When the file ...\R1\TP\ArcTechAnalog\ARC_MSG.SRC is opened, the window shown in Fig. 53 is displayed.
Fig. 53 ARC_MSG.SRC program
13 Customized messages (continued)
When the fold PREPARED SYSTEM INPUTS is opened, the window shown in Fig. 54 is displayed.
Fig. 54 ARC_MSG.SRC program -- FOLD “PREPARED SYSTEM INPUTS”
The system inputs in question are the signal groups defined in A_FLT_CYCFLAG for weld seam monitoring.
In the event of a fault, a bit--coded fault marker is generated in the variable TMP_WLD_CTRL in order to generate a cause--specific message after deactivation. Four inputs are preprogrammed in $CONFIG.DAT:
These four configured inputs can trigger a periphery error:
A_FLT_CYCFLAG[1]={NO 13,STATE TRUE}; group fault A_FLT_CYCFLAG[2]={NO 2,STATE TRUE}; current A_FLT_CYCFLAG[3]={NO 11,STATE TRUE}; gas A_FLT_CYCFLAG[4]={NO 10,STATE TRUE}; water
In addition to the four predefined messages, other prepared messages (e.g. for KPI systems) are displayed when the fold USER ERROR MESSAGES is opened. The length of the text may not exceed 7 characters!
You can enter your own texts from line S_MSG[5]... (Fig. 55) onwards. The length of the text must be entered in the structure at “LENGTH.”
Fig. 55 ARC_MSG.SRC program -- entering your own text
Fig. 56 ARC_MSG.SRC program -- FOLD “Coding of fault information”
Fig. 56 shows how the fault information is coded in the variable TMP_WLD_CTRL_B. The position of the set bit in the bit sequence (from the right) determines which text is generated.
The bit sequence B00100000 thus refers to error message S_MSG[6]... in USER ERROR MESSAGES. The total number of bits which can be set in this way is 12. The bit sequence B100000000000 thus refers to the message S_MSG[12]....
13 Customized messages (continued)
Fig. 57 shows an example of a dynamically generated error message.
Fig. 57 Example of a dynamically generated error message
14 Fault location, fault elimination
For additional information on fault location and fault elimination when operating with the
“KUKA.ArcSense” option, see the [KUKA.ArcSense] documentation.
Fault Cause Remedy
Error message “Interrupt
not defined” -- A10 option not set -- ARC_INI has not been
executed
-- Set A10_OPTION -- Stop PLC*) -- Set PLC*) -- Boot system with
ARC.INI FLT_SERV program:
Function cannot be taught, or messages such as ori-entation velocity have not been programmed
INIT section must be deactivated by turning it into a comment then deactivate it again by turning it into a comment).) Wire feed keys have no
effect No A10_Option or wire
feed not configured Set A10_OPTION=#AC-TIVE
Incorrect Submit module Set $PRO_I_O[ ]=
“/R1/SPS()”
A10_Option or wire feed
not configured Set A10_OPTION=
#ACTIVE Incorrect configuration of
the wire feed keys A_WLD_OUT[15].OUT_Nr (feed) or
A_WLD_OUT[16].OUT_Nr (retract) must be set to a value other than zero Short ignition pulse
followed by error message: Current not established
“Current flowing” signal may be suspended briefly in the event of an unstable ignition process
Increase value of $CON-FIG.DAT A_TIME_OUT1 (n * 10 ms)
Seam faults with a
customized error message generated, e.g.
“CURRENT”, following a short and successful ignition
Caused by seam fault
monitoring Check
A_FLT_CYC-FLAG]1..4] and A_WLD_IN[ ] structure
Weaving not possible $TECH_OPTION possibly
not activated STEU/$CUSTOM.DAT:
Set $TECH_OPTION to TRUE
Heat distribution in thermal
weaving on the wrong side Values in the parameter list
for weld voltage and wire Switch the default weld values and the thermal
14 Fault location, fault elimination (continued)
Fault Cause Remedy
Spiral weaving results in
strange weave patterns Weave pattern only
vaguely resembles a spiral Set weave amplitude to half weave length, and observe frequency
dependence and amplitude Absence of phase
synchronization during thermal weaving
Heat distribution on the workpiece material some-times sporadic and changeable
Set $CUSTOM.DAT:
$TECH_ANA_FLT_OFF[3]
=TRUE; the weave motion filtering is manipulated Thermal weaving has no
effect A static analog value is
generated Activate cyclical analog channels.
A_WEAV_GEN[3]=3 Reinitialize HMI; restart Submit and application program
Wire feed keys pressed.
Wire is fed at unsuitable speed
With some power sources, the analog channel for wire feed must first be set.
If this has been adapted to the wire feed channel using
$ANOUT[2], this may nonetheless remain without effect if cyclical analog channels have been used.
Default setting:
A_WEAV_GEN[3]=3
Once activation of the wire feed key has been
detected, set
A_TH2_ACT_G=0 in the PLC and set
A_TH2_ACT_O to a velocity--proportional value between 0.0 and 0.1. A value < 0.2 is suitable here (i.e. 20% of the max. wire feed velocity).
This is a customer--specific adaptation.
After a short, successful ignition process the error message “Seam fault” or a programmed customized message is generated.
The monitoring delay value
has been set too low. -- Set the variable A_CTRL_DELAY in
$CONFIG.DAT to a higher value (default:
1200 [ms])
-- Check the configuration:
the signal to be monitored on the seam is missing.
*) Depending on whether the “KUKA.ArcSense” option has been installed and activated.
15 Error messages / troubleshooting
Messages of all categories are displayed in the message window. These can be either informative messages that do not need to be acknowledged or messages that have to be acknowledged.
A message consists of the following items of information, for example:
Message group Message time
Message number Originator
Message text