medium with KU-
KA.ServoGun Basic.

Expansions

The range of functions of KUKA.ServoGun Basic 3.0 can be expanded

with the following software products: These products are described in sep-
arate documentation.
KUKA.ServoGun Advanced 3.0
ServoGun Advanced enables the operation of sensor-guided, force-control-
led weld guns.
KUKA.EqualizingTech 3.0
With EqualizingTech, a conventional gun compensation system is no lon-
ger required.
• This makes it possible to dispense with the complicated start-up pro-
cedures for pneumatic compensation systems, for example.
• Furthermore, conventional systems require specific mechanical and/or
pneumatic components such as switchover valves, hoses, etc. With
EqualizingTech, these components are no longer required.
EqualizingTech enables position compensation irrespective of the gun ori-
entation. Conventional systems are limited in this regard, as they are de-
pendent on gravity.
KUKA.RoboSpin 3.0
• RoboSpin makes it possible to execute a spin motion about the TCP
during the welding process. The spin motion increases the weld
quality and reduces the tip wear.

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Product description
Cell overview

Fig. 2-1: Overview of a welding cell

1 KR C4 robot controller
2 Weld timer
3 Tool rack
4 Robot
5 Energy supply system
6 Stationary servo gun
7 Servo gun
8 Tip dresser

2.2 Constant motion speed

Description

The option package regulates the speed of motion in proportion to the tar-
get force and gun flexion. The larger the target force (= setpoint force),
the higher the rotational speed.
The time for the pressure build-up is dependent on the gun flexion and
the target force.
The proportionality is limited by the maximum speed of the constant mo-
tion phase.

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Product description KUKA.ServoGun Basic 3.0

Fig. 2-2: Relationship between force and rpm

1 Speed
2 Maximum speed of the constant motion phase
3 Force

2.3 Overview of connecting cables

Fig. 2-3: Overview of connecting cables

1 Weld timer
2 Robot controller
3 Motor cable to the gun
4 Weld gun
5 Field bus module on the weld gun (Not necessary if Equalizing-
Tech is used. Otherwise, depending on the weld gun used.)

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Product description
6 Field bus connection between the following components:

• Weld timer
• Robot controller
• If used: Field bus module on the weld gun
7 Robot

The following connections depend on the type of weld gun being used:

• Connection for water cooling of the weld gun and the motor
• Air connection for the gun compensation
• Connection for the weld current

Further information about the connections on the weld gun can be ob-
tained from the gun manufacturer.

2.4 KUKA CFS10 (force gauge)

The KUKA CFS10 is an option belonging to KUKA.ServoGun Basic. It can

be purchased separately. Purpose: automatic calibration of the welding
force for servo spot weld guns
Article designation:
Clamping force sensor for weld gun CFS10
Advantages of the KUKA CFS10:
• No falsification of the measurement, as no force is exerted on the gun
electrode
• Very simple handling due to connection option on robot base
• The force values are transferred directly to the robot controller, thus
avoiding errors due to manual transfer.
• Force calibration is possible in automatic mode with process velocity.
The calibration is thus coordinated with the real production conditions.
• The KUKA CFS10 is only required for calibration and is then discon-
nected again: low investment, but great benefits.

Fig. 2-4: Clamping force sensor for weld gun CFS10

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2.5 Intended use of the technology package

Use

The KUKA.ServoGun Basic 3.0 option package is intended exclusively for

spot welding with electric motor-driven guns and for use in an industrial
environment.
The option package must only be operated in compliance with the speci-
fied system requirements. The technology package must only be operated
using gun motors validated or approved by KUKA Deutschland GmbH.
Operation in accordance with the intended use also requires compliance
with the configuration descriptions in this documentation and constant ob-
servance of the assembly and operating instructions for the cell compo-
nents used.

Misuse

Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. KUKA Deutschland GmbH accepts no liability
for damage or injury caused thereby. The risk lies entirely with the user.
Examples of such misuse include:
• Use in a cell which does not conform to the applicable safety regula-
tions for spot welding.
• Use in a non-industrial environment
• Use with gun motors that do not have the required validation and/or
approval from KUKA Deutschland GmbH.

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Safety
3 Safety
This documentation contains safety instructions which refer specifically to
the option package described here.
The fundamental safety information for the industrial robot can be found in
the “Safety” chapter of the Operating and Programming Instructions for
System Integrators or the Operating and Programming Instructions for End
Users.
The “Safety” chapter in the operating and programming instructions of
the KUKA System Software (KSS) must be observed. Death to persons,
severe injuries or considerable damage to property may otherwise re-
sult.

DANGER
If the secondary neutral of the welding transformer is not grounded, this
will endanger persons working at the cell. In particular, a voltage of
500 V is liable to be generated on the gun and not discharged. To avoid
this hazard, one of the following elements must be installed in the pri-
mary weld power supply:
• Isolating contactor
• Residual-current circuit-breaker matching the welding technology
(medium frequency or mains frequency)
Failure to observe this may result in severe injuries or death to persons.

WARNING
For calibration in T2, no force gauge may be used that requires the op-
erator to be present in the safeguarded area during operation. There
must be no persons inside the safeguarded area during operation in T2
mode. Death to persons or severe injuries may otherwise result.
A suitable force gauge for calibration in T2 is the KUKA CFS10, for ex-
ample.

NOTICE
Calibration must be performed on the same system on which the gun is
subsequently operated. If calibration is carried out on a different system,
if the system is modified after calibration, or if a necessary step is left
out, the results could be failure to weld, faulty welding and/or damage to
property.

NOTICE
If an archive is restored while a mastered gun is decoupled, the data re-
lating to the decoupling position might be overwritten with old data. This
can also happen with similar operations. The following operations are
affected:
• File > Restore
• File > Backup Manager > Restore / Restore from
• Activation of a project from WorkVisual
The following applies in all cases: After recoupling a gun, its mastering
must be checked. If the mastering is not correct, the gun must be re-
mastered.
Failure to observe this precaution may result in damage to property.

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Installation
4 Installation

4.1 System requirements

Hardware

• KR C4 or KR C4 extended robot controller

• Servo gun with motor
Required flexion values:
Minimum 0.3 mm/ 1,000 N
Maximum 2.0 mm/ 1,000 N

KUKA must be consulted if guns with different flexion values are to be

used.

Software – robot controller

• KUKA System Software 8.5.x

The number of the required release must be taken from the file Release-
Notes_[…].txt. The file is located on the data storage medium containing
KUKA.ServoGun Basic 3.0.
The following KRL resources must be free:
KRL resource Number
Interrupts 1, 11, 17, 20, 21, 25, 27, 98, 99
Timers 11 … 18, 21, 24, 33, 34
Cyclical flags 16, 35, 36, 42, 80, 256
Flags 129

Software – laptop/PC

• WorkVisual
The number of the required version must be taken from the file Release-
Notes_[…].txt. The file is located on the data storage medium containing
KUKA.ServoGun Basic 3.0.

Compatibility

Welding packages:
No further option packages for the operation of welding guns may be in-
stalled on the robot controller alongside KUKA.ServoGun Basic.
• Example:
KUKA.ServoGun FC or KUKA.ServoGun TC must NOT be installed to-
gether with KUKA.ServoGun Basic.
The specific expansions for KUKA.ServoGun Basic (e.g. KUKA.Equalizing-
Tech) are of course possible.
KUKA.RoboTeam:
KUKA.RoboTeam must not be installed on the same robot controller to-
gether with KUKA.ServoGun Basic.

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Installation KUKA.ServoGun Basic 3.0

4.2 Installing or updating KUKA.ServoGun Basic 3.0

Description

The option package is installed in WorkVisual and added to the project.

During project deployment, the option package is automatically installed
on the robot controller.
In the case of an update, the previous version of the option package in
WorkVisual must first be uninstalled.
It is advisable to archive all relevant data before updating a software
package.

Precondition

• User group “Expert”

• T1 or T2 mode
• No program is selected.
• Network connection between PC and robot controller
• The option package is available as a KOP file.

Procedure

1. Only for an update: Uninstall the previous version of the KUKA.Servo-

Gun Basic 3.0 option package in WorkVisual.
2. Install the KUKA.ServoGun Basic 3.0 option package in WorkVisual.
3. Load the active project from the robot controller.
4. Insert the KUKA.ServoGun Basic 3.0 option package into the project.
5. Configure the option package in WorkVisual as required.
6. Deploy the project from WorkVisual to the robot controller and activate
it.
7. The request for confirmation Do you want to activate the project […]?
is displayed on the smartHMI. The active project is overwritten during
activation. If no relevant project will be overwritten: Answer the query
with Yes.
8. An overview with the changes and a request for confirmation are dis-
played on the smartHMI. Answer this with Yes. The option package is
installed and the robot controller carries out a reboot.

Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.

LOG file

A LOG file is created under C:\KRC\ROBOTER\LOG.

4.3 Uninstalling KUKA.ServoGun Basic 3.0

Description

The option package can be uninstalled via WorkVisual.

It is advisable to archive all relevant data before uninstalling a software
package.

Precondition

• User group “Expert”

• T1 or T2 mode

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Installation
• No program is selected.
• Network connection between PC and robot controller

Procedure

1. Load the project from the robot controller.

2. Remove the KUKA.ServoGun Basic 3.0 option package from the
project. A window with modifications is displayed.
3. Deploy the project from WorkVisual to the robot controller and activate
it.
4. Answer the request for confirmation Do you want to activate the
project […]? on the smartHMI with Yes.
5. An overview with the changes and a request for confirmation are dis-
played on the smartHMI. Answer this with Yes. The option package is
uninstalled and the robot controller carries out a reboot.

Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.

LOG file

A LOG file is created under C:\KRC\ROBOTER\LOG.

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Operation
5 Operation

5.1 Displaying status keys

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T1 or T2 mode

Procedure

Displaying the status keys for the first time:

• In the main menu, select Configuration > Status keys > ServoGun.
Then select a submenu item.
Display other ServoGun status keys:
• Either: In the main menu, select Configuration > Status keys > Ser-
voGun again. Then select the desired submenu item.
• Or: Click in the gray area between two status keys. A selection of sta-
tus key groups is displayed.
Click on the desired group.
Refreshing the status keys:
If the compensation type has been changed, the status keys can be re-
freshed as follows:
• Carry out a cold restart.
• Or, if a further option package other than ServoGun is installed which
uses status keys:
Display the status keys of this package. Then display the status keys
of ServoGun again.

Status keys

Each status key group contains:

Status key Name / description
Gun
Gun to which the status keys refer
Group General/SGKB:
Status key Name / description
Welding with current
Welding is carried out normally with current. For this, ig-
nition must be activated in the weld timer. Pressing the
key activates welding without current.
Welding without current
The gun is closed with process force at every weld spot,
but no current flows. Pressing the key activates welding
with current.
Teach mode off
Teach mode is deactivated. Pressing the status key
switches Teach mode on.

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Operation KUKA.ServoGun Basic 3.0

Status key Name / description

Teach mode on
Teach mode is activated. Pressing the status key
switches Teach mode off.
Group Initialization/SGIC:
Status key Name / description
First initialization

Cyclical initialization

Decouple

Couple

Group Close gun/SGCL:

Only for compensation type Pneumatic:
Status key Name / description
Compensator 1
Close gun with compensator 1
Compensator 2
Close gun with compensator 2
Compensators 1 and 2
Close gun with compensator 1 and compensator 2

5.2 Manually opening/closing the gun

Precondition

• T1 mode
• Settings on the Keys tab in the Jog options window:
‒ The check box Activate keys is activated.
‒ Under Kinematic groups, a group is selected that contains the
external axis, e.g. External axes.
The type and number of kinematics groups available depend on
the system configuration.
‒ Under Coordinate system, the option Axes is selected.
• The current setting of the parameter Direction of the closing gun is
known.

Procedure

1. Set the jog override.

2. Press and hold down the enabling switch. The axes of the selected
kinematics group are now displayed next to the jog keys.
3. Press the keys next to the indication of the gun axis.
If Direction of the closing gun = NEGATIVE:
• Press Plus to open the gun.

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Operation
• Press Minus to close the gun.
If Direction of the closing gun = POSITIVE:
• Press Minus to open the gun.
• Press Plus to close the gun.

If the gun exhibits the opposite behavior, the Negative transmission

ratio parameter is not set correctly. Either the gun has not been config-
ured yet or the ratio sign has not been checked.

5.3 Manually coupling / decoupling the gun (in the software)

• When coupling a gun that has not yet been mastered, the opening
width of the gun is not relevant.
• When decoupling a mastered gun, the gun must not be in the mas-
tering position or a multiple thereof (360°, 720° motor revolution).
Mastering is otherwise lost on recoupling.
• On recoupling, the gun must have the same opening width as when
it was decoupled. If this is not the case, the mastering will be lost.

A weld gun may only be assigned to one robot. A weld gun must not
be used on more than one robot.

Procedure

1. Select the gun using the Gun status key.

2. Couple the gun with the Couple status key, or decouple it using De-
couple.

Status keys

Status key Name / description

Decouple

Couple

5.4 Manually activating gun compensation

Description

This functionality is only relevant for the compensation type Pneumatic.

This can be used to check the pneumatic compensation.

Precondition

• T1 or T2 operating mode
• The gun is coupled.

Procedure

1. Move the gun to the panel/position where the check is to be carried

out.
2. Select the gun using the Gun status key.
3. Press the status key for the desired compensator, e.g. Compensator
1.

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 KUKA.ServoGun Basic 3.0

The gun closes and opens again after 0.5 s.

Operation

4. If the panel deforms in an undesired manner, change the setting of

the pneumatic compension on the gun.
5. Repeat steps 3 and 4 until compensation is carried out as desired.

Status keys

Status key Name / description

Compensator 1
Close gun with compensator 1
Compensator 2
Close gun with compensator 2
Compensators 1 and 2
Close gun with compensator 1 and compensator 2.

5.5 Displaying electrode shank wear / resetting wear after a shank change

Description

ServoGun Basic determines the wear of the electrode shanks every time
first initialization is carried out. It automatically corrects the gun position
and opening width in order to compensate for the wear.
In order to enable correct determination of the wear, the user must reset
the value for the total wear after every shank change.
Strictly speaking, the user does not reset the value directly, but requests
the reset. The robot controller then resets the value before the next first
initialization.

Precondition

• User rights: Function group Configuration of the technology pack-

ages

Procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. At the bottom of the page, select Gun service.
The GunServiceView view opens.
3. The Current shank wear box indicates the current value.
4. If the value is to be reset:
Press the Reset button. A check mark to the left of it now indicates
that resetting has been requested.
The robot controller applies the setting immediately. No saving is re-
quired!

The request can be canceled by touching Reset again. The check mark
disappears.
An activated check mark disappears automatically when the robot control-
ler has reset the wear value.

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Operation
Fig. 5-1: Activated: resetting of the wear value is requested

5.6 Displaying user rights

Description

The functions of a software package are assigned various function groups.

In the rights management, the minimum user group required to execute a
function is defined for each function group.
• The administrator can assign other user groups to the function groups.
• The assignment of the individual functions to the function groups can-
not be changed.
• Every user can display which user groups are currently assigned to
which function groups.

Further information about function groups and user rights is contained in

the operating and programming instructions for the KUKA System Soft-
ware (KSS).

If a function group is relevant for a procedure, this is indicated under Pre-

condition.

Procedure

The user groups assigned to the function groups can be displayed:

1. In the main menu, select Start-up > Rights management.
The Rights management window opens.
2. Select the Function groups tab.

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 KUKA.ServoGun Basic 3.0

Start-up and configuration

6 Start-up and configuration

6.1 Start-up and configuration – overview

A wizard is available for the steps “Master the gun” through to

“Calibrate the gun”. The wizard performs the steps in sequence in the
correct order.
(>>> 6.13 "Calling the start-up wizard on the robot controller" Page 51)

Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.

Step Description
1 Mount the gun and connect the connecting cables.
2 Enter the weld parameters in the weld timer.
Note: Information can be found in the documentation for the weld timer.
In WorkVisual:
Note: Parameters configured in WorkVisual can only be displayed and not edited on the robot
controller. An exception is compensation of the sliding effect with X guns.
3 Install ServoGun Basic in WorkVisual.
4 Load the project from the robot controller. Add the option ServoGun Basic to
the project.
5 In WorkVisual, carry out the necessary settings for the project.
Specifically for ServoGun Basic:

• Insert a weld timer into the project.

(>>> 6.2 "Inserting a weld timer into the project" Page 31)
• Configure options and inputs/outputs for the weld timer.
(>>> 6.3 "Configuring options and inputs/outputs for the weld timer in
WorkVisual" Page 32)
• Configure the gun motor.
(>>> 6.4 "Configuring the gun motor" Page 38)
• Configure options and inputs/outputs for the gun.
Important! The parameter Direction of the closing gun must be set be-
fore the next steps are performed.
If Direction of the closing gun is later modified, all subsequent start-up
steps must be performed again. In the same way, ServoGun programs that
have already been created must be created again.
(>>> 6.6 "Configuring options and inputs/outputs for the gun in WorkVisual"
Page 40)
• Configure KUKA CFS10 if present.
(>>> 6.7 "Configuring the KUKA CFS10 (force gauge)" Page 45)
• If required: Adapt the velocity monitoring of the gun for T1.
(>>> 6.8 "Adapting the velocity monitoring of the gun for T1" Page 47)
6 Transfer the project back from WorkVisual to the robot controller and activate
it.
On the robot controller:
7 Check the sign of the gear ratio of the gun.
(>>> 6.11 "Checking the sign of the gear ratio of the gun" Page 49)

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Step Description
8 Calibrate the gun as the tool.
Note: Observe the information about calibration in this documentation:
(>>> 6.12 "TCP calibration and tool direction" Page 50)
9 Master the gun.
(>>> 6.14 "Gun mastering" Page 53)
10 Determine the gear ratio.
(>>> 6.15 "Determining the gear ratio of the gun" Page 54)
11 Set the software limit switches for the gun.
(>>> 6.16 "Setting the software limit switches" Page 55)
12 Determine the thickness of the force gauge.
(>>> 6.17 "Determining the thickness of the force gauge" Page 56)
13 Calibrate the gun.
(>>> 6.18 "Calibration – overview" Page 58)
14 Optimize the controller parameters.

• If a different motor is used instead of the default motor: optimization must

be carried out.
• If the default motor is used: optimization is recommended.
(>>> 6.25 "Controller parameters – overview" Page 72)
15 If the controller parameters have been optimized: perform fine calibration.
(>>> 6.18.4 "Performing fine calibration (recalibration)" Page 62)
16 • Only for X guns: determine the asymmetrical flexion.
(>>> 6.19 "Determining and compensating for the asymmetrical flexion of X
guns" Page 66)
• Only for X guns with oblique electrode shanks: determine the offset.
(>>> 6.20 "Determining and compensating for the sliding effect with X
guns" Page 67)
• Only for C guns: activate or deactivate flexion compensation.
17 Carry out first initialization of the electrode tips.
(>>> 6.21 "Tip initialization – overview" Page 68)
18 If required: configure message communication with the PLC.
(>>> 6.22 "Having dialog messages answered by the PLC" Page 70)
(>>> 6.23 "Linking error messages to outputs" Page 70)
19 Open the safety configuration, check it and confirm the changes made by the
weld gun.

Sequence diagrams for background processes between the PLC and ro-
bot can be found in the DOC directory on the data storage medium for
KUKA.ServoGun Basic.

Tip for standard operation: If the gun does not always reach the precise
required force after a certain period of time, then the gun needs to un-
dergo fine calibration again (= recalibration). Depending on the required
force accuracy, the customer must establish an appropriate recalibration
schedule.

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Start-up and configuration

6.2 Inserting a weld timer into the project

Precondition

• ServoGun Basic is installed in WorkVisual.

• The option package ServoGun Basic has been added to the project.
• The robot controller has been set as the active controller.

Procedure

1. Expand the catalog ServoGun Basic on the Options tab in the Cata-
logs window. This contains the catalog elements of the weld timer.
2. Drag the required weld timer into the Project structure window: into
the Hardware tab, onto the robot controller there.
3. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
Or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
4. Make the desired settings.
5. Repeat steps 2 to 4 for all the required weld timers.
6. Save the project.

6.2.1 Catalog elements for weld timers

In addition to the conventional weld timers, ServoGun Basic also pro-

vides the Custom Timer. With this timer, the communication between
the timer and the robot controller is not predefined, but can be program-
med. If use of a Custom Timer is desired, please contact KUKA
Deutschland GmbH.

The options in Weld timer editor were developed for the weld timer fami-
lies PSI 63Cx (with firmware 729) and PSI6xxx (with firmware 373 or
201) from Bosch.
The options can also be used with other timers, e.g. with the Tecna
TE550. A precondition is that they conform to the same communication
principle (handshake mechanism).
Communication principle of Bosch PSI 63Cx.729: ValidBit

1. The robot controller requests the program from the weld timer via the
input New point selection.
2. The weld timer acknowledges this request with the output Program
number accepted.
(If the program number is not stored in the weld timer, the output is
not set to TRUE.)
3. The robot controller resets New point selection to FALSE.
4. The weld timer sends the data for Force, Part thickness, etc.
5. The weld timer is ready for welding.
Communication principle of Bosch PSI6xxx.373: Invalid Program
Number

1. The robot controller sends a program number that is not stored in the
weld timer.
2. The output Point selection valid of the weld timer switches to
FALSE.

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Start-up and configuration KUKA.ServoGun Basic 3.0

3. The robot controller sends the program number that is programmed in

the inline form.
4. The output Point selection valid of the weld timer switches to TRUE.
5. The weld timer also sends the data for Force, Part thickness, etc.
Communication principle of Bosch PSI6xxx.201: CheckForce

1. The robot controller sends a valid program number for which an ex-
pected force is stored.
2. The weld timer sends the data for Force to the robot controller.
3. The robot controller compares the data from the weld timer with the
expected data.
4. If the expected force deviates from the received force by no more
than 5%, the robot controller sends the current program number to the
weld timer.
5. The weld timer sends the data for Force, Part thickness, etc.
6. If the force is greater than the force sent in step 2, welding can be
performed.
Communication principle of Tecna TE550: ValidBit

1. The robot controller requests the program from the weld timer via the
input New point selection.
2. The weld timer acknowledges this request with the output Program
number accepted.
If the program number is not stored in the weld timer, the output is not
set to TRUE.
3. The weld timer also sends the data for Force, Part thickness, etc.
4. The robot controller reads the data and sets New point selection to
FALSE.
5. The weld timer is ready for welding.

6.3 Configuring options and inputs/outputs for the weld timer in WorkVisu-
al

6.3.1 Weld timer options

Weld timer settings

Parameter Description
Inverted Hot / Cold • TRUE: The with current flow output is inverted.
signal
• FALSE (default): No inversion

If TRUE is selected for one of the following options, the desired value
must be assigned in the weld timer for every program number used.

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Start-up and configuration

Parameter Description
Force from weld Where is the robot controller to obtain the value for the closing force
timer of the gun?
Sources:

• TRUE: from the weld timer (N)

• FALSE:
‒ For regular welding and tip dressing: from the inline forms
‒ For background welding and tip dressing: from the PLC
Force correction Scale factor for the force values
factor
The robot controller always interprets the force values as values in N.
The scale factor enables the values supplied by the weld timer to be
appropriately converted if this is necessary.
The value of the scale factor depends on the transmission width of
the signal, the scale factor of the weld timer, and the unit for values
in the weld timer.
Default: 1
Force offset The robot controller adds this value to the force value supplied by the
weld timer.
Sequence:

1. The robot controller multiplies the value from the timer by the
scale factor.
2. The robot controller then adds the offset.
Default: 0.0
Part thickness from Where is the robot controller to obtain the following values?
weld timer
• For welding: total thickness of the workpieces to be welded
• For tip dressing: thickness of the tip dresser
Sources:

• TRUE: from the weld timer (mm)

• FALSE:
‒ For regular welding and tip dressing: from the inline forms
‒ For background welding and tip dressing (KSS): from the PLC
‒ For background welding and tip dressing (VSS): from the
source specified by the VW Group standard
Sheet thickness cor- Scale factor for the part thickness
rection factor
The robot controller always interprets the values as values in mm.
The scale factor enables the values supplied by the weld timer to be
appropriately converted if this is necessary.
The value of the scale factor depends on the transmission width of
the signal, the scale factor of the weld timer, and the unit for values
in the weld timer.
Default: 1

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Start-up and configuration KUKA.ServoGun Basic 3.0

Parameter Description
Part thickness offset The robot controller adds this value to the part thickness value sup-
plied by the weld timer.
Sequence:

1. The robot controller multiplies the value from the timer by the
scale factor.
2. The robot controller then adds the offset.
Default: 0.0
Part thickness toler- Where is the robot controller to obtain the value for the permissible
ance from weld tim- deviation in thickness? (Not relevant for tip dressing and background
er welding.)

• TRUE: from the weld timer (mm)

• FALSE: from the inline forms
For example, if the thickness is 2 mm and the permissible deviation is
1 mm, then the total thickness may lie between 1 and 3 mm.
Part thickness toler- Scale factor for the part thickness tolerance
ance correction fac-
The robot controller always interprets the values as values in mm.
tor
The scale factor enables the values supplied by the weld timer to be
appropriately converted if this is necessary.
The value of the scale factor depends on the transmission width of
the signal, the scale factor of the weld timer, and the unit for values
in the weld timer.
Default: 1
Part thickness toler- The robot controller adds this value to the part thickness tolerance
ance offset value supplied by the weld timer.
Sequence:

1. The robot controller multiplies the value from the timer by the
scale factor.
2. The robot controller then adds the offset.
Default: 0.0
Weld time from weld Where is the robot controller to obtain the value for the dressing
timer time?

• TRUE: from the weld timer

• FALSE: from the inline form TippDress
Note: This parameter does not determine where the robot controller
obtains the value for the weld time! The weld time must always be
obtained from the timer.
If KUKA.ServoGun Basic is used with KUKA.RoboSpin, this parame-
ter has an additional meaning.
Parameters for KUKA.ServoGun Basic used with KUKA.RoboSpin:

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Start-up and configuration

Parameter Description
Weld time from weld Where is the spin time to be obtained?
timer
• FALSE: must be specified via the inline form with Spin time.
• TRUE: in the inline form, the entry Source of spin time can be
used to select where the spin time is to be obtained – either from
the inline form or from the weld controller.
In the latter case, the robot controller obtains the value for the du-
ration of the welding process (ms) from the weld controller. An off-
set is added to this value. This results in the spin time.
Note: Detailed information can be found in the KUKA.RoboSpin docu-
mentation.
Weld time correc- Scale factor for the weld time
tion factor
The robot controller always interprets the values as values in ms. The
scale factor enables the values supplied by the weld timer to be ap-
propriately converted if this is necessary.
The value of the scale factor depends on the transmission width of
the signal, the scale factor of the weld timer, and the unit for values
in the weld timer.
Default: 1
Weld time offset The robot controller adds this value to the weld time value supplied
by the weld timer.
Sequence:

1. The robot controller multiplies the value from the timer by the
scale factor.
2. The robot controller then adds the offset.
Default: 0.0

Limitations

The transmission of the values from the weld timer to the robot controller
takes time. In the following cases, this can mean that the robot controller
has to wait for the values and is therefore unable to approximate the gun
motions:
• With very small distances between points
• With a very small opening of the gun
In the following case it is not possible to obtain the values from the real
weld timer:
• The Test timer active option is selected under Weld timer in the Ser-
voGun configuration window.
In this case, the robot controller uses the values entered in the Servo-
Gun configuration window.

Weld program selection

These settings define how the weld program is to be selected by the

robot controller.

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Start-up and configuration KUKA.ServoGun Basic 3.0

Parameter Description
Point name The weld program is selected via the name of the weld spot.
Number of entities This box is only active if Point name is selected.
The user defines the point name in the inline forms for weld spots or
tip dressing points on the robot controller. The last x characters of the
name must be digits. The robot controller communicates these digits
to the weld timer as the program number.
The number of relevant final characters can be configured here in
Number of entities.

• 1 … 9
Program number The weld program is selected via a number. The number is specified
by the user in a separate box in the inline form.

Point name as program number

Example:
• The option Point name has been selected.
• Number of entities has been set to the value 7.
• The point name SG12345678 is now assigned in the inline form.
The robot controller communicates the last 7 characters (counting from
the right) to the weld timer as the program number: 2345678
These characters must be digits.
All characters located further to the left are irrelevant for the program
number; these may be digits or any other characters.

Weld timer-specific settings

The following options must be set in accordance with the weld timer used
and its communication test:
Parameter Description
Handshake program Depending on the weld timer used, either a valid program number is
number entered here for the communication test, or an invalid program num-
ber that the weld timer rejects as a communication test.
Handshake test val- If a valid program number is transferred using the parameter Hand-
ue shake program number, the force value returned by the weld timer
is compared with this value and must match it.
Specify the test value using the unit indicated.
Handshake factor Scale factor for the force value sent as a communication test.
The robot controller always interprets the force values as values in N.
The scale factor enables the values supplied by the weld timer to be
appropriately converted if this is necessary.
The value of the scale factor depends on the transmission width of
the signal, the scale factor of the weld timer, and the unit for values
in the weld timer.
Default: 1

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Start-up and configuration

Parameter Description
Handshake offset The robot controller adds this value to the force value supplied by the
weld timer.
Sequence:

1. The robot controller multiplies the value from the timer by the
scale factor.
2. The robot controller then adds the offset.
Default: 0.0
Further information about the options to be set: (>>> 6.2.1 "Catalog ele-
ments for weld timers" Page 31)

6.3.2 “Weld timer inputs/outputs” area

If a function is not to be used, set the corresponding input or output to

0.

Weld timer inputs:

Input Description
Weld error TRUE = Weld timer signals an error
FALSE = Weld timer signals no error
Weld timer ready Status of weld timer
TRUE = Weld timer ready
TRUE = Weld timer not ready
Program accepted Weld timer confirms program number. Dependent on the weld timer
used; not required for all timers.
TRUE = Confirmation
FALSE = No confirmation from the weld timer
Current flowing Weld current from the weld timer
TRUE = Current present
FALSE = No current present
Welding ended TRUE = End of weld reached
FALSE = End of weld not reached
Transformer temper- Monitoring of the temperature of the transformer on the gun
ature OK
TRUE = Transformer has normal operating temperature
FALSE = Transformer is overheating
Error from PLC TRUE = External error
FALSE = No external error
The following inputs only need to be configured if the corresponding options were selected in
Weld timer editor.
In this case, it is necessary to specify here the input range via which the robot controller re-
ceives the corresponding value from the weld timer.
Force Input range for the force values sent by the weld timer
Part thickness Input range for the thickness values sent by the weld timer
Part thickness toler- Input range for the values for the thickness tolerance sent by the
ance weld timer

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 KUKA.ServoGun Basic 3.0

The following input is only relevant if using KUKA.RoboSpin.

Start-up and configuration

Input Description
Duration of welding Input range for the values for the weld time sent by the weld timer
Weld timer outputs:
Output Description
Reset error Reset errors currently active in the weld timer.
TRUE = Reset the errors.
FALSE = Do not reset the errors.
Send new program When changing program numbers, transfer the new program number.
number Dependent on the weld timer used; not required for all timers.
TRUE = A new program number is sent.
FALSE = No new program number is sent.
Program number Address range for transfer of the program number. The bit width must
not exceed 32 bits.
with current flow Request to close the gun with the correct force and time, and with
the correct current
For this, the program number must also be programmed in the weld
timer with current flow.
TRUE = Request
FALSE = No request
Note: This output can be inverted. For this, activate the check box
next to Inverted Hot / Cold signal.
Weld start Start the welding process (also start of cycle)
TRUE = Weld start
FALSE = No weld start
Weld repeat Weld spot is started again after a fault without opening the gun and
closing it again.
The function must be supported by the weld timer.
TRUE = Repetition
FALSE = No repetition

6.4 Configuring the gun motor

Precondition

• ServoGun Basic is installed in WorkVisual.

• The option package ServoGun Basic has been added to the project.

Procedure

1. Expand the catalog ServoGun Basic on the Options tab in the Cata-
logs window. This contains the gun motors.
The gun motors contained in the catalog have been validated or ap-
proved by KUKA Deutschland GmbH. If a different motor is to be
used, it must first be validated by KUKA Deutschland GmbH.

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If the name does not contain any specification of the gun type, then
it does not matter which gun type the motor is combined with in re-
ality.

2. Drag the required motor into the Project structure window: into the
Hardware tab, onto the robot controller there.
3. If the gun is used as a stationary gun, continue directly with step 4.
If the gun is used on the robot flange, select the Geometry tab. Here,
drag the motor onto the Flange Base node of the robot.
(This defines the gun as a robot-guided gun and not a stationary gun.
It does not specify whether the gun is actually coupled, but merely
that coupling is possible.)
4. Double-click on the motor element in the tree structure. The Machine
data configuration editor is opened.
5. Edit the machine data as required.
Information about the individual machine data can be found in the
documentation Configuration of Kinematic Systems.

During gun configuration in WorkVisual, it may be necessary to tem-

porarily cancel the coupling of the axis motors in the drive configura-
tion. The coupling of the axes must not be canceled permanently.
(>>> 6.9 "Temporarily canceling axis coupling in the drive configura-
tion" Page 47)

6. Repeat steps 2 to 5 for all the required guns.

7. If more than one external axis (guns or other axes) is used, change
the axis numbers as appropriate:
a. In the Project structure window, on the Hardware tab, expand
every external axis element as far as possible.
The numbers of the external axes (E1, E2, etc.) are now dis-
played. The numbers are always arranged in ascending order from
top to bottom.
b. To assign an axis a different number, move the corresponding ele-
ment up or down using Drag&Drop.
8. Save the project.

6.5 Calling the ServoGun editor in WorkVisual

Description

The ServoGun editor is used to configure the ServoGun options and the
inputs/outputs.

Procedure

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. Make the desired settings.
4. Save the project.

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6.6 Configuring options and inputs/outputs for the gun in WorkVisual

6.6.1 “Gun settings” area

Global settings
Parameter Description
Displayed force unit Changes the indicated force unit at a global level:

• Newton (N)
• Kilonewton (kN)
• Pound-force (lbf)
Direction of the Whether the gun closes in the positive or negative direction of motion
closing gun is defined here.

• POSITIVE (default for KSS): “Plus” closes the gun.

• NEGATIVE (default for VSS): “Minus” closes the gun.
Important! The parameter Direction of the closing gun must be set
before further start-up steps are performed.
If Direction of the closing gun is later modified, all subsequent start-
up steps must be performed again. In the same way, ServoGun pro-
grams that have already been created must be created again.
(>>> 6.1 "Start-up and configuration – overview" Page 29)
External force sen- Must be selected if a KUKA CFS10 is configured.
sor active
(>>> 6.7 "Configuring the KUKA CFS10 (force gauge)" Page 45)

Settings for electrode shank wear

ServoGun Basic determines the wear of the electrode shanks every time
first initialization is carried out. It automatically corrects the gun position
and opening width in order to compensate for the wear.
A precondition for correct determination of the wear is that the value for
the total wear is reset after every shank change.

ServoGun Basic checks the values in the following order:

1. Wear that has occurred since the last first initialization
2. Total wear

Parameter Description
Max. shank wear Maximum permissible shank wear between two first initializations
per InitNew
Default: 1 mm
Message if the value is exceeded: Geometry check error: tips have
settled by {0} mm since the last check, limit value = {1} mm per tip
change!
Max. permitted wear Maximum permissible total shank wear
In other words, the wear since the last reset of the wear value. Or, if
resetting has not yet been carried out, since the initial first initializa-
tion.
Default: 3 mm
Message if the value is exceeded: Tips settled by {0} mm. Limit value
for tip settling is {1} mm!

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Parameter Description
Message type Are the messages to be generated if the values are exceeded and, if
so, as what type?

• No message (default): No messages are generated.

• Notify: Generate messages as notification messages
Notification messages have no effect on the robot motions or pro-
gram execution. They do not require acknowledgement.
• Acknowledge: Generate messages as acknowledgement messag-
es
In the case of a ServoGun acknowledgement message, the robot
stops. The robot can only be moved again after the message has
been acknowledged (by the user or the PLC).
Gun settings
Parameter Description
Weld timer index Select the weld timer that controls the weld gun.
Gun name Gun name to be displayed on the robot controller
Gun type • X gun
• C gun
Gun direction The working direction of the gun (TCP) must be specified here.

• -X (default), -Y, -Z, +X, +Y, +Z

The choice of X, Y or Z depends on the value defined in $TOOL_DI-
RECTION. The same value must be selected here.
The choice of plus or minus depends on the definition of the direction:

• Plus points in the direction of the fixed electrode, minus points in

the opposite direction: select Plus
• Minus points in the direction of the fixed electrode, plus points in
the opposite direction: select Minus
(>>> 6.12 "TCP calibration and tool direction" Page 50)
Compensation type • Air compensation/ Pneumatic: The gun position is corrected
pneumatically.
• No compensation: The gun position is corrected by means of
compensation motion by the robot.
• EqualizingTech: Must be selected if EqualizingTech is to be used
on the robot controller.
Maximum gun force Maximum force which may act on the gun. Checked globally for each
gun and not exceeded.
Max. positive force Determines the positive tolerance range for the force test.
deviation
(>>> 6.18.5 "Carrying out a force test" Page 63)
Default: 0.05 kN
Max. negative force Determines the negative tolerance range for the force test.
deviation
(>>> 6.18.5 "Carrying out a force test" Page 63)
Default: 0.1 kN

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Parameter Description
Initialization force The force with which the gun is closed during the first motion during
with new tips first initialization.
(>>> 6.21.1 "First initialization via status key" Page 69)
Note: Suitable values are values of 2 kN or higher.

• 1.2 kN … max. gun force

Default: 2 kN
Tip initialization The force with which the gun is closed during cyclical initialization.
force
(>>> 6.21.2 "Cyclical initialization via status key" Page 69)

• 1.2 kN … max. gun force

Default: 1.5 kN
Number of repeti- KSS:
tions after fault
Defines the default value for the box Maximum number of error re-
peats in the option window Servo gun parameters.
(>>> 7.11 "Option window “Servo gun parameters”" Page 95)
Default: 3
VSS:
Determines how often a weld spot can be repeated in the case of a
fault. The spot does not have to be repeated this many times; the
setting merely determines the maximum possible number of repeti-
tions.
Default: 3
Couplable Must be selected if the gun is managed by an automatic tool chang-
ing system.

• The setting does not couple or decouple the gun.

• The setting has nothing to do with whether or not the gun is gen-
erally couplable.
Background Only with stationary guns:
process active
• Enabling asynchronous tip dressing
• Enabling asynchronous welding
(>>> 8.4 "Programming background processes" Page 103)

• Inactive (default), Active

Burn-off control ac- • Active (default): The robot controller checks at the weld spot
tive whether the detected workpiece thickness corresponds to the ex-
pected thickness. If not, it generates the following message: Incor-
rect gun position; repeat point?
Expected thickness = workpiece thickness + thickness tolerance
• Inactive: No check.

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Parameter Description
Burn-off determina- Method for determining the tip burn-off:
tion type
• Ratio in %: The overall burn-off is calculated. The robot controller
assigns the burn-off to the two electrodes using a defined ratio.
(Default = 50:50).
The ratio can be configured using Burn-off ratio.
• Individual measurement: The overall burn-off is calculated. After
this, the burn-off is determined for the moving electrode. The
burn-off of the fixed electrode is derived from the difference.
Burn-off ratio The robot controller assigns the burn-off to the two electrodes using
this ratio. The value refers to the moving electrode.
Maximum tip wear Maximum permissible value of the tip burn-off (both tips together)

• 0 … 20 mm
X-compensation Activate/deactivate offset compensation
Only relevant for X • Inactive (default), Active
guns with oblique
electrode shanks This can also be configured on the robot controller.
X-compensation di- Select the determined compensation direction.
rection
• -X (default), -Y, -Z, +X, +Y, +Z
This can also be configured on the robot controller.
Flexion compensa- • Check box not active: flexion compensation is deactivated.
tion
• Check box active: flexion compensation is activated.
Only relevant for C Note: Compensation is not entirely synchronized with gun pres-
guns sure. In rare cases, it is possible that the workpiece is first moved
Asymmetric flexion slightly in one direction by the gun pressure and then in the other
compensation direction as the compensation starts to take effect.

Only relevant for X This can also be configured on the robot controller.
guns
Negative transmis- Specify here whether the gear ratio is negative. The ratio is depend-
sion ratio ent on the mechanical design of the gun. (Default: Inactive = positive
ratio)

• Either: Refer to the gun documentation for the gear ratio.

• Or: Leave the default setting Inactive.
Note: The actual sign of the ratio must be checked during start-up.
Depending on the result, it may subsequently be necessary to modify
the parameter here once again.

6.6.2 PLC input and output ranges

If certain options have not been activated under Gun settings, the corre-
sponding inputs/outputs are also deactivated and cannot be assigned.
If a function is not to be used, set the corresponding input or output to
0.

PLC inputs

Signals from the PLC to the robot controller:

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Input Description
Stop after end of Request for the robot to stop after welding
welding
TRUE = Request
FALSE = No request
Test run without Motion with/without closing
component
TRUE = Gun remains open at the weld spot
FALSE = Gun closes at the weld spot
On query, do not re- As standard, dialog messages must be responded to by the user.
peat point They can also be configured to receive their response from the PLC,
On query, repeat however.
point (>>> 6.22 "Having dialog messages answered by the PLC" Page 70)
For messages that have been configured to receive their response
from the PLC, the following applies:
These two inputs receive the response from the PLC. Whether or not
the spot is repeated depends on which input is TRUE.

• Both inputs must not be TRUE at the same time!

• If both inputs are FALSE, this means “no response”, and the mes-
sage remains in the message window.
Note: After the dialog message has been answered, the input must
be reset by the PLC for the program to be resumed!
Water monitor, sup- Monitoring of the cooling water volume at the gun intake
ply OK
TRUE = No alarm
FALSE = Alarm triggered
Water monitor, re- Monitoring of the cooling water volume at the gun outflow
turn OK
TRUE = No alarm
FALSE = Alarm triggered
External force sen- Input/output range for the KUKA CFS10
sor
Enter the inputs to which the KUKA CFS10 is mapped here.
(>>> 6.7 "Configuring the KUKA CFS10 (force gauge)" Page 45)

PLC outputs

Signals from the robot controller to the PLC:

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Output Description
Stop after end of Confirmation of the input Stop after end of welding
welding executed
TRUE = End of weld reached
FALSE = End of weld not yet reached
Query “Repeat As standard, dialog messages must be responded to by the user.
point” is active They can also be configured to receive their response from the PLC,
however.
(>>> 6.22 "Having dialog messages answered by the PLC" Page 70)
For messages that have been configured to receive their response
from the PLC, the following applies:
This output signals to the PLC when the message window displays a
message of this kind. The PLC can then send its answer.

• TRUE = Dialog message is present

• FALSE = No dialog message present
Note: The signal should be set for at least 1 second. For the robot to
resume motion, the signal must then be reset.
New electrodes re- Indicates whether the electrodes have reached the maximum permis-
quired sible burn-off.
TRUE = Maximum tip wear reached
FALSE = Maximum tip wear not yet reached
Wear measurement Indicates whether the burn-off is more than the tolerance value lower
exceeds tolerance than at the last measurement. In other words, indicates whether the
electrode tips have “grown”.
TRUE = Tips have “grown”.
FALSE = No detection that the tips have “grown”
Compensation cylin- Only effective for gun with pneumatic compensation: activate compen-
der 1 sator 1.
TRUE = Compensation activated
FALSE = Compensation deactivated
Compensation cylin- Only effective for gun with pneumatic compensation: activate compen-
der 2 sator 2.
TRUE = Compensation activated
FALSE = Compensation deactivated

6.7 Configuring the KUKA CFS10 (force gauge)

Description

The KUKA CFS10 can be connected to the RDC box of the robot via
EMD interface X32. It transfers its measurement data directly to the robot
controller via this interface.
The KUKA CFS10 must be configured in WorkVisual.

Precondition

• ServoGun Basic is installed in WorkVisual.

• The option package ServoGun Basic has been added to the project.
• The weld timer has been added to the project.

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Start-up and configuration KUKA.ServoGun Basic 3.0

• The gun has been added to the project.

Procedure

1. Set the robot controller to inactive in the Project structure window if

this is not already the case.
2. Expand the catalog ServoGun Basic on the Options tab in the Cata-
logs window.
3. Drag the entry External Force Sensor into the Project structure win-
dow: into the Hardware tab, onto the robot controller there.
4. The following message is displayed:
The device "{0}" contains additional information about field bus
configuration, signal connections and long texts. Should these al-
so be imported?
Confirm the message with Yes. The information is imported. (Takes a
few moments.)
5. The Adjust signal connections window opens.
If the signals to which the device is to be connected in accordance
with the default settings are already mapped in the project, this is
shown in the Current conflicts: area.
If necessary, adapt the signal connections.
Information on editing signal connections is contained in the Work-
Visual documentation.

6. Confirm the settings with OK in the Adjust signal connections win-

dow. The window closes.
7. Select the menu sequence Extras > Generate code. The code is
generated. Once this process is complete, the following occurs:
• The following message is displayed: The project <"{0}" V{1}>
has been compiled. The results can be seen in the file tree.
• The robot controller is set to active automatically.
• The I/O Mapping window opens.
8. In the I/O Mapping window:
• Open the KR C I/Os tab at the top left and select the Digital in-
puts element.
• Select the Field buses tab at the top right and select the Elec-
tronic Mastering Device (EMD) element.
(The KUKA CFS10 makes use of the EMD interface. As such, this
element must be selected.)
9. Check the connections of the KUKA CFS10 in the lower section of the
I/O Mapping window. It must correspond to what was entered at step
5.
If necessary, the connections can be modified again in the I/O Map-
ping window.
10. In the Project structure window, select the gun and click the Servo-

Gun Editor button: .

The ServoGun Editor opens.
11. Activate the check box External force sensor active in the Global
settings area.
12. In the External force sensor field of the PLC inputs area, check the
input range displayed: It must correspond to what is displayed in the I/
O Mapping window.

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If the input range needs to be modified again, repeat steps 8 to 12.
Modifying the input range in the ServoGun Editor will not suffice.

The KUKA CFS10 is now configured.

6.8 Adapting the velocity monitoring of the gun for T1

The gun moves in T1 at process velocity with asynchronous motions. De-

pendent on the gun and the specific application, this is either possible di-
rectly, or the parameter Maximum velocity T1 must be modified in the
safety configuration.
WARNING
Only alter the default value of Maximum velocity T1 if it is necessary
to do so. The safety recovery technician or safety maintenance techni-
cian must check whether and to what extent the value needs to be
modified in each specific application. He must also check whether the
modification makes additional safety measures necessary, e.g. installa-
tion of a gate lock.

WARNING
Following modifications to the Maximum velocity T1 parameter, the
new value must be checked. The new value must also be checked if it
is smaller than the previous value.
Information about the parameter Maximum velocity T1 and how to
check it can be found in the following documentation:
• KUKA System Software Operating and Programming Instructions for
System Integrators
Or: VW System Software Operating and Programming Instructions
for System Integrators
• WorkVisual

The safety controller monitors whether the maximum velocity in T1 re-

mains below the configured values even for axes which are configured as
couplable or grouped together in coupling groups.
To be able to alter the configured values for these axes, the coupling
must be temporarily canceled.
The coupling of the axes can be canceled and set again in WorkVisual.
Information about this can be found in the WorkVisual documentation.

The coupling of the axes must not be canceled permanently.

(>>> 6.9 "Temporarily canceling axis coupling in the drive configuration"
Page 47)

6.9 Temporarily canceling axis coupling in the drive configuration

During gun configuration in WorkVisual, it may be necessary to temporari-

ly cancel the coupling of the axis motors in the drive configuration. It is
important that the coupling is reactivated before (re-)starting operation.

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WARNING
Axis motors of servo guns must be coupled in the Drive configuration
editor during operation.
If the axis motor is not coupled, the gun cannot be uncoupled in the
software using the status keys. In the event of a collision, this can pre-
vent the required rescue measures. Death to persons, severe injuries or
damage to property may result.

Whether or not a motor is coupled in the Drive configuration editor can

be ascertained as follows:

Fig. 6-1: Motor is coupled

Coupled: Motor with frame and small chain icon at the bottom left-hand
side of the frame

Fig. 6-2: Motor is not coupled

Not coupled: Motor without frame and without chain icon

6.10 Exporting/importing the weld timer and gun configuration

6.10.1 Exporting and importing the WorkVisual configuration

Description

If, for example, multiple identical systems are to be configured, the Work-
Visual configuration of weld timers and guns can be exported as an XML
file and imported into another project.
The following configuration contents can be imported:
• Settings
• Inputs and outputs
• Machine Data (only for guns)
• Calibration data (only for guns)

Precondition

• The ServoGun Editor or Weld timer editor is open.

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Procedure

1. Click on Import/Export in the editor.

A dialog window is opened.
2. Select whether an import or export is to be carried out.
3. For an import, select an XML file.
For an export, either select an existing file to be overwritten or assign
a new file name.
4. In the next dialog window, select which parts of the configuration are
to be imported.
In the case of an export, everything is automatically exported.
5. In the next dialog window, check whether all parts of the configuration
can be imported successfully.
If any part cannot be imported completely, it will not be imported at all
(not even partially). The other parts are not affected by this.
6. Complete the import/export with Finish.
The import/export is not carried out until the dialog has been comple-
ted.
If any part cannot be imported, the entire import can be reset with
Cancel.

6.10.2 Exporting and importing the configuration on the robot controller

Precondition

• User rights: Function group Configuration of the technology pack-

ages
• T1 mode
• No program is selected.

Procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. At the bottom of the page, select Import/Export.
3. Select the gun or the weld timer to import/export the configuration.
4. To export: Press Export.
The export file is created in the directory C:\KRC\ROBOTER\LOG.
5. To import: Select Import and then a valid XML file.
6. To import: Select which parts of the configuration are to be imported:
• Settings
• Inputs and outputs
• Machine data
• Calibration
7. Press Execute.

6.11 Checking the sign of the gear ratio of the gun

Description

It is necessary to check whether the parameter Negative transmission

ratio is set correctly in WorkVisual.

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Precondition

• T1 mode
• The project has been configured in WorkVisual and is active on the ro-
bot controller.
• The current setting of the parameter Direction of the closing gun is
known.

Procedure

1. Refer to the table below.

2. Move the gun with the Plus key and observe whether it opens or
closes.
3. If the result of the check is that the parameter Negative transmission
ratio is not set correctly:
Modify the parameter in WorkVisual and redeploy the project to the ro-
bot controller and activate it.

The parameter Direction of the closing gun must not be modified in-
stead of Negative transmission ratio.
The ratio is dependent on the mechanical design of the gun. The result
of the check would then, once again, be that the setting of Negative
transmission ratio does not correspond to the mechanical system.

Parameter “Direction of the Move the gun with the Plus

Result
closing gun”? key > Reaction?
Negative Gun opens OK
Gun closes Not OK
Parameter Negative trans-
mission ratio must be
changed.
Positive Gun closes OK
Gun opens Not OK
Parameter Negative trans-
mission ratio must be
changed.

6.12 TCP calibration and tool direction

• When calibrating the servo gun, the TCP must always be positioned
on the fixed electrode.
• Recommendation: Define the tool direction as shown in the illustra-
tion (>>> Fig. 6-3):
‒ Plus points in the direction of the fixed electrode.
‒ Minus points in the opposite direction from the fixed electrode.
• The direction defined must then be entered as the parameter Gun di-
rection under Gun settings in the ServoGun editor in WorkVisual.

Information about calibration and definition of the tool direction is con-

tained in the operating and programming instructions for the KUKA Sys-
tem Software (KSS).

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Fig. 6-3: TCP and tool direction

6.13 Calling the start-up wizard on the robot controller

Description

A wizard is available for the start-up steps that are carried out on the ro-
bot.

Precondition

• User rights: Function group Configuration of the technology pack-

ages

Procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. Under Gun selection, select the gun that is to be configured.
The gun parameters already configured in WorkVisual are displayed.
3. Press Wizard.
The window for the first configuration step opens.
4. Use the Next arrow key to follow the wizard through the configuration
windows.
The data are automatically saved at every change of page.
5. Terminate the wizard with Finish.
If the wizard is not terminated with Finish, all changes except the
mastering are discarded.
6. Repeat steps 2 to 5 for each gun.

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Fig. 6-4: Gun configuration with wizard

Item Description
1 Status of the configuration step

• Gray: The configuration step has not yet been completed

successfully. It is not possible to continue with the next
page.
• Green: The configuration step has been completed success-
fully. Continue configuration with the next page.
2 Available option
3 This option is currently disabled, as not all conditions have
been met (e.g. steps to be performed first on the same page).
4 Direct selection of enabled configuration windows
5 Navigation bar with:

• Progress bar
• Back and Next arrow keys
• Direct selection of enabled configuration windows

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6.14 Gun mastering

Description

A gun must be mastered in the following cases:

• Commissioning a gun (first mastering)
• After exchanging gun components
• After a loss of mastering
Mastering can be performed automatically or manually. Recommendation:
If possible, carry out automatic mastering because of the better reproduci-
bility. Manual mastering is suitable if mastering has to be carried out with
a program selected.

Precondition

• T1 mode
• New electrode tips
• Only for automatic mastering: no program selected.
Instead of new electrode tips: it is also possible to perform the mastering
with a spacer, e.g. a feeler gauge. The distance must be adjusted in such
a way that it corresponds to the current wear of the electrode shanks.
Ensure that tips are fitted correctly. No automatic pressing-in motion is
carried out.

NOTICE
Used electrodes must not be used in this case, as this would result in
an incorrect mastering value. This could damage the gun.

Procedure

Automatic mastering
1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select the gun that is to be mastered.
3. Select Mastering. A new window opens.
4. Press and hold down the enabling switch.
5. Press Automatic mastering.
The gun is moved to the zero position and automatically mastered.
Manual mastering
1. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
2. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
3. Select the gun that is to be mastered.
4. Select Mastering. A new window opens.

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5. Press Mastering.

6.15 Determining the gear ratio of the gun

Precondition

• The gun is mastered.

• Operating mode T1

Procedure for X guns

The gear ratio is the change in the opening width over 1 motor revolution.
1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Gun data.
3. Open the gun manually until the distance between the electrodes can
be measured easily.
4. Measure the distance between the electrodes.
5. Enter the distance in the Opening width box and save it.
The robot controller automatically calculates the gear ratio of the gun
from Opening width and Actual position E and indicates it in the
Transmission ratio box.
Plausibility test:
1. In the main menu, select Display > Actual position. Then select the
Axis-specific view.
2. Check whether the position values displayed for the relevant gun cor-
respond to the gear ratio calculated by the robot controller. It is not an
exact mathematical match that is required here: the objective here is
to test the plausibility.
3. If the values are not plausible, check the entry under Opening width.
An incorrect value may inadvertently have been entered here, e.g. 100
instead of 10.

NOTICE
An incorrect gear ratio can lead to collisions of the gun or other damage
to property. It is thus recommended that the plausibility test be carried
out in all cases.

Procedure for C guns

The gear ratio generally corresponds to the screw pitch of the spindle.
1. Consult the gun manufacturer’s data sheet to find out the value for the
screw pitch of spindle.
2. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
3. Select Gun data.
4. Enter and save the value in the Screw pitch of spindle box.
If no value for the spindle screw pitch is available from the manufacturer,
the gear ratio can be determined manually:
1. Close the gun without exerting any force.
2. In the main menu, select Display > Actual position. The Cartesian
actual position is displayed.

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3. Press Axis-specific to display the axis-specific actual position. The
gun position is displayed as 0 in the Motor [deg] column.
4. Open the gun manually until the value 360 is displayed in the Motor
[deg] column.
5. Measure the distance between the electrodes.
6. Enter and save the value in the Screw pitch of spindle box on the
Gun data page in the ServoGun configuration window.

If the opening width of the gun is not large enough to be measured af-
ter one motor revolution, open the gun 2 or 3 motor revolutions before
taking the measurement. Then divide the measured distance by the
number of revolutions.

6.16 Setting the software limit switches

The software limit switches for opening and closing of the gun (external
axis) must be set. This limits the stroke of the gun.

6.16.1 Setting the limit switch for opening of the gun

Precondition

• User rights: Function group Configuration of the technology pack-

ages
• Gun is mastered
• Gun data have been entered.
• New electrode tips

NOTICE
Do not open the gun all the way. If in doubt, stop a little earlier. Dam-
age to property may otherwise result.

Procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. Select Software limit switches.
3. Set the value for the maximum opening width:
a. Open the gun until it is almost completely open.
b. Apply the Actual position to the Maximum opening width box
with Save actual position.
c. Adapt the value if required: Value sought = value of Actual posi-
tion variable + reserve (recommended: magnitude of 2 motor rev-
olutions)
4. Save the page.

Alternative procedure

1. Take the value from the gun data sheet, and enter and save it under
Maximum opening width on the Software limit switches page in
the ServoGun configuration window.
2. Check that the value is correct.
• To do this, open the gun manually and observe whether it stops
automatically at the point corresponding to the entered value, be-
fore reaching the stop.

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• If the gun does not stop automatically, stop manual motion before
the stop is reached. The value from the data sheet is not correct.
The maximum opening width must be set as described in the first
procedure.

6.16.2 Setting the limit switch for closing of the gun

Precondition

• User rights: Function group Configuration of the technology pack-

ages
• Gun is mastered
• Gun data have been entered.
• New electrode tips

Preparation

Determine the value for the maximum flexion of the gun.

• Either: Refer to the gun data sheet for the maximum flexion.
• Or: Determine the maximum gun flexion during force calibration.
(>>> 6.18.1 "Precalibration – determining the calibration positions"
Page 58)

Procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. Select Software limit switches.
3. Enter the determined value under Gun closing with maximum flex-
ion.
4. Save.

NOTICE
Do not close the gun with maximum flexion for test purposes. Material
damage to the gun may otherwise result.

6.17 Determining the thickness of the force gauge

Description

For correct calibration of a gun, the robot controller needs to know the
thickness of the sensor plate on the force gauge used. The following
methods can be used for determining the thickness and communicating it
to the robot controller:
• Determine the thickness manually and enter the value in the configu-
ration.
• Determine the thickness by closing the gun.

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Fig. 6-5: Measuring with the force gauge (example)

Accessories

• KUKA CFS10
• Or a different force gauge
(if necessary, consult gun manufacturer for a suitable model)

Precondition

• The gun is mastered.

• Operating mode T1

Procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. Call the Force gauge data page and enter the force gauge thickness
determined manually.
Or:
3. Set the jog override to 3%.
4. Close the gun until the moving electrode just touches the sensor plate.
5. Apply the Actual position as the force gauge thickness with Save ac-
tual position.

Alternative procedure

1. In the main menu, select Configuration > ServoGun.

The ServoGun configuration window opens.
2. Select Force gauge data.
3. Open the gun manually.
4. Place the force gauge on the fixed electrode.
5. Press enabling switch.
6. Select Automatic determination of the force gauge thickness.
7. Release the enabling switch, then press it and hold it down again. If
the KUKA CFS10 is being used, pressing again is not necessary.

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The gun is moved. Once the force gauge has been detected and cali-
Start-up and configuration

brated, the gun is moved back to its original position.

6.18 Calibration – overview

NOTICE
Calibration must be performed on the same system on which the gun is
subsequently operated. If calibration is carried out on a different system,
if the system is modified after calibration, or if a necessary step is left
out, the results could be failure to weld, faulty welding and/or damage to
property.

The accuracy that can be achieved during calibration depends on the

specific gun and motor.

Overview

Step Description
1 Precalibration
Defines the calibration positions.
2 Coarse calibration
The calibration positions are addressed and the correspond-
ing forces are measured.
3 Fine calibration
Each of the target forces determined during coarse calibra-
tion is addressed. The actual force is recorded.
4 Force test
Move the gun to defined setpoint forces and measure the
resulting actual forces.
5 Necessary if the force test results in too high a deviation
between the setpoint and actual force values:

• Repeat fine calibration

Tip for standard operation: If the gun does not always reach the precise
required force after a certain period of time, then the gun needs to un-
dergo fine calibration again (= recalibration). Depending on the required
force accuracy, the customer must establish an appropriate recalibration
schedule.

6.18.1 Precalibration – determining the calibration positions

Description

The flexion defines the ratio between the travel and the force [mm/kN] of
the gun.
The calibration positions for coarse calibration are determined automatical-
ly in accordance with the maximum flexion.

Accessories

• KUKA CFS10
• Or a different force gauge
(if necessary, consult gun manufacturer for a suitable model)

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Precondition

• User rights: function group Configuration of the technology pack-

ages
• The gun is mastered.
• The electrode tips are firmly pressed on.
• The gear ratio has been entered.
• The thickness of the force gauge has been entered.
• The maximum gun force is known (see data sheet from the gun man-
ufacturer)
• T1 mode

Procedure

Determination using maximum flexion

1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Precalibration.
3. Select the Flexion radio button.
4. Enter the maximum gun flexion (source: gun manufacturer) under De-
termination using max. flexion and press Calculate.
The 5 calibration positions are calculated and entered under Calibra-
tion positions.
5. Exit the Precalibration page. The values are saved automatically.
Determination using actual position
1. Select the Precalibration page in the ServoGun configuration win-
dow.
2. Select the Actual position radio button.
3. Place the force gauge on the fixed electrode.
4. Close the gun with at least 40% of the maximum force.
5. Enter the force displayed on the force gauge in the box under Deter-
mination using actual position.
6. Have the calibration positions calculated using Save actual position.
With this procedure, the calibration positions are calculated using the
actual position of the gun and the corresponding force.
7. Exit the Precalibration page. The values are saved automatically.

If the calibration positions are modified after start-up, the corresponding

forces must be determined again under Coarse calibration.

6.18.2 Description of coarse calibration

The gun is closed under position control.

The calibration determines the relationship between the gun flexion and
the forces on the force gauge (kN).
Gun flexion characteristic:
In 5 measurements, 5 flexion/force pairs are determined. The flexion/force
pairs are saved and added to the flexion/force characteristic of the gun,
with interpolation of the intermediate values.

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Fig. 6-6: Gun flexion characteristic

G Gun flexion (mm)

F Forces measured with the force gauge (kN)

6.18.3 Performing coarse calibration

WARNING
During calibration, the gun closes at process velocity, not at reduced ve-
locity.

Accessories

• KUKA CFS10
• Or a different force gauge
(if necessary, consult gun manufacturer for a suitable model)

Precondition

• The gun is mastered.

• The gear ratio has been entered.
• The thickness of the force gauge has been entered.
• The maximum gun force is known.
• Calibration positions have been entered.
• New electrode tips
• User rights: function group Configuration of the technology pack-
ages
• T1 or T2 mode

WARNING
For calibration in T2, no force gauge may be used that requires the op-
erator to be present in the safeguarded area during operation. There
must be no persons inside the safeguarded area during operation in T2
mode. Death to persons or severe injuries may otherwise result.
A suitable force gauge for calibration in T2 is the KUKA CFS10, for ex-
ample.

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Procedure

Procedure with KUKA CFS10:

1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Coarse calibration.
3. Attach KUKA CFS10.
4. Press and hold down the enabling switch.
5. Press Start measurement next to the display of the first calibration
position. The following occurs:
a. The gun closes until the calibration position is reached.
b. The force value is automatically entered in the Actual force box.
c. The gun moves back to the starting position.
6. Repeat the operation for each of the other 4 calibration points.
7. Exit the Coarse calibration page. The values are saved automatically.
Procedure with a different force gauge:
1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Coarse calibration.
3. Press and hold down the enabling switch.
4. Press Start measurement next to the display of the first calibration
position.
The following message is displayed: Please release the enabling
switch. After confirmation of the dialog and repeated pressing of
the enabling switch, the robot moves the selected gun.
5. Confirm the message with OK.
The following message is displayed: Measurement is running...
6. Release the enabling switch.
7. Hold the force gauge in the gun.
8. Press the enabling switch again and hold it down.
The gun now closes automatically until the target force has been
reached and remains closed for approx. 2 s.
9. While the gun is closed: read the force value.
Once the 2 s have elapsed, the gun opens to the starting position
again.
10. Enter the force value in the Actual force box with the unit indicated.
11. Repeat the operation for each of the other 4 calibration points.
12. Exit the Coarse calibration page. The values are saved automatically.

NOTICE
If it becomes apparent during the measuring process that the maximum
gun force will be exceeded at the next measuring step, do not start the
next measurement! Force gauge and/or gun may otherwise be dam-
aged.
The calibration positions must be determined under Precalibration in
the ServoGun configuration window.

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The measured values should cover the force range of the gun. If the
values are too low, higher values must be entered at the following
place: In the ServoGun configuration window under Precalibration.
Then restart the coarse calibration.
The force range is dependent on the gun. Guide values:
• Force 1 in kN: about 1.2 kN
• Force 5 in kN: Maximum force

6.18.4 Performing fine calibration (recalibration)

Description

During fine calibration, each of the 5 target forces determined during

coarse calibration is addressed and the actual force recorded.
WARNING
During calibration, the gun closes at process velocity, not at reduced ve-
locity.

Accessories

• KUKA CFS10
• Or a different force gauge
(if necessary, consult gun manufacturer for a suitable model)

Precondition

• The gun is mastered.

• The gear ratio has been entered.
• The thickness of the force gauge has been entered.
• The maximum gun force is known.
• Calibration positions have been entered.
• Coarse calibration has been carried out.
• New electrode tips
(Only required for start-up. Not required if fine calibration is carried out
separately during standard operation.)
• User rights: function group Configuration of the technology pack-
ages
• T1 or T2 mode

WARNING
For calibration in T2, no force gauge may be used that requires the op-
erator to be present in the safeguarded area during operation. There
must be no persons inside the safeguarded area during operation in T2
mode. Death to persons or severe injuries may otherwise result.
A suitable force gauge for calibration in T2 is the KUKA CFS10, for ex-
ample.

Procedure

Procedure with KUKA CFS10:

1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Recalibration.
3. Attach KUKA CFS10.

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4. Press and hold down the enabling switch.
5. Press Start measurement next to the display of the first target force.
a. A message indicates that the gun will close after confirmation.
Confirm the message.
b. The gun closes until the target force is reached.
c. The force value is automatically entered in the Actual force box.
If necessary, the gun may close up to 5 times for this purpose.
d. The gun moves back to the starting position.
6. Repeat the operation for each of the other 4 calibration points.
7. Exit the Recalibration page. The values are saved automatically.
Procedure with a different force gauge:
1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Recalibration.
3. If required: modify the values in the Target force column.
The Target force column contains the forces determined during
coarse calibration. If required, the user can manually modify individual
values or all of these values.
If the Actual force column already contains values: modifying a Tar-
get force value automatically deletes the corresponding Actual force
value and all subsequent ones, as they are now no longer valid.
4. Press and hold down the enabling switch.
5. Press Start measurement next to the display of the first target force.
The following message is displayed: Please release the enabling
switch. After confirmation of the dialog and repeated pressing of
the enabling switch, the robot moves the selected gun.
6. Confirm the message with OK.
The following message is displayed: Measurement is running...
7. Release the enabling switch.
8. Hold the force gauge in the gun.
9. Press the enabling switch again and hold it down.
The gun now closes automatically until the target force has been
reached and remains closed for approx. 2 s.
10. While the gun is closed: read the force value.
Once the 2 s have elapsed, the gun opens to the starting position
again.
11. Enter the force value in the Actual force box with the unit indicated.
12. Repeat the operation for each of the other 4 calibration points.
13. Exit the Recalibration page. The values are saved automatically.

6.18.5 Carrying out a force test

Description

The force test is used to check the force characteristic. A force sensor is
placed in the gun. The user selects the force with which the gun is to be
closed. The actual force on the gun can then be read off on the force
gauge.
The values indicated under Tolerances are the values entered in WorkVi-
sual under Max. positive force deviation and Max. negative force devi-
ation. The values can be changed.

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Accessories

• KUKA CFS10
• Or a different force gauge
(if necessary, consult gun manufacturer for a suitable model)

Precondition

• User rights: function group Configuration of the technology pack-

ages
• For individual selection of the forces: T1 mode
• For group selection via All forces:
‒ KUKA CFS10
‒ T1 or AUT mode

WARNING
For the force test in AUT, no force gauge may be used that requires the
operator to be present in the safeguarded area during operation. There
must be no persons inside the safeguarded area during operation in
AUT mode. Death to persons or severe injuries may otherwise result.
A suitable force gauge for the force test is the KUKA CFS10, for exam-
ple.

Procedure

1. In the main menu, select Configuration > ServoGun. The ServoGun

configuration window opens.
2. Open the Force test page.
3. If required, adapt the tolerance range with Upper limit and Lower
limit.
4. In the Measurements box, enter how many measurements are to be
carried out for each force.
5. Connect the KUKA CFS10 or place the force gauge on the fixed elec-
trode.
6. Press enabling switch.
7. Start the measurements:
• Either by selecting them individually: in which case, start with the
lowest force.
• Or using All forces (only possible with KUKA CFS10)
The gun closes.
8. Measure the actual force with the force gauge and note it down.
If a KUKA CFS10 is connected, the actual forces are recorded auto-
matically.
NOTICE
If the measured force is significantly higher than the selected force,
cancel the force test without performing any further measurements,
and carry out fine calibration. This also applies to the following
steps. Further measurements may cause damage to property.

9. In the case of individual selection: Repeat steps 6 to 8 for the desired

forces, taking the next force up in each case.
10. If a KUKA CFS10 is connected, the diagram with the force character-
istic curve now shows the determined forces.

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11. If the actual force values deviate too greatly from the setpoint values,
carry out fine calibration again.

“Force test” page

Fig. 6-7: Force test

Item Description
1 Setpoint force/actual force diagram (only for KUKA CFS10)
2 Measurement point outside tolerance range (red)
3 Measurement point inside tolerance range (green)
4 Number of measurements to be carried out for each selected force

• 1 … 10
5 Group selection (only for KUKA CFS10):
All forces starts a series of measurements with the forces indicated under Item
6, starting with the lowest force.
Each individual force is applied the number of times entered under Measure-
ments, e.g. 10 times. The next force up is then applied 10 times, etc.
6 Individual selection:
Setpoint forces that can be applied. The lowest force is always 1,200 N. The oth-
er forces depend on the force range of the gun and cover this range evenly.
The selected force is applied the number of times entered under Measurements.

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Item Description
7 Tolerances
8 Display of the most recently measured force (in the illustration 0 N)
9 Generates a file ForceTest[…] .txt in the path C:\KRC\ROBOTER\LOG. The file
name contains the gun name and the date and time the file was saved.

• The file contains the results of the current tests. These are tests that have
been conducted since the last time the Force test page was opened. A maxi-
mum of 10 results are specified per setpoint force.
Format (example):
Test 3: 1800N : 1796; N
• Under certain circumstances, the file may also contain the results of old tests.
Old results can be recognized by the following format:
Test 3: 1800N 1796N
If Export log file is actuated and no tests, or not all tests, have yet been con-
ducted again since the last time the Force test page was opened, the results
of old tests are displayed in this case. These are not necessarily the most re-
cent results.
• If no force test has ever yet been performed, the value “0” is specified in the
file.

6.19 Determining and compensating for the asymmetrical flexion of X guns

Description

With X guns, it is possible that the fixed and moving gun arms may have
different flexion rates when the gun is closed under force. This means that
the point at which welding is carried out no longer corresponds to the
taught point. So that the software can compensate for this, the difference
must be measured and entered in the configuration.

Precondition

• The gun is calibrated.

• New electrode tips are fitted on the gun.
• Means of marking the position of the closing point
• Operating mode T1

Procedure

1. Close the gun manually. Do not exert any force when doing so.
2. Mark the position of the closing point.
3. Close the gun with maximum force via the inline form Close gun.
4. Measure how far the closing point has moved from the mark.
5. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
6. Call the Compensation page.
7. Asymmetr. flexion compensation box: If required, activate or deacti-
vate compensation here using the check box Asymmetr. comp..
8. If the compensation has been switched on: Enter the determined value
in the Asymmetric flexion distance box.

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Example

Fig. 6-8: Example: without force – with force

Item Description
1 Closed electrodes, without force
2 Moving electrode
3 Mark
The mark is at the same height as the closing point.
4 Closed electrodes, now with force
In this example, the closing point has shifted in the negative
TCP direction due to the application of the force.
5 Caliper gauge
The caliper gauge is used to measure the difference between
the mark and the current height of the closing point.

6.20 Determining and compensating for the sliding effect with X guns

The sliding effect can be determined for X guns with oblique electrode
shanks. This effect does not normally occur with C guns.

Description

On X guns with oblique electrode shanks, the electrodes can shift when
the gun is closed under force. This means that the point at which welding
is carried out no longer corresponds to the taught point. So that the soft-
ware can compensate for this, the difference must be measured and en-
tered in the configuration.

Precondition

• The gun is calibrated.

• New electrode tips are fitted on the gun.
• Means of marking the position of the closing point
• Operating mode T1

Procedure

1. Close the gun manually. Do not exert any force when doing so.
2. Mark the position of the closing point.
3. Close the gun with maximum force via the inline form Close gun.
4. Measure how far the closing point has moved from the mark.

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In addition, note the direction in which it has moved (relative to the

Start-up and configuration

TOOL coordinate system).

5. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
6. Call the Compensation page.
7. Activate or deactivate compensation, as required, in the X-compensa-
tion box.
8. With the X-compensation box active, select and enter the calculated
values for X-compensation direction and X-compensation distance.

Example

Fig. 6-9: Sliding effect with X guns: example without force – with
force

Item Description
1 Direction of offset
2 Compensation direction
The compensation direction is the direction that is relevant for
the parameter X-compensation direction.

6.21 Tip initialization – overview

During tip initialization, the current electrode burn-off is measured and

saved. This enables the gun opening to be automatically adapted to the
burn-off.
Initialization can be carried out in the following ways:
• By status key
• In the program
There are 2 types of tip initialization:
First initialization
Must be carried out in the following cases:
• During commissioning
• Every time the electrode tips are exchanged
Cyclical initialization
• Cyclical initialization must be carried out after tip dressing.

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6.21.1 First initialization via status key

Precondition

• T1 or T2 mode
• The gun is mastered.
• The gun is calibrated.
• New electrode tips are fitted on the gun.
• The initialization force has been configured in WorkVisual.

Procedure

1. Set program override to 100%.

2. Open the gun manually at least 40 mm.
3. Press and hold down the enabling switch.
4. Press the status key First initialization. First initialization is per-
formed:

Sequence

With this first initialization, the following occurs:

• The gun closes at a constant velocity until the first initialization force is
reached. The electrode tips are pressed firmly onto the electrodes.
• The gun opens.
• The gun closes with initialization force.
• The robot controller reinitializes the tip wear.

6.21.2 Cyclical initialization via status key

Precondition

• T1 or T2 mode
• The gun is mastered.
• The gun is calibrated.
• First initialization has been performed.

Procedure

1. Set program override to 100%.

2. Open the gun manually at least 40 mm.
3. Press and hold down the enabling switch.
4. Press the Cyclical initialization status key. Cyclical initialization is
carried out.

Procedure

With this cyclical initialization, the following occurs:

• The gun closes with initialization force.
• The robot controller saves the current tip wear in SG_WEAR[].
The controller generates a message if the current wear is greater than
the maximum permissible wear ServoGun[].WearMax and sets the out-

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 KUKA.ServoGun Basic 3.0

put New electrodes required. The electrode tips must then be ex-
Start-up and configuration

changed.
The controller generates a message if the current wear since the last
value is less than SG_WEARTOLERANCE[] and sets the output Wear
measurement exceeds tolerance.

6.22 Having dialog messages answered by the PLC

Description

As standard, dialog messages must be responded to by the user. They

can also be configured to receive their response from the PLC, however.
This can be defined for each dialog message.

Preconditions in WorkVisual

The following I/Os have been configured in the ServoGun editor:

• PLC inputs area:
On query, do not repeat point or On query, repeat point
• PLC outputs area:
Query “Repeat point” is active

From a technical perspective, the procedure below can also be carried out
without the I/Os being configured. They must then be configured subse-
quently. This requires transfer of the project to WorkVisual and back to the
controller.

Preconditions on the robot controller:

• User group “Expert”

• No program is selected.

Procedure

1. In the Navigator, open the following file in the directory KRC:\R1\TP

\ServoGun\Userfiles.
• SG_UserSRErrorToQuit.dat
The file contains a list of variables. These represent the dialog mes-
sages that can be answered by the PLC.
As standard, all variables are set to FALSE.
2. For the dialog messages that are to be answered by the PLC, set the
corresponding variable to TRUE. Example:

GLOBAL BOOL SG_NoEnablingDev_PLC=TRUE

3. Close the file. Respond to the request for confirmation asking whether
the changes should be saved by pressing Yes.

6.23 Linking error messages to outputs

Description

Numerous error messages can be assigned outputs. This option can be

used to provide the PLC with more detailed information about the current
error.

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The robot controller sets the output when it generates the message. When

Start-up and configuration

the message is acknowledged or answered (by the user or by the PLC),
the robot controller resets the output.

Precondition

• “Expert” user group

• No program is selected.

Procedure

1. In the Navigator, open the following file in the directory KRC:\R1\TP

\ServoGun\Userfiles.
• SG_UserSRErrorToQuit.src
The file contains the branch SWITCH MsgNumber … ENDSWITCH.
This contains CASES/statement blocks for the different error messag-
es. The CASE numbers correspond to the message numbers.
2. For the messages that require it, enter the desired output in the corre-
sponding CASE.
3. Close the file. Respond to the request for confirmation asking whether
the changes should be saved by pressing Yes.

Example 1

Link message 103 “MSG NoReCalibration” to output 112

1st option:

CASE 103 ; MSG NoReCalibration

SGL_SetOut (112, valueOut)

2nd option (= alternative):

CASE 103 ; MSG NoReCalibration

$OUT[112] = valueOut

Example 2

Link message 116 “DLG ForceLowerForceLim” to output 111

1st option:

CASE 101,116 ; MSG ForceLowerForceLim

; DLG ForceLowerForceLim
SGL_SetOut (111, valueOut)

2nd option (= alternative):

CASE 101,116 ; MSG ForceLowerForceLim

; DLG ForceLowerForceLim
$OUT[111] = valueOut

In this example, the robot controller only sets the output for message 116,
but not for message 101. Message 101 is a notification message; mes-
sages of this category cannot be linked to outputs, i.e. the entry in CASE
101,116 affects “DLG ForceLowerForceLim”, but not “MSG ForceLower-
ForceLim”.
The following applies for SG_UserSRErrorToQuit.src: Notification messag-
es are the messages that are listed together with a dialog message of the
same name (keyword: DLG) in a CASE.

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Start-up and configuration KUKA.ServoGun Basic 3.0

6.24 Hybrid mode – re-application of pressure in the case of air gaps, incor-
rectly positioned point, etc.

Description

Air or adhesive between the workpieces can prevent the gun from reach-
ing its target force. This can also be caused by incorrectly taught points.
The “Hybrid mode” functionality ensures that the guns are gradually
closed further in such cases in order to reach the target force.
Hybrid mode has an effect in the following cases:
• Weld spots
• Close gun without welding
Hybrid mode has no effect in the following cases:
• Tip dressing
• Background processes
The functionality is activated as standard.
Hybrid mode may lead to cycle time losses.

Activation/deactivation

The functionality is activated if both variables are TRUE.

Variable Description
SG_TorqueCloseActive Default = TRUE
SG_TorqueCloseActiveUser Default = TRUE
The following variable governs the maximum torque at which the function-
ality, if enabled, actually becomes active:
Variable
SG_TorqMonLow_Percent
Description
Default = 50%
Example:
The value “30” means:
If the actual torque falls short of the target torque by 30% or more, the
functionality becomes active. In other words, if less than 70% of the tar-
get torque has been reached, pressure is re-applied.
If, on the other hand, at least 70% of the target torque has been
reached, the functionality does NOT become active. In this case, pres-
sure is not re-applied.
The variable can be modified via the variable correction function or KRL.

6.25 Controller parameters – overview

Description

The controller tool can be used to determine and optimize the motor-spe-
cific and gun-specific controller parameters for PTP and CP motions.
The parameters must be determined in the following order:

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Start-up and configuration

Step Parameter/description
1 Proportional factor of the speed controller for PTP and CP
motions
VEL GAIN (Speed controller gain)
2 Integration time constant of the speed controller for PTP
and CP motions
VEL INT TIME (Reset time of speed controller)
3 Position controller gain for PTP and CP motions
POS GAIN (Position controller gain)
4 Force controller gain for PTP and CP motions
FORCE GAIN (force controller gain)

Procedure

The controller tool calls up programs which execute a defined motion pro-
file cyclically with the active weld gun. At each program cycle, the param-
eter is increased by the defined increment (‘step size’), starting from the
lower limit and continuing until the upper limit is reached. The entire se-
quence for a parameter is recorded as a measurement curve (trace).
While the parameters for the speed and position controllers are being de-
termined, the active gun moves between a position before the maximum
opening and the mastering position.
If the controller parameters are modified on an already functioning, cali-
brated system, recalibrate the weld gun following the change. The result
could otherwise be that the welding forces attained are no longer suffi-
ciently accurate, or that incorrect tip wear is determined.

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Start-up and configuration KUKA.ServoGun Basic 3.0

6.25.1 ServoGun configuration window – SGControlView

Fig. 6-10: ServoGun configuration window – SGControlView

1 Table
2 Enter the determined parameters here.

Button Description
Motor param. Selects the program SG_SET_MOTOR_PAR-
AM. This program is used to determine the pa-
rameters for the speed and position controllers.
Force parameters Selects the program SG_SET_FORCE_PAR-
AM. This program is used to determine the pa-
rameters for the force controller.
Trace > [controller_pa- Opens the measurement curve for the selected
rameter] parameter.
Trace > AUTO For automatic transmission of the calculated
FORCE GAIN FORCE GAIN
(>>> 6.25.3 "Optimizing the parameters for the
force controller" Page 76)
Table > Load table Loads the default values for the following pa-
rameters: Lower limit, Upper limit, Steps
The default values depend on what is selected
in the following boxes: Motor type, Gun type,
Stiffness

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Start-up and configuration

Button Description
Table > Discard table Discards the current entries in the following
boxes: Lower limit, Upper limit, Steps. In-
stead, the most recently saved values are dis-
played.
Save table > […] Saves the values for Lower limit, Upper limit,
Steps.

• Save as default: sets default values for the

option Load table
• Save: saves the values for Lower limit,
Upper limit, Steps for the current gun.

6.25.2 Optimizing the parameters for the speed and position controllers

Precondition

• User rights: Function group Configuration of the technology pack-

ages
• The weld gun is fully configured.
• The software limit switches have been set.
• The weld gun is mastered.
• The gun has been calibrated.
• The gear ratio has been entered.
• T2 mode
• There is nothing between the electrode tips.
In other words, the force gauge has also been removed.

Procedure

1. In the main menu, select Configuration > ServoGun. The ServoGun

configuration window opens.
2. Select the gun to be configured. Then press Motor parameter at the
bottom.
The SGControlView opens.
(>>> 6.25.1 "ServoGun configuration window – SGControlView"
Page 74)
3. Check the following boxes and adapt it if necessary: Lower limit, Up-
per limit and Steps.
Not the boxes for the parameter FORCE GAIN, however!
4. Press button Motor param.. The program SG_SET_MOTOR_PARAM
is selected.
5. Switch to T2 if this has not already been done.
6. Set the program override to 100% and start the program.
If the program override is not set to 100%, the measurements will
be incorrect.

7. Execute the program through to the first “HALT”.

8. A message is displayed: Confirm with OK.
SGControlView is then displayed again.
9. Call the measurement curve for VEL GAIN using the Trace button.
10. On the measurement curve, read off the value at which the motor cur-
rent begins to oscillate.

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 KUKA.ServoGun Basic 3.0

Halve this value.

Start-up and configuration

11. Close the measurement curve and enter the halved value in the
Motor parameters window in the following box: VEL GAIN (Speed
controller gain).
12. Press the Motor parameters button again and then press “Program”.
Execute the program through to the next “HALT”.
13. A message is displayed: Confirm with OK.
SGControlView is then displayed again.
14. Call the measurement curve for VEL INT TIME using the Trace but-
ton.
15. On the measurement curve, read off the value at which the following
error at standstill is smallest.
16. Close the measurement curve and enter the determined value in the
Motor parameters window in the following box: VEL INT TIME (Reset
time of speed controller).
17. Press the Motor parameters button again and then press “Program”.
Execute the program through to the next “HALT”.
18. A message is displayed: Confirm with OK.
SGControlView is then displayed again.
19. Call the measurement curve for POS GAIN using the Trace button.
20. On the measurement curve, read off the value at which the motor cur-
rent begins to oscillate.
Halve this value.
21. Close the measurement curve and enter the halved value in the
Motor parameters window in the following box: POS GAIN (Position
controller gain).
22. Close the Motor parameters window and save the entered values.
The PTP parameters are automatically saved in addition as CP pa-
rameters.

6.25.3 Optimizing the parameters for the force controller

Precondition

• User rights: Function group Configuration of the technology pack-

ages
• The weld gun is fully configured.
• The software limit switches have been set.
• The weld gun is mastered.
• The gun has been calibrated.
• The gear ratio has been entered.
• T2 mode
• There is nothing between the electrode tips.
In other words, the force gauge has also been removed.

Procedure

With this procedure, the controller automatically enters the calculated val-
ue in the box provided.
1. In the main menu, select Configuration > ServoGun. The ServoGun
configuration window opens.
2. Select the gun to be configured. Then press Motor parameter at the
bottom.

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The SGControlView opens.

Start-up and configuration

(>>> 6.25.1 "ServoGun configuration window – SGControlView"
Page 74)
3. Check the following values for the parameter FORCE GAIN and
change them if necessary: Lower limit, Upper limit and Steps.
Calculation of the FORCE GAIN is based on these values. Only if
meaningful values are stored here can a good result be achieved.

If changes have been made, save them with Save table.

4. Press the Force parameters button.
The program SG_SET_MOTOR_PARAM is selected.
5. Switch to T2 if this has not already been done.
6. Set the program override to 100% and start the program.
If the program override is not set to 100%, the measurements will
be incorrect.

The gun executes the motion profile for determination of FORCE

GAIN. This may take several minutes.
7. A message is displayed at the end of the program: Confirm with OK.
SGControlView is then displayed again.
8. Press the Trace button and select AUTO FORCE GAIN in the subme-
nu.
9. A message is displayed: Confirm the message with OK.
The value determined during program execution is now entered in the
FORCE GAIN (force controller gain) box.
10. Close SGControlView. Respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
11. The ServoGun configuration window is again displayed. The window
can now be closed.

Alternative procedure

With this procedure, the user manually enters the calculated value in the
box provided.
1. In the main menu, select Configuration > ServoGun. The ServoGun
configuration window opens.
2. Select the gun to be configured. Then press Motor parameter at the
bottom.
The SGControlView opens.
(>>> 6.25.1 "ServoGun configuration window – SGControlView"
Page 74)
3. Check the following values for the parameter FORCE GAIN and
change them if necessary: Lower limit, Upper limit and Steps.
Calculation of the FORCE GAIN is based on these values. Only if
meaningful values are stored here can a good result be achieved.

If changes have been made, save them with Save table.

4. Press the Force parameters button.
The program SG_SET_MOTOR_PARAM is selected.
5. Switch to T2 if this has not already been done.
6. Set the program override to 100% and start the program.
The gun executes the motion profile for determination of FORCE
GAIN. This may take several minutes.

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Start-up and configuration KUKA.ServoGun Basic 3.0

7. A message is displayed at the end of the program: Confirm with OK.

SGControlView is then displayed again.
8. Press the Trace button and select FORCE GAIN in the submenu.
A window opens. It displays the measurement curve for FORCE GAIN.
• At the top of the screen is the line Optimal ForceGain = Value.
The controller has automatically determined the optimal value here.
9. Either: Note the value of Optimal ForceGain variable.
Or: Read and note the value for FORCE GAIN from the curve.
(FORCE GAIN = value with the fastest correction of the force and the
smallest overshoot.)
10. Close the window containing the measurement curve. Then enter the
noted value in the following box in SGControlView: FORCE GAIN
(force controller gain).
11. Close SGControlView. Respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
12. The ServoGun configuration window is again displayed. The window
can now be closed.

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Programming
7 Programming

7.1 Inline forms – overview

Inline form Description

SPOT Programming a weld spot
(>>> 7.3 "Programming a weld spot" Page 80)
INIT Tip initialization (= measuring and saving the current burn-off)
(>>> 7.4 "Programming tip initialization" Page 82)
COUPLE/DECOUPLE Couple/decouple the gun.
(>>> 7.5 "Inline form COUPLE and DECOUPLE" Page 89)
Background tip dressing Only with stationary guns:
Background welding • Enabling asynchronous tip dressing
• Enabling asynchronous welding (only for test welding with-
out a real workpiece, e.g. for resistance checks)
(>>> 8.4 "Programming background processes" Page 103)
Tip dressing Tip dressing
(>>> 7.6 "Programming tip dressing" Page 89)
Close gun Close the gun to the defined thickness with the force defined in
the inline form. Any force and thickness values from the weld
timer are ignored.
(>>> 7.7 "Closing the gun" Page 92)

7.2 Instructions for programming

General

• Welding is possible in all modes. Welding can be deactivated in T1

and T2 modes using a status key. Deactivation affects all operating
modes.
• In all operating modes, an override less than 100% can cause the at-
tained forces to deviate from the target force.
• Weld programs can only be executed in the program run mode #GO.
#MSTEP and #ISTEP are not possible.

Minimum opening during teaching

Minimum opening of the gun during teaching:

• 30 mm, excluding material, e.g. sheet pairing or force transducer
Wear does not have to be taken into consideration.

7.2.1 Instructions for use of stationary guns

The descriptions regarding programming refer to guns mounted on the ro-

bot flange. For stationary guns, the programming must be adapted accord-
ingly.
Aspects requiring special consideration:

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Programming KUKA.ServoGun Basic 3.0

• In the option window Frames, the check box next to External TCP
must be activated.
‒ SPOT
‒ INIT
‒ TippDress
‒ Close gun

7.3 Programming a weld spot

Distances

The following distances are required for the position of the gun during
teaching:
Electrode Distance
Moving electrode Min. 30 mm from workpiece
Fixed electrode 0 mm from workpiece
The fixed electrode must be in contact
with the workpiece, without exerting any
force on it.

Precondition

• User rights: Function group Basic operation of the technology pack-

ages

Procedure

1. Position the gun on the desired weld spot. Observe the required dis-
tances.
2. Select the menu sequence Commands > ServoGun > SPOT.
3. Set the parameters in the inline form.
4. Press Cmd OK to save the instruction.

7.3.1 Inline form “SPOT”

Fig. 7-1: SPOT

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Programming
Item Description
1 Motion type

• PTP or LIN
2 Name of the end point. Touch the arrow to edit the point
data.
(>>> 7.8 "Option window “Frames”" Page 93)
(>>> 7.9 "Option window “Parameter”" Page 94)
Only with the option Point name: The last 7 characters (=
default number) must be digits. The robot controller commu-
nicates these digits to the weld timer as the program num-
ber. The number of relevant final characters can be config-
ured using the parameter Number of entities in WorkVisu-
al.

• […]0 000 001… […]9 999 999

Vel Velocity

• PTP: 0 ... 100%

• LIN: 0.001 … 2 m/s
3 Name for the motion data set. The system automatically
generates a name. The name can be overwritten.
(>>> 7.10 "Option window “Motion parameters”" Page 95)
ProgNr Program number for the weld timer

• 1 … 100 000 000

This box is only displayed if the Program number option is
configured.
ServoGun Active gun with number and designation

• 1 … 6
Cont • CLS OPN: Approximate positioning during closing and
opening motions
• OPN: Approximate positioning during opening motion
• CLS: Approximate positioning during closing motion
• NO: Without approximate positioning
Part Total thickness of the workpieces to be welded

• 0 … 100 mm
This box is only displayed if the option Part thickness
from weld timer FALSE is configured.
PartTol Permissible deviation from the programmed workpiece thick-
ness

• 0 … [max. gun flexion] mm

This box is only displayed if the option Part thickness tol-
erance from weld timer FALSE is configured.

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Programming KUKA.ServoGun Basic 3.0

Item Description
Force Closing force of the gun in the unit configured in WorkVisu-
al

• Maximum value: Value of the configuration parameter

Maximum gun force
This box is only displayed if the option Force from weld
timer FALSE is configured.
4 Servo gun parameters
(>>> 7.11 "Option window “Servo gun parameters”"
Page 95)

7.4 Programming tip initialization

During tip initialization, the current electrode burn-off is measured and

saved. This enables the gun opening to be automatically adapted to the
burn-off.
Initialization can be carried out in the following ways:
• By status key
• In the program
There are 2 types of tip initialization:
First initialization
Must be carried out in the following cases:
• During commissioning
• Every time the electrode tips are exchanged
Cyclical initialization
• Cyclical initialization must be carried out after tip dressing.

7.4.1 Programming first initialization (Ratio in % option)

Description

One position must be taught for initialization. This is taught directly as a

motion point in the inline form INIT.

Distances

The same distances apply as for the weld spot.

(>>> "Distances" Page 125)

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T1 or T2 mode
• The gun is mastered.
• The gun is calibrated.
• New electrode tips are fitted on the gun.
• The initialization force has been configured in WorkVisual.
(>>> 6.6.1 "“Gun settings” area" Page 40)

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Programming
Procedure

1. Move the gun to the position at which initialization is to be performed.

Observe the required distances.
2. Select the menu sequence Commands > ServoGun > INIT.
3. Teach the point with Touch-up in the inline form.
4. Select the gun in the inline form.
5. Select New in the inline form.
6. Press Cmd OK to save the instruction.

Sequence

With this first initialization, the following occurs:

• The gun closes at a constant velocity until the first initialization force is
reached. The electrode tips are pressed firmly onto the electrodes.
• The gun opens.
• The gun closes with initialization force.
• The robot controller reinitializes the tip wear.

7.4.2 Programming cyclical initialization (Ratio in % option)

Description

One position must be taught for initialization. This is taught directly as a

motion point in the inline form INIT.

Distances

The same distances apply as for the weld spot.

(>>> "Distances" Page 125)

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T1 or T2 mode
• The gun is mastered.
• The gun is calibrated.
• First initialization has been performed.
• New electrode tips

Procedure

1. Move the gun to the position at which initialization is to be performed.

Observe the required distances.
2. Select the menu sequence Commands > ServoGun > INIT.
3. Teach the point with Touch-up in the inline form.
4. Select the gun in the inline form.
5. Select Same in the inline form.
6. Press Cmd OK to save the instruction.

Procedure

With this cyclical initialization, the following occurs:

• The gun closes with initialization force.

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Programming KUKA.ServoGun Basic 3.0

• The robot controller saves the current tip wear in SG_WEAR[].

The controller generates a message if the current wear is greater than
the maximum permissible wear ServoGun[].WearMax and sets the out-
put New electrodes required. The electrode tips must then be ex-
changed.
The controller generates a message if the current wear since the last
value is less than SG_WEARTOLERANCE[] and sets the output Wear
measurement exceeds tolerance.

7.4.3 Inline form “INIT” (Ratio in % option)

Fig. 7-2: Inline form “INIT” (Ratio in % option)

Item Description
1 Motion type

• PTP or LIN
2 Name of the end point. Touch the arrow to edit the point
data.
(>>> 7.8 "Option window “Frames”" Page 93)
(>>> 7.9 "Option window “Parameter”" Page 94)
Vel Velocity

• PTP: 0 ... 100%

• LIN: 0.001 … 2 m/s
3 Name for the motion data set. The system automatically
generates a name. The name can be overwritten.
(>>> 7.10 "Option window “Motion parameters”" Page 95)
Cont • CLS OPEN: Approximate positioning during closing and
opening motions
• OPEN: Approximate positioning during opening motion
• CLOSE: Approximate positioning during closing motion
• NO: Without approximate positioning
ServoGun Active gun with number and designation

• 1 ... 6
4 • NEW: First initialization
• SAME: Cyclical initialization

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Programming
7.4.4 Programming first initialization (Individual measurement option)

Description

2 points must be taught for first initialization.

• 1st point:
The point is taught freely in space with INIT NEW.
• 2nd point:
The point is taught with INIT WEARREF.
The point must be taught on a fixed plate, e.g. a plate fastened to the
tip dresser.

For first initialization and cyclical initialization, teach the identical point
as the 2nd point. Recommendation: Teach the point as a global point.

Fig. 7-3: Example: Determining the burn-off using a plate

1 1st point 2 2nd point

Distances

The same distances apply for the 2nd point as for the weld spot.
(>>> "Distances" Page 125)

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T2 mode
• The gun has been calibrated as a tool. This tool is currently selected.
• The gun is mastered.
• The gun is calibrated.
• New electrode tips are fitted on the gun.
• An adequately fastened plate is available for teaching the 2nd point.

Procedure

It is advisable to program both INIT commands in such a way that they

directly succeed one another. It is described in this way in this proce-
dure.

1. Move the gun to the desired 1st point.

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Programming KUKA.ServoGun Basic 3.0

2. Select the menu sequence Commands > ServoGun > INIT.

(>>> 7.4.6 "Inline form “INIT” (Individual measurement option)"
Page 88)
3. Teach the point with Touch-up in the inline form.
4. Select the setting NEW in the inline form. Also make the other set-
tings.
5. Save the command with Cmd OK.
6. Move the gun to the 2nd point (point on the plate). Observe the re-
quired distances.
7. Select the menu sequence Commands > ServoGun > INIT.
8. Teach the point with Touch-up in the inline form.
9. Select the setting WEARREF in the inline form.
Also make the other settings, including entering the thickness of the
plate.
10. Save the command with Cmd OK.

Sequence

With this first initialization, the following occurs:

• The gun moves to the 1st position.
• The gun closes at a constant velocity until the first initialization force is
reached. The electrode tips are pressed firmly onto the electrodes.
• The gun opens.
• The gun closes with initialization force.
• The robot controller saves the current tip wear in SG_WEAR[].
• The gun moves to the 2nd position.
• The moving gun arm performs a motion with initialization force.
• The robot controller saves the wear of the moving electrode in
SG_WearFlex[]. It saves the difference from the overall wear in
SG_WearFix[].

7.4.5 Programming cyclical initialization (Individual measurement option)

Description

2 points must be taught for cyclical initialization.

• 1st point:
The point is taught freely in space with INIT SAME.
• 2nd point:
The point is taught with INIT WEARMEAS.
The point must be taught on a fixed plate, e.g. a plate fastened to the
tip dresser.

For first initialization and cyclical initialization, teach the identical point
as the 2nd point. Recommendation: Teach the point as a global point.

Distances

The same distances apply for the 2nd point as for the weld spot.
(>>> "Distances" Page 125)

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Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T2 mode
• The gun has been calibrated as a tool. This tool is currently selected.
• The gun is mastered.
• The gun is calibrated.
• First initialization has been performed.
• New electrode tips
• An adequately fastened plate is available for teaching the 2nd point.

Procedure

It is advisable to program both INIT commands in such a way that they

directly succeed one another. It is described in this way in this proce-
dure.

1. Move the gun to the desired 1st point.

2. Select the menu sequence Commands > ServoGun > INIT.
(>>> 7.4.6 "Inline form “INIT” (Individual measurement option)"
Page 88)
3. Teach the point with Touch-up in the inline form.
4. Select the setting SAME in the inline form. Also make the other set-
tings.
5. Save the command with Cmd OK.
6. Move the gun to the 2nd point (point on the plate). Observe the re-
quired distances.
7. Select the menu sequence Commands > ServoGun > INIT.
8. Teach the point with Touch-up in the inline form.
9. Select the setting WEARMEAS in the inline form.
Also make the other settings, including entering the thickness of the
plate.
10. Save the command with Cmd OK.

Sequence

With this cyclical initialization, the following occurs:

• The gun moves to the 1st point.
• The gun closes at a constant velocity until the initialization force is
reached.
• The robot controller saves the current tip wear in SG_WEAR[].
• The gun opens.
• The gun moves to the 2nd point.
• The moving gun arm performs a motion with initialization force.
• The robot controller saves the wear of the moving electrode in
SG_WearFlex[]. It saves the difference from the overall wear in
SG_WearFix[].

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7.4.6 Inline form “INIT” (Individual measurement option)

Fig. 7-4: Inline form “INIT” (Individual measurement option)

Item Description
1 Motion type

• PTP or LIN
2 Name of the end point. Touch the arrow to edit the point
data.
(>>> 7.8 "Option window “Frames”" Page 93)
(>>> 7.9 "Option window “Parameter”" Page 94)
Vel Velocity

• PTP: 0 ... 100%

• LIN: 0.001 … 2 m/s
3 Name for the motion data set. The system automatically
generates a name. The name can be overwritten.
(>>> 7.10 "Option window “Motion parameters”" Page 95)
Cont • CLS OPEN: Approximate positioning during closing and
opening motions
• OPEN: Approximate positioning during opening motion
• CLOSE: Approximate positioning during closing motion
• NO: Without approximate positioning
ServoGun Active gun with number and designation

• 1 ... 6
Part Thickness of the plate on which the wear is measured

• 0 … 100 mm
This value must always be specified here, i.e. via the inline
form. It cannot be acquired from the weld timer.
4 For a first initialization:

• For the point before the plate: NEW

• For the point on the plate: WEARREF
For a cyclical initialization:

• For the point before the plate: SAME

• For the point on the plate: WEARMEAS

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Programming
7.5 Inline form COUPLE and DECOUPLE

Description

This command couples or decouples the gun within the software. The in-
line form does not control any hardware, inputs or outputs.

• When coupling a gun that has not yet been mastered, the opening
width of the gun is not relevant.
• When decoupling a mastered gun, the gun must not be in the mas-
tering position or a multiple thereof (360°, 720° motor revolution).
Mastering is otherwise lost on recoupling.
• On recoupling, the gun must have the same opening width as when
it was decoupled. If this is not the case, the mastering will be lost.

A weld gun may only be assigned to one robot. A weld gun must not
be used on more than one robot.

Fig. 7-5: COUPLE and DECOUPLE

Item Description
1 • Couple
• Decouple
2 Active gun with number and designation

• 1 ... 6

7.6 Programming tip dressing

Description

TippDress executes a weld spot without approximate positioning.

The following parameters must be set in the weld timer:
• Cycle without weld current
• Dressing time (overall cycle time) if the dressing time is not set in the
inline form TippDress

NOTICE
Dressing must be performed without weld current. If dressing is carried
out with weld current, damage to property is liable to occur.

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Fig. 7-6: Tip dressing

Distances

The same distances apply as for the weld spot.

(>>> "Distances" Page 125)

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• The thickness of the tip dresser has been determined.

Procedure

1. Position the gun on the desired tip dressing point. Observe the re-
quired distances.
2. Select the menu sequence Commands > ServoGun > Tip dressing
and then select the desired motion type.
3. Set the parameters in the inline form.
(>>> 7.6.2 "Inline form “TippDress”" Page 91)
4. Press Cmd OK to save the instruction.

After tip dressing, cyclical initialization must be performed.

Sequence

The sequence for tip dressing corresponds to the sequence for welding.
The gun closes until the defined force is reached. The robot controller
then sets the output Weld start and waits for the input Weld end.
If a different sequence is required for tip dressing, this can be program-
med in the subprogram SG_UserDress. In order for the robot controller to
perform this different sequence, i.e. in order for SG_UserDress to be exe-
cuted, the variable SG_NonKukaDress must be set to TRUE.

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Programming
7.6.1 Determining the thickness of the tip dresser

Description

The thickness of the tip dresser is required for the inline form TippDress.

Precondition

• The gun is mastered.

• New electrode tips are fitted on the gun.
• T1 or T2 operating mode

Procedure

1. Position the gun with both electrodes on the tip dresser.

2. Close the gun until contact is made.
3. In the main menu select Display > Actual position and in the
window that appears select Axis-specific.
The Robot position window opens.
4. Select the option Axis-specific.
5. Read and note the value for the axis on which the gun is configured.

7.6.2 Inline form “TippDress”

Fig. 7-7: Tip dressing

Item Description
1 Motion type

• PTP or LIN
2 Name of the end point. Touch the arrow to edit the point
data.
(>>> 7.8 "Option window “Frames”" Page 93)
(>>> 7.9 "Option window “Parameter”" Page 94)
Only with the option Point name: The last 7 characters (=
default number) must be digits. The robot controller commu-
nicates these digits to the weld timer as the program num-
ber. The number of relevant final characters can be config-
ured in the parameter Number of entities.

• […]0 000 001… […]9 999 999

Vel Velocity

• PTP: 0 ... 100%

• LIN: 0.001 … 2 m/s

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Item Description
3 Name for the motion data set. The system automatically
generates a name. The name can be overwritten.
(>>> 7.10 "Option window “Motion parameters”" Page 95)
Servo Active gun with number and designation
Gun
• 1 … 6
Dress Thickness of the tip dresser
Tool
• 0 … 100 mm
This box is only displayed if the option Part thickness
from weld timer FALSE is configured.
Dress Closing force of the gun
Force
• Maximum value: Value of the configuration parameter
Maximum gun force
This box is only displayed if the option Force from weld
timer FALSE is configured.
ProgNr Program number for the weld timer

• 1 … 100 000
This box is only displayed if the Program number option is
configured.
Dress Duration of the tip-dressing process
Time
• 0 … 20 s
This box is only displayed if the option Weld time from
weld timer FALSE is configured.

7.7 Closing the gun

Description

Close the weld gun to a defined force with a defined part thickness. The
force and the part thickness are specified via the inline form. There is no
communication with the weld timer.
The command is used, for example, for automatic tip changers or for
force gauges for checking the gun.
Close gun points can also be taught with worn tips. If the tip wear dur-
ing teaching is greater than 0, it is not the current gun position that is
saved, but a position corrected to take the wear into account.

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T1 or T2 mode

Procedure

1. Position the gun at the desired point.

2. Select the menu sequence Commands > ServoGun > Close gun.
3. Set the parameters in the inline form.
4. Press Cmd OK to save the instruction.

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Programming
7.7.1 Inline form Close gun

Fig. 7-8: Close gun

Item Description
1 Motion type

• PTP or LIN
2 Name of the end point. Touch the arrow to edit the point
data.
(>>> 7.8 "Option window “Frames”" Page 93)
(>>> 7.9 "Option window “Parameter”" Page 94)
Vel Velocity

• PTP: 0 ... 100%

• LIN: 0.001 … 2 m/s
3 Name for the motion data set. The system automatically
generates a name. The name can be overwritten.
(>>> 7.10 "Option window “Motion parameters”" Page 95)
ServoGun Active gun with number and designation

• 1 … 6
Tool Part thickness

• 0 … 100 mm
Force Closing force of the gun in the unit configured in WorkVisu-
al

• Maximum value: Value of the configuration parameter

Maximum gun force

7.8 Option window “Frames”

Fig. 7-9: Option window “Frames”

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Programming KUKA.ServoGun Basic 3.0

Item Description
1 Select the gun or the workpiece on the flange.
Range of values: TOOL[1] … TOOL[16]
2 Select the base or the stationary gun.
Range of values: BASE[1] … BASE[32]
3 Specify the interpolation mode.

• FALSE (check box not active): Set if the following combina-

tion has been selected above:
‒ Tool: A gun on the flange
‒ Base: A base
• TRUE (check box active): Set if the following combination
has been selected above:
‒ Tool: A workpiece on the flange
‒ Base: A stationary gun

7.9 Option window “Parameter”

Fig. 7-10: Option window “Parameter”

Item Description
Global • FALSE: The point is the local point
point
• TRUE: The point is a global point
Only the motion data are saved globally. Process data,
e.g. force specifications or program numbers in the in-
line form, are saved locally.
Required user rights for modifications: Function group
Teach global points

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Programming
7.10 Option window “Motion parameters”

Fig. 7-11: Option window “Motion parameters”

Item Description
1 Path acceleration
Refers to the maximum value specified in the machine data.
The maximum value depends on the robot type and the selec-
ted operating mode.
2 This box is only displayed if it is specified in the inline form that
the point is to be approximated.
Furthest distance before the end point at which approximate po-
sitioning can begin
The maximum permissible value is half the distance between
the start point and the end point. If a higher value is entered,
this is ignored and the maximum value is used.
3 Only for LIN: select orientation control

7.11 Option window “Servo gun parameters”

Fig. 7-12: Option window “Servo gun parameters”

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Item Description
1 Only for compensation type Pneumatic:

• NONE: without compensation

• CYLINDER 1: compensator 1
• CYLINDER 2: compensator 2
• BOTH: compensators 1 and 2
2 Distance after which compensation is deactivated on opening
the gun
3 Determines how often a weld spot can be repeated in the case
of a fault. The spot does not have to be repeated this many
times; the setting merely determines the maximum possible
number of repetitions.
Depending on the configuration, the weld spot is repeated in
the following manner:

• Either: a dialog is displayed. The user can select whether to

repeat the spot or not.
• Or: the PLC requests repetition of the spot.
The default value is configured in WorkVisual as Number of
repetitions after fault.
(>>> 6.6.1 "“Gun settings” area" Page 40)
4 Maintain force at weld spot – melt compensation
Due to the melting of material during welding, the gun force at
the weld spot may drop. This functionality ensures that the gun
closes further in such cases as soon as the material diminishes.
Particularly suitable for very stiff guns.

• FALSE: deactivated (default)

• TRUE: activated

7.12 Using Teach mode/correcting weld spots

Description

In Teach mode, the robot moves to the weld spots and tip dressing points
and stops there. The robot moves to the originally taught position, without
compensation. This allows the user to check the position and to reteach it
if necessary. The robot does not stop at points which are not specific to
ServoGun (e.g. at conventional PTP points).

Precondition

• A program is selected.
• Operating mode T1 or T2

Procedure

1. Press and hold down the enabling switch.

2. Press the Toggle status keys status key until the Teach Mode Off
status key is displayed.
3. Press the Teach Mode Off status key. Teach mode is now activated.
4. Press and hold down the Start key. The gun stops at the taught posi-
tion.

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Programming
5. Check the position and reteach it if necessary.
6. Press and hold down the Start key. The gun closes to the program-
med force and then moves to the next taught position, where it stops.
7. Repeat steps 5 and 6 until all points that are to be checked have
been executed.
8. Press the Teach Mode On status key in order to deactivate Teach
mode again.

Status keys

Status key Name / description

Teach mode off
Teach mode is deactivated. Pressing the status key
switches Teach mode on.
Teach mode on
Teach mode is activated. Pressing the status key
switches Teach mode off.

7.13 Adaptable subprograms

Description

KUKA.ServoGun Basic contains subprograms which are called automati-

cally at various points in time by the robot controller. The subprograms
are provided to allow the user to program the instructions that are to be
executed at the relevant points in the process, e.g. setting outputs or poll-
ing inputs.
The following general conditions must be observed:
• No parameters can be transferred in the subprograms.
• The subprograms must not contain wait instructions.
• The subprograms must not contain instructions that trigger an advance
run stop.

The adaptations in these subprograms are preserved if the option pack-

age is updated. If the package is uninstalled, the adaptations will be
lost. The data must therefore be backed up beforehand if required.

Precondition

• User group Expert

SG_UserPrograms.src

Subprograms in SG_UserPrograms.src in the directory R1\TP\SERVO-

GUN:
Point in time at which the robot controller calls the sub-
Subprogram
program
SG_UserErrorHandlTimer When the weld timer signals to the robot controller that a rel-
evant error has occurred on the timer side.
SG_UserErrorHandlMain When a relevant error occurs on the robot controller. Many,
but not all, errors from ServoGun Basic are relevant errors.
Relevant errors include, for example, excessive electrode
wear, error on coupling, too many weld attempts, and many
more.

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Point in time at which the robot controller calls the sub-

Subprogram
program
SG_UserPreCurrentAct Directly before the start of welding
SG_UserResetError At the start of a weld
SG_UserResetError is intended to enable users to reset their
specific error flags in it.
SG_UserPostSpot Following welding, after the gun has reopened
SG_UserPreCheckNumb Only relevant for Bosch PSI6xxx.201 and Bosch PSI6xxx.373
weld timers
The robot controller checks a program number before trans-
ferring it to the weld timer. Before the check, it calls
SG_UserPreCheckNumb.
SG_UserPreProgNum Before the robot controller transfers a program number to the
weld timer
SG_UserPostProgNum After the robot controller has transferred a program number to
the weld timer
SG_UserPreWeldSpot Before the start of welding, but before the check whether the
system is ready for welding
SG_UserPostWeldSpot After the start of welding.
SG_UserPreInit Before cyclical tip initialization
SG_UserPostInit After cyclical tip initialization
SG_UserDress As user-defined sequence for tip dressing

• Precondition for the call: SG_NonKukaDress == TRUE

And/or as user-defined sequence for background tip dressing

• Precondition for the call: SG_NonKukaBGDress == TRUE

Note: If SG_UserDress is to be used for background tip
dressing, it may only contain statements that are also allowed
in submit programs.
SG_UserPreTipDress Before tip dressing
SG_UserTipDressGunClose After the gun has been closed for tip dressing
SG_UserPostTipDress After tip dressing
SG_UserForceClose After the gun has been closed using the inline form Close
gun (ForceClose)

SG_UserPrograms1.src

Subprograms in SG_UserPrograms1.src in the directory R1\TP\SERVO-

GUN:

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Programming
Point in time at which the robot controller calls the sub-
Subprogram
program
SG_UserPreErrHandlMain When a relevant error occurs on the robot controller. Many,
but not all, errors from ServoGun Basic are relevant errors.
Relevant errors include, for example, excessive electrode
wear, error on coupling, too many weld attempts, and many
more.
SG_UserPreErrHandlMain (unlike SG_UserErrorHandlMain) is
called before the messages corresponding to the errors have
been generated.
SG_UserPreErrHandlTimer When the weld timer signals to the robot controller that a rel-
evant error has occurred on the timer side.
SG_UserPreErrHandlTimer (unlike SG_UserErrorHandlTimer)
is called before the messages corresponding to the errors
have been generated.
SG_UserPreCouple Before a gun is coupled via inline form
SG_UserPostCouple After a gun is coupled via inline form
SG_UserPreDeCouple Before a gun is decoupled via inline form
SG_UserPostDeCouple After a gun is decoupled via inline form

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Background welding and tip dressing

8 Background welding and tip dressing

8.1 Functionality of background processes

While tip dressing is being carried out with a stationary gun, the robot is
normally not available for other work (e.g. fetching a new workpiece).
The reason for this is that the robot axes and the external axis (= gun)
are moved synchronously. This means they perform common motions that
start and finish simultaneously. Even though the robot axes are usually
stationary during dressing, this is nevertheless part of the overall motion.
With the Background commands, however, it is possible to move the sta-
tionary gun asynchronously. At the same time, the robot axes are able to
execute other movements independently of the gun.
The asynchronous gun motion is not only possible during tip dressing, but
also during welding. However, this only applies to test welding where no
real workpiece is used (e.g. for resistance checks).
Sequence diagrams for background processes between the PLC and ro-
bot can be found in the DOC directory on the data storage medium for
KUKA.ServoGun Basic.

8.2 Configuring background processes – weld timer and gun

Area Remarks
Weld timer No separate parameters available for the background
processes.
The general parameters, e.g. Force from weld tim-
er, also affect the background processes, however.
(>>> 6.3.1 "Weld timer options" Page 32)
The weld timer settings are configured in the weld
timer editor in WorkVisual.
Gun • Background process active: The check box
must be activated in order for background pro-
cesses to be possible.
(>>> 6.6.1 "“Gun settings” area" Page 40)
The gun settings are configured in the ServoGun edi-
tor in WorkVisual.

8.3 Configuring background processes – PLC inputs/outputs

The PLC inputs/outputs are configured in the ServoGun editor in WorkVi-

sual.
The PLC inputs/outputs can only be configured if the Background proc-
ess active check box in the Gun settings area is activated (also in the
ServoGun editor). Otherwise, the boxes for the inputs/outputs cannot be
edited.
If a function is not to be used, set the corresponding input or output to
0.

PLC inputs for background process

Signals from the PLC to the robot controller:

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Background welding and tip dressing KUKA.ServoGun Basic 3.0

Input Description
Start tip dressing Request to start background tip dressing
TRUE = Request
FALSE = No request
Weld start Request to start background welding
TRUE = Request
FALSE = No request
Start reinitialization Request first initialization
TRUE = Request
FALSE = No request
Starting cyclical ini- Request cyclical initialization
tialization
TRUE = Request
FALSE = No request
Weld gun number Input range for the gun number with which background welding or tip
dressing is to be carried out
Weld program num- Input range for the program number
ber
Welding force Input range for the welding force in N
Only relevant if the force value does not come from the weld timer.
Part thickness Input range for the workpiece thickness in 1/10 mm
Only relevant if the thickness value does not come from the weld tim-
er.
Compensation num- Input range for specifying which compensator should be activated
ber
• 1: Cylinder 1
• 2: Cylinder 2
• 3: Both
PLC confirms result PLC must confirm that it has received the result of the background
process.
TRUE = Confirmation carried out
FALSE = Confirmation not carried out

PLC outputs for background process

Signals from the robot controller to the PLC:

Output Description
Ready for back- TRUE = Ready for background tip dressing
ground tip dressing
FALSE = Not ready
Background TRUE = Background welding or tip dressing running
process active
FALSE = Background welding or tip dressing not running
Background TRUE = Background welding or tip dressing has been performed suc-
process successful cessfully
FALSE = Background welding or tip dressing has not been performed
successfully
Background welding TRUE = Ready for background welding
ready
FALSE = Not ready

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Background welding and tip dressing

Output Description
Background TRUE = Background welding or tip dressing not successful
process errors

8.4 Programming background processes

Precondition

• User rights: Function group Basic operation of the technology pack-

ages
• T1 or T2 mode

Procedure

1. Select the menu sequence Commands > ServoGun >.

Then select either Background tip dressing or Background weld-
ing.
2. Set the parameters in the inline form.
(>>> 8.5 "Inline form Background tip dressing and Background weld-
ing" Page 103)
3. Press Cmd OK to save the instruction.

The inline form enables the selected background process, i.e. the proc-
ess may be executed. The inline form does not start the process, how-
ever! It is started by means of communication with the PLC.
(>>> 8.6 "Sequence of background processes" Page 104)

8.5 Inline form Background tip dressing and Background welding

Fig. 8-1: Background tip dressing and Background welding

Item Description
1 • TipDress: Background tip dressing
• Weld: Background welding
2 • Enable: Asynchronous motion of the stationary gun during
tip dressing/welding is possible.
• Disable: Waits until a background process that may have
started has been completed and then disables the back-
ground process. Asynchronous motion of the stationary gun
during tip dressing/welding is then no longer possible.
3 Active gun with number and designation

• 1 … 6
Only guns for which the option Background process active is
activated are displayed in the list.

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Background welding and tip dressing KUKA.ServoGun Basic 3.0

8.6 Sequence of background processes

• The inline form enables the selected background process, i.e. the
process may be executed.
The external axis (= gun) is switched to asynchronous mode.
• The robot controller sets the output Ready for background tip dress-
ing or Background welding ready.
• The robot controller waits for the selection of the background process
by the PLC via the relevant inputs and with the corresponding param-
eters.
Inputs from the PLC:
Process Inputs from the PLC
Tip dressing Start tip dressing
Welding Weld start
First initialization Start reinitialization
and
Start tip dressing
Cyclical initialization Starting cyclical initialization
and
Start tip dressing
Corresponding parameters:
‒ Weld gun number
‒ Weld program number
‒ Compensation number
‒ (Welding force)
‒ (Part thickness)
Depending on the configuration, the values in brackets can also be
obtained from the weld timer.
• The robot controller acknowledges successful selection by means of
the output Background process active.
• The background process is executed.
• The robot controller signals any errors to the PLC (output Back-
ground process errors).
• If no errors occur, the robot controller signals successful completion of
the background process (output Background process successful).
• The robot controller waits for confirmation from the PLC via the input
PLC confirms result.
• The background process has ended.
• The background process is disabled using the inline form Back-
ground.
The external axis (= gun) is switched back to synchronous mode.

8.7 Adaptable subprograms for background processes

Description

KUKA.ServoGun Basic contains subprograms which are called automati-

cally at various points in time by the robot controller. The subprograms
are provided to allow the user to program the instructions that are to be

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executed at the relevant points in the process, e.g. setting outputs or poll-

Background welding and tip dressing

ing inputs.
The following general conditions must be observed:
• No parameters can be transferred in the subprograms.
• The subprograms must not contain wait instructions.
• The subprograms must not contain instructions that trigger an advance
run stop.

The adaptations in these subprograms are preserved if the option pack-

age is updated. If the package is uninstalled, the adaptations will be
lost. The data must therefore be backed up beforehand if required.

Precondition

• User group Expert

Subprograms for background processes

The subprograms are located in the program SG_UserBackground.SRC in

the directory R1\TP\SERVOGUN.
Welding:
Point in time at which the robot controller calls the sub-
Subprogram
program
SG_UserPreBG_Weld Before background welding is started.
SG_UserPostPG_Weld After background welding has been carried out.
Tip dressing:
Point in time at which the robot controller calls the sub-
Subprogram
program
SG_UserDress As user-defined sequence for background tip dressing
Precondition for the call: SG_NonKukaBGDress == TRUE
Note: If SG_UserDress is used for background tip dressing, it
may only contain statements that are allowed in submit pro-
grams.
SG_UserPreBG_TD Before background tip dressing is started.
SG_UserGunCloseBG_TD After the gun has been closed for background tip dressing.
SG_UserPostBG_TD After background tip dressing has been carried out.

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Diagnosis
9 Diagnosis

9.1 Displaying I/O states

Precondition

• User rights: Function group Configuration of the technology pack-

ages

Procedure

1. In the main menu, select Configuration > ServoGun. The ServoGun

configuration window opens.
2. At the bottom, select Diagnostic monitor. The Diagnostic monitor
window opens.
The Weld timer and PLC tabs indicate the states of the different I/Os.

Weld timer

The tab displays the I/O configuration between the robot controller and the
weld timer.
Lamps indicate the states of the I/Os.
Lamps State / description
Green TRUE • TRUE = normal or desired
state
Green FALSE • FALSE = abnormal or unde-
and gray sired state

Red TRUE • TRUE = abnormal or undesired

state
Red and FALSE • FALSE = normal or desired
gray state

PLC

The tab displays the I/O configuration between the robot controller and the
PLC.
(>>> 6.6.2 "PLC input and output ranges" Page 43)
Lamps indicate the states of the I/Os.

9.2 Displaying detailed information about weld spots

Description

The Overview tab displays the weld spots of a program together with all
the values which the robot controller has received from the weld timer for
each spot. Which values these are depends on the configuration of the
ServoGun options. Additionally, information about expansions is displayed,
e.g. KUKA.EqualizingTech (if used).
The values displayed are those from the last program execution. By de-
fault, the overview can display programs located at the following levels:
• R1\Program
• R1\Program[Sublevel]

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Diagnosis KUKA.ServoGun Basic 3.0

Precondition

• User rights: Function group Configuration of the technology pack-

ages

Procedure

1. In the main menu, select Configuration > ServoGun. The ServoGun

configuration window opens.
2. At the bottom, select Diagnostic monitor. The Diagnostic monitor
window opens.
3. Select a program in the Module name box on the Overview tab.
The weld spots of this program are now displayed in a table.
• Touch the header to expand it and display the detailed headings.
• Touch a row in the table to expand it and display the detailed in-
formation about the point.

Overview tab

Fig. 9-1: Overview tab

Item Description
1 Select the program whose weld spots are to be displayed.
2 Exports the data to C:\KRC\USER\WeldData\WeldTimerData in
a CSV file.
The file may also contain blank columns that are intended for
information about future functionalities.
3 Closes all expanded table rows.
4 Header (expanded state)
Touch the header to display or hide the detailed headings.
5 Table row (expanded state)
Touch a row in the table to display or hide the detailed informa-
tion of the point.
The following information is shown in color:

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Diagnosis
Column Color / meaning
Opening width • Green: opening width OK
• Yellow: process is possible, but opening width is
unfavorable for cycle time
• Red: opening width is too narrow, process may
not be possible
When assessing the opening width, the robot control-
ler also takes the workpiece thickness into account.
EQ mode • Green: OK
• Yellow: EqualizingTech works with reduced accu-
racy.
Remedy: move to point with modified axis angles
if possible.
• Red: EqualizingTech may possibly not work as
expected.
Remedy: move to point with modified axis angles.
Since the gun is generally perpendicular to the work-
piece and should stay in this orientation, rotation
about the tool direction is required in order to change
the axis angles.

9.3 Configuring program selection for Overview tab (detailed information)

Default setting

Detailed information about the weld spots can be displayed via Configu-
ration > ServoGun > Diagnostic monitor > Overview. By default, the
overview can display programs located at the following levels:
• R1\Program
• R1\Program[Sublevel]
The path in the corresponding configuration file is:

<KrlProgramPath>KRC:\R1\Program\</KrlProgramPath>

Specific setting

It is also possible to display programs from lower levels. The search is al-
ways carried out in the lowest directory specified in the configuration file
plus 1 sublevel.
Example:

<KrlProgramPath>KRC:\R1\Program\my_folder\</KrlProgramPath>

With this setting, the programs located here, for example, would be dis-
played:
• R1\Program\my_folder
• R1\Program\my_folder\subfolder_1
• R1\Program\my_folder\subfolder_2
• R1\Program\my_folder\[…]
Programs in R1\Program are no longer displayed with this setting!

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Diagnosis KUKA.ServoGun Basic 3.0

Precondition

• “Expert” user group

• T1, T2 or AUT mode
• No program is selected.

Procedure

1. In the Navigator, open the following file in the directory C:\KRC\TP

\ServoGunBasic\SmartHMI:
• SmartHMI.exe.ServoGun.User.config
2. Search for the entry KrlProgramPath. This is the default setting:

<KrlProgramPath>KRC:\R1\Program\</KrlProgramPath>

3. Expand the path specification as required.

4. Close the file and answer the request to confirm saving with Yes.
5. Reboot the robot controller with the settings Cold start and Reload
files.

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Messages
10 Messages

10.1 Information about the messages

The “Messages” chapter contains selected messages. It does not cover all
the messages displayed in the message window.

10.2 Information on dialog messages after a welding error

This information is only for the compensation type Pneumatic.

If an error occurs at a weld spot, the controller displays a message. This

can be a dialog message offering the user the option to repeat the point,
stop or move to the next point.
Information: If the user selects Next point, the robot controller does not
reset the input for the compensation cylinder to FALSE, but rather leaves
it on TRUE.
If it is not desired to have the input remain on TRUE, the user must reset
it. For this, select Display > Inputs/outputs > Digital outputs in the
main menu and set the input to FALSE.
One or two inputs may be affected. The relevant outputs to the PLC are:
• Compensation cylinder 1
• Compensation cylinder 2
(>>> "PLC outputs" Page 44)

10.3 System messages from module: ServoGunMessages

10.3.1 ServoGunMessages 00101

Message code ServoGunMessages 00101

Message text The command force is lower than the switch-on threshold for force
control!
Message type Notification message

Possible cause(s) Cause: Welding force programmed too low (>>> Page 111)
Solution: Correct programming (>>> Page 112)

Cause: Welding force programmed too low

Description

If welding commands are programmed by means of KRL (Expert user

group) and not using inline forms, it is possible for welding forces to be
programmed that are lower than the switch-on threshold for force control.
Such welding commands cannot be executed. The switch-on threshold for
force control cannot be modified.

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Messages KUKA.ServoGun Basic 3.0

Checking instructions

• Check the programmed welding force.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

10.3.2 ServoGunMessages 00103

Message code ServoGunMessages 00103

Message text The gun has not yet been recalibrated!
Message type Error message

Possible cause(s) Cause: Recalibration of gun required (>>> Page 112)

Solution: Carry out recalibration of gun (>>> Page 112)

Cause: Recalibration of gun required

Description

The gun must be recalibrated.

Solution: Carry out recalibration of gun

Description

Recalibrate the weld gun.

Each of the 5 calibration positions is addressed and the actual force re-
corded.
WARNING
During calibration, the gun closes at process velocity, not at reduced ve-
locity.

Accessories

• KUKA CFS10
• Or a different force gauge
(if necessary, consult gun manufacturer for a suitable model)

Precondition

• The gun is mastered.

• The gear ratio has been entered.
• The thickness of the force gauge has been entered.
• The maximum gun force is known.

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Messages
• Calibration positions have been entered.
• Coarse calibration has been carried out.
• New electrode tips
(Only required for start-up. Not required if fine calibration is carried out
separately during standard operation.)
• User group “Expert”
• T1 or T2 mode

WARNING
For calibration in T2, no force gauge may be used that requires the op-
erator to be present in the safeguarded area during operation. There
must be no persons inside the safeguarded area during operation in T2
mode. Death to persons or severe injuries may otherwise result.
A suitable force gauge for calibration in T2 is the KUKA CFS10, for ex-
ample.

Procedure

Procedure with KUKA CFS10:

1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Recalibration.
3. Attach KUKA CFS10.
4. Press and hold down the enabling switch.
5. Press Start measurement next to the display of the first target force.
a. A message indicates that the gun will close after confirmation.
Confirm the message.
b. The gun closes until the target force is reached.
c. The force value is automatically entered in the Actual force box.
If necessary, the gun may close up to 5 times for this purpose.
d. The gun moves back to the starting position.
6. Repeat the operation for each of the other 4 calibration points.
7. Exit the Recalibration page. The values are saved automatically.
Procedure with a different force gauge:
1. In the main menu, select Configuration > ServoGun.
The ServoGun configuration window opens.
2. Select Recalibration.
3. If required: modify the values in the Target force column.
The Target force column contains the forces determined during
coarse calibration. If required, the user can manually modify individual
values or all of these values.
If the Actual force column already contains values: modifying a Tar-
get force value automatically deletes the corresponding Actual force
value and all subsequent ones, as they are now no longer valid.
4. Press and hold down the enabling switch.
5. Press Start measurement next to the display of the first target force.
The following message is displayed: Please release the enabling
switch. After confirmation of the dialog and repeated pressing of
the enabling switch, the robot moves the selected gun.
6. Confirm the message with OK.
The following message is displayed: Measurement is running...
7. Release the enabling switch.

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Messages KUKA.ServoGun Basic 3.0

8. Hold the force gauge in the gun.

9. Press the enabling switch again and hold it down.
The gun now closes automatically until the target force has been
reached and remains closed for approx. 2 s.
10. While the gun is closed: read the force value.
Once the 2 s have elapsed, the gun opens to the starting position
again.
11. Enter the force value in the Actual force box with the unit indicated.
12. Repeat the operation for each of the other 4 calibration points.
13. Exit the Recalibration page. The values are saved automatically.

10.3.3 ServoGunMessages 00104

Message code ServoGunMessages 00104

Message text Initialization error. The electrode burn-off is out of tolerance!
Message type Error message

Possible cause(s) Cause: Excessive wear on electrode tips (>>> Page 114)
Solution: Use new electrode tips (>>> Page 114)

Cause: The gun is not correctly mastered. (>>> Page 114)

Solution: Master the gun. (>>> Page 115)

Cause: Maximum permissible tip wear configured incorrectly

(>>> Page 115)
Solution: Correct the configuration with WorkVisual. (>>> Page 115)

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

Solution: Use new electrode tips

Description

Exchange the electrode tips.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is

as follows:

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Messages
Precondition

• T1 mode
• New electrode tips

Inspection instructions

1. In the main menu, select Display > Actual position. The Robot po-
sition window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.
3. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
4. Read the value in the Pos. [deg, mm] column, in the E[Axis no.] line,
in the Robot position window:
• If the value has a zero before the comma, the mastering is correct.
• If the value has a different digit before the comma, the mastering
is incorrect.

Solution: Master the gun.

Depending on the option package used, different mastering methods

may be available.
Information about mastering is contained in the documentation of the
relevant option package.

Cause: Maximum permissible tip wear configured incorrectly

Description

The value for the maximum permissible tip wear has been configured in-
correctly. The value is configured via the parameter Maximum tip wear.
The procedure for checking the configuration of the tip wear is as
follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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Messages KUKA.ServoGun Basic 3.0

10.3.4 ServoGunMessages 00105

Message code ServoGunMessages 00105

Message text Command force is higher than the maximum gun force
Message type Notification message

Possible cause(s) Cause: Welding force set too high (>>> Page 116)
Solution: Correct programming (>>> Page 116)

Cause: Welding force set too high

Description

If welding commands are programmed by means of KRL (Expert user

group) and not using inline forms, it is possible for welding forces to be
programmed that are higher than the maximum force of the gun. Such
welding commands cannot be executed.
The maximum force is configured via the parameter Maximum gun force.
The procedure for checking which maximum force is configured is
as follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

10.3.5 ServoGunMessages 00106

Message code ServoGunMessages 00106

Message text Incorrect force gauge thickness!
Message type Error message

Possible cause(s) Cause: Force gauge thickness incorrectly configured

(>>> Page 117)
Solution: Correct the configuration on the controller (>>> Page 117)

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Cause: Force gauge thickness incorrectly configured

Messages
Description

The parameter Force gauge thickness was configured incorrectly.

The procedure for checking which force gauge thickness is config-
ured is as follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct the configuration on the controller

Description

Correct the configuration on the controller.

This activity must be carried out in accordance with the procedure de-
scribed in the operating and programming instructions.

10.3.6 ServoGunMessages 00107

Message code ServoGunMessages 00107

Message text Action cannot be performed because the gun is decoupled.
Message type Error message

Possible cause(s) Cause: The gun has been decoupled by the software.
(>>> Page 117)
Solution: If necessary, decouple the other gun. Couple the desired
gun. (>>> Page 118)

Cause: The gun has been decoupled by the software.

Description

The action cannot be performed with the desired gun, as this gun has
been decoupled. A different gun may still be coupled.
The procedure for checking whether a different gun is coupled is as
follows:

Precondition:

• The total number of configured guns is known.

Inspection instructions

1. Touch the message in the message window. The message window ex-
pands and all active messages are displayed.
2. Check whether the following message is displayed for every gun:

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 KUKA.ServoGun Basic 3.0

{Axis number} decoupled external axis

Messages

If this message is not displayed for one gun, this gun is coupled.

Solution: If necessary, decouple the other gun. Couple the desired gun.

• When coupling a gun that has not yet been mastered, the opening
width of the gun is not relevant.
• When decoupling a mastered gun, the gun must not be in the mas-
tering position or a multiple thereof (360°, 720° motor revolution).
Mastering is otherwise lost on recoupling.
• On recoupling, the gun must have the same opening width as when
it was decoupled. If this is not the case, the mastering will be lost.

Information on coupling/decoupling guns can be found in the documen-

tation of the ServoGun option package.

10.3.7 ServoGunMessages 00108

Message code ServoGunMessages 00108

Message text The selected gun has not yet been calibrated.
Message type Error message

Possible cause(s) Cause: Gun is not calibrated (>>> Page 118)

Solution: Calibrate the gun (>>> Page 118)

Cause: Gun is not calibrated

Description

The selected weld gun has not yet been calibrated.

Solution: Calibrate the gun

NOTICE
Calibration must be performed on the same system on which the gun is
subsequently operated. If calibration is carried out on a different system,
if the system is modified after calibration, or if a necessary step is left
out, the results could be failure to weld, faulty welding and/or damage to
property.

The accuracy that can be achieved during calibration depends on the

specific gun and motor.

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Messages
Overview

Step Description
1 Precalibration
Defines the calibration positions.
2 Coarse calibration
The calibration positions are addressed and the correspond-
ing forces are measured.
3 Fine calibration
Each of the target forces determined during coarse calibra-
tion is addressed. The actual force is recorded.
4 Force test
Move the gun to defined setpoint forces and measure the
resulting actual forces.
5 Necessary if the force test results in too high a deviation
between the setpoint and actual force values:

• Repeat fine calibration

Tip for standard operation: If the gun does not always reach the precise
required force after a certain period of time, then the gun needs to un-
dergo fine calibration again (= recalibration). Depending on the required
force accuracy, the customer must establish an appropriate recalibration
schedule.

10.3.8 ServoGunMessages 00109

Message code ServoGunMessages 00109

Message text New electrode tips required!
Message type Error message

Possible cause(s) Cause: Excessive wear on electrode tips (>>> Page 119)
Solution: Use new electrode tips (>>> Page 119)

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

Solution: Use new electrode tips

Description

Exchange the electrode tips.

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Messages KUKA.ServoGun Basic 3.0

10.3.9 ServoGunMessages 00110

Message code ServoGunMessages 00110

Message text Incorrect gun position; repeat point?
Message type Dialog message

Possible cause(s) Cause: The value set for the workpiece thickness in the inline form
is invalid. (>>> Page 120)
Solution: Change the value in the inline form. (>>> Page 120)

Cause: Excessive wear on electrode tips (>>> Page 120)

Solution: Use new electrode tips (>>> Page 121)

Cause: The gun is not correctly mastered. (>>> Page 121)

Solution: Master the gun. (>>> Page 121)

Cause: The value set for the workpiece thickness in the inline form is invalid.

Description

In the Part box (= workpiece thickness) in the inline form, a value has
been set that does not correspond to the actual thickness.
The value must specify the total thickness of the workpieces to be welded.

Solution: Change the value in the inline form.

Precondition

• Program is selected or open.

• T1, T2 or AUT mode
• The overall thickness of the workpieces to be welded has been meas-
ured and is known.

Procedure

1. Position the cursor in the line with the inline form that is to be modi-
fied.
2. Press the Change button. The inline form is opened.
3. Modify the value.
4. Save the change by pressing Cmd Ok.

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

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Solution: Use new electrode tips

Messages
Description

Exchange the electrode tips.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is

as follows:

Precondition

• T1 mode
• New electrode tips

Inspection instructions

1. In the main menu, select Display > Actual position. The Robot po-
sition window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.
3. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
4. Read the value in the Pos. [deg, mm] column, in the E[Axis no.] line,
in the Robot position window:
• If the value has a zero before the comma, the mastering is correct.
• If the value has a different digit before the comma, the mastering
is incorrect.

Solution: Master the gun.

Depending on the option package used, different mastering methods

may be available.
Information about mastering is contained in the documentation of the
relevant option package.

10.3.10 ServoGunMessages 00111

Message code ServoGunMessages 00111

Message text No WELD END signal, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 122)
Solution: Correct the configuration with WorkVisual. (>>> Page 122)

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 KUKA.ServoGun Basic 3.0

Cause: Signal incorrectly configured or mapped

Messages

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.11 ServoGunMessages 00112

Message code ServoGunMessages 00112

Message text Programmed force not reached; repeat point?
Message type Dialog message

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Messages
Possible cause(s) Cause: The value set for the workpiece thickness in the inline form
is invalid. (>>> Page 123)
Solution: Change the value in the inline form. (>>> Page 123)

Cause: Excessive wear on electrode tips (>>> Page 123)

Solution: Use new electrode tips (>>> Page 123)

Cause: The gun is not correctly mastered. (>>> Page 124)

Solution: Master the gun. (>>> Page 124)

Cause: Gun incorrectly positioned against the sheet metal

(>>> Page 124)
Solution: Reteaching points (>>> Page 125)

Cause: The value set for the workpiece thickness in the inline form is invalid.

Description

In the Part box (= workpiece thickness) in the inline form, a value has
been set that does not correspond to the actual thickness.
The value must specify the total thickness of the workpieces to be welded.

Solution: Change the value in the inline form.

Precondition

• Program is selected or open.

• T1, T2 or AUT mode
• The overall thickness of the workpieces to be welded has been meas-
ured and is known.

Procedure

1. Position the cursor in the line with the inline form that is to be modi-
fied.
2. Press the Change button. The inline form is opened.
3. Modify the value.
4. Save the change by pressing Cmd Ok.

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

Solution: Use new electrode tips

Description

Exchange the electrode tips.

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 KUKA.ServoGun Basic 3.0

Cause: The gun is not correctly mastered.

Messages

The procedure for checking whether the gun is correctly mastered is

as follows:

Precondition

• T1 mode
• New electrode tips

Inspection instructions

1. In the main menu, select Display > Actual position. The Robot po-
sition window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.
3. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
4. Read the value in the Pos. [deg, mm] column, in the E[Axis no.] line,
in the Robot position window:
• If the value has a zero before the comma, the mastering is correct.
• If the value has a different digit before the comma, the mastering
is incorrect.

Solution: Master the gun.

Depending on the option package used, different mastering methods

may be available.
Information about mastering is contained in the documentation of the
relevant option package.

Cause: Gun incorrectly positioned against the sheet metal

Description

The moving electrode is positioned against the sheet metal. The fixed
electrode is not positioned against the sheet metal. The gun is therefore
incorrectly positioned against the sheet metal for executing a spot weld.
The procedure for checking whether the weld gun is correctly posi-
tioned is as follows:

Checking instructions

1. Check whether the fixed electrode is positioned against the sheet met-
al.
2. Check whether the moving electrode is positioned away from the
sheet metal.

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Messages
Distances

The following distances are required for the position of the gun during
teaching:
Electrode Distance
Moving electrode Min. 30 mm from workpiece
Fixed electrode 0 mm from workpiece
The fixed electrode must be in contact
with the workpiece, without exerting any
force on it.

Solution: Reteaching points

Description

The coordinates of a taught point can be modified. This is done by mov-

ing to the new position and overwriting the old point with the new position.

Precondition

• A program is selected.
• Operating mode T1

Procedure

1. Move the TCP to the desired position.

2. Position the cursor in the line containing the motion instruction that is
to be changed.
3. Press Change. The inline form for this instruction is opened.
4. For PTP and LIN motions: Press Touch Up to accept the current po-
sition of the TCP as the new end point.
For CIRC motions:
• Press Teach Aux to accept the current position of the TCP as the
new auxiliary point.
• Or press Teach End to accept the current position of the TCP as
the new end point.
5. Confirm the request for confirmation with Yes.
6. Save change by pressing Cmd Ok.

10.3.12 ServoGunMessages 00113

Message code ServoGunMessages 00113

Message text Welding error from welding controller, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 126)
Solution: Correct the configuration with WorkVisual. (>>> Page 126)

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 KUKA.ServoGun Basic 3.0

Cause: Signal incorrectly configured or mapped

Messages

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.13 ServoGunMessages 00114

Message code ServoGunMessages 00114

Message text Welding start signal is already true, output {Output}; repeat point?
Message type Dialog message

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Messages
Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 127)
Solution: Correct the configuration with WorkVisual. (>>> Page 127)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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Messages KUKA.ServoGun Basic 3.0

10.3.14 ServoGunMessages 00115

Message code ServoGunMessages 00115

Message text Weld end signal already set before welding, input {Input}; reset weld
timer and repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 128)
Solution: Correct the configuration with WorkVisual. (>>> Page 129)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

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Solution: Correct the configuration with WorkVisual.

Messages
Procedure

• Correct the configuration with WorkVisual.

10.3.15 ServoGunMessages 00116

Message code ServoGunMessages 00116

Message text The command force is lower than the switch-on threshold for force
control; repeat point?
Message type Dialog message

Possible cause(s) Cause: Welding force programmed too low (>>> Page 129)
Solution: Correct programming (>>> Page 129)

Cause: Welding force programmed too low

Description

If welding commands are programmed by means of KRL (Expert user

group) and not using inline forms, it is possible for welding forces to be
programmed that are lower than the switch-on threshold for force control.
Such welding commands cannot be executed. The switch-on threshold for
force control cannot be modified.

Checking instructions

• Check the programmed welding force.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

10.3.16 ServoGunMessages 00117

Message code ServoGunMessages 00117

Message text Program number from weld timer not accepted!
Message type Error message

Possible cause(s) Cause: Program number not saved in weld timer (>>> Page 130)
Solution: Use a valid program number (>>> Page 130)

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Messages KUKA.ServoGun Basic 3.0

Cause: ServoGun configured I/O range for program number too

small (>>> Page 130)
Solution: Use a valid program number (>>> Page 130)

Cause: Program number not saved in weld timer (>>> Page 130)
Solution: Adapt the configuration of the weld timer (>>> Page 131)

Cause: ServoGun configured I/O range for program number too

small (>>> Page 131)
Solution: Correct the configuration with WorkVisual. (>>> Page 131)

Cause: Program number not saved in weld timer

Description

The requested program number is not saved in the weld timer.

Solution: Use a valid program number

Description

Use a valid program number (ProgNr) in the inline form.

Cause: ServoGun configured I/O range for program number too small

Description

The address range for transfer of the program number to the weld timer is
configurable. The bit width must not exceed 32 bits.
The procedure for checking the configured address range in WorkVi-
sual is as follows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the address range in the Program number boxes in the Weld
timer outputs area.

Solution: Use a valid program number

Description

Use a valid program number (ProgNr) in the inline form.

Cause: Program number not saved in weld timer

Description

The requested program number is not saved in the weld timer.

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Solution: Adapt the configuration of the weld timer

Messages
Description

Check the configuration of the weld timer and adapt it if necessary.

Information on configuration of the weld timer can be found in the man-
ufacturer documentation for the weld timer.

Cause: ServoGun configured I/O range for program number too small

Description

The address range for transfer of the program number to the weld timer is
configurable. The bit width must not exceed 32 bits.
The procedure for checking the configured address range in WorkVi-
sual is as follows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the address range in the Program number boxes in the Weld
timer outputs area.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.17 ServoGunMessages 00119

Message code ServoGunMessages 00119

Message text Command force is higher than the maximum gun force; repeat
point?
Message type Dialog message

Possible cause(s) Cause: Welding force set too high (>>> Page 131)
Solution: Correct programming (>>> Page 132)

Cause: Welding force set too high

Description

If welding commands are programmed by means of KRL (Expert user

group) and not using inline forms, it is possible for welding forces to be
programmed that are higher than the maximum force of the gun. Such
welding commands cannot be executed.

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 KUKA.ServoGun Basic 3.0

The maximum force is configured via the parameter Maximum gun force.
Messages

The procedure for checking which maximum force is configured is

as follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

10.3.18 ServoGunMessages 00120

Message code ServoGunMessages 00120

Message text No WELD TIMER READY signal, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 132)
Solution: Correct the configuration with WorkVisual. (>>> Page 133)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.

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Messages
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.19 ServoGunMessages 00121

Message code ServoGunMessages 00121

Message text Process monitoring is disabled, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 133)
Solution: Correct the configuration with WorkVisual. (>>> Page 134)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.

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Messages KUKA.ServoGun Basic 3.0

2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.20 ServoGunMessages 00122

Message code ServoGunMessages 00122

Message text No CURRENT ON signal, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 134)
Solution: Correct the configuration with WorkVisual. (>>> Page 135)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

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Messages
Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.21 ServoGunMessages 00123

Message code ServoGunMessages 00123

Message text No WATER MONITOR SUPPLY signal, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Error in the cooling circuit (>>> Page 136)
Solution: Eliminate periphery fault (>>> Page 136)

Cause: Signal incorrectly configured or mapped (>>> Page 136)

Solution: Correct the configuration with WorkVisual. (>>> Page 137)

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 KUKA.ServoGun Basic 3.0

Cause: Error in the cooling circuit

Messages

Description

The cooling circuit is not working correctly.

Checking instructions

1. Check the coolant supply.

2. Check the coolant flow.
3. Check the cooling circuit for leaks.
The exact procedure depends on the peripheral equipment used.

Solution: Eliminate periphery fault

Procedure

• Eliminate the periphery fault.

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

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Messages
Information on configuration of the weld timer can be found in the man-
ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.22 ServoGunMessages 00124

Message code ServoGunMessages 00124

Message text No THERMO CONTACT, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 137)
Solution: Correct the configuration with WorkVisual. (>>> Page 138)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

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Messages KUKA.ServoGun Basic 3.0

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.23 ServoGunMessages 00125

Message code ServoGunMessages 00125

Message text Caution! Weld timer type is TEST!
Message type Notification message

Possible cause(s) Cause: Welding not possible, as test timer is active (>>> Page 138)
Solution: Correct the configuration on the controller (>>> Page 138)

Cause: Welding not possible, as test timer is active

Description

Welding cannot be carried out if Test timer is selected as the weld timer.
The procedure for checking whether the test timer is active is as fol-
lows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Press the Weld timer button.
3. Select the entry Test timer under Weld timer selection.
4. Check whether the check box at Test timer active has been activa-
ted.

Solution: Correct the configuration on the controller

Description

Correct the configuration on the controller.

This activity must be carried out in accordance with the procedure de-
scribed in the operating and programming instructions.

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Messages
10.3.24 ServoGunMessages 00128

Message code ServoGunMessages 00128

Message text Tip wear is out of tolerance. Please check the tip wear and the gun
mastering! Do you want to proceed?
Message type Dialog message

Possible cause(s) Cause: The value set for the workpiece thickness in the inline form
is invalid. (>>> Page 139)
Solution: Change the value in the inline form. (>>> Page 139)

Cause: Excessive wear on electrode tips (>>> Page 139)

Solution: Use new electrode tips (>>> Page 140)

Cause: The gun is not correctly mastered. (>>> Page 140)

Solution: Master the gun. (>>> Page 140)

Cause: The value set for the workpiece thickness in the inline form is invalid.

Description

In the Part box (= workpiece thickness) in the inline form, a value has
been set that does not correspond to the actual thickness.
The value must specify the total thickness of the workpieces to be welded.

Solution: Change the value in the inline form.

Precondition

• Program is selected or open.

• T1, T2 or AUT mode
• The overall thickness of the workpieces to be welded has been meas-
ured and is known.

Procedure

1. Position the cursor in the line with the inline form that is to be modi-
fied.
2. Press the Change button. The inline form is opened.
3. Modify the value.
4. Save the change by pressing Cmd Ok.

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

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 KUKA.ServoGun Basic 3.0

Solution: Use new electrode tips

Messages

Description

Exchange the electrode tips.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is

as follows:

Precondition

• T1 mode
• New electrode tips

Inspection instructions

1. In the main menu, select Display > Actual position. The Robot po-
sition window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.
3. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
4. Read the value in the Pos. [deg, mm] column, in the E[Axis no.] line,
in the Robot position window:
• If the value has a zero before the comma, the mastering is correct.
• If the value has a different digit before the comma, the mastering
is incorrect.

Solution: Master the gun.

Depending on the option package used, different mastering methods

may be available.
Information about mastering is contained in the documentation of the
relevant option package.

10.3.25 ServoGunMessages 00129

Message code ServoGunMessages 00129

Message text No WATER MONITOR RETURN signal, input {Input}; repeat point?
Message type Dialog message

Possible cause(s) Cause: Error in the cooling circuit (>>> Page 141)
Solution: Eliminate periphery fault (>>> Page 141)

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Messages
Cause: Signal incorrectly configured or mapped (>>> Page 141)
Solution: Correct the configuration with WorkVisual. (>>> Page 142)

Cause: Error in the cooling circuit

Description

The cooling circuit is not working correctly.

Checking instructions

1. Check the coolant supply.

2. Check the coolant flow.
3. Check the cooling circuit for leaks.
The exact procedure depends on the peripheral equipment used.

Solution: Eliminate periphery fault

Procedure

• Eliminate the periphery fault.

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

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Messages KUKA.ServoGun Basic 3.0

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.26 ServoGunMessages 00135

Message code ServoGunMessages 00135

Message text Please switch to 100% OV and T2/AUT
Message type Notification message

Possible cause(s) Cause: The action must be executed at process velocity

(>>> Page 142)
Solution: Change operating mode (>>> Page 142)

Cause: The action must be executed at process velocity

Description

The action must be executed at process velocity. Process velocity is

reached at 100% override in T2 or AUT mode.

Solution: Change operating mode

Do not change the operating mode while a program is running. If the

operating mode is changed during program execution, the industrial ro-
bot is stopped with a safety stop 2.

Precondition

• The robot controller is not executing a program.

• If the mode selector switch is the variant with a key: the key is inser-
ted in the switch.

Procedure

1. Turn the mode selector switch on the smartPAD. The connection man-
ager is displayed.
2. Select the operating mode.
3. Return the mode selector switch to its original position.
The selected operating mode is displayed in the status bar of the
smartPAD.

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Messages
KR C4 operating modes

Operating
Use Velocities
mode

• Program verification:
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
• Program verification:
T2 For test operation Programmed velocity
• Jog mode: Not possible

For industrial robots • Program operation:

AUT without higher-level Programmed velocity
controllers • Jog mode: Not possible

For industrial robots • Program operation:

AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible

VKR C4 operating modes

Operating
Use Velocities
mode

• Program verification:
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
• Program verification:
T2 For test operation Programmed velocity
• Jog mode: Not possible

For industrial robots • Program operation:

EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible

10.3.27 ServoGunMessages 00149

Message code ServoGunMessages 00149

Message text Incorrect gun position!
Message type Notification message

Possible cause(s) Cause: The value set for the workpiece thickness in the inline form
is invalid. (>>> Page 144)
Solution: Change the value in the inline form. (>>> Page 144)

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Messages KUKA.ServoGun Basic 3.0

Cause: Excessive wear on electrode tips (>>> Page 144)

Solution: Use new electrode tips (>>> Page 144)

Cause: Workpiece thickness outside permissible deviation

(>>> Page 145)
Solution: Correct programming (>>> Page 145)

Cause: The gun is not correctly mastered. (>>> Page 145)

Solution: Master the gun. (>>> Page 146)

Cause: The value set for the workpiece thickness in the inline form is invalid.

Description

In the Part box (= workpiece thickness) in the inline form, a value has
been set that does not correspond to the actual thickness.
The value must specify the total thickness of the workpieces to be welded.

Solution: Change the value in the inline form.

Precondition

• Program is selected or open.

• T1, T2 or AUT mode
• The overall thickness of the workpieces to be welded has been meas-
ured and is known.

Procedure

1. Position the cursor in the line with the inline form that is to be modi-
fied.
2. Press the Change button. The inline form is opened.
3. Modify the value.
4. Save the change by pressing Cmd Ok.

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

Solution: Use new electrode tips

Description

Exchange the electrode tips.

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Cause: Workpiece thickness outside permissible deviation

Messages
Description

The workpiece thickness is outside the permissible deviation.

For example, if the thickness is 2 mm and the permissible deviation is
1 mm, then the total thickness may lie between 1 and 3 mm.
The procedure for checking the value of the permissible deviation is
as follows:

Checking instructions

• If the value is programmed using inline forms:

Under the parameter PartTol in the inline form of the welding com-
mand
• If the value is supplied by the weld timer:
In the configuration of the weld timer
The source of the value for the permissible deviation is configured in
WorkVisual by means of the parameter Part thickness tolerance from
weld timer under Weld timer settings.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is

as follows:

Precondition

• T1 mode
• New electrode tips

Inspection instructions

1. In the main menu, select Display > Actual position. The Robot po-
sition window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.
3. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
4. Read the value in the Pos. [deg, mm] column, in the E[Axis no.] line,
in the Robot position window:

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Messages KUKA.ServoGun Basic 3.0

• If the value has a zero before the comma, the mastering is correct.
• If the value has a different digit before the comma, the mastering
is incorrect.

Solution: Master the gun.

Depending on the option package used, different mastering methods

may be available.
Information about mastering is contained in the documentation of the
relevant option package.

10.3.28 ServoGunMessages 00153

Message code ServoGunMessages 00153

Message text Tip wear is out of tolerance. Please check the tip wear and the gun
mastering!
Message type Notification message

Possible cause(s) Cause: Excessive wear on electrode tips (>>> Page 146)
Solution: Use new electrode tips (>>> Page 146)

Cause: The tips are incorrect or of the wrong length.

(>>> Page 147)
Solution: Use tips of the correct length; fit the tips correctly.
(>>> Page 147)

Cause: The gun is not correctly mastered. (>>> Page 147)

Solution: Master the gun. (>>> Page 147)

Cause: Maximum permissible tip wear configured incorrectly

(>>> Page 148)
Solution: Correct the configuration with WorkVisual. (>>> Page 148)

Cause: Excessive wear on electrode tips

Description

The wear on the electrode tips is greater than the maximum permissible
wear.

Checking instructions

• Perform a visual inspection of the electrode tips.

Solution: Use new electrode tips

Description

Exchange the electrode tips.

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 KUKA.ServoGun Basic 3.0

Cause: The tips are incorrect or of the wrong length.

Messages
Description

During first initialization, the robot controller compares the position of the
gun with the mastering position. A tolerance range is taken into consider-
ation. The tolerance range may have been exceeded for the following rea-
sons:
• Tips of a different length have been fitted than those with which the
gun was mastered.
• The tips are not seated correctly, e.g. because metal swarf has got
beneath the tips.

Solution: Use tips of the correct length; fit the tips correctly.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is

as follows:

Precondition

• T1 mode
• New electrode tips

Inspection instructions

1. In the main menu, select Display > Actual position. The Robot po-
sition window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.
3. Close the gun manually with the jog keys until the electrodes are just
touching.
NOTICE
The gun must not exert any force, otherwise it may become dam-
aged.

Whether or not the electrodes are just touching can be ascertained by

a visual check, or using a strip of paper held between the electrodes.
(Close the gun until the strip of paper is lightly clamped.)
4. Read the value in the Pos. [deg, mm] column, in the E[Axis no.] line,
in the Robot position window:
• If the value has a zero before the comma, the mastering is correct.
• If the value has a different digit before the comma, the mastering
is incorrect.

Solution: Master the gun.

Depending on the option package used, different mastering methods

may be available.
Information about mastering is contained in the documentation of the
relevant option package.

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 KUKA.ServoGun Basic 3.0

Cause: Maximum permissible tip wear configured incorrectly

Messages

Description

The value for the maximum permissible tip wear has been configured in-
correctly. The value is configured via the parameter Maximum tip wear.
The procedure for checking the configuration of the tip wear is as
follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.29 ServoGunMessages 00154

Message code ServoGunMessages 00154

Message text Motor current limit exceeded!
Message type Notification message

Possible cause(s) Cause: Welding force set too high (>>> Page 148)
Solution: Correct programming (>>> Page 149)

Cause: Gun is not calibrated (>>> Page 149)

Solution: Calibrate the gun (>>> Page 149)

Cause: Welding force set too high

Description

If welding commands are programmed by means of KRL (Expert user

group) and not using inline forms, it is possible for welding forces to be
programmed that are higher than the maximum force of the gun. Such
welding commands cannot be executed.
The maximum force is configured via the parameter Maximum gun force.
The procedure for checking which maximum force is configured is
as follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

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Solution: Correct programming

Messages
Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Gun is not calibrated

Description

The selected weld gun has not yet been calibrated.

Solution: Calibrate the gun

NOTICE
Calibration must be performed on the same system on which the gun is
subsequently operated. If calibration is carried out on a different system,
if the system is modified after calibration, or if a necessary step is left
out, the results could be failure to weld, faulty welding and/or damage to
property.

The accuracy that can be achieved during calibration depends on the

specific gun and motor.

Overview

Step Description
1 Precalibration
Defines the calibration positions.
2 Coarse calibration
The calibration positions are addressed and the correspond-
ing forces are measured.
3 Fine calibration
Each of the target forces determined during coarse calibra-
tion is addressed. The actual force is recorded.
4 Force test
Move the gun to defined setpoint forces and measure the
resulting actual forces.
5 Necessary if the force test results in too high a deviation
between the setpoint and actual force values:

• Repeat fine calibration

Tip for standard operation: If the gun does not always reach the precise
required force after a certain period of time, then the gun needs to un-
dergo fine calibration again (= recalibration). Depending on the required
force accuracy, the customer must establish an appropriate recalibration
schedule.

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Messages KUKA.ServoGun Basic 3.0

10.3.30 ServoGunMessages 00155

Message code ServoGunMessages 00155

Message text Motor current limit exceeded; repeat point?
Message type Dialog message

Possible cause(s) Cause: Welding force set too high (>>> Page 150)
Solution: Correct programming (>>> Page 150)

Cause: Gun is not calibrated (>>> Page 150)

Solution: Calibrate the gun (>>> Page 151)

Cause: Welding force set too high

Description

If welding commands are programmed by means of KRL (Expert user

group) and not using inline forms, it is possible for welding forces to be
programmed that are higher than the maximum force of the gun. Such
welding commands cannot be executed.
The maximum force is configured via the parameter Maximum gun force.
The procedure for checking which maximum force is configured is
as follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Gun is not calibrated

Description

The selected weld gun has not yet been calibrated.

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Solution: Calibrate the gun

Messages
NOTICE
Calibration must be performed on the same system on which the gun is
subsequently operated. If calibration is carried out on a different system,
if the system is modified after calibration, or if a necessary step is left
out, the results could be failure to weld, faulty welding and/or damage to
property.

The accuracy that can be achieved during calibration depends on the

specific gun and motor.

Overview

Step Description
1 Precalibration
Defines the calibration positions.
2 Coarse calibration
The calibration positions are addressed and the correspond-
ing forces are measured.
3 Fine calibration
Each of the target forces determined during coarse calibra-
tion is addressed. The actual force is recorded.
4 Force test
Move the gun to defined setpoint forces and measure the
resulting actual forces.
5 Necessary if the force test results in too high a deviation
between the setpoint and actual force values:

• Repeat fine calibration

Tip for standard operation: If the gun does not always reach the precise
required force after a certain period of time, then the gun needs to un-
dergo fine calibration again (= recalibration). Depending on the required
force accuracy, the customer must establish an appropriate recalibration
schedule.

10.3.31 ServoGunMessages 00156

Message code ServoGunMessages 00156

Message text Weld end signal already set before welding, input {Output}!
Message type Notification message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 152)
Solution: Correct the configuration with WorkVisual. (>>> Page 152)

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 KUKA.ServoGun Basic 3.0

Cause: Signal incorrectly configured or mapped

Messages

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.32 ServoGunMessages 00158

Message code ServoGunMessages 00158

Message text Programmed force not reached!
Message type Notification message

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Messages
Possible cause(s) Cause: Gun incorrectly positioned against the sheet metal
(>>> Page 153)
Solution: Reteaching points (>>> Page 153)

Cause: Gun incorrectly positioned against the sheet metal

Description

The moving electrode is positioned against the sheet metal. The fixed
electrode is not positioned against the sheet metal. The gun is therefore
incorrectly positioned against the sheet metal for executing a spot weld.
The procedure for checking whether the weld gun is correctly posi-
tioned is as follows:

Checking instructions

1. Check whether the fixed electrode is positioned against the sheet met-
al.
2. Check whether the moving electrode is positioned away from the
sheet metal.

Distances

The following distances are required for the position of the gun during
teaching:
Electrode Distance
Moving electrode Min. 30 mm from workpiece
Fixed electrode 0 mm from workpiece
The fixed electrode must be in contact
with the workpiece, without exerting any
force on it.

Solution: Reteaching points

Description

The coordinates of a taught point can be modified. This is done by mov-

ing to the new position and overwriting the old point with the new position.

Precondition

• A program is selected.
• Operating mode T1

Procedure

1. Move the TCP to the desired position.

2. Position the cursor in the line containing the motion instruction that is
to be changed.
3. Press Change. The inline form for this instruction is opened.
4. For PTP and LIN motions: Press Touch Up to accept the current po-
sition of the TCP as the new end point.
For CIRC motions:
• Press Teach Aux to accept the current position of the TCP as the
new auxiliary point.

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Messages KUKA.ServoGun Basic 3.0

• Or press Teach End to accept the current position of the TCP as

the new end point.
5. Confirm the request for confirmation with Yes.
6. Save change by pressing Cmd Ok.

10.3.33 ServoGunMessages 00160

Message code ServoGunMessages 00160

Message text No CURRENT ON signal, input {Input}!
Message type Notification message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 154)
Solution: Correct the configuration with WorkVisual. (>>> Page 155)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

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Messages
Information on configuration of the weld timer can be found in the man-
ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.34 ServoGunMessages 00163

Message code ServoGunMessages 00163

Message text No WELD END signal, input {Input}!
Message type Notification message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 155)
Solution: Correct the configuration with WorkVisual. (>>> Page 156)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

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Messages KUKA.ServoGun Basic 3.0

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.35 ServoGunMessages 00164

Message code ServoGunMessages 00164

Message text No WELD TIMER READY signal, input {Input}!
Message type Notification message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 156)
Solution: Correct the configuration with WorkVisual. (>>> Page 157)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.

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Messages
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.36 ServoGunMessages 00167

Message code ServoGunMessages 00167

Message text Welding start signal is already true, output {Output}!
Message type Notification message

Possible cause(s) Cause: Signal incorrectly configured or mapped (>>> Page 157)
Solution: Correct the configuration with WorkVisual. (>>> Page 158)

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

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Messages KUKA.ServoGun Basic 3.0

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.37 ServoGunMessages 00206

Message code ServoGunMessages 00206

Message text Wrong wear ratio configured
Message type Error message

Possible cause(s) Cause: Burn-off ratio incorrectly configured (>>> Page 158)
Solution: Correct the configuration with WorkVisual. (>>> Page 159)

Cause: Burn-off ratio incorrectly configured

Description

Method for determining the tip burn-off:

• Ratio in %: The overall burn-off is calculated. The robot controller as-
signs the burn-off to the two electrodes using a defined ratio. (Default:
50:50).
The ratio can be configured via the parameter Burn-off ratio.
The robot controller assigns the burn-off to the two electrodes using this
ratio. The value refers to the moving electrode.
The parameter Ratio in % must have a value between 0 and 100.
The procedure for checking what value is set for the burn-off ratio is
as follows:

Checking instructions

1. In the main menu, select Configuration > ServoGun.

The configuration plug-in opens.

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Messages
2. Select the gun concerned.
3. Check the value of the parameter.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.38 ServoGunMessages 00210

Message code ServoGunMessages 00210

Message text Gun cannot be coupled since another gun of the coupling group is
coupled.
Message type Error message

Possible cause(s) Cause: The gun has been decoupled by the software.
(>>> Page 159)
Solution: If necessary, decouple the other gun. Couple the desired
gun. (>>> Page 159)

Cause: The gun has been decoupled by the software.

Description

The action cannot be performed with the desired gun, as this gun has
been decoupled. A different gun may still be coupled.
The procedure for checking whether a different gun is coupled is as
follows:

Precondition:

• The total number of configured guns is known.

Inspection instructions

1. Touch the message in the message window. The message window ex-
pands and all active messages are displayed.
2. Check whether the following message is displayed for every gun:
{Axis number} decoupled external axis
If this message is not displayed for one gun, this gun is coupled.

Solution: If necessary, decouple the other gun. Couple the desired gun.

• When coupling a gun that has not yet been mastered, the opening
width of the gun is not relevant.
• When decoupling a mastered gun, the gun must not be in the mas-
tering position or a multiple thereof (360°, 720° motor revolution).
Mastering is otherwise lost on recoupling.
• On recoupling, the gun must have the same opening width as when
it was decoupled. If this is not the case, the mastering will be lost.

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Messages KUKA.ServoGun Basic 3.0

Information on coupling/decoupling guns can be found in the documen-

tation of the ServoGun option package.

10.3.39 ServoGunMessages 00212

Message code ServoGunMessages 00212

Message text Force from weld timer is larger than the maximum force of the weld
gun, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 160)
Solution: Correct the configuration with WorkVisual. (>>> Page 161)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.

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or: Select the weld timer in the tree structure. Select the menu se-

Messages
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.40 ServoGunMessages 00214

Message code ServoGunMessages 00214

Message text Message buffer could not deleted, robot stationary
Message type Error message

Possible cause(s) Cause: Message buffer full (>>> Page 161)

Solution: Empty the message buffer (>>> Page 162)

Cause: Message buffer full

Description

The message buffer contains too many messages that cannot be deleted.
The message buffer can be read as follows:

Description

The function Get_MsgBuffer() reads the message buffer and writes the
messages in the buffer to the OUT parameter MsgBuf[].
The size of the buffer is 150.
Get_MsgBuffer() can read the following message types from the buffer:

• Status messages from the kernel system (#sys_state)

• Acknowledgement messages from the kernel system (#sys_quit)
• User-defined status messages (#usr_state)
• User-defined acknowledgement messages (#usr_quit)
• User-defined dialog messages (#usr_dlg)
• User-defined wait messages (#usr_wait)

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Messages KUKA.ServoGun Basic 3.0

Syntax

count = Get_MsgBuffer(MsgBuf[])

Explanation of the syntax

Element Description
count Type: INT
Return value: Number of messages in the message buf-
fer
This value can be used with a FOR loop for the array
MsgBuf[] to read the details about the messages.
MsgBuf Type: MsgBuf_T; OUT parameter
Array of buffer elements containing all the messages in
the buffer. The array is filled in ascending order, without
gaps, starting with Index=1. If there are fewer messages
in the buffer than represented by the size of the array,
these array elements are not initialized.
Contents of the structure MsgBuf_T:

Solution: Empty the message buffer

Description

The function Clear_KrlMsg() can be used to delete a message. This

means that the message is removed from the message buffer and the
message window.
Notification messages cannot be deleted in this way, as they are not man-
aged in the message buffer. Notification messages can only be deleted
using the buttons OK and Confirm all.

Syntax

result = Clear_KrlMsg(clear)

Explanation of the syntax

Element Description
result Type: BOOL
Return value

• TRUE: The message has been deleted.

• FALSE: The message could not be deleted.
clear IN parameter

• The handle provided by the function Set_KrlMsg():

the message to which the handle refers is deleted.
• -1: All messages initiated by this process are deleted.
• -99: All user-defined messages are deleted. (All pro-
cesses: robot interpreter, Submit interpreter, com-
mand interpreter)

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Messages
10.3.41 ServoGunMessages 00215

Message code ServoGunMessages 00215

Message text Error, block selection or reset required!
Message type Error message

Possible cause(s) Cause: Error in program or during block selection (>>> Page 163)
Solution: Reset program (>>> Page 163)

Cause: Error in program or during block selection (>>> Page 163)

Solution: Carry out block selection (>>> Page 163)

Cause: Error in program or during block selection

Description

The error requires block selection or a restart of the program.

Solution: Reset program

Precondition

• Program is selected.

Procedure

• Select the menu sequence Edit > Reset program.

Alternative procedure

• In the status bar, touch the Robot interpreter status indicator. A win-
dow opens.
Select Reset program.

Cause: Error in program or during block selection

Description

The error requires block selection or a restart of the program.

Solution: Carry out block selection

Description

A program can be started at any point by means of a block selection.

Precondition

• A program is selected.
• Operating mode T1 or T2

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Messages KUKA.ServoGun Basic 3.0

Procedure

1. Select the program run mode.

2. Select the motion block at which the program is to be started.
3. Press Block selection. The block pointer indicates the motion block.
4. Hold the enabling switch down and wait until the status bar indicates
“Drives ready”:

5. Carry out a BCO run: Press the Start key and hold it down until the
message “Programmed path reached (BCO)” is displayed in the mes-
sage window. The robot stops.
CAUTION
The BCO run is executed as a LIN or PTP motion from the actual
position to the target position. The velocity is automatically reduced.
The path of the motion cannot be predicted reliably. Observe the
motion during the BCO run so that the robot can be stopped in time
if a collision becomes imminent.

6. The program can now be started manually or automatically. It is not

necessary to carry out a BCO run again.

10.3.42 ServoGunMessages 00352

Message code ServoGunMessages 00352

Message text The force from the weld timer is lower than the switch-on threshold
for force control!
Message type Notification message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 164)
Solution: Correct the configuration with WorkVisual. (>>> Page 165)

Cause: Signal incorrectly configured or mapped (>>> Page 165)

Solution: Correct the configuration with WorkVisual. (>>> Page 166)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm

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Messages
Parameter Unit
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

Cause: Signal incorrectly configured or mapped

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

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Messages KUKA.ServoGun Basic 3.0

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.43 ServoGunMessages 00303

Message code ServoGunMessages 00303

Message text Part thickness from weld timer too great; repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 167)
Solution: Correct the configuration with WorkVisual. (>>> Page 167)

Cause: Signal incorrectly configured or mapped (>>> Page 168)

Solution: Correct the configuration with WorkVisual. (>>> Page 168)

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Cause: Unit of transfer value from weld timer interpreted incorrectly

Messages
Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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 KUKA.ServoGun Basic 3.0

Cause: Signal incorrectly configured or mapped

Messages

Description

The signal is not present although all the conditions for it have been met
by the weld timer or the PLC, or the signal has been set incorrectly. This
may be caused by a non-matching configuration of the weld timer/PLC
and the WorkVisual project.
The procedure for checking the configuration in WorkVisual is as fol-
lows:

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the signal assignment in the areas Weld timer inputs and
Weld timer outputs.
Check the signal assignment in the weld timer and compare it with the
WorkVisual configuration.
3. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

4. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
5. Check the settings under PLC inputs for background process and
PLC outputs for background process.
6. Check the signal mapping of the field bus that is used.

Further information about the bus systems can be found in the corre-
sponding KUKA documentation. Information about bus configuration is
contained in the WorkVisual documentation.

Information on configuration of the weld timer can be found in the man-

ufacturer documentation for the weld timer.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.44 ServoGunMessages 00304

Message code ServoGunMessages 00304

Message text Part thickness from weld timer too small, repeat point?
Message type Dialog message

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Messages
Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 169)
Solution: Correct the configuration with WorkVisual. (>>> Page 170)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

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 KUKA.ServoGun Basic 3.0

Solution: Correct the configuration with WorkVisual.

Messages

Procedure

• Correct the configuration with WorkVisual.

10.3.45 ServoGunMessages 00305

Message code ServoGunMessages 00305

Message text Part thickness tolerance from weld timer too large, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 170)
Solution: Correct the configuration with WorkVisual. (>>> Page 171)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

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Messages
Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.46 ServoGunMessages 00306

Message code ServoGunMessages 00306

Message text Part thickness tolerance from weld timer too small, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 171)
Solution: Correct the configuration with WorkVisual. (>>> Page 172)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms

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 KUKA.ServoGun Basic 3.0

If the weld timer transfers the values in a different unit, each value can be
Messages

adapted by means of a scale factor and an offset.

Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.47 ServoGunMessages 00307

Message code ServoGunMessages 00307

Message text Weld time from weld timer too long, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 173)
Solution: Correct the configuration with WorkVisual. (>>> Page 173)

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Cause: Unit of transfer value from weld timer interpreted incorrectly

Messages
Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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Messages KUKA.ServoGun Basic 3.0

10.3.48 ServoGunMessages 00308

Message code ServoGunMessages 00308

Message text Weld time from weld timer too short, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 174)
Solution: Correct the configuration with WorkVisual. (>>> Page 175)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:

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Messages
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.49 ServoGunMessages 00212

Message code ServoGunMessages 00212

Message text Force from weld timer is larger than the maximum force of the weld
gun, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 175)
Solution: Correct the configuration with WorkVisual. (>>> Page 176)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.

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 KUKA.ServoGun Basic 3.0

The value of the scale factor depends on the transmission width of the
Messages

signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.50 ServoGunMessages 00301

Message code ServoGunMessages 00301

Message text Force from weld timer lower than switch-on threshold for force con-
trol, repeat point?
Message type Dialog message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 177)
Solution: Correct the configuration with WorkVisual. (>>> Page 177)

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 KUKA.ServoGun Basic 3.0

Cause: Unit of transfer value from weld timer interpreted incorrectly

Messages
Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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Messages KUKA.ServoGun Basic 3.0

10.3.51 ServoGunMessages 00353

Message code ServoGunMessages 00353

Message text No WATER MONITOR SUPPLY signal, input {Input}!
Message type Notification message

Possible cause(s) Cause: Error in the cooling circuit (>>> Page 178)
Solution: Eliminate periphery fault (>>> Page 178)

Cause: Error in the cooling circuit

Description

The cooling circuit is not working correctly.

Checking instructions

1. Check the coolant supply.

2. Check the coolant flow.
3. Check the cooling circuit for leaks.
The exact procedure depends on the peripheral equipment used.

Solution: Eliminate periphery fault

Procedure

• Eliminate the periphery fault.

10.3.52 ServoGunMessages 00354

Message code ServoGunMessages 00354

Message text No WATER MONITOR 2 signal, input {Input}!
Message type Notification message

Possible cause(s) Cause: Error in the cooling circuit (>>> Page 178)
Solution: Eliminate periphery fault (>>> Page 179)

Cause: Error in the cooling circuit

Description

The cooling circuit is not working correctly.

Checking instructions

1. Check the coolant supply.

2. Check the coolant flow.

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 KUKA.ServoGun Basic 3.0

Messages
3. Check the cooling circuit for leaks.
The exact procedure depends on the peripheral equipment used.

Solution: Eliminate periphery fault

Procedure

• Eliminate the periphery fault.

10.3.53 ServoGunMessages 00355

Message code ServoGunMessages 00355

Message text Part thickness from weld timer too great!
Message type Notification message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 179)
Solution: Correct the configuration with WorkVisual. (>>> Page 180)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.

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Messages KUKA.ServoGun Basic 3.0

• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.54 ServoGunMessages 00356

Message code ServoGunMessages 00356

Message text Part thickness from weld timer too small!
Message type Notification message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 180)
Solution: Correct the configuration with WorkVisual. (>>> Page 181)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm

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Messages
Parameter Unit
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.55 ServoGunMessages 00357

Message code ServoGunMessages 00357

Message text Part thickness tolerance from weld timer too large!
Message type Notification message

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Messages KUKA.ServoGun Basic 3.0

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 182)
Solution: Correct the configuration with WorkVisual. (>>> Page 183)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

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 KUKA.ServoGun Basic 3.0

Solution: Correct the configuration with WorkVisual.

Messages
Procedure

• Correct the configuration with WorkVisual.

10.3.56 ServoGunMessages 00358

Message code ServoGunMessages 00358

Message text Part thickness tolerance from weld timer too small!
Message type Notification message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 183)
Solution: Correct the configuration with WorkVisual. (>>> Page 184)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

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Messages KUKA.ServoGun Basic 3.0

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.57 ServoGunMessages 00359

Message code ServoGunMessages 00359

Message text Weld time from weld timer too long!
Message type Notification message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 184)
Solution: Correct the configuration with WorkVisual. (>>> Page 185)

Cause: Unit of transfer value from weld timer interpreted incorrectly

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms

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If the weld timer transfers the values in a different unit, each value can be

Messages
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.58 ServoGunMessages 00360

Message code ServoGunMessages 00360

Message text Weld time from timer too short!
Message type Notification message

Possible cause(s) Cause: Unit of transfer value from weld timer interpreted incorrectly
(>>> Page 186)
Solution: Correct the configuration with WorkVisual. (>>> Page 186)

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 KUKA.ServoGun Basic 3.0

Cause: Unit of transfer value from weld timer interpreted incorrectly

Messages

Description

The robot controller expects the transfer values from the weld timer for
specific weld parameters in defined units. These units are not configura-
ble.
The parameters are interpreted by the robot controller in the following
units:
Parameter Unit
Force N
Part thickness mm
Part thickness tolerance mm
Weld time ms
If the weld timer transfers the values in a different unit, each value can be
adapted by means of a scale factor and an offset.
Sequence:
1. The robot controller multiplies the value from the timer by the scale
factor.
2. The robot controller then adds the offset.
The value of the scale factor depends on the transmission width of the
signal, the scale factor of the weld timer, and the unit for values in the
weld timer.
The procedure for checking which scale factors are configured in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the tree structure. The Weld timer
editor opens.
or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the following parameters in the sectionWeld timer settings:
• Force correction factor
• Force offset
• Sheet thickness correction factor
• Part thickness offset
• Part thickness tolerance correction factor
• Part thickness tolerance offset
• Weld time correction factor
• Weld time offset

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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Messages
10.3.59 ServoGunMessages 00361

Message code ServoGunMessages 00361

Message text No implementation of the function available for this weld timer!
Message type Error message

Possible cause(s) Cause: CustomTimer used but not configured (>>> Page 187)
Solution: Correct the configuration with WorkVisual. (>>> Page 187)

Cause: CustomTimer used but not configured

Description

The CustomTimer catalog element is available to allow weld timers to be

used whose catalog element is not supplied with the ServoGun option
package as standard. It refers to KRL functions that are empty on deliv-
ery. The functions must be programmed by the customer.

Configuration file

Directory C:\KRC\Roboter\KRC\R1\TP\ServoGun\WeldTimer
File SG_TimerImplCustom.src
The procedure for checking the configuration of the CustomTimer in
WorkVisual is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Check whether the CustomTimer weld timer is used in the project.

2. Check whether the file has been adapted.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.60 ServoGunMessages 00368

Message code ServoGunMessages 00368

Message text Communication error: invalid program number from weld timer ac-
cepted as valid!
Message type Dialog message

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Messages KUKA.ServoGun Basic 3.0

Possible cause(s) Cause: Communication test failed (>>> Page 188)

Solution: Correct the configuration with WorkVisual. (>>> Page 188)

Cause: Communication test failed

Description

When program numbers are changed, the following communication test is

carried out: an invalid program number is transferred first and the system
waits for an error bit from the weld timer.
However, the weld timer has accepted the invalid program number as val-
id.
The procedure for checking in WorkVisual the program number
transferred as a communication test is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
Or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the value that is set under Handshake program number.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.61 ServoGunMessages 00369

Message code ServoGunMessages 00369

Message text Communication error: invalid program number from weld timer ac-
cepted as valid!
Message type Notification message

Possible cause(s) Cause: Communication test failed (>>> Page 189)

Solution: Correct the configuration with WorkVisual. (>>> Page 189)

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Cause: Communication test failed

Messages
Description

When program numbers are changed, the following communication test is

carried out: an invalid program number is transferred first and the system
waits for an error bit from the weld timer.
However, the weld timer has accepted the invalid program number as val-
id.
The procedure for checking in WorkVisual the program number
transferred as a communication test is as follows:

Precondition

• A project is open.
• The robot controller has been set as the active controller.

Checking instructions

1. Double-click on the weld timer in the Project structure window. The

Weld timer editor opens.
Or: Select the weld timer in the tree structure. Select the menu se-
quence Editors > Options packages > Weld timer editor.
The editor is opened.
2. Check the value that is set under Handshake program number.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.62 ServoGunMessages 00371

Message code ServoGunMessages 00371

Message text Background process: Is requested!
Message type Dialog message

Possible cause(s) Cause: Other background process already active (>>> Page 189)
Solution: Request background process again (>>> Page 190)

Cause: Other background process already active

Description

Another background process is already active. Before a background proc-

ess can be requested, the active process must be ended.

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 KUKA.ServoGun Basic 3.0

Solution: Request background process again

Messages

Description

Request the background process again.

10.3.63 ServoGunMessages 00372

Message code ServoGunMessages 00372

Message text Background process: Is requested!
Message type Notification message

Possible cause(s) Cause: Other background process already active (>>> Page 190)
Solution: Request background process again (>>> Page 190)

Cause: Other background process already active

Description

Another background process is already active. Before a background proc-

ess can be requested, the active process must be ended.

Solution: Request background process again

Description

Request the background process again.

10.3.64 ServoGunMessages 00373

Message code ServoGunMessages 00373

Message text Background process: Incorrect configuration of the background proc-
ess!
Message type Dialog message

Possible cause(s) Cause: Background process incorrectly configured or programmed

(>>> Page 191)
Solution: Correct programming (>>> Page 191)

Cause: Background process incorrectly configured or programmed

(>>> Page 191)
Solution: Correct the configuration with WorkVisual. (>>> Page 192)

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 KUKA.ServoGun Basic 3.0

Cause: Background process incorrectly configured or programmed

Messages
Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

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Messages KUKA.ServoGun Basic 3.0

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.65 ServoGunMessages 00374

Message code ServoGunMessages 00374

Message text Background process: Incorrect configuration of the background proc-
ess!
Message type Notification message

Possible cause(s) Cause: Background process incorrectly configured or programmed

(>>> Page 192)
Solution: Correct programming (>>> Page 193)

Cause: Background process incorrectly configured or programmed

(>>> Page 193)
Solution: Correct the configuration with WorkVisual. (>>> Page 193)

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

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 KUKA.ServoGun Basic 3.0

Solution: Correct programming

Messages
Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.66 ServoGunMessages 00375

Message code ServoGunMessages 00375

Message text Background process: Aborted!
Message type Dialog message

Possible cause(s) Cause: Background process incorrectly configured or programmed

(>>> Page 194)
Solution: Correct programming (>>> Page 194)

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Messages KUKA.ServoGun Basic 3.0

Cause: Termination by PLC (>>> Page 194)

Solution: Identify and remedy cause in PLC (>>> Page 194)

Cause: Background process incorrectly configured or programmed

(>>> Page 195)
Solution: Correct the configuration with WorkVisual. (>>> Page 195)

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Termination by PLC

Description

The higher-level PLC has terminated the background process.

Solution: Identify and remedy cause in PLC

Description

Determine the cause of the response in the higher-level PLC and remedy
the condition there.

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 KUKA.ServoGun Basic 3.0

Cause: Background process incorrectly configured or programmed

Messages
Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.67 ServoGunMessages 00376

Message code ServoGunMessages 00376

Message text Background process: Aborted!
Message type Error message

Possible cause(s) Cause: Background process incorrectly configured or programmed

(>>> Page 195)
Solution: Correct programming (>>> Page 196)

Cause: Background process incorrectly configured or programmed

(>>> Page 196)
Solution: Correct the configuration with WorkVisual. (>>> Page 197)

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

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 KUKA.ServoGun Basic 3.0

The procedure for checking the configuration of the background

Messages

process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

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 KUKA.ServoGun Basic 3.0

Solution: Correct the configuration with WorkVisual.

Messages
Procedure

• Correct the configuration with WorkVisual.

10.3.68 ServoGunMessages 00377

Message code ServoGunMessages 00377

Message text Background process:Timeout during the background process. Motion
has been aborted!
Message type Error message

Possible cause(s) Cause: Background process incorrectly configured or programmed

(>>> Page 197)
Solution: Correct programming (>>> Page 197)

Cause: Background process incorrectly configured or programmed

(>>> Page 198)
Solution: Correct the configuration with WorkVisual. (>>> Page 198)

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct programming

Procedure

• Correct programming

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Messages KUKA.ServoGun Basic 3.0

Further information is contained in the documentation for the rele-

vant software.

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

10.3.69 ServoGunMessages 00378

Message code ServoGunMessages 00378

Message text Background process:Timeout during the background process. Motion
has been aborted!
Message type Error message

Possible cause(s) Cause: Background process incorrectly configured or programmed

(>>> Page 199)
Solution: Correct programming (>>> Page 199)

Cause: Background process incorrectly configured or programmed

(>>> Page 199)
Solution: Correct the configuration with WorkVisual. (>>> Page 200)

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 KUKA.ServoGun Basic 3.0

Cause: Background process incorrectly configured or programmed

Messages
Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct programming

Procedure

• Correct programming
Further information is contained in the documentation for the rele-
vant software.

Cause: Background process incorrectly configured or programmed

Description

The background process has been incorrectly configured or programmed.

The procedure for checking the configuration of the background
process in WorkVisual is as follows:

Checking instructions

1. In the Project structure window, select the element for the gun motor,
e.g. SDTE008[…].

2. Click on the ServoGun Editor button.

or: Select the menu sequence Editors > Options packages > Servo-
Gun Editor.
The editor is opened.
3. In the Gun settings area, check the entry Background process ac-
tive.
4. Check the settings under PLC inputs for background process and
PLC outputs for background process.

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Messages KUKA.ServoGun Basic 3.0

User-specific subprograms for background processes are located in the

program SG_UserBackground.SRC in the directory R1\TP\SERVO-
GUN.
Check these if applicable.

Solution: Correct the configuration with WorkVisual.

Procedure

• Correct the configuration with WorkVisual.

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 KUKA.ServoGun Basic 3.0

KUKA Service
11 KUKA Service

11.1 Requesting support

Introduction

This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.

Information

The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used

11.2 KUKA Customer Support

Availability

KUKA Customer Support is available in many countries. Please do not

hesitate to contact us if you have any questions.

Argentina
Ruben Costantini S.A. (Agentur)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

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KUKA Service KUKA.ServoGun Basic 3.0

Australia
KUKA Robotics Australia Pty Ltd
45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
info@kuka-robotics.com.au
www.kuka-robotics.com.au

Belgium
KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be

Brazil
KUKA Roboter do Brasil Ltda.
Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
info@kuka-roboter.com.br
www.kuka-roboter.com.br

Chile
Robotec S.A. (Agency)
Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl

China
KUKA Robotics China Co., Ltd.
No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
info@kuka-robotics.cn
www.kuka-robotics.com

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 KUKA.ServoGun Basic 3.0

KUKA Service
Germany
KUKA Deutschland GmbH
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka.com

France
KUKA Automatisme + Robotique SAS
Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr

India
KUKA India Pvt. Ltd.
Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in

Italy
KUKA Roboter Italia S.p.A.
Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

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KUKA Service KUKA.ServoGun Basic 3.0

Japan
KUKA Japan K.K.
YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
info@kuka.co.jp

Canada
KUKA Robotics Canada Ltd.
2865 Argentia Road, Unit 4-5
Mississauga
Ontario L5N 8G6
Canada
Tel. +1 905 858‑5852
Fax +1 905 858-8581
KUKAFocusCenter@KUKARobotics.com
www.kukarobotics.ca

Korea
KUKA Robotics Korea Co. Ltd.
RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com

Malaysia
KUKA Robot Automation (M) Sdn Bhd
South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
info@kuka.com.my

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 KUKA.ServoGun Basic 3.0

KUKA Service
Mexico
KUKA de México S. de R.L. de C.V.
Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
www.kuka-robotics.com/mexico

Norway
KUKA Sveiseanlegg + Roboter
Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no

Austria
KUKA CEE GmbH
Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 732 784 752 0
Fax +43 732 793 880
KUKAAustriaOffice@kuka.com
www.kuka.at

Poland
KUKA CEE GmbH Poland
Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka.com

Portugal
KUKA Robots IBÉRICA, S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
info.portugal@kukapt.com
www.kuka.com

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KUKA Service KUKA.ServoGun Basic 3.0

Russia
KUKA Russia OOO
1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
support.robotics.ru@kuka.com

Sweden
KUKA Svetsanläggningar + Robotar AB
A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se

Switzerland
KUKA Roboter CEE GmbH
Linz, Zweigniederlassung Schweiz
Heinrich Wehrli-Strasse 27
5033 Buchs
Switzerland
Tel. +41 62 837 43 20
info@kuka-roboter.ch

Slovakia
KUKA CEE GmbH
organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
support.robotics.cz@kuka.com

Spain
KUKA Iberia, S.A.U.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
comercial@kukarob.es

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 KUKA.ServoGun Basic 3.0

KUKA Service
South Africa
Jendamark Automation LTD (Agentur)
76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan
KUKA Automation Taiwan Co. Ltd.
1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
info@kuka.com.tw

Thailand
KUKA (Thailand) Co. Ltd.
No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
HelpdeskTH@kuka.com

Czech Republic
KUKA Roboter CEE GmbH
organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
support.robotics.cz@kuka.com

Hungary
KUKA HUNGÁRIA Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

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KUKA Service KUKA.ServoGun Basic 3.0

USA
KUKA Robotics Corporation
51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
CustomerService@kuka.com
www.kuka.com

United Kingdom
KUKA Robotics UK Ltd
Great Western Street
Wednesbury West Midlands
WS10 7LL
United Kingdom
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk

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 KUKA.ServoGun Basic 3.0

Index F
#GO................................................................ 79 First initialization............................................... 8
#ISTEP............................................................79 First initialization (status key)........................ 24
#MSTEP..........................................................79 First initialization, tips, status key..................69
#WEAR_RATIO.............................................. 43 Flags............................................................... 19
Flags, cyclical................................................. 19
Flexion characteristic......................................59
A Flexion, maximum.......................................... 56
Approximate positioning................................. 95 Force controller...............................................76
Force from timer (optional)............................ 33
FORCE GAIN................................................. 76
Force gauge..................................................... 8
B Force gauge (KUKA)......................................15
Background tip dressing...............................103 Force gauge, thickness.................................. 56
Background welding..................................... 103 ForceClose............................................... 92, 98
Burn-off............................................................. 8 Function groups..............................................27
Burn-off, compensation...................................11

G
C Gear ratio of gun.................................9, 49, 54
Calibrating the gun, overview........................ 58 Gun (status key).............................................23
Calibration.........................................................8 Gun flexion....................................................... 9
CFS10.............................................................15 Gun motor, validated...................................... 16
Communication, weld timer............................31 Gun, close...................................................... 93
Compensation...................................................8 Gun, closing............................................. 24, 92
Compensator (status key)....................... 24, 26 Gun, compensation-free................................... 8
Configuration...................................................29 Gun, fixed....................................................... 79
Configuration, overview.................................. 29 Gun, opening.................................................. 24
Connecting cables.......................................... 14 Gun, stationary............................................... 79
Constant motion speed.................................. 13
Controller parameters, overview.................... 72
Correction, spots............................................ 96
COUPLE......................................................... 89 H
Couple (status key)..................................24, 25 Handshake......................................................31
Couple, inline form......................................... 89
Coupling..........................................................25
Custom Timer................................................. 31 I
Cyclical initialization..........................................9 Individual measurement (optional)................. 43
Cyclical initialization (status key)................... 24 Initialization
Tips, cyclical.............................................. 69
Inline forms, overview.................................... 79
D Installation.......................................................19
DECOUPLE.................................................... 89 Intended use...................................................16
Decouple (status key)..............................24, 25 Interrupts.........................................................19
Decouple, inline form..................................... 89 Introduction....................................................... 7
Decoupling...................................................... 25
Deviation, thickness........................................34
Diagnosis...................................................... 107 K
Documentation, industrial robot....................... 7 KRL resources................................................19
Dressing............................................................8 KSS...................................................................8
KUKA CFS10..................................................15
KUKA Customer Support............................. 201
E KUKA Service...............................................201
EqualizingTech................................................41
Exchangeable gun............................................9
Expansions, KUKA.ServoGun Basic..............12 L
EXT (operating mode)..................................143 Licenses............................................................9

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KUKA.ServoGun Basic 3.0

M T2 (operating mode).....................................143
Mastering.......................................................... 8 Target group..................................................... 7
Mastering, automatic...................................... 53 Teach mode.................................................... 96
Mastering, manual.......................................... 53 Teach mode, reteaching.................................96
Messages...................................................... 111 Terms used....................................................... 8
Thickness, deviation....................................... 34
Thickness, force gauge.................................. 56
Thickness, tolerance.......................................34
O Thickness, workpieces................................... 33
Open source..................................................... 9 Timers............................................................. 19
Opening width, maximum...............................55 Tip dresser, thickness........................33, 91, 92
Operation........................................................ 23 Tip dressing...................................................... 8
Orientation control.......................................... 95 Tip initialization
Cyclical.......................................................69
Tip initialization, new tips............................... 69
P Tip initialization, overview.............................. 68
Pneumatic (optional).......................................41 Tip wear.......................................................... 43
Product description......................................... 11 Tolerance, thickness....................................... 34
Program run mode......................................... 79 Tool direction............................................ 41, 50
Programming.................................................. 79 Training............................................................. 7
Programming, asynchronous motion........... 103
Programming, tip dressing............................. 89
Programming, tip initialization........................ 82 U
Programming, weld spot................................ 80 Uninstalling via WorkVisual............................20
Updating via WorkVisual................................ 20
Use, intended................................................. 16
R User rights, displaying....................................27
Ratio in % (optional)...................................... 43
Required knowledge and skills........................ 7
Reteaching......................................................96 V
Validated, gun motor...................................... 16
VSS...................................................................8
S
Safety..............................................................17
Safety instructions............................................ 7 W
Screw pitch of spindle....................................54 Warnings........................................................... 7
Servo gun......................................................... 8 Water monitor................................................... 9
SG_NonKukaBGDress........................... 98, 105 Weld controller..................................................8
SG_NonKukaDress.................................. 90, 98 Weld timer........................................................ 8
SG_SET_FORCE_PARAM.............................74 Welding cell.................................................... 13
SG_SET_MOTOR_PARAM..................... 74, 75 Welding force..................................................33
SG_TorqMonLow_Percent..............................72 WorkVisual...................................................... 12
SG_TorqueCloseActive...................................72
SG_TorqueCloseActiveUser........................... 72
SG_UserDress................................................90
Software limit switch, for closing................... 56
Software limit switch, for opening..................55
Software limit switches, setting......................55
Spin time.........................................................35
Start-up........................................................... 29
Start-up wizard............................................... 51
Start-up, overview...........................................29
Status keys..................................................... 23
Subprograms, adaptable........................97, 104
Support request............................................ 201
System requirements......................................19

T
T1 (operating mode).....................................143

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