KUKA System Technology KUKA Roboter GmbH

KUKA.ServoGun FC 2.1

For KUKA System Software 8.3

KUKA.Servo-

Gun FC 2.1

Issued: 04.08.2017

Version: KST ServoGun FC 2.1 V2

 KUKA.ServoGun FC 2.1

© Copyright 2017
KUKA Roboter 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 Roboter 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 software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub KST ServoGun FC 2.1 (PDF) en

Book structure: KST ServoGun FC 2.1 V2.1
Version: KST ServoGun FC 2.1 V2

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 Contents

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 Trademarks ................................................................................................................ 8
1.5 Terms used ................................................................................................................ 8
1.6 Licenses ..................................................................................................................... 9

2 Product description ..................................................................................... 11

2.1 ServoGun FC – overview ........................................................................................... 11
2.2 Motor/SDC combinations for ServoGun FC 2.1 ......................................................... 12
2.2.1 Motors ................................................................................................................... 13
2.2.2 SDC2 .................................................................................................................... 13
2.3 Functional principle .................................................................................................... 14
2.4 Overview of connecting cables .................................................................................. 15
2.5 Electrical connections on the weld gun motor ............................................................ 16
2.6 Connector pin allocation X52 ..................................................................................... 16
2.7 Intended use .............................................................................................................. 17

3 Safety ............................................................................................................ 19
4 Installation .................................................................................................... 21
4.1 System requirements ................................................................................................. 21
4.2 Installing ServoGun FC on the robot controller .......................................................... 21
4.3 Uninstalling ServoGun FC on the robot controller ..................................................... 22

5 Operation ...................................................................................................... 23
5.1 Menus ........................................................................................................................ 23
5.2 Status keys ................................................................................................................ 23
5.3 Manually opening / closing the gun ............................................................................ 24
5.4 Manually coupling / decoupling the gun ..................................................................... 25
5.5 Manually activating gun compensation ...................................................................... 25
5.6 Calling the variable overview ..................................................................................... 25
5.7 Displaying configuration parameters .......................................................................... 26

6 Start-up and configuration ......................................................................... 27

6.1 Start-up and configuration – overview ....................................................................... 27
6.2 Inserting the SDC into the KUKA Controller Bus (KCB) in WorkVisual ..................... 29
6.3 Inserting a gun into the project in WorkVisual ............................................................ 29
6.4 TCP calibration and tool direction .............................................................................. 30
6.5 Setting configuration parameters ............................................................................... 30
6.5.1 Loading gun data from a TXT file ......................................................................... 31
6.5.2 Saving gun data in a TXT file ................................................................................ 32
6.5.3 Configuration parameters ..................................................................................... 32
6.5.3.1 “Inputs” screen ................................................................................................ 32
6.5.3.2 “Outputs” screen ............................................................................................. 34
6.5.3.3 “General” screen ............................................................................................. 35
6.5.3.4 “Gun” screen ................................................................................................... 37
6.5.3.5 “Force calibration” screen .............................................................................. 37

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6.6 Configuring ServoGun options .................................................................................. 38

6.7 Configuring detailed settings for ServoGun options .................................................. 41
6.8 Configuring the turning funtionality ............................................................................ 43
6.9 Manual gun mastering ............................................................................................... 44
6.10 Checking the gun mastering ...................................................................................... 45
6.11 Determining the gear ratio ......................................................................................... 45
6.12 Determining the thickness of the force gauge ........................................................... 46
6.13 Determining the thickness of the tip dresser ............................................................. 47
6.14 Determining the calibration step size ......................................................................... 47
6.14.1 Calculating the first calibration position and the calibration step size ................... 48
6.15 Calibration ................................................................................................................. 48
6.15.1 Coarse calibration with EG_CAL_F program ....................................................... 49
6.15.2 Description of coarse calibration .......................................................................... 50
6.15.3 Force test with EG_FORCE_F program ............................................................... 51
6.15.4 Fine calibration with the EG_RECAL_F program ................................................. 52
6.16 Setting the software limit switches ............................................................................. 52
6.16.1 Setting the negative software limit switch ............................................................. 52
6.16.2 Setting the positive software limit switch .............................................................. 53
6.17 Checking the residual travel and software limit switches .......................................... 53
6.17.1 Dimensions and distances on a C gun ................................................................. 54
6.17.2 Checking the residual travel and software limit switches for C guns .................... 54
6.17.3 Checking the residual travel and software limit switches for X guns .................... 56
6.18 Tip initialization – overview ........................................................................................ 58
6.18.1 First initialization via status key ............................................................................ 58
6.18.2 Cyclical initialization via status key ....................................................................... 59
6.19 Controller parameters ................................................................................................ 59
6.19.1 Controller parameters – overview ......................................................................... 59
6.19.2 Determining and optimizing controller parameters ............................................... 61

7 Programming ............................................................................................... 65
7.1 Inline forms – overview .............................................................................................. 65
7.2 Instructions ................................................................................................................ 65
7.2.1 Instructions for use of stationary guns .................................................................. 65
7.3 Programming a weld spot .......................................................................................... 66
7.3.1 Inline form “SPOT” ................................................................................................ 66
7.4 Programming a weld spot with EqualizingTech ......................................................... 68
7.4.1 Inline form “SPOT” (EqualizingTech) .................................................................... 69
7.5 Programming tip initialization ..................................................................................... 71
7.5.1 Programming first initialization .............................................................................. 71
7.5.2 Programming cyclical initialization ........................................................................ 71
7.5.3 Inline form “INIT” ................................................................................................... 72
7.6 Programming SetTip (pressing on tips) ..................................................................... 72
7.6.1 Inline form “INIT” (for SetTip) ................................................................................ 73
7.7 Programming tip dressing .......................................................................................... 73
7.7.1 Inline form “TippDress” ........................................................................................ 75
7.8 Programming tip dressing with EqualizingTech ......................................................... 76
7.8.1 Inline form “TippDress” (EqualizingTech) .......................................................... 77
7.9 Manually coupling / decoupling the gun via inline form ............................................. 78
7.9.1 Inline form “ServoGun Decouple” ....................................................................... 78

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 Contents

7.9.2 Inline form “ServoGun Couple” ........................................................................... 79

7.10 Initializing EqualizingTech .......................................................................................... 79
7.10.1 Inline form “INIT Equalizing” ................................................................................ 80
7.11 Option window “Frames” ........................................................................................... 80
7.12 Option window “Motion parameters” (LIN, CIRC, PTP) ........................................... 81
7.13 Option window “Weld timer parameters” ................................................................. 82
7.14 Adaptable subprograms ............................................................................................. 83
7.15 Subprograms for user-specific stiffness parameters .................................................. 83

8 Diagnosis ..................................................................................................... 87
8.1 Checking the sensor reset and function of the force sensor ...................................... 87
8.2 Carrying out tests ....................................................................................................... 87
8.3 Description of the tests .............................................................................................. 88
8.4 Determining the gun flexion (independently of the force sensor) ............................... 90
8.5 Displaying and exporting weld timer data .................................................................. 90
8.6 Displaying ServoGun I/Os .......................................................................................... 90

9 System variables ......................................................................................... 93

9.1 Important variables in EG_EXTERN.DAT .................................................................. 93
9.2 Important kernel system variables ............................................................................. 94

10 Messages ..................................................................................................... 95
10.1 Information about the messages ................................................................................ 95
10.2 System messages from module: EGSPOT ................................................................ 95
10.2.1 EGSPOT 00101 .................................................................................................... 95
10.2.2 EGSPOT 00105 .................................................................................................... 95
10.2.3 EGSPOT 00107 .................................................................................................... 97
10.2.4 EGSPOT 00110 .................................................................................................... 98
10.2.5 EGSPOT 00112 .................................................................................................... 99
10.2.6 EGSPOT 00116 .................................................................................................... 101
10.2.7 EGSPOT 00117 .................................................................................................... 102
10.2.8 EGSPOT 00118 .................................................................................................... 103
10.2.9 EGSPOT 00119 .................................................................................................... 105
10.2.10 EGSPOT 00125 .................................................................................................... 106
10.2.11 EGSPOT 00126 .................................................................................................... 107
10.2.12 EGSPOT 00151 .................................................................................................... 107
10.2.13 EGSPOT 00158 .................................................................................................... 108
10.2.14 EGSPOT 00170 .................................................................................................... 109
10.2.15 EGSPOT 00182 .................................................................................................... 110

11 KUKA Service .............................................................................................. 113

11.1 Requesting support .................................................................................................... 113
11.2 KUKA Customer Support ........................................................................................... 113

Index ............................................................................................................. 121

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 1 Introduction

1 Introduction
t

1.1 Target group

t

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 ob-
tained directly from our subsidiaries.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

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 KUKA.ServoGun FC 2.1

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 Trademarks

Windows is a trademark of Microsoft Corporation.

1.5 Terms used

Term Description
Burn-off (tip Deformation of the electrode tips caused by the weld-
wear) ing 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
First initializa- Pressing in the new electrode tips and remeasuring the
tion tip burn-off (EG_WEAR[])
Mastering Definition of the zero point (closed position) of the weld
gun
Calibration The calibration determines the relationship between
the values of the force sensor (increments) and the
forces on the force gauge (kN). It also determines the
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
Force control During force control, the position of the axis/gun is cor-
rected until the force acting on the gun is equal to the
setpoint force (welding force).
Force sensor Sensor in the motor of the spot weld gun, for determin-
ing the welding force
Position control During position control, the position of the axis/gun is
corrected until the setpoint position is reached.
Pole pair Signal pick-up in the resolver of the gun motor
A pole pair consists of two poles.
RDC Resolver Digital Converter
Card for position evaluation and digitization of the posi-
tion values
The RDC is located in the RDC box on the base frame.
Reset Resetting the force sensor (zeroing)

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 1 Introduction

Term Description
Residual travel The residual travel is the distance between the soft-
ware limit switch and the hardware limit stop; serves to
protect the spindle and motor.
Weld timer (= weld controller)
Device for controlling the welding time and welding cur-
rent
SDC Servo Digital Converter
The SDC is a hardware expansion required for Servo-
Gun FC. It is located on the RDC box.
Servo gun Weld gun with servomotor drive
Trace The trace is the recorded measurement curve for a
parameter, which is determined using the controller
tool.
Water monitor Monitoring unit in the cooling water circuit of the weld
gun. The water monitor monitors the cooling water vol-
ume at the input and output of the cooling water circuit.
Exchangeable Exchangeable weld gun which can be decoupled from
gun the gun mount on the robot by the program
Gun flexion Deformation of the weld gun caused by the action of
the closing force
Gear ratio Ratio between the motor stroke and gun opening
Cyclical initial- Determination of the current electrode burn-off and
ization adjustment to the current closing position

1.6 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

Further information about open-source licenses can be requested

from the following address: opensource@kuka.com

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 2 Product description

2 Product description
2

2.1
t
ServoGun FC – overview

ServoGun FC is an add-on technology package with the following functions:

s

KUKA.ServoGun
FC  Force control of the gun via force sensor
 Control of up to 6 force-controlled, electric motor-driven weld guns:
 Up to 6 exchangeable guns
 Or 1 stationary gun and up to 5 exchangeable guns
 Or 2 stationary guns
If other external kinematic systems are used (e.g. a KUKA linear unit), then
one less stationary gun can be operated for each external kinematic sys-
tem used.
 Force calibration of guns
 Force control or position control may be active during welding.
 Automatic TCP correction after tip dressing (electrode burn-off)
 The weld program can be selected via the name of the weld spot, or sep-
arately via a program number.
The desired method can be defined for each gun.
With program selection via point name: the number of characters relevant
for selection can be configured.
 Certain weld parameters can be defined in the inline form or communicat-
ed to the robot controller by the weld timer.
The desired method can be defined for each parameter and each gun.
 Display functions for the data received from the weld timer
 Monitoring of various parameters
 Turning functionality:
Under certain conditions, the electrode tips may “stick” to the metal after
welding. The turning functionality allows the gun to be turned several de-
grees about the TCP at the end of welding. This frees the tips from the
metal.
The servo gun is implemented as an external axis. Every taught point contains
the positions of the 6 robot axes and the opening width of the gun.

Restriction Only servo guns with a positive gear ratio may be operated using Servo-
Gun FC.

WorkVisual The following software is required for configuring the servo guns:
 WorkVisual 4.0

Expansion The range of functions of ServoGun FC can be expanded with the following
software products:
 KUKA.EqualizingTech
With EqualizingTech, conventional gun compensation systems are no lon-
ger required. This makes it possible to dispense with e.g. the complicated
start-up procedures for pneumatic compensation systems.
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.

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 KUKA.ServoGun FC 2.1

 KUKA.RoboSpin
RoboSpin makes it possible to execute a rotational motion about the TCP
during the welding process. The rotational motion increases the weld qual-
ity and reduces the tip wear.
These products are described in separate documentation. The descriptions of
the inline forms and subprograms of KUKA.EqualizingTech are also found in
this documentation, however.

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 Motor/SDC combinations for ServoGun FC 2.1

ServoGun FC 2.1 may only be operated with an SDC2 force sensor interface
module and the corresponding motors.
Motors:
 ARO servo motor 600V 6-pole for C gun
 ARO servo motor 600V 6-pole for X gun
There are 2 variants of the SDC2:
 Force sensor signal converter
 Force sensor signal converter

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 2 Product description

2.2.1 Motors

On the servomotor, the color of the self-adhesive label shows which SDC it
can be combined with.
 Orange label: for combination with SDC2

Fig. 2-2: Orange label: for combination with SDC2

Further information about the motors is contained in the data sheets

from the manufacturer.

2.2.2 SDC2

To distinguish between SDC2 and SDC1:

On the SDC1, there are connections between item 7 and item 8. These are not
present on the SDC2.

SDC2

Fig. 2-3: Overview of the SDC2

1 Power infeed
2 Power supply status indicator: control voltage
3 Status indicator, signal
4 EtherCAT signal input
5 EtherCAT signal output
6 Signal connection, channel 1 (M12 screw connector)
7 Signal connection, channel 2 (M12 screw connector)
8 Power supply status indicator: load voltage
9 Onward power supply

Further information can be found in the manufacturer’s data sheet.

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 KUKA.ServoGun FC 2.1

2.3 Functional principle

The robot approaches the taught weld spot using position control. Before the
gun makes contact with the workpiece, the robot is braked to a defined veloc-
ity. The gun closes and presses the workpiece together. When the switch-on
threshold (normally 0.8 kN) is reached, the robot controller switches from po-
sition control to force control (during the motion). The gun continues to press
the workpiece together under force control until the welding force is reached.
The signal for the start of welding is set, and the force on the gun is controlled
during the welding process. The spot is welded. During the welding process,
the force sensor measures the force acting on the gun and transfers the mea-
surement result to the robot controller. When the weld timer gives the signal
for the end of welding, the robot controller switches back to position control,
and the gun opens.

Fig. 2-4: Position and force control during the welding cycle

FZ Measured force acting on the gun

t Time
1 Welding force reached
2 Force reaches switch-on threshold
3 Electrodes in contact with the workpiece
4 Switchover to force control on reaching the switch-on threshold
5 Weld timer starts and the spot is welded
6 Weld timer signals the end of welding; switchover to position
control
7 Electrodes lift off the workpiece and the gun opens

Alternatively to the sequence described here, the robot controller can

also switch to position control on reaching the welding force. This is
defined in the inline form for the weld spot. Which method is appropri-
ate depends on the workpiece.

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 2 Product description

2.4 Overview of connecting cables

Fig. 2-5: Overview of connecting cables

1 Weld timer
2 Robot controller
3 Resolver-sensor cable
4 Motor cable to the gun
5 Weld gun
6 Field bus module on the weld gun (Not necessary if EqualizingTech is
used. Otherwise, depending on the weld gun used.)
7 Field bus connection between the following components:
 Weld timer
 Robot controller
 If used: Field bus module on the weld gun
8 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.

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 KUKA.ServoGun FC 2.1

2.5 Electrical connections on the weld gun motor

Fig. 2-6: Position of the electrical connections

Fig. 2-7: Electrical connections (detail view)

1 XM7: Connection for motor cable

2 X52: Connection for resolver-sensor cable
3 Sensor cable
4 The assignment of this connection can vary according to the
motor. Information about the assignment can be found in the
manufacturer’s data sheet.

2.6 Connector pin allocation X52

Description The connector is a 19-contact (16+3) Intercontec connector with female crimp
contacts on the P side.

Further information can be found in the parts list of the energy supply
system.

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 2 Product description

Fig. 2-8: Connector pin allocation X52

Pin Designation
1 24 V sensor (IO-2)
2 GND sensor (IO-2)
3 Analog IN (IO-2)
4 n. c.
5 n. c.
6 n. c.
7 n. c.
8 Digital OUT (IO-2)
9 n. c.
10 SIN OUT 4+ (R1)
11 SIN OUT 4- (R2+)
12 n. c.
13 S2
14 S4
15 S1
16 S3
17 GND TMP (temp.)
18 TMP 7 (temp.)
19 n. c.

The shields of the wire pairs for "24 V sensor" (pin 1) / "GND sensor" (pin 2)
and "Analog IN" (pin 3) / "Digital OUT" (pin 8) are connected to the connector
housing.

2.7 Intended use

Use The KUKA.ServoGun FC technology package is intended exclusively for spot

welding with force-controlled electric motor-driven guns and for use in an in-
dustrial environment.
The technology package must only be operated in compliance with the speci-
fied system requirements.
Operation in accordance with the intended use also requires compliance with
the configuration descriptions in this documentation and constant observance
of the assembly and operating instructions for the cell components used.

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. The manufacturer cannot be held liable for any damage re-
sulting from such use. The risk lies entirely with the user.
Examples of such misuse include:
 Use in a cell which does not conform to the applicable safety regulations
for spot welding.

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 KUKA.ServoGun FC 2.1

 Use in a non-industrial environment

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 3 Safety

3 Safety
f

y 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 In-
tegrators 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 per-
sons, severe injuries or considerable damage to property may other-
wise result.

The force signal is measured in analog form at the sen-

sor box without electrically isolated voltage supply. This
measurement can be disrupted by discharged currents from the welding pro-
cess. Interference is particularly liable to occur if the following constellation is
used in the cell:
 The secondary neutral of the welding transformer is grounded.
 And: the workpiece fixture (e.g. a clamping fixture) is grounded.
It must be ensured that the force signal is transmitted to the sensor box with-
out any interference. In particular, the constellation described above must not
be used in the cell. If this precaution is not observed, the robot controller
might receive corrupted force signals. Injuries or damage to property may re-
sult.

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 in-
stalled in the primary weld power supply:
 Isolating contactor
 Residual-current circuit-breaker matching the welding technology (medi-
um frequency or mains frequency)
Failure to observe this may result in severe injuries or death to persons.

Weld spots and tip dressing points that were taught with-
out EqualizingTech must not be used with Equalizing-
Tech. Weld spots and tip dressing points that were taught with
EqualizingTech must not be used without EqualizingTech.
If such existing points are to be reused, they must be retaught. Damage to
the gun or the workpiece may otherwise result.

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.

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 KUKA.ServoGun FC 2.1

If an archive is restored while a mastered gun is decou-

pled, the data relating 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 remastered.
Failure to observe this precaution may result in damage to property.

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 4 Installation

4 Installation
4

4.1 System requirements

t

Hardware  KR C4 robot controller

 Robot with SDC2
 Energy supply system with sensor cable for force-controlled electric mo-
tor-driven spot weld gun
If a stationary gun is used: Suitable connecting cable
 Servo gun with force sensor and positive gear ratio

Software  KUKA System Software 8.3.x

The number of the required release must be taken from the file
ReleaseNotes_[…].TXT. This file is located on the data storage medium Ser-
voGun FC 2.1.

Compatibility KUKA.ServoGun FC, KUKA.EqualizingTech and KUKA.RoboSpin must not

be installed together with one or more of the following technology packages
on the same robot controller:
 KUKA.ServoGun FC SDA
 KUKA.EqualizingTech SDA
 KUKA.RoboSpin SDA
 KUKA.ServoGun TC

4.2 Installing ServoGun FC on the robot controller

During installation of ServoGun, one gun is automatically installed as

external axis E1. Any existing E1 is overwritten.

It is advisable to archive all relevant data before updating a software

package.

When installing the technology packages, the following sequence

must be observed:
1.ServoGun FC
2. EqualizingTech (if used)
3. RoboSpin (if used)

We recommend using a KUKA USB stick. Data may be

lost if a stick from a different manufacturer is used.

Precondition  “Expert” user group

 T1 or T2 mode
 No program is selected.
 USB stick with the software to be installed
 ZIP files must be unzipped.
 There must be no other files in the directory in which the individual files
are located.

We recommend using a KUKA USB stick. Data may be

lost if a stick from a different manufacturer is used.

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 KUKA.ServoGun FC 2.1

Procedure 1. Connect the USB stick to the robot controller or smartPAD.

2. In the main menu, select Start-up > Additional software.
3. Press New software: The entry ServoGun FC must be displayed in the
Name column and drive E:\ or K:\ in the Path column.
If not, press Refresh.
4. If the specified entries are now displayed, continue with step 5.
Otherwise, the path from which the software is to be installed must be con-
figured first:
a. Press the Configure button.
b. Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwritten.
c. Press Path selection. The available drives are displayed.
d. If the stick is connected to the robot controller: On E:\ navigate to the
directory with the software. Select the directory.
If the stick is connected to the smartPAD: K:\ instead of E:\
e. Press Save. The Installation paths for options area is displayed
again. It now contains the new path.
f. Mark the line with the new path and press Save again.
5. Mark the entry ServoGun FC and click on Install. Answer the request for
confirmation with Yes.
6. Confirm the reboot prompt with OK.
7. Remove the stick.
8. Reboot the robot controller.

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

4.3 Uninstalling ServoGun FC on the robot controller

It is advisable to archive all relevant data before uninstalling a soft-

ware package.

When uninstalling the technology packages, the following sequence

must be observed:
1.RoboSpin (if used)
2. EqualizingTech (if used)
3. ServoGun FC

Precondition  User group "Expert".

 Operating mode T1 or T2.

Procedure 1. In the main menu, select Start-up > Additional software.

2. Mark the entry ServoGun FC and click on Uninstall. Answer the request
for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.

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

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 5 Operation

5 Operation

5.1 Menus
t

The following menus and commands are specific to this technology package:
Main menu:
 Configuration > Status keys > ServoTech
 Configuration > Servo Gun FC
 Inputs
 Outputs
 Settings
 General
 Gun
 Force calibration
 Load all
 Save all
 Controller parameters
 Diagnosis > Servo Gun FC
 Servo Gun
 Weld timer data
 Inputs and outputs
Menu sequence Commands > ServoTech:
 SPOT
 PTP, LIN, CIRC
 INIT
 TippDress
 PTP, LIN
 ServoGun Decouple
 ServoGun Couple

5.2 Status keys

Procedure Displaying the status keys for the first time:

 In the main menu, select Configuration > Status keys > ServoTech.
Refreshing the status keys:
If the compensation type has been changed, the status keys can be refreshed
as follows:
 Carry out a cold restart
 Or, if a further technology 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.

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 KUKA.ServoGun FC 2.1

Description Status key Name / description

Toggle status keys
Displays additional status keys.

First initialization

Cyclical initialization

Gun
Gun to which the status keys refer

Compensator 1
Close gun with compensator 1
(>>> 5.5 "Manually activating gun compensation"
Page 25)
Compensator 2
Close gun with compensator 2
(>>> 5.5 "Manually activating gun compensation"
Page 25)
Decouple

Couple

5.3 Manually opening / closing the gun

Precondition  Operating mode T1

 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 exter-
nal 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.

Procedure 1. Set jog override.

2. Hold down the enabling switch.
3. The axes of the selected kinematics group are displayed next to the jog
keys.
 Press the “plus” key of the external axis to close the gun.

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 5 Operation

 Press the “minus” key of the external axis to open the gun.

5.4 Manually coupling / decoupling the gun

Description The gun is coupled or decoupled by 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). Mas-
tering 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.

If an archive is restored while a mastered gun is decou-

pled, the data relating 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 remastered.
Failure to observe this precaution may result in damage to property.

Procedure 1. Select the gun using the Gun status key.

2. Couple the gun with the Couple status key, or decouple it using Decou-
ple.

5.5 Manually activating gun compensation

Description This functionality can be used to check the pneumatic compensation. It is not
required if the option Compensation #EQUALIZING is configured.

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.
The gun closes and opens again after 0.5 s.
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.

5.6 Calling the variable overview

Description The variable overview displays the different ServoGun parameters and the
corresponding values.

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 KUKA.ServoGun FC 2.1

Procedure  In the main menu, select Display > Variable > Overview > Display. The
variable overview is opened.

5.7 Displaying configuration parameters

Description Configuration parameters can only be changed on certain conditions. They

can be displayed at any time, however, making them easier to check.

Procedure 1. In the main menu, select Configuration > Servo Gun FC and then one of
the following menu items:
 Inputs
 Outputs
 Settings
 General
 Gun
 Force calibration
 Load all
 Save all
The corresponding configuration screen is opened.
2. If there is more than one gun configured: Select the desired gun (no.) in
the Gun selection box.
The parameters are displayed.

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 6 Start-up and configuration

6 Start-up and configuration

t

6.1 Start-up and configuration – overview

The force signal is measured in analog form at the sen-

sor box without electrically isolated voltage supply. This
measurement can be disrupted by discharged currents from the welding pro-
cess. Interference is particularly liable to occur if the following constellation is
used in the cell:
 The secondary neutral of the welding transformer is grounded.
 And: the workpiece fixture (e.g. a clamping fixture) is grounded.
It must be ensured that the force signal is transmitted to the sensor box with-
out any interference. In particular, the constellation described above must not
be used in the cell. If this precaution is not observed, the robot controller
might receive corrupted force signals. Injuries or damage to property may re-
sult.

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 in-
stalled in the primary weld power supply:
 Isolating contactor
 Residual-current circuit-breaker matching the welding technology (medi-
um frequency or mains frequency)
Failure to observe this may result in severe injuries or death to persons.

Information about procedures in WorkVisual is contained in the

WorkVisual 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.
On the robot controller:
3  Install ServoGun FC.
(>>> 4.2 "Installing ServoGun FC on the robot control-
ler" Page 21)
 (If used: install EqualizingTech.)
 (If used: install RoboSpin.)
In WorkVisual:
4  Install ServoGun FC.
 (If used: install EqualizingTech.)
 (If used: install RoboSpin.)
5 Transfer the project from the robot controller to WorkVisual.

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 KUKA.ServoGun FC 2.1

Step Description
6 Make the necessary settings for the project.
For ServoGun FC:
 (>>> 6.2 "Inserting the SDC into the KUKA Controller
Bus (KCB) in WorkVisual" Page 29)
 (>>> 6.3 "Inserting a gun into the project in WorkVisual"
Page 29)
7 Transfer the project back from WorkVisual to the robot con-
troller and activate it.
On the robot controller:
8 Calibrate the gun as the tool.
(>>> 6.4 "TCP calibration and tool direction" Page 30)
9 Enter and save the gun name.
(>>> 6.5 "Setting configuration parameters" Page 30)
10 Configure the inputs/outputs.
(>>> 6.5.3.1 "“Inputs” screen" Page 32)
(>>> 6.5.3.2 "“Outputs” screen" Page 34)
11 Configure the parameters for General.
With the exception of the following parameters: Force
gauge, First calibration position, Calibration steps
(>>> 6.5.3.3 "“General” screen" Page 35)
12 Configure parameters in the file eg_extern.DAT.
(>>> 6.6 "Configuring ServoGun options" Page 38)
If required: (>>> 6.8 "Configuring the turning funtionality"
Page 43)
13 Master the gun.
(>>> 6.9 "Manual gun mastering" Page 44)
14 Determine the gear ratio.
(>>> 6.11 "Determining the gear ratio" Page 45)
15 Determine the thickness of the force gauge.
(>>> 6.12 "Determining the thickness of the force gauge"
Page 46)
16 Determine the thickness of the tip dresser.
(>>> 6.13 "Determining the thickness of the tip dresser"
Page 47)
17 Test the sensor reset.
(>>> 8.1 "Checking the sensor reset and function of the
force sensor" Page 87)
18 Determine the calibration step size.
(>>> 6.14 "Determining the calibration step size" Page 47)
19 Calibration
(>>> 6.15 "Calibration" Page 48)
20 Set the software limit switches for the gun.
(>>> 6.16 "Setting the software limit switches" Page 52)

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 6 Start-up and configuration

Step Description
21 Check the residual travel and software limit switches.
(>>> 6.17 "Checking the residual travel and software limit
switches" Page 53)
22 Carry out first initialization of the electrode tips.
(>>> 6.18 "Tip initialization – overview" Page 58)
23 If required: Optimize the controller parameters.
(>>> 6.19.1 "Controller parameters – overview" Page 59)

6.2 Inserting the SDC into the KUKA Controller Bus (KCB) in WorkVisual

Bus structure On the Project structure tab, the correct SDC must be inserted into the KCB.

Real SDC Insert into the KCB in WorkVisual

SDC2 Sensor Digital Converter 2 (SDC2) (EP3162-1002)

Topology On the Topology tab, the SDC must be inserted under connection B of the
RDC.
The connection between the RDC and SDC must be a permanent connection.

6.3 Inserting a gun into the project in WorkVisual

Description The following guns/combinations can be configured:

 Up to 6 exchangeable guns
 Or 1 stationary gun and up to 5 exchangeable guns
 Or 2 stationary guns
If other external kinematic systems are used (e.g. a KUKA linear unit), then
one less stationary gun can be operated for each external kinematic system
used.

Precondition  The robot controller has been set as the active controller.

Procedure 1. Select the gun motor in the Options catalog in the Catalogs window.

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 reality.

2. Drag the motor into the Project structure window:

into the Hardware tab, onto the robot controller there. (Not onto the node
Unassigned active devices.)
3. Select the Geometry tab.
 If the gun is to be used on the robot flange, the gun must be located in
the Flange Base node of the robot.
If the gun is not located there, drag it to this node.
This specifies that the gun may be coupled to this robot. It does not
specify whether the gun is actually coupled, but merely that coupling
is possible.
 If the gun is to be operated as a stationary gun:
Drag the gun onto the World: … node. (= Top level on the Geometry
tab.)
The gun is now shown in the geometry structure under the robot but at
the same level, i.e. not indented.

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 KUKA.ServoGun FC 2.1

4. Save the project.

System variables The following ServoGun system variables are adapted by the configuration in
WorkVisual:
EG_EXTAX_ACTIVE
EG_SERVOGUN_EXAXIS[1] … [6]
EG_COUPLE_AXIS

6.4 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 illustration
(>>> Fig. 6-1 ):
 Plus points in the direction of the fixed electrode.
 Minus points in the opposite direction from the fixed electrode.
 The direction defined must then entered on the General configuration
screen under the parameter TCP orientation.

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

tained in the operating and programming instructions for the KUKA
System Software (KSS).

Fig. 6-1: TCP and tool direction

6.5 Setting configuration parameters

Precondition  User group “Expert”

 Operating mode T1 or T2.
 No program is selected.

Procedure 1. In the main menu, select Configuration > Servo Gun FC and then one of
the following menu items:
 Inputs
 Outputs

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 6 Start-up and configuration

 Settings
 General
 Gun
 Force calibration
The corresponding configuration screen is opened.
2. If there is more than one gun configured: In the Gun selection box, select
the gun (no.) to which the settings are to apply.
3. In the Gun description box, enter a distinctive name for the gun.

This needs to be done only once per gun, on one of the screens.

4. Configure the parameters as required on the selected screen.

(>>> 6.5.3 "Configuration parameters" Page 32)
5. Press Save. The changes are saved.
6. Close the screen via the Close icon.
7. Configure the parameters as required on the other screens.

Alternative The parameters can also be loaded from a data medium.

procedure  The parameters can be loaded for each screen.
(>>> "Buttons" Page 31)
 The parameters can be loaded for a number of screens at once.
(>>> 6.5.1 "Loading gun data from a TXT file" Page 31)

Buttons The following buttons are available on the configuration screens:

Button Description
Import If the data for this screen are available in a TXT file, they
can be loaded using this button.
Precondition: The TXT file is located on a drive to which
the robot controller has access. Or a USB stick with the
TXT file is connected.
Export Saves the data in this screen to a TXT file. A name can
be assigned to the file. As the memory location, it is pos-
sible to select a drive to which the robot controller has
access, or a USB stick.
Load Updates the data in this screen in accordance with the
current state of the robot controller.
If changes have been entered but not yet saved on this
screen, the initial state can be restored in this way.
Save Saves the changes on this screen.
Calculate Only available in the Force calibration screen.
Calculates the current calibration of the gun on the ba-
sis of the values Force 1 in kN, etc. The calibration is
not saved.

6.5.1 Loading gun data from a TXT file

Description If the data for the following configuration screens are available in a TXT file,
they can be loaded:
 General
 Gun
 Force calibration

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 KUKA.ServoGun FC 2.1

Precondition  The TXT file is located on a drive to which the robot controller has access.
Or: A USB stick with the TXT file is connected.
 “Expert” user group

Procedure
On loading the data, the gun name stored in the TXT file overwrites
the name configured in the ServoGun software.

1. In the main menu, select Configuration > Servo Gun FC > Load all.
2. In the Gun selection box, select the gun for which the data are to be load-
ed.
3. Navigate to the TXT file and select it.
4. Press Load.
5. A request for confirmation is displayed, asking if the existing data should
be overwritten. Confirm with Yes.
The data are loaded and the following message is displayed: Data suc-
cessfully imported.

6.5.2 Saving gun data in a TXT file

Description This procedure saves the data in the following configuration screen to a TXT
file:
 General
 Gun
 Force calibration

Precondition  “Expert” user group

Procedure 1. If data are to be saved to a USB stick, this must be connected.

2. In the main menu, select Configuration > Servo Gun FC > Save all.
3. Select the desired gun in the Gun selection box. Only data for one gun
can be saved in a file.
4. Navigate to the desired memory location and select it.
5. A default name for the file is displayed in the Select file box. Change the
name if required.
6. Press Save. The data are saved and the following message is displayed:
Saving successful

6.5.3 Configuration parameters

6.5.3.1 “Inputs” screen

Inputs/outputs If an input or output is set, the LED icon next to the box is green (otherwise
gray).

Fig. 6-2: Lamps for inputs/outputs

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 6 Start-up and configuration

Input Description
Motion with/without HIGH = Gun remains open at the weld spot
closing
LOW = Gun closes at the weld spot
Weld end HIGH = End of weld reached
LOW = End of weld not reached
Error from timer HIGH = Error from weld timer present
LOW = No error from weld timer present
With/without weld Weld instruction executed with/without current.
current
In AUT and EXT modes, an error message is displayed if the weld cur-
rent is deactivated.
HIGH = With weld current
LOW = Without weld current
Acknowledge with- Certain dialog messages can also be answered by the PLC instead of
out repeat the user. These two inputs receive the answer from the PLC.
Acknowledge with (>>> "Messages answered by the PLC" Page 34)
repeat HIGH for Acknowledge without repeat = NO (The program is contin-
ued without repeating the point.)
HIGH for Acknowledge with repeat = YES (The last point is repeated.)
Both inputs must not be HIGH at the same time. If both inputs are LOW,
this means “no answer”, and the message remains in the message win-
dow.
Note: After the dialog message has been answered, the input must be
reset by the PLC for the program to be resumed.
New electrodes For customization
Stop after end of Robot stops after weld instruction.
point
HIGH = Robot stops
LOW = Robot continues to move
Dressing start For customization
request
Timer valid bit Weld timer confirms program number.
HIGH = Weld timer confirms program number
LOW = No confirmation from the weld timer
Timer ready Status of weld timer
HIGH = Weld timer ready
LOW = Weld timer not ready
Process monitoring For customization
Water monitor 1 Monitoring of the cooling water volume at the gun intake
HIGH = No alarm
LOW = Alarm triggered
Water monitor 2 Monitoring of the cooling water volume at the gun outflow
HIGH = No alarm
LOW = Alarm triggered
Thermo contact Monitoring of the temperature of the transformer on the gun
transformer
HIGH = Transformer has normal operating temperature
LOW = Transformer is overheating

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 KUKA.ServoGun FC 2.1

Input Description
Turning function for Input via which turning can be started early
thin sheets
Turning is normally started by the input Weld end. If necessary, how-
ever, it can be started earlier via this input.
Note: This input only has an effect if EG_TURN_ACTIVE == TRUE.
Force from the weld Input range for the force values sent by the weld timer
timer
Note: Must only be configured if the option ForceTimer TRUE has been
selected.
Part thickness from Input range for the thickness values sent by the weld timer
the weld timer
Note: Must only be configured if the option ThicknessTimer TRUE has
been selected.
Part thickness toler- Input range for the values for the thickness tolerance sent by the weld
ance from weld timer
timer
Note: Must only be configured if the option ThicknessTolTimer TRUE
has been selected.
Weld time from the Input range for the values for the weld time sent by the weld timer
weld timer
Note: Must only be configured if the following preconditions are met:
 KUKA.RoboSpin is installed.
 The WeldTimeTimer TRUE option has been selected.

Messages The following dialog messages can be answered by the PLC:

answered by the  No cycle end signal, input ..., repeat point?
PLC
 Welding controller error, input ..., repeat point?
 No TIMER READY signal, input ..., repeat point?

6.5.3.2 “Outputs” screen

Inputs/outputs If an input or output is set, the LED icon next to the box is green (otherwise
gray).

Fig. 6-3: Lamps for inputs/outputs

Output Description
Weld start Start the welding process (also start of cycle)
HIGH = Start of welding
LOW = No start of welding
Compensator 1 Only effective for gun with pneumatic compensation: activate compen-
sator 1
HIGH = Compensation activated
LOW = Compensation deactivated

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 6 Start-up and configuration

Output Description
Compensator 2 Only effective for gun with pneumatic compensation: activate compen-
sator 2
HIGH = Compensation activated
LOW = Compensation deactivated
Program number Address range for transfer of the program number. The bit width must
not exceed 32 bits.
HIGH = Bit set
LOW = Bit not set
With/without weld This input is LOW if the timer type “TEST” or T1 mode is selected.
current
Otherwise, this input is HIGH.
Acknowledge weld Reset error in the weld timer
error
HIGH = Error will be reset
LOW = Error will not be reset
New electrodes This output is used by the robot controller to signal to the weld timer that
first initialization with new electrodes has taken place.
Stop after end of Confirmation, stop after end of welding
point
HIGH = End of weld reached
LOW = End of weld not yet reached
Timer valid bit Confirmation by the robot controller that it has received the Timer valid
bit input
TRUE = Confirmation
FALSE = No confirmation

6.5.3.3 “General” screen

Input Description
Timer type Manufacturer of the weld timer used
If TEST is selected, the gun is closed for 0.5 seconds with the define
force and then opened again. No welding is carried out.
 TEST (default), ARO, BOSCH, FASE, SERRA
Gun type  X: X gun (default)
 C, G, J: C gun
TCP orientation The working direction of the tool (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_DIRECTION. 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
(>>> 6.4 "TCP calibration and tool direction" Page 30)

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 KUKA.ServoGun FC 2.1

Input Description
TCP correction Automatic correction of the point coordinates, corresponding to the tip
wear
 On (default): The point coordinates are corrected, i.e. they are adapt-
ed in accordance with the tip wear determined during tip initialization.
 Off: The point coordinates are not corrected. If the burn-off has been
determined, this is ignored.
Tip detection The system checks for the presence of tips on the gun.
 On (default): Tip detection activated.
If an electrode tip falls off, this is detected and an error message is
generated. After force build-up, the closing width of the gun is mea-
sured. This value is compared with the value entered under Part in
the inline form TippDress, taking into account the flexion.
 Off: Tip detection deactivated
X-Compensation Maximum comp.: The distance traveled by the tips at maximum force.
 0 ... 10 mm
Default: 0.00
Direction: The direction in which the tips travel.
 -X (default), -Y, -Z, +X, +Y, +Z
Compensation active: X-compensation on/off
 Off (default), On
Force gauge Thickness: Thickness of the force gauge
 0 … 100 mm
Default: 50.00
Calibration posi- First calibration position: First measurement position during calibra-
tions tion.
 0 … 100 mm
Default: 0.10
Calibration steps: Size of the calibration step for the 4 subsequent
measurements of the calibration in [mm/kN].
 0 … 100 mm
Default: 0.10
First Init force The force with which the gun is closed during the first motion during first
initialization
Note: Suitable values are values from 2.5 kN.
 2 … max. gun force
Default: 3.00
Tip wear (burn-off) Maximum permissible value of the tip burn-off (both tips together)
 0 … 20 mm
Default: 8.00

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 6 Start-up and configuration

6.5.3.4 “Gun” screen

Input Description
Motor file The files currently used are displayed here.
Servo file (display only)
Position control file
If other files are to be loaded, this must be done in WorkVisual.
Force control file
Gear ratio Distance moved by electrodes in [mm] per revolution of the motor
 -100 … 100 mm
Default: 5.00
Note: Enter the value without sign, or with a positive sign.
(>>> 6.11 "Determining the gear ratio" Page 45)
Max. opening (mm) Enter the negative software limit switch.
 0 … 1,000 mm
Default: 100.00
(>>> 6.16.1 "Setting the negative software limit switch" Page 52)
Software limit (mm) Enter the positive software limit switch.
 0 … 1,000 mm
Default: 35.00
(>>> 6.16.2 "Setting the positive software limit switch" Page 53)
Max. flexion (mm) Maximum flexion of the gun (calculated from the calibration) + 5 mm
reserve
(display only)
Max. speed (rpm) Revolutions per minute of the gun motor
(display only)

6.5.3.5 “Force calibration” screen

Input Description
Force 1 in kN … Enter here the values determined during calibration.
Force 5 in kN Default: 0.001
Force 1 in Inc … These values are determined during coarse and fine calibration and dis-
played here automatically.
Force 5 in Inc
(display only)
Calibration position Gun positions during the 5 calibration measurements. The values are
1 in degrees … displayed here automatically.
Calibration position (display only)
5 in degrees
Position / Force Ratio of position (degrees) to force (kN)
(display only)
Force-control Switching threshold between position control and force control (kN)
switch-on in kN
 0.1 … 10.00
Default: 0.80
Recommendation: Do not change the default value.

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 KUKA.ServoGun FC 2.1

Input Description
Maximum gun force After coarse calibration, enter here the maximum closing force of the
in kN gun. This can be taken from the gun manufacturer’s data sheet. (kN)
 1 … 20.00
Default: 5.00
Note:
 If the maximum force specified by the manufacturer could not be
achieved during determination of the calibration step size, then enter
here the highest force measured instead.
 If the maximum closing force is 20 kN, for technical reasons only a
maximum force of 19.5 kN is available in the process.
Proportional factor Gain factor of the force controller
 0.00001 … 1.00
Default: 0.01
Recommendation: Do not change the default value.
Lower limit in kN Tolerance relative to the switch-on threshold, below which the force
must not drop during force control (kN)
 0 … 2.00
Default: 2.00
Recommendation: Do not change the default value.
Upper limit in kN Tolerance relative to the maximum force of the weld gun, which must not
be exceeded during force control (kN)
 0 … 2.00
Default: 0.50
Recommendation: Do not change the default value.
Max. speed of con- Maximum speed of the constant motion phase (rpm).
stant motion phase
Default: 1000.00
(rpm)
Recommendation: Do not change the default value.
Workpiece detection Factor which is multiplied by the value of Maximum gun force in kN
monitoring toler- and then converted into a distance, taking account of the gun flexion
ance (Max. flexion (mm)). If this distance is exceeded after contact with the
workpiece has been detected, without the force sensor signal exceeding
the force controller switch-on threshold, then it is assumed that there
has been a fault in the measuring chain (force sensor, splitter box, sen-
sor cable, A/D converter module) and the robot stops.
 0.5 … 1
Default: 0.50
Recommendation: Do not change the default value.

6.6 Configuring ServoGun options

The following options were developed for the weld timer family PSI 63Cx (with
firmware 729) from BOSCH:
 ForceTimer TRUE
 ThicknessTimer TRUE
 ThicknessTolTimer TRUE
 WeldTimeTimer TRUE

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The options can also be used with other timers if these use the same commu-
nication principle. Communication principle:
1. Robot controller requests program from weld timer (data bit & Valid bit).
2. Weld timer responds with the following data: ForceTimer, ThicknessTimer,
ThicknessTolTimer and WeldTimeTimer.
3. When all the data are present at the interface, the weld timer sends the
Valid bit to the robot controller.
4. The robot controller reads the data and executes the weld.

Restrictions
The transmission of the values from the weld timer to the robot con-
troller takes time. In the following cases, this can mean that the robot
controller has to wait for the values and is therefore unable to approx-
imate the gun motions:
 With very small distances between points
 With a very small opening of the gun

In the following cases it is not possible to obtain the values from the
weld timer:
The value TEST is selected in the configuration parameter Timer
type.
 In Office mode

Precondition  “Expert” user group

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

Procedure 1. In the Navigator, open the file eg_extern.DAT in the directory

R1\TP\ServoGun_FC.
2. Open the fold gun typ.
3. The fold contains the variables ServogunFC[1] to ServogunFC[6].
Configure each gun used.
4. Close the file. Respond to the query asking whether the changes should
be saved by pressing Yes.

Description

Fig. 6-4: Excerpt from the open fold “gun typ”

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 KUKA.ServoGun FC 2.1

Line Description
6 ServogunFC[1]: The options for servo gun 1 are configured here.
The options for ServogunFC[2] to ServogunFC[6] follow in the file
(not shown here).

Parameter Description
ProgSelect How is the robot controller to select the weld program?
 TRUE: The weld program is selected via a number. The number is
specified by the user in the inline form.
 FALSE: The weld program is selected via the name of the weld spot.
ProgDigits This parameter is only relevant if ProgSelect FALSE is selected.
The user defines the name of the weld spot or tip dressing point in the
inline forms SPOT and TippDress on the robot controller. The last x
characters of the name (default = 7 characters) must be digits. The
robot controller communicates these digits to the weld timer as the pro-
gram number.
The number of relevant final characters can be configured here in the
file eg_extern.DAT.
 1 … 10
(>>> "Point name as program number" Page 40)
Compensation Type of equalization:
 #AIR: The gun position is corrected pneumatically.
 #EQUALIZING: Must be selected if KUKA.EqualizingTech is to be
used on the robot controller.
Only available if EqualizingTech is installed on the robot controller.
ForceTimer Where is the value for the closing force of the gun to come from?
 TRUE: The robot controller obtains the value from the weld timer.
 FALSE: The user defines the value via the inline form.
ThicknessTimer Where is the value for the overall thickness of the parts to be welded to
come from?
 TRUE: The robot controller obtains the value from the weld timer.
 FALSE: The user defines the value via the inline form.
ThicknessTolTimer Where is the value for the permissible thickness tolerance to come
from?
 TRUE: The robot controller obtains the value from the weld timer.
 FALSE: The user defines the value via the inline form.
WeldTimeTimer Note: This parameter is only relevant if KUKA.RoboSpin is used.
Where is the value for the spin time to come from?
 TRUE: The robot controller obtains the value for the duration of the
welding process from the weld timer. An offset is added to this value.
This results in the spin time.
 FALSE: The user defines the value via the inline form.

Point name as Example:

program number  The option ProgSelect FALSE has been selected.
 For ProgDigits, the default value 7 has been left unchanged.
 The following point name is defined in the inline form: SG12345678

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 6 Start-up and configuration

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.

6.7 Configuring detailed settings for ServoGun options

Description The parameters explained here are only relevant if one or more of the follow-
ing settings were made:
 ForceTimer TRUE
 ThicknessTimer TRUE
 ThicknessTolTimer TRUE
 WeldTimeTimer TRUE

Precondition  “Expert” user group

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

Procedure 1. In the Navigator, open the file eg_extern.DAT in the directory

R1\TP\ServoGun_FC.
2. Open the fold signals timer data.
3. Configure the variables as required.
4. Close the file. Respond to the query asking whether the changes should
be saved by pressing Yes.

ForceTimer TRUE
Variable Description
EG_FORCE_TMR_START_ Note: Configurable on the configuration screen Inputs, input
IN Force from the weld timer.
EG_FORCE_TMR_END_IN
EG_FORCE_SCALE Type: REAL
Scale factor for the values
The robot controller always interprets the force values as values
in kN. The scale factor enables the values supplied by the weld
timer to be correctly 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 val-
ues in the weld timer.
Default: 0.001
EG_FORCE_MIN Type: REAL
Minimum value for the force
Default: 0.8 kN
EG_FORCE_MAX Type: REAL
Maximum value for the force
Default: 6.0 kN

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ThicknessTimer
TRUE
Variable Description
EG_THICK_TMR_START_I Note: Configurable on the configuration screen Inputs, input Part
N thickness from the weld timer.
EG_THICK_TMR_END_IN
EG_THICK_SCALE Type: REAL
Scale factor for the thickness values
The robot controller always interprets the thickness values as val-
ues in mm. The scale factor enables the values supplied by the
weld timer to be correctly 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 val-
ues in the weld timer.
Default: 1.0
EG_THICK_MIN Type: REAL
Minimum value for the thickness
Default: 0.1 mm
EG_THICK_MAX Type: REAL
Maximum value for the thickness
Default: 25.0 mm

Thickness-
TolTimer TRUE
Variable Description
EG_THICKTOL_TMR_STA Note: Configurable on the configuration screen Inputs, input Part
RT_IN thickness tolerance from weld timer.
EG_THICKTOL_TMR_END
_IN
EG_THICKTOL_SCALE Type: REAL
Scale factor for the thickness tolerance values
The robot controller always interprets the values as values in mm.
The scale factor enables the values supplied by the weld timer to
be correctly 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 val-
ues in the weld timer.
Default: 1.0
EG_THICKTOL_MIN Type: REAL
Minimum value for the thickness tolerance
Default: 0.1 mm
EG_THICKTOL_MAX Type: REAL
Maximum value for the thickness tolerance
Default: 25.0 mm

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 6 Start-up and configuration

WeldTimeTimer
TRUE
Variable Description
EG_WELDTIME_TMR_STA Note: Configurable on the configuration screen Inputs, input
RT_IN Weld time from the weld timer.
EG_WELDTIME_TMR_EN
D_IN
EG_WELDTIME_SCALE Type: REAL
Scale factor for the weld time values
The robot controller always interprets the values as values in ms.
The scale factor enables the values supplied by the weld timer to
be correctly 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 val-
ues in the weld timer.
Default: 1.0
EG_WELDTIME_MIN Type: REAL
Minimum value for the weld time
Default: 100 ms
EG_WELDTIME_MAX Type: REAL
Maximum value for the weld time
Default: 4600 ms
EG_WELDTIME_OFFSET Type: REAL
Default: -96 ms
Note: Information about this parameter is contained in the
KUKA.RoboSpin documentation.

6.8 Configuring the turning funtionality

Description After tip dressing, the tips may “stick” to the metal at the next weld spots and
subsequently slip from the shank when the gun is opened. The effect occurs
under certain circumstances, e.g. during thin sheet welding.
This effect can be avoided using the turning functionality. The functionality al-
lows the gun to be turned several degrees about the TCP at the end of weld-
ing. This frees the tips from the metal, and the gun can then be opened without
the tips slipping from the shank. As it opens, the gun returns to the orientation
it had prior to the turning motion.
The number of degrees and direction in which the gun is to turn are pro-
grammed by the user in the inline form for each weld spot. The other settings
can be configured in the file eg_extern.DAT.

This functionality is only available for standard weld spots with or

without Equalizing. It is not available for RoboSpin weld spots.

Precondition  “Expert” user group

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

Procedure 1. In the Navigator, open the file eg_extern.DAT in the directory

R1\TP\ServoGun_FC.

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 KUKA.ServoGun FC 2.1

2. Open the fold Thin metal turning. The fold is located at the end of the file.
3. Configure the variables as required.
4. Close the file. Respond to the query asking whether the changes should
be saved by pressing Yes.

Variables
Variable Description
EG_TURN_ACTIVE  TRUE (default): Inline forms for weld spots contain the Turn
box.
When changing from FALSE to TRUE, the Turn box is also
displayed in existing inline forms:
 If the inline form had previously ever contained Turn be-
forehand, the box now displays the value from that time.
 If the inline form had never contained the Turn box, it takes
the value which was last programmed for the same motion
type. For example, a LIN form takes the value which was
last programmed in a LIN form. If no previous value exists,
the value is “0”.
 FALSE: Inline forms for weld spots do not contain the Turn
box. In existing inline forms, the box is hidden and has no fur-
ther effect.
Turning after welding is not possible.
The following variables only have an effect if EG_TURN_ACTIVE == TRUE.
EG_TURN_TESTMODE For test modes T1 and T2 only:
 TRUE (default): The gun carries out the turn programmed in
the inline form at each weld spot.
 FALSE: If EG_TURN_COUNT <> 0, the gun then carries out
the turn programmed in the inline form at each weld spot.
EG_TURN_IN[x] Note: Configurable on the configuration screen Inputs, input
Turning function for thin sheets.
EG_TURN_COUNT For AUT and AUT EXT modes only:
Number of weld spots following tip dressing at which the pro-
grammed turn is to be carried out
For example, if EG_TURN_COUNT = 3 is set, the gun will no lon-
ger turn at the 4th weld spot, even if a degree setting has been
programmed in the inline form. The same is true if “0 deg” is pro-
grammed for the first 3 weld spots and the gun has not turned
there.
No limitation. Default: 10
EG_TURN_FORCE Factor by which the welding force is reduced prior to turning.
 0 … 100 %
Default: 30 %

6.9 Manual 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

Precondition  Operating mode T1

 New electrode tips are fitted on the gun.

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 6 Start-up and configuration

Used electrodes must not be used in this case, as this

would result in an incorrect mastering value. This could
damage the gun.

Procedure 1. Close the gun manually with the jog keys until the electrodes are just
touching.

The gun must not exert any force, otherwise it may be-
come damaged.

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 Start-up > Master > Dial. A window opens.
3. In this window, select the external axis to be mastered and press the Mas-
ter softkey. The axis is removed from the window.
4. Close the window.

6.10 Checking the gun mastering

Preparation  Determine the value of EG_WEAR[gun number].

That is the current tip wear.

Precondition  Operating mode T1

Procedure 1. In the main menu, select Display > Actual position. The Robot position
window opens. 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.

The gun must not exert any force, otherwise it may be-
come damaged.

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.
The mastering is correct if the value is “0 + current tip wear”.

6.11 Determining the gear ratio

The servo gun must have a positive gear ratio.

Precondition  The gun is mastered.

 Operating mode T1

Procedure For C guns:

The gear ratio generally corresponds to the screw pitch of spindle.
1. Consult the gun manufacturer’s data sheet to find out the value for the
screw pitch of spindle.
2. Enter the value in the Gear ratio box in the Gun configuration screen and
save.

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If no value for the spindle screw pitch is available from the manufacturer, the
gear ratio can be determined using the same method as for X guns.
For X guns:
The gear ratio is the change in the opening width over 1 motor revolution.
1. Close the gun without exerting any force.
2. In the main menu, select Display > Actual position. The Cartesian actual
position is displayed.
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 the distance in the Gear ratio box in the Gun configuration screen
and save.

If the opening width of the gun is not large enough to be measured

after one motor revolution, open the gun 2 or 3 motor revolutions be-
fore taking the measurement. Then divide the measured distance by
the number of revolutions.

6.12 Determining the thickness of the force gauge

Description The thickness of the sensor plate of the force gauge is determined and entered
in the configuration. This is the basis for measuring the closing forces of the
gun with the force gauge during subsequent gun calibration.

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

Precondition  The gun is mastered.

 Operating mode T1

Accessories  Force gauge

(if necessary, consult gun manufacturer for a suitable model.)

Procedure 1. Set the jog override to 3%.

2. Open the gun manually.

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 6 Start-up and configuration

3. Place the force gauge on the fixed electrode.

4. Close the gun until the moving electrode just touches the sensor plate.
5. In the main menu, select Display > Actual position. A window opens.
Then press the Axis-specific button.
6. In the Pos. [deg, mm] column, read off the position of the gun and note
the value.
7. Open the gun and remove the force gauge.
8. Enter the value in the Thickness box on the configuration screen Gener-
al.

6.13 Determining the thickness of the tip dresser

Description The thickness of the tip dresser is required for the following purpose:
 If the option ThicknessTimer FALSE has been selected:
The thickness must be entered in the inline form TippDress.
 If the option ThicknessTimer TRUE has been selected:
The thickness must be set in the weld timer.

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 the tip dresser.
2. Close the gun until build-up of tip dressing force.
3. In the main menu, select Display > Variable > Overview > Display.
4. Read and note the value of the Position variable.

6.14 Determining the calibration step size

Description The calibration step defines the ratio between the travel and the force [mm/kN]
of the gun and must be determined for the coarse calibration.

Precondition  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 manufac-
turer)
 Operating mode T1

Accessories  Force gauge

(if necessary, consult gun manufacturer for a suitable model.)

Procedure 1. Set the jog override to 3%.

2. Open the gun manually.
3. In the main menu, select Display > Actual position > Axis-specific.
4. Place the force gauge on the fixed electrode.
5. Close the gun until the force gauge shows a value of approx. 0.8 kN.
6. Note the actual position of the external axis.
7. Continue to close the gun until the maximum gun force is displayed on the
force gauge.
If the maximum force is not reached, note the highest force achieved.
8. Note the actual position of the external axis at maximum force.

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If the maximum force was not reached in the previous step, note the actual
position at the highest force achieved.
9. Open the gun and remove the force gauge.
10. Calculate the first calibration position and the size of the calibration step.
(>>> 6.14.1 "Calculating the first calibration position and the calibration
step size" Page 48)
11. Enter the value in the boxes First calibration position and Calibration
steps in the configuration screen General.

6.14.1 Calculating the first calibration position and the calibration step size

Example values Thickness of the force gauge 23 mm

Lower gun force Always use the following value:
0.8 kN
Maximum gun force If the maximum force specified by
the manufacturer is not reached on
the force gauge, enter the highest
force achieved.
3.4 kN
Actual position for lower force 21 mm
Actual position for maximum force 3 mm

First calibration First calibration position = Force gauge thickness – Actual position for lower
position force
First calibration position = 23 mm – 21 mm
Result: 2 mm

Calibration steps Calibration steps = (Actual position for lower force – Actual position for max-
imum force) / 4
The divisor “4” is determined by the number of calibration steps for coarse cal-
ibration.
Calibration steps = (21 mm – 3 mm) / 4
Result = 4.5 mm

6.15 Calibration

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 The gun supplier frequently provides calibration data along with the gun. If this
is the case, coarse calibration with EG_CAL_F is not necessary.

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 6 Start-up and configuration

Step Description
1 Necessary if the gun supplier has not provided calibration da-
ta:
Coarse calibration with EG_CAL_F program
(>>> 6.15.1 "Coarse calibration with EG_CAL_F program"
Page 49)
2 The following is necessary in all cases:
Force test with EG_FORCE_F program
(>>> 6.15.3 "Force test with EG_FORCE_F program"
Page 51)
3 Necessary if the force test with EG_FORCE_F results in too
high a deviation between the setpoint and actual force values:
Fine calibration with the EG_RECAL_F program
(>>> 6.15.4 "Fine calibration with the EG_RECAL_F pro-
gram" Page 52)

The programs can only be executed in T1 mode.

6.15.1 Coarse calibration with EG_CAL_F program

(>>> 6.15.2 "Description of coarse calibration" Page 50)

During calibration, the gun closes at process velocity, not

at reduced velocity.

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.
 The calibration step size and first calibration position have been entered.
 New electrode tips
 Operating mode T1

Accessories  Force gauge

(if necessary, consult gun manufacturer for a suitable model.)

If it becomes apparent during the measuring process that

the maximum gun force will be exceeded at the next
measuring step, the EG_CAL_F program must be aborted. If this is not done,
the force gauge and/or gun may be damaged.
On the configuration screen General, a lower value must be entered under
Calibration steps. Then restart EG_CAL_F.

Procedure 1. Select and start the program EG_CAL_F.

2. Follow the dialog messages and note the values of the 5 measurements.
3. After the 5th measurement, take the force gauge out of the gun.

If the force gauge is not removed from the gun, this may
result in damage to property.

4. The gun moves to the mastering position and stops there. Carry out a vi-
sual check that the mastering position is correct.
 If it is: continue with the next step.
 If not: remaster the gun. Then repeat the entire calibration.

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5. Execute the program through to the end.

6. The values noted must be entered on the Force calibration configuration
screen in Force 1 in kN to Force 5 in kN.
7. In addition, fill out the box Maximum gun force in kN on the same page.
If the maximum force specified by the manufacturer could not be achieved
during determination of the calibration step size, then enter the highest
force measured.
8. Click on Calculate, then save.

The measured values should cover the force range of the gun. If the
measured values are too low, a higher value must be entered at the
following place: On the configuration screen General under Calibra-
tion steps.
Then restart EG_CAL_F.
The force range is dependent on the gun. Guide values:
 Force 1 in kN: 0.8 kN … 1.2 kN
 Force 5 in kN: Maximum force

6.15.2 Description of coarse calibration

The gun is closed under position control.

The calibration determines the relationship between the values of the force
sensor (increments) and the forces on the force gauge (kN). It also determines
the flexion of the gun.
Force characteristic:
In 5 measurements, 5 increment/force pairs are determined. The incre-
ment/force pairs are saved and added to the force characteristic of the force
sensor, with interpolation of the intermediate values.

Fig. 6-6: Force characteristic

F 1… F 5 Forces measured with the force gauge (kN)

Pos1… Pos5 Measurement positions of the sensor (increments)

Gun flexion characteristic:

During calibration, the gun flexion characteristic, i.e. the relationship between
the force gauge and the gun flexion, is also determined.

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Fig. 6-7: Gun flexion characteristic

G Gun flexion (mm)

F Force (kN)

6.15.3 Force test with EG_FORCE_F program

Description The EG_FORCE_F program 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 robot controller closes the gun with the selected setpoint force. The actual
force on the gun can then be read off on the force gauge.

Precondition  The gun is mastered.

 The gear ratio has been entered.
 The thickness of the force gauge has been entered.
 The maximum gun force has been entered.
 The calibration step size and first calibration position have been entered.
 Coarse calibration with EG_CAL_F has been carried out.
 Operating mode T1

Procedure 1. Select and start the program EG_FORCE_F.

2. Follow the dialog messages.
3. Select the lowest setpoint force using the corresponding button.
4. Measure the actual force with the force gauge and note it down.

If the measured force is significantly higher than the se-

lected force, cancel the program without performing any
further measurements, and carry out calibration with EG_CAL. This also ap-
plies to the following steps. Further measurements may cause damage to
property.

5. Repeat steps 3 and 4 for all forces.

The -> button is used to display further buttons with higher forces.
6. If the actual force values deviate from the setpoint values by more than
±3%, carry out fine calibration with the program EG_RECAL_F.
(>>> 6.15.4 "Fine calibration with the EG_RECAL_F program" Page 52)

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6.15.4 Fine calibration with the EG_RECAL_F program

Description If the force test with EG_FORCE_F results in too high a deviation between the
setpoint and actual force values, fine calibration must be carried out.
EG_RECAL_F performs the same measurements as EG_CAL_F, but closes
the gun under force control.

During calibration, the gun closes at process velocity, not

at reduced velocity.

Precondition  The gun is mastered.

 The gear ratio has been entered.
 The thickness of the force gauge has been entered.
 The maximum gun force has been entered.
 The calibration step size and first calibration position have been entered.
 Coarse calibration with EG_CAL_F has been carried out.
 Operating mode T1

Accessories  Force gauge

(if necessary, consult gun manufacturer for a suitable model.)

Procedure 1. Select and start the program EG_RECAL_F.

2. Follow the dialog messages and note the values of the 5 measurements.
3. After the 5th measurement, take the force gauge out of the gun.

If the force gauge is not removed from the gun, this may
result in damage to property.

4. The gun moves to the mastering position and stops there. Carry out a vi-
sual check that the mastering position is correct.
 If it is: continue with the next step.
 If not: remaster the gun. Then repeat the entire calibration.
5. Execute the program through to the end.
6. The values noted must be entered on the Force calibration configuration
screen in Force 1 in kN to Force 5 in kN.
7. Click on Calculate, then save.
8. Test the obtained force values with the program EG_FORCE_F.

If the deviation between the setpoint and actual force is still too great
for the application after fine calibration with EG_RECAL_F, execute
the program EG_RECAL_F again.

6.16 Setting the software limit switches

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

6.16.1 Setting the negative software limit switch

Precondition  “Expert” user group

 The gun is mastered.
 The gear ratio has been entered.
 The gun is calibrated.
 New electrode tips

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

Procedure 1. Determine the value for the negative software limit switch:
a. Open the gun until it is almost completely open.
b. In the main menu, select Display > Variable > Overview > Display.
Note the value of the Position variable.
c. Value sought = value of Position variable + reserve (recommended:
height of 2 motor revolutions)
2. Enter this value in the Gun configuration screen under Software limit
(mm) and save.

Alternative 1. Take the value from the gun data sheet, and enter and save it in the Gun
procedure configuration screen under Software limit (mm).
2. Check that the value is correct.
 To do this, open the gun manually and observe whether it stops auto-
matically at the point corresponding to the entered value, before
reaching the stop.
 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 pos-
itive limit switch must be determined as described in the first proce-
dure.

6.16.2 Setting the positive software limit switch

Precondition  “Expert” user group

 The gun is mastered.
 The gear ratio has been entered.
 The gun is calibrated.
 New electrode tips

Procedure 1. Calculate the value for the positive software limit switch:
Max. flexion (mm) + Tip wear (burn-off) + reserve (approx. 3 mm)
The values can be taken from the following sources:
 Max. flexion (mm): configuration screen Gun
 Tip wear (burn-off): configuration screen General
 Reserve: This value can be chosen freely as required. Guide value:
3 mm
2. Enter the calculated value in the Gun configuration screen under Soft-
ware limit (mm) and save.

6.17 Checking the residual travel and software limit switches

To prevent mechanical damage to the spindle, the residual travel and software
limit switches must be checked.

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6.17.1 Dimensions and distances on a C gun

Fig. 6-8: Dimensions and distances on a C gun

1 Hardware stop
2 Negative software limit switch
3 Mastering position
4 Positive software limit switch
5 Hardware stop
A Residual travel before negative software limit switch (min. 1
revolution of the motor)
B Maximum opening width of the gun
C Maximum tip burn-off (sum of the tip burn-off for both elec-
trodes)
D Maximum gun flexion
E 3 mm reserve
F Residual travel before positive software limit switch (min. 2 rev-
olutions of the motor)
G Reserve distance
H Complete spindle travel

6.17.2 Checking the residual travel and software limit switches for C guns

Precondition  The gun is mastered.

 The gun is calibrated.
 The positive and negative software limit switches have been configured.
 New electrode tips

Procedure 1. Calculate the residual travel between the positive software limit switch and
the hardware stop using the following formula:

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Residual travel = Total spindle travel – (positive software limit switch +

maximum opening width specified by gun manufacturer + negative soft-
ware limit switch)

Result Activity
Residual travel ≥ 2 revolutions of ----------
the motor
Residual travel < 2 revolutions of Reduce the Maximum tip wear
the motor value in the configuration plug-in so
that the residual travel = 2 motor
revolutions.

2. Calculate the reserve distance using the following formula:

Reserve distance = positive software limit switch + residual travel after
positive software limit switch
3. Calculate the spindle opening using the following formula:
Spindle opening = Total spindle travel – reserve distance
4. Move the weld gun to the mastering position.
5. Measure the spindle opening on the weld gun motor.

Fig. 6-9: Spindle opening of an extended C gun motor

Result Activity
Measured spindle opening > calcu- Reduce the Maximum tip wear
lated spindle opening value in the configuration plug-in so
that the measured spindle opening
is no greater than the calculated
spindle opening.
Measured spindle opening ≤ calcu- ----------
lated spindle opening

6. Move the weld gun to the negative software limit switch.

7. Measure the spindle opening on the weld gun motor.

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Fig. 6-10: Spindle opening of a retracted C gun motor

Result Activity
Spindle opening ≥ 1 revolution of ----------
the motor
Spindle opening < 1 revolution of Reduce the Max. opening (mm)
the motor value in the configuration plug-in so
that the spindle opening = 1 motor
revolution.

6.17.3 Checking the residual travel and software limit switches for X guns

Precondition  The gun is mastered.

 The gun is calibrated.
 The positive and negative software limit switches have been configured.
 The minimum and maximum spindle dimension of the X gun motor are
known.
 New electrode tips
The minimum or maximum spindle dimension is the distance between the mo-
tor flange and the outer surface of the eye when the motor is at the hardware
stop.

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Fig. 6-11: Spindle dimensions on the X gun motor

1 Minimum spindle dimension of the X gun motor

2 Maximum spindle dimension of the X gun motor

Procedure 1. Check the gear ratio:

 Open the gun until the distance between the electrodes is exactly
10 mm. (Measure the distance.)
 In the main menu, select Display > Actual position > Axis-specific.
The gun opening width is displayed in the column Pos. [deg, mm].
 Compare the measured value with the value displayed.
 If the displayed value deviates by more than ±0.2 mm from the mea-
sured value, the gear ratio must be determined again.
2. Calculate the gear ratio using the following formula:
Gear ratio = change in the opening width over 1 motor revolution / spindle
screw pitch
3. Convert the positive software limit switch to the spindle using the following
formula:
Positive software limit switch on the spindle = value for positive software
limit switch / gear ratio
4. Calculate the reserve distance using the following formula:
Reserve distance = positive software limit switch on the spindle + residual
travel (2 revolutions of the motor)
5. Calculate the spindle dimension in the mastering position using the follow-
ing formula:
Spindle dimension in the mastering position = maximum spindle dimen-
sion – reserve distance
6. Move the gun to the mastering position and measure the spindle dimen-
sion on the motor.
7. If the measured spindle dimension is larger than the calculated spindle di-
menstion in the mastering position, then the maximum tip burn-off must be
reduced.

The measured spindle dimension must not be larger than the calcu-
lated spindle dimension in the mastering position.

8. Move the gun to the negative software limit switch and measure the spin-
dle dimension on the motor.

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Result Activity
Measured spindle dimension ≥ min- ----------
imum spindle dimension + 1 motor
revolution
Measured spindle dimension < min- Reduce the Max. opening (mm)
imum spindle dimension + 1 motor value in the configuration plug-in so
revolution that the measured spindle dimen-
sion = minimum spindle dimension
+ 1 motor revolution.

6.18 Tip initialization – overview

Description During tip initialization, the current electrode burn-off is measured and saved.
This enables the TCP and the gun opening to be automatically adapted to the
burn-off.

The gun opening is adapted to the current burn-off if the parameter

TCP correction is set to On in the configuration screen Configura-
tion.

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.

Overview Initialization can be performed using a status key or via a KRL program.
 First initialization
Via status key: (>>> 6.18.1 "First initialization via status key" Page 58)
Via KRL:
 Cyclical initialization
Via status key: (>>> 6.18.2 "Cyclical initialization via status key" Page 59)
Via KRL: (>>> 7.5.2 "Programming cyclical initialization" Page 71)

6.18.1 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 value First Init force has been entered in the configuration screen
General.

Procedure 1. Set program override to 100%.

2. Open the gun manually at least 10 mm.
3. Hold down the enabling switch.
4. Press the status key First initialization. First initialization is performed:

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.

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 The gun opens.

 The gun closes twice with initialization force.
 The robot controller saves the current tip wear in EG_WEAR[]. The vari-
able EG_WORN is set to FALSE. The output New electrodes is set and
reset.

6.18.2 Cyclical initialization via status key

Precondition  T1 or T2 operating 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 10 mm.
3. Hold down the enabling switch.
4. Press the Cyclical initialization status key. Cyclical initialization is carried
out.

Sequence With this cyclical initialization, the following occurs:

 The gun closes twice with initialization force.
 The robot controller saves the current tip wear in EG_WEAR[]. It gener-
ates a message if the current wear is greater than the maximum permissi-
ble wear (EG_WEAR_MAX). The electrode tips must then be exchanged.

6.19 Controller parameters

6.19.1 Controller parameters – overview

For determining and optimizing the controller parameters, expert

knowledge in the start-up of guns is required.

Description The controller tool can be used to determine and optimize the motor-specific
and gun-specific controller parameters for PTP and CP motions. In addition,
the proportional factor for the force controller can be determined.
The parameters must be determined in the following order:

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 control gain for PTP and CP motions
POS GAIN (Position controller gain)
4 Proportional factor for force controller
FORCE GAIN (Force controller gain)

Sequence The controller tool calls up programs which execute a defined motion profile
cyclically with the active weld gun. At each program cycle, the parameter is in-

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creased by the defined increment (‘step size’), starting from the lower limit and
continuing until the upper limit is reached. The entire sequence for a parame-
ter is recorded as a measurement curve (trace).
While the parameters for the position and speed controllers are being deter-
mined, the axis of the active gun moves between a position before the nega-
tive software limit switch and the mastering position.
While the parameter for the force controller is being determined, the measure-
ment curve is recorded at 3 different forces for each value of FORCE GAIN.

Servo Gun
parameter finding

Fig. 6-12: Window: Servo Gun parameter finding

1 Table
2 Enter the determined controller parameters here.

The following buttons are available:

Button Description
Motor param. Selects the program
EG_SET_MOTOR_PARAM. This program is
used to determine the parameters for the speed
and position controllers.
Force parameter Selects the program EG_SET_FORCE_PARAM.
This program is used to determine the parame-
ters for the force controller.
Trace > Only available to the user group “Expert” or
[controller_parameter] higher.
Opens the measurement curve for the selected
parameter.

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 6 Start-up and configuration

Button Description
Table > Load table Only available to the user group “Expert” or
higher.
Loads the default values for the following param-
eters: Lower limit, Upper limit, Steps
The default values depend on what is selected in
the following boxes: Motor type, Gun type,
Stiffness
Table > Discard table Only available to the user group “Expert” or
higher.
Discards the current entries in the following
boxes: Lower limit, Upper limit, Steps. Instead,
the most recently saved values are displayed.
Save table Saves the following values: Lower limit, Upper
limit, Steps
Save values Saves the entered controller parameters.

6.19.2 Determining and optimizing controller parameters

Precondition  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.
 Operating mode T2
 “Expert” user group

Preparation 1. In the main menu, select Configuration > Servo Gun FC > Controller
parameters.
The Servo Gun parameter finding window opens.
2. Select the appropriate number, type, etc. in the following boxes:
 Gun number
 Motor type
 Gun type
 Stiffness
3. Select the menu sequence Table > Load table.
The boxes in the table are automatically filled with values.

Procedure 1 Parameters for speed and position controllers:

1. Press button Motor param.. The program EG_SET_MOTOR_PARAM is
selected.
2. Set program override to 100% and execute the program up to the first
HALT.

If the program override is not set to 100%, the measurements will be

incorrect.

3. In the main menu, select Configuration > Servo Gun FC > Controller
parameters.
4. Select the menu sequence Trace > VEL GAIN. The measurement curve
for VEL GAIN opens.

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5. On the measurement curve, read off the value at which the motor current
begins to oscillate.
Halve this value.
6. Close the measurement curve and enter the halved value in the Servo
Gun parameter finding window in the following box: VEL GAIN (Speed
controller gain).
Then press Save values.
7. Close the Servo Gun parameter finding window and execute the select-
ed program until the next HALT.
8. In the main menu, select Configuration > Servo Gun FC > Controller
parameters.
9. Select the menu sequence Trace > VEL INT TIME. The measurement
curve for VEL INT TIME opens.
10. On the measurement curve, read off the value at which the graph for the
holding current of the gun closed to force is at its flattest.
11. Close the measurement curve and enter the determined value in the Ser-
vo Gun parameter finding window in the following box: VEL INT TIME
(Reset time of speed controller).
Then press Save values.
12. Close the Servo Gun parameter finding window and execute the select-
ed program until the next HALT.
13. In the main menu, select Configuration > Servo Gun FC > Controller
parameters.
14. Select the menu sequence Trace > POS GAIN. The measurement curve
for POS GAIN opens.
15. On the measurement curve, read off the value at which the motor current
begins to oscillate.
Halve this value.
16. Close the measurement curve and enter the halved value in the Servo
Gun parameter finding window in the following box: POS GAIN (Posi-
tion controller gain).
Then press Save values.
17. Close the Servo Gun parameter finding window and execute the select-
ed program through to the end.
The PTP parameters are automatically saved in addition as CP parame-
ters.

If the motor current does not start to oscillate:

Return to the Servo Gun parameter finding window.
Adapt the following values there: Lower limit, Upper limit, Steps.
 Then restart this procedure.

Procedure 2 Parameters for force controller:

1. In the main menu, select Configuration > Servo Gun FC > Controller
parameters.
2. Press button Force parameter. The program EG_SET_FORCE_PARAM
is selected.
3. Set program override to 100% and execute the program up to the first
HALT.

If the program override is not set to 100%, the measurements will be

incorrect.

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4. In the main menu, select Configuration > Servo Gun FC > Controller
parameters.
5. Select the menu sequence Trace > FORCE GAIN. The measurement
curve for FORCE GAIN opens.
6. Read and note the value of FORCE GAIN from the measurement curve.
(FORCE GAIN = value with the fastest correction of the force and the
smallest overshoot.)
7. Close the measurement curve and enter the determined value in the Ser-
vo Gun parameter finding window in the following box: FORCE GAIN
(Force controller gain).
Then press Save values.
8. Close the Servo Gun parameter finding window and execute the select-
ed program through to the end.
The PTP parameters are automatically saved in addition as CP parame-
ters.

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 7 Programming

7 Programming

7.1 Inline forms – overview

Inline form Description

SPOT Programming a weld spot with/without EqualizingTech
(>>> 7.3 "Programming a weld spot" Page 66)
(>>> 7.4 "Programming a weld spot with EqualizingTech"
Page 68)
INIT Measuring and saving the current wear
(>>> 7.5.1 "Programming first initialization" Page 71)
(>>> 7.5.2 "Programming cyclical initialization" Page 71)
SetTip instruction Closing and opening the gun once with initialization force
(contained in the inline form (>>> 7.6 "Programming SetTip (pressing on tips)" Page 72)
INIT)
TippDress Tip dressing with/without EqualizingTech
(>>> 7.7 "Programming tip dressing" Page 73)
(>>> 7.8 "Programming tip dressing with EqualizingTech"
Page 76)
ServoGun Decouple Decoupling the gun
(>>> 7.9.1 "Inline form “ServoGun Decouple”" Page 78)
ServoGun Couple Coupling the gun
(>>> 7.9.2 "Inline form “ServoGun Couple”" Page 79)
INIT Equalizing (>>> 7.10 "Initializing EqualizingTech" Page 79)
Note: Only available if EqualizingTech is installed.

7.2 Instructions

Recommendation: Do not weld in T1 mode. In T1, the velocity is lim-

ited: force build-up takes a long time and can therefore trigger moni-
toring functions.

Weld spots and tip dressing points that were taught with-
out EqualizingTech must not be used with Equalizing-
Tech. Weld spots and tip dressing points that were taught with
EqualizingTech must not be used without EqualizingTech.
If such existing points are to be reused, they must be retaught. Damage to
the gun or the workpiece may otherwise result.

7.2.1 Instructions for use of stationary guns

The descriptions regarding programming refer to guns mounted on the robot

flange. For stationary guns, the programming must be adapted accordingly.
Aspects requiring special consideration:
 In the option window Frames the interpolation mode must be set to True,
indicating that a stationary gun is being used. This concerns the following
inline forms:
 SPOT

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 TippDress
 While tip dressing or initialization is being carried out with a stationary gun,
the robot is not available for other work (e.g. fetching a new workpiece).
Reason: Robot axes and an external axis (= gun) are moved synchronous-
ly. This means they perform common motions that start and finish simulta-
neously. Even though the robot axes are usually stationary during
dressing and initialization, this is nevertheless part of the overall motion.
The robot axes are therefore not able to execute other movements inde-
pendently of the external axis.

7.3 Programming a weld spot

This description applies if Compensation #AIR is configured.

A different description applies in the case of Compensation
#EQUALIZING. (>>> 7.4 "Programming a weld spot with Equalizing-
Tech" Page 68)

Distances The following distances are required for the position of the gun during teach-
ing:

Distance … Value
Moving electrode Min. 15 mm distance from the workpiece
Fixed electrode Max. 5 mm distance from the workpiece
Gun opening Must be at least 4 mm less than the nega-
tive software limit switch.

Procedure 1. Position the gun on the desired weld spot. Observe the required distances.
2. Select the menu sequence Commands > ServoTech > SPOT and then
select the desired motion type.
3. Set the parameters in the inline form.
4. Press Cmd OK to save the instruction.

7.3.1 Inline form “SPOT”

The instruction performs a motion and executes a weld spot at the end point.

Fig. 7-1: Inline form: SPOT with CIRC

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Item Description
1 Motion type
 PTP, LIN or CIRC
2 Only for CIRC motions: Auxiliary point
3 Name of the end point
(>>> 7.11 "Option window “Frames”" Page 80)
 […]0 000 001… […]9 999 999
Only with the option ProgSelect FALSE: The last 7 characters (=
default number) must be digits. The robot controller communi-
cates these digits to the weld timer as the program number. The
number of relevant final characters can be configured in the
parameter ProgDigits.
4 Velocity
 For PTP: 0 … 100%
 For LIN or CIRC: 0.001 … 2 m/s
5 Name for the motion data set
The system automatically generates a name. The name can be
overwritten. Touch the arrow to edit the point data. The corre-
sponding option window is opened.
(>>> 7.12 "Option window “Motion parameters” (LIN, CIRC,
PTP)" Page 81)
6 Program number for the weld timer
 1 … 100 000
Note: This box is only displayed if the option ProgSelect TRUE is
configured.
7 Active gun
 1…6
8  CLS OPN: Approximate positioning during closing and open-
ing motions
 OPN: Approximate positioning during opening motion
 CLS: Approximate positioning during closing motion
 (blank): Without approximate positioning
9 Total thickness of the workpieces to be welded
 0 … 100 mm
Note: This box is only displayed if the option ThicknessTimer
FALSE is configured.
10 Amount by which the actual thickness may deviate from the value
in Part
For example, if the thickness is 2 mm and the permissible devia-
tion is 1 mm, then the total thickness may lie between 1 and
3 mm.
 1 … 100 mm
Note: This box is only displayed if the option ThicknessTolTimer
FALSE is configured.

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Item Description
11 Welding force
 Maximum value: Value of the configuration parameter Maxi-
mum gun force in kN
Note: This box is only displayed if the option ForceTimer FALSE
has been selected.
12 Should force control remain active after the target force is
reached?
 On during welding: Yes, force control is active during the
welding process.
 Off during welding: No, there is no force control during weld-
ing. Position control is active during the welding process.
Which method is appropriate depends on the workpiece.
13  0: Without compensation
 1: Compensator 1
 2: Compensator 2
Note: This box is only displayed if the option Compensation
#AIR is configured.
14 Distance after which compensation is deactivated on opening the
gun. The lower the value, the earlier the deactivation of compen-
sation.
 -9 999 … 0 mm:
Note: This box is only displayed if the option Compensation
#AIR is configured.
15 Degrees and direction for the turning functionality
 -10 … 10 °
Note: This box is only displayed if the option EG_TURN_ACTIVE
= TRUE is configured.
16 Welding parameters
(>>> 7.13 "Option window “Weld timer parameters”" Page 82)
Note: This box is only displayed if at least one of the following
options has been configured: ForceTimer TRUE, Thickness-
Timer TRUE, ThicknessTolTimer TRUE, WeldTimeTimer
TRUE

7.4 Programming a weld spot with EqualizingTech

Distances The following distances are required for the position of the gun during teach-
ing:

Distance … Value
Fixed electrode No distance from the workpiece; must be
in contact with the workpiece.
Gun opening Must be at least 4 mm away from the neg-
ative software limit switch.

Procedure 1. Position the gun on the desired weld spot. Observe the required distances.
2. Select the menu sequence Commands > ServoTech > SPOT and then
select the desired motion type.
3. Set the parameters in the inline form.

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4. Press Cmd OK to save the instruction.

Sequence Program sequence for welding:

When approaching points, the robot maintains a certain distance from the
workpiece so that the fixed electrode does not scrape against the workpiece.
The user can configure this distance via the REAL variable
EG_TOUCH_DIFF[] in the file EG_EXTERN.DAT. Default setting: 3 mm.
The actual opening width of the gun at the point is the sum of the taught open-
ing width and this distance.

7.4.1 Inline form “SPOT” (EqualizingTech)

Fig. 7-2: SPOT (EqualizingTech)

Item Description
1 Motion type
 PTP, LIN or CIRC
2 Only for CIRC motions: Auxiliary point
3 Name of the end point
(>>> 7.11 "Option window “Frames”" Page 80)
 […]0 000 001… […]9 999 999
Only with the option ProgSelect FALSE: The last 7 characters (=
default number) must be digits. The robot controller communi-
cates these digits to the weld timer as the program number. The
number of relevant final characters can be configured in the
parameter ProgDigits.
4 Velocity
 For PTP: 0 … 100%
 For LIN or CIRC: 0.001 … 2 m/s
5 Name for the motion data set
The system automatically generates a name. The name can be
overwritten. Touch the arrow to edit the point data. The corre-
sponding option window is opened.
(>>> 7.12 "Option window “Motion parameters” (LIN, CIRC,
PTP)" Page 81)

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Item Description
6 Program number for the weld timer
 1 … 100 000
Note: This box is only displayed if the option ProgSelect TRUE is
configured.
7 Active gun
 1…6
8  CLS OPN: Approximate positioning during closing and open-
ing motions
 OPN: Approximate positioning during opening motion
 CLS: Approximate positioning during closing motion
 (blank): Without approximate positioning
9 Total thickness of the workpieces to be welded
 0 … 100 mm
Note: This box is only displayed if the option ThicknessTimer
FALSE is configured.
10 Amount by which the actual thickness may deviate from the value
in Part
For example, if the thickness is 2 mm and the permissible devia-
tion is 1 mm, then the total thickness may lie between 1 and
3 mm.
 1 … 100 mm
Note: This box is only displayed if the option ThicknessTolTimer
FALSE is configured.
11 Welding force
 Maximum value: Value of the configuration parameter Maxi-
mum gun force in kN
Note: This box is only displayed if the option ForceTimer FALSE
has been selected.
12 Should force control remain active after the target force is
reached?
 On during welding: Yes, force control is active during the
welding process.
 Off during welding: No, there is no force control during weld-
ing. Position control is active during the welding process.
Which method is appropriate depends on the workpiece.
13 Degrees and direction for the turning functionality
 -10 … 10 °
Note: This box is only displayed if the option EG_TURN_ACTIVE
= TRUE is configured.
14 Welding parameters
(>>> 7.13 "Option window “Weld timer parameters”" Page 82)
Note: This box is only displayed if at least one of the following
options has been configured: ForceTimer TRUE, Thickness-
Timer TRUE, ThicknessTolTimer TRUE, WeldTimeTimer
TRUE

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7.5 Programming tip initialization

Overview Initialization can be performed using a status key or via a KRL program.
 First initialization
Via status key: (>>> 6.18.1 "First initialization via status key" Page 58)
Via KRL:
 Cyclical initialization
Via status key: (>>> 6.18.2 "Cyclical initialization via status key" Page 59)
Via KRL: (>>> 7.5.2 "Programming cyclical initialization" Page 71)

7.5.1 Programming first initialization

Description 1 position must be taught for initialization. This is taught as a normal motion
point.

Precondition  T1 or 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.
 The following values have been entered in the configuration screen Gen-
eral: First Init force, TCP orientation
 The software limit switches have been set.

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

The position must be at least 4 mm away from the negative software limit
switch.
2. Teach a conventional PTP, LIN or CIRC point at this position.
3. Select the menu sequence Commands > ServoTech > INIT.
4. Select the gun in the inline form.
5. Select New in the inline form.
(>>> 7.5.3 "Inline form “INIT”" Page 72)
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 twice with initialization force.
 The robot controller saves the current tip wear in EG_WEAR[].
 The gun moves to the initialization position.
 The moving gun arm performs a motion with initialization force.
 The variable EG_WORN is set to FALSE. The output New electrodes is
set and reset.

7.5.2 Programming cyclical initialization

Description 1 position must be taught for initialization. This is taught as a normal motion
point.

Precondition  T1 or T2 operating mode

 The gun has been calibrated as a tool. This tool is currently selected.

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 KUKA.ServoGun FC 2.1

 The gun is mastered.

 The gun is calibrated.
 The software limit switches have been set.
 First initialization has been performed.

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

The position must be at least 4 mm away from the negative software limit
switch.
2. Teach a conventional PTP, LIN or CIRC point at this position.
3. Select the menu sequence Commands > ServoTech > INIT.
4. Select the gun in the inline form.
5. Select Same in the inline form.
(>>> 7.5.3 "Inline form “INIT”" Page 72)
6. Press Cmd OK to save the instruction.

Sequence With this cyclical initialization, the following occurs:

 The gun closes twice with initialization force.
 The robot controller saves the current tip wear in EG_WEAR[]. It gener-
ates a message if the current wear is greater than the maximum permissi-
ble wear (EG_WEAR_MAX). The electrode tips must then be exchanged.

7.5.3 Inline form “INIT”

This instruction is used for initializing the tips. (First initialization or cyclical ini-
tialization)

The inline form does not contain any position data; the preceding
point is used. The point must be at least 4 mm away from the negative
software limit switch.

Fig. 7-3: Inline form: INIT

Item Description
1 Select the active gun.
 1…6
2  New: First initialization
 Same: Cyclical initialization

7.6 Programming SetTip (pressing on tips)

Description This instruction is used to press on new electrode tips. The gun moves to the
point, closes once and opens again. The point is always addressed with a PTP
motion.
No initialization or measurement is carried out.

Procedure 1. Move the gun to the desired position. The position must be at least 4 mm
away from the negative software limit switch.
2. Select the menu sequence Commands > ServoTech > INIT.
3. Select SetTip in the inline form.

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(>>> 7.6.1 "Inline form “INIT” (for SetTip)" Page 73)

4. Set the other parameters in the inline form.
5. Press Cmd OK to save the instruction.

7.6.1 Inline form “INIT” (for SetTip)

Fig. 7-4: Inline form “INIT” (for SetTip)

Item Description
1 Select the active gun.
 1…6
2  SetTip: The gun closes once and opens again.
3 Name of the end point
(>>> 7.11 "Option window “Frames”" Page 80)
 […]0 000 001… […]9 999 999
4 Workpiece thickness if tips are to be pressed onto a workpiece. If
this is not the case, i.e. if the tips are to be pressed directly onto
one another, enter “0”.
 0 … 100 mm
Note: This value is used for SetTip irrespective of how the option
ThicknessTimer is configured.
5 Closing force of the gun
 Maximum value: Value of the configuration parameter Maxi-
mum gun force in kN
Note: This value is used for SetTip irrespective of how the option
ForceTimer is configured.

7.7 Programming tip dressing

This description applies if Compensation #AIR is configured.

A different description applies in the case of Compensation
#EQUALIZING. (>>> 7.8 "Programming tip dressing with Equalizing-
Tech" Page 76)

Description TippDress executes a weld spot without approximate positioning.

Dressing must be performed without weld current. If

dressing is carried out with weld current, damage to
property is liable to occur.

The default sequence for tip dressing corresponds to the sequence for weld-
ing: the robot controller sends the point index to the weld timer and the gun
closes until the force programmed in the inline form is reached. Once the force

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 KUKA.ServoGun FC 2.1

is reached, the robot controller sets the output Weld start and waits for the in-
put Weld end.
If a different sequence is required for tip dressing, this can be programmed in
the subprogram EG_USERDRESS. In order for the robot controller to perform
this different sequence, the variable EG_NON_KUKA_DRESS must be set to
TRUE.

Fig. 7-5: Tip dressing

Distances The following distances are required for the position of the gun during teach-
ing:

Distance … Value
Moving electrode Min. 15 mm distance from the workpiece
Fixed electrode Max. 5 mm distance from the workpiece
Gun opening Must be at least 4 mm less than the nega-
tive software limit switch.

Precondition  Only relevant if the ThicknessTimer FALSE option has been configured:
The thickness of the tip dresser is known.
(>>> 6.13 "Determining the thickness of the tip dresser" Page 47)

Procedure 1. Position the gun on the desired tip dressing point. Observe the required
distances.
2. Select the menu sequence Commands > ServoTech > TippDress and
then select the desired motion type.
3. Set the parameters in the inline form. Also enter the thickness of the tip
dresser.
(>>> 7.7.1 "Inline form “TippDress”" Page 75)
4. Press Cmd OK to save the instruction.

After tip dressing, cyclical initialization must be performed.

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7.7.1 Inline form “TippDress”

Fig. 7-6: Inline form: TippDress with PTP

Item Description
1 Motion type
 PTP or LIN
2 Name of the end point
Touch the arrow to edit the point data. The corresponding option
window is opened.
(>>> 7.11 "Option window “Frames”" Page 80)
Only with the option ProgSelect FALSE:
The last 7 characters (= default number) must be digits. The robot
controller communicates these digits to the weld timer as the pro-
gram number.
 […]0 000 001… […]9 999 999
The number of relevant final characters can be configured in the
parameter ProgDigits.
3 Motion velocity
 For PTP: 0 … 100 %
 For LIN: 0.001 … 2 m/s
4 Name for the motion data set
The system automatically generates a name. The name can be
overwritten. Touch the arrow to edit the point data. The corre-
sponding option window is opened.
(>>> 7.12 "Option window “Motion parameters” (LIN, CIRC,
PTP)" Page 81)

5 Program number for the weld timer

 1 … 100 000
Note: This box is only displayed if the option ProgSelect TRUE
has been configured.
6 Active gun
 1…6
7 Thickness of the tip dresser
 0 … 100 mm
Note: This box is only displayed if the option ThicknessTimer
FALSE has been configured.

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Item Description
8 Closing force of the gun
 Maximum value: Value of the configuration parameter Maxi-
mum gun force in kN
Note: This box is only displayed if the option ForceTimer FALSE
has been selected.
9  0: Without compensation
 1: Compensator 1
 2: Compensator 2
Note: This box is only displayed if the option Compensation
#AIR has been configured.
10 Distance after which compensation is deactivated on opening the
gun. The lower the value, the earlier the deactivation of compen-
sation.
 -9,999 … 0 mm
Note: This box is only displayed if the option Compensation
#AIR has been configured.
11 Weld parameters
Touch the arrow to display the data. The corresponding option
window is opened.
(>>> 7.13 "Option window “Weld timer parameters”" Page 82)
Note: This box is only displayed if at least one of the following
options has been configured: ForceTimer TRUE, Thickness-
Timer TRUE, ThicknessTolTimer TRUE, WeldTimeTimer
TRUE

7.8 Programming tip dressing with EqualizingTech

Description TippDress executes a weld spot without approximate positioning.

Dressing must be performed without weld current. If

dressing is carried out with weld current, damage to
property is liable to occur.

Distances The following distances are required for the position of the gun during teach-
ing:

Distance … Value
Fixed electrode No distance from the workpiece; must be
in contact with the workpiece.
Gun opening Must be at least 4 mm away from the neg-
ative software limit switch.

Precondition  Only relevant if the ThicknessTimer FALSE option has been configured:
The thickness of the tip dresser is known.
(>>> 6.13 "Determining the thickness of the tip dresser" Page 47)

Procedure 1. Position the gun on the desired tip dressing point. Observe the required
distances.
2. Select the menu sequence Commands > ServoTech > TippDress > PTP
or LIN.

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3. Set the parameters in the inline form. (>>> 7.8.1 "Inline form “TippDress”
(EqualizingTech)" Page 77)
4. Press Cmd OK to save the instruction.

After tip dressing, cyclical initialization must be performed.

Sequence Program sequence for tip dressing:

The default sequence corresponds to the sequence for welding.
If a different sequence is required for tip dressing, this can be programmed in
the subprogram EG_USERDRESS. In order for the robot controller to perform
this different sequence, the variable EG_NON_KUKA_DRESS must be set to
TRUE.

7.8.1 Inline form “TippDress” (EqualizingTech)

Fig. 7-7: TippDress (EqualizingTech)

Item Description
1 Motion type
 PTP or LIN
2 Name of the end point
Touch the arrow to edit the point data. The corresponding option
window is opened.
(>>> 7.11 "Option window “Frames”" Page 80)
Only with the option ProgSelect FALSE:
The last 7 characters (= default number) must be digits. The robot
controller communicates these digits to the weld timer as the pro-
gram number.
 […]0 000 001… […]9 999 999
The number of relevant final characters can be configured in the
parameter ProgDigits.
3 Motion velocity
 For PTP: 0 … 100 %
 For LIN: 0.001 … 2 m/s

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Item Description
4 Name for the motion data set
The system automatically generates a name. The name can be
overwritten. Touch the arrow to edit the point data. The corre-
sponding option window is opened.
(>>> 7.12 "Option window “Motion parameters” (LIN, CIRC, PTP)"
Page 81)

5 Program number for the weld timer

 1 … 100 000
Note: This box is only displayed if the option ProgSelect TRUE
has been configured.
6 Active gun
 1…6
7 Thickness of the tip dresser
 0 … 100 mm
Note: This box is only displayed if the option ThicknessTimer
FALSE has been configured.
8 Closing force of the gun
 Maximum value: Value of the configuration parameter Maxi-
mum gun force in kN
Note: This box is only displayed if the option ForceTimer FALSE
has been selected.
9 Weld parameters
Touch the arrow to display the data. The corresponding option win-
dow is opened.
(>>> 7.13 "Option window “Weld timer parameters”" Page 82)
Note: This box is only displayed if at least one of the following op-
tions has been configured: ForceTimer TRUE, ThicknessTimer
TRUE, ThicknessTolTimer TRUE, WeldTimeTimer TRUE

7.9 Manually coupling / decoupling the gun via inline form

If an archive is restored while a mastered gun is decou-

pled, the data relating 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 remastered.
Failure to observe this precaution may result in damage to property.

7.9.1 Inline form “ServoGun Decouple”

Description This command decouples the gun within the software. The inline form does not
control any hardware, inputs or outputs.

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On decoupling, the gun must not be in the mastering position or

closed to force, otherwise the mastering will be lost on recoupling.

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

Fig. 7-8: ServoGun Decouple

Item Description
1 Select the current gun.
 1 ... 6

7.9.2 Inline form “ServoGun Couple”

Description This command couples the gun within the software. The inline 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 recoupling a mastered gun, the gun must have the same
opening width as when it was decoupled. If this is not the case, the mas-
tering 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. 7-9: ServoGun Couple

Item Description
1 Select the gun that has been physically coupled.
 1 ... 6

7.10 Initializing EqualizingTech

This instruction is only available if EqualizingTech is installed.

Description This instruction is used to activate the Equalizing function. This is done by se-
lecting a value other than Off. The other values activate compensation and si-
multaneously adapt the behavior of the gun to the workpiece.

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To perform spot welding without compensation, the function is deactivated

again by selecting Off. Off is used, for example, before the following points:
 Before weld spots at which the gun is not to adapt to the position of the
workpiece, but where the gun is instead to fix the workpiece in the taught
position.
 Before tip dressing points at which dressing is to be carried out without
EqualizingTech.
The instruction is valid until the next INIT Equalizing instruction.

Procedure 1. Select the menu sequence Commands > EqualizingTech > INIT Equal-
izing.
2. Set the desired value in the inline form.
(>>> 7.10.1 "Inline form “INIT Equalizing”" Page 80)
3. Press Cmd OK to save the instruction.

7.10.1 Inline form “INIT Equalizing”

Fig. 7-10: Inline form “INIT Equalizing”

Item Description
1  Weak: For flexible workpieces
 Medium (default): For medium-stiff workpieces
 Strong: For very stiff workpieces
 Off: Deactivates the Equalizing functionality.
 User1; User2; User3: User-specific data set
The user can configure the desired behavior of the gun in the
corresponding subprogram.
(>>> 7.15 "Subprograms for user-specific stiffness parame-
ters" Page 83)

7.11 Option window “Frames”

Fig. 7-11: Option window “Frames”

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 7 Programming

Item Description
1 Tool selection.
If True in the box External TCP: workpiece selection.
Range of values: [1] … [16]
2 Base selection.
If True in the box External TCP: fixed tool selection.
Range of values: [1] … [32]
3 Interpolation mode
 False: The tool is mounted on the mounting flange.
 True: The tool is a fixed tool.
4  True: For this motion, the robot controller calculates the axis
torques. These are required for collision detection.
 False: For this motion, the robot controller does not calculate
the axis torques. Collision detection is thus not possible for this
motion.

7.12 Option window “Motion parameters” (LIN, CIRC, PTP)

Fig. 7-12: Option window “Motion parameters” (LIN, CIRC, PTP)

Item Description
1 Acceleration
Refers to the maximum value specified in the machine data. The
maximum value depends on the robot type and the selected oper-
ating mode.

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Item Description
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 posi-
tioning 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 This box is only displayed for LIN and CIRC motions.
Orientation control selection.
 Standard
 Wrist PTP
 Constant orientation

7.13 Option window “Weld timer parameters”

The boxes in this window are only displayed if the corresponding ServoGun
option was set to TRUE.
The values come from the weld timer. They are only displayed and cannot be
modified.
Exception: If the configuration parameter Timer type is set to TEST, the val-
ues can be edited. In this case, the values displayed are those which the robot
controller last received from a weld timer.

Fig. 7-13: Option window “Weld timer parameters”

Item Description
1 Welding force
2 Total thickness of the workpieces to be welded
3 Amount by which the actual total thickness may deviate from the
value in Part thickness
Example: If Part thickness is set to 2 mm and Part thickness tol-
erance to 1 mm, then the total thickness may lie between 1 and
3 mm.
4 This box is only relevant for KUKA.RoboSpin.
Duration of weld operation: This value plus the value of
EG_WELDTIME_OFFSET[axis no.] results in the spin time.

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7.14 Adaptable subprograms

The following subprograms can be adapted to the specific requirements by the

user.
The subprograms can be found here:
 In the directory R1\TP\ServoGun_FC, in the file EG_User.SRC

Precondition  “Expert” user group

Subprograms
When does the robot controller call the
Subprogram
subprogram?
EG_PRE Before each weld spot
EG_POST After each weld spot
EG_PRE_INITSAME Before a cyclical initialization (but only in the
case of cyclical initialization via inline form)
EG_POST_INITSAME After a cyclical initialization (but only in the
case of cyclical initialization via inline form)
EG_PRE_INITNEW Before a first initialization (but only in the
case of first initialization via inline form)
EG_POST_INITNEW After a first initialization (but only in the case
of first initialization via inline form)
EG_PRE_INITSETTIP With the SetTip instruction, before the gun is
closed
EG_POST_INITSETTIP With the SetTip instruction, after the gun is
opened
EG_PRED Before each tip dressing point
EG_POSTD After each tip dressing point
EG_USERDRESS If the default sequence is not desired for tip
dressing, the user can program a different
sequence here. In order for the robot control-
ler to perform this different sequence, the
variable EG_NON_KUKA_DRESS must be
set to TRUE.

7.15 Subprograms for user-specific stiffness parameters

These subprograms are only available if EqualizingTech is installed.

Description These subprograms enable the user to adapt EqualizingTech particularly ac-
curately to the stiffness of the specific workpieces used. The subprograms can
be found here:
 In the directory R1\TP\EqualizingTech, in the file EQ_User.SRC
The subprograms are called EQ_USERPARAM_1, EQ_USERPARAM_2 and
EQ_USERPARAM_3.
To use a subprogram, it must be selected in the inline form INIT Equalizing.

Precondition  “Expert” user group

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Parameter
The suitable values for the parameters must be determined through
practical tests.
The moving electrode should touch the workpiece first. The fixed
electrode should touch the workpiece shortly after the moving electrode.

Parameter Description
EG_EQ_BUILD_PRESURE_VEL Gun velocity during pressure build-up between
P_APPROX and P_WELD [%]
 P_APPROX: Taught gun opening width at the
weld spot plus EG_TOUCH_DIFF
 P_WELD: Point at which pressure build-up is
complete
Default: 100%
Note: EG_EQ_BUILD_PRESURE_VEL must be set
so that the time for the pressure build-up corresponds
to PARAMS_PROG.TIME_EXPECTED. If one of the
two parameters is changed, the other one must be
adapted accordingly.
PARAMS_PROG.PROZ_EXPECTED For program mode:
How far should the fixed electrode move in the direc-
tion of the workpiece? [as a percentage of the vector
= in tenths of a millimeter]
Recommended value: Distance of the fixed elec-
trode from the workpiece + expected flexion
Default: 30%. This corresponds to 30% of the vector
length of 10 mm = 3 mm.
PARAMS_PROG.TIME_EXPECTED For program mode:
Within what time should the robot have completed its
active motion toward the workpiece? [s]
Default: 0.5 s
Note: EG_EQ_BUILD_PRESURE_VEL must be set
so that the time for the pressure build-up corresponds
to PARAMS_PROG.TIME_EXPECTED. If one of the
two parameters is changed, the other one must be
adapted accordingly.

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Parameter Description
PARAMS_MAN.PROZ_EXPECTED For manual mode:
How far should the fixed electrode move in the direc-
tion of the workpiece? [as a percentage of the vector
= in tenths of a millimeter]
Recommended value: Distance of the fixed elec-
trode from the workpiece + expected flexion
Default: 30%. This corresponds to 30% of the vector
length of 10 mm = 3 mm.
PARAMS_MAN.TIME_EXPECTED For manual mode:
Within what time should the robot have completed its
active motion toward the workpiece? [s]
Recommended values:
 For stiff workpieces: twice the gun closing time
from the start of VectorMove
 For very soft workpieces: the gun closing time
from the start of VectorMove
Default: 0.5 s

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 8 Diagnosis

8 Diagnosis

8.1
s
Checking the sensor reset and function of the force sensor
s

Precondition  The gun motor is connected.

 The outputs are configured.
 The gun is mastered.

Procedure 1. Set the system variable $SG_SENSOR_RESET[Axis no.] to TRUE.

Carefully close the gun manually.
 On closing the gun, observe the value of $FORCE_ACT[Axis no.]: The
value must remain the same.
 The LED on the distributor box of the weld gun motor must light up.
2. Open the gun again until there is no more pressure acting.
3. Set the system variable $SG_SENSOR_RESET[Axis no.] to FALSE.
Carefully close the gun manually.
 On closing the gun, observe the value of $FORCE_ACT[Axis no.]: The
value must increase continuously as the actual force increases.
 The LED must go out.

If the LED or $FORCE_ACT responds in a different way

from that described, the force sensor is supplying incor-
rect values. There is a risk of damage to the gun and/or the workpiece.
Check the cabling and correct if necessary.

8.2 Carrying out tests

Precondition  Operating mode T2

 Program override 100%
 For Calibration test: The gun flexion has been determined.
(>>> 8.4 "Determining the gun flexion (independently of the force sensor)"
Page 90)

There must be no object positioned between the elec-

trode tips, otherwise damage to property may result.

Procedure 1. Press and hold down the enabling switch.

2. Start the program EG_DIAGNOSE.
The robot controller performs all the tests and displays the relevant messages.
A trace is generated for each test in the directory KRC:\Roboter\Trace.
If an error occurs during a test, the robot controller generates an error mes-
sage. The remaining tests are then no longer carried out.
(>>> 8.2 "Carrying out tests" Page 87)

Alternative This procedure can be used to perform the tests individually. It is suitable for
procedure users with experience in fault diagnosis.
Additional precondition: User group “Expert”
1. In the main menu, select Diagnosis > Servo Gun FC > Servo Gun.
The ServoGun Diagnosis Tool window opens.
2. Select the number of the active gun in the Active gun number box.
3. Press and hold down the enabling switch.
4. Start the desired test.

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Description

Fig. 8-1: “ServoGun Diagnosis Tool” window

Item Description
1 Select the active gun.
2 Descriptions of the tests
3 LED icon showing the test status. If a test is running, the icon is
green.
4 Click on a button to start the corresponding test. A trace recording
is generated for each test.

8.3 Description of the tests

Reset test The sensor value is polled after sensor reset.

 Sensor value < 450: message The sensor reset works well
 Sensor value ≥ 450: message The sensor reset does not work. See "Reset" tra-
ce, channel 11/24
The name of the trace recording is RESET.

Noise test The test checks the sensor value of the motor. The test is executed without
moving the gun. The tolerances are configured in the file EG_EXTERN.DAT
using the variables EG_NOISE_TOL_P (positive direction) and
EG_NOISE_TOL_N (negative direction).
Default value for both directions: 250 incr.
 Value within tolerance: message The noise test was OK
 Value out of tolerance: message The noise test failed. See "Noise" trace,
channel 11/24
The test also records the bandwidth of the force signal.
The name of the trace recording is NOISE.

Friction test The test checks the ease of motion of the gun. The test also records the force
signal during operation of the gun.
The test opens and closes the gun twice (5 mm from the negative software lim-
it switch to 5 mm from the gun mastering) and checks the sensor value. The

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 8 Diagnosis

maximum value is configured in the file EG_EXTERN.DAT using the variable

EG_FRIC_INC_LIM.
Default value: 250 incr.
 Limit value is complied with: message The friction test was OK
 Limit value is exceeded: message The friction test failed. See FRICTION trace,
channel 11/24
The name of the trace recording is FRICTION.

Mastering test The gun is checked in the mastering position to see if a force is out of toler-
ance. In addition, the user must check the mastering position visually.
The name of the trace recording is MASTER.
Procedure:
1. Start Mastering test.
The gun is closed to the mastering position. The message Check the gun
mastering. Is it OK? is displayed.
2. Check the mastering position visually.
3. Answer the prompt with Yes or No. The gun opens.
The tolerance is configured in the file EG_EXTERN.DAT using the variable
EG_MASTER_TOL_P.
Default value: 100 N
 Value within tolerance: message The gun mastering is OK
 Value out of tolerance: message The gun mastering is not OK. See "Master"
trace, channel 10/23

Calibration test Description:

The test closes the gun once to ¼ and once to ¾ of the maximum force, check-
ing in each position whether the force corresponds to the calibrated force. The
tolerances are configured in the file EG_EXTERN.DAT using the variables
EG_CALIB_TOL_P (positive direction) and EG_CALIB_TOL_N (negative di-
rection).
Default value for both directions: 100 N
 Value within tolerance: message The gun calibration is OK
 Value out of tolerance: message The gun calibration is not OK. See "Calib" tra-
ce, channel 10/23
The name of the trace recording is CALIB.

Welding test This test checks the constancy of the force value. The gun is closed to initial-
ization force for welding. The tolerances are configured in the file
EG_EXTERN.DAT using the variables EG_WELDTEST_TOL_P (positive di-
rection) and EG_WELDTEST_TOL_N (negative direction).
Default value for both directions: 50 N
The test is only carried out if the configuration parameter Timer type is not set
to TEST.
 Value within tolerance: message The welding test was OK
 Value out of tolerance: message The welding test failed. See "WeldTest" trace,
channel 10/23
 No timer configured: message The welding test is not possible because the
timer type is "test"
The name of the trace recording is WELD.

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8.4 Determining the gun flexion (independently of the force sensor)

Description The program EG_FLEXXX determines the gun flexion. Unlike with calibration,
the gun flexion is determined independently of the flexion of the force sensor.
This value is not needed for welding, but is required for the calibration test as
part of diagnosis.

Precondition  Operating mode T2

 Program override 100%
 The gun is calibrated.

Precondition  Operating mode T2

 Program override 100%

There must be no object positioned between the elec-

trode tips, otherwise damage to property may result.

Procedure 1. If a force sensor is still attached to the gun, this must be removed.
2. In the Navigator, start the program KRC:\R1\Program\EG_FLEXXX.
3. Follow the messages.
The flexion is determined. The determined value is not displayed, but
saved internally.

8.5 Displaying and exporting weld timer data

Description This overview displays the weld spots of a program, together with all the val-
ues which the robot controller has received from the weld timer for each point.
Which values these are depends on the configuration of the ServoGun op-
tions.
The values displayed are those from the last program execution.

Procedure  In the main menu, select Diagnosis > Servo Gun FC > Weld timer data.
The Overview of weld timer data window opens.
 In the Module name box, select the program whose data are to be dis-
played.
 If required: To export the displayed data, press Export.
The data are exported to a CSV file in the directory C:\KRC\USER\Weld-
Data.

8.6 Displaying ServoGun I/Os

Procedure 1. In the main menu, select Diagnosis > Servo Gun FC > Inputs and out-
puts.
The I/Os for weld timer / PLC window opens.
2. Select the desired tab.
The Zoom button can be used to zoom in and out.

Description The I/Os for weld timer / PLC window contains 2 tabs: one shows the I/O
configuration between the robot controller and the weld timer, the other shows
the I/O configuration between the robot controller and the PLC.
Lamps indicate the states of the I/Os.

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 8 Diagnosis

Lamps State / description

Green TRUE  TRUE = normal or desired state
 FALSE = abnormal or undesired
state
Green FALSE
and gray

Red TRUE  TRUE = abnormal or undesired

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

Fig. 8-2: “Weld timer” tab

Fig. 8-3: “PLC” tab

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 9 System variables

9 System variables
y

9.1
v
Important variables in EG_EXTERN.DAT

Only those variables are listed here which were not explained earlier in this
documentation.

Variable Description
EG_COMPENSATE_DELAY INT
Distance after resetting compensation until settling of the
gun position
Default value: 0 mm
EG_FORCE_INIT[1] ... [6] REAL
Initialization force
Default value: 2.0 kN
EG_FORCE_INIT_NEW[1] ... [6] REAL
First initialization force
Default value: 3 kN
EG_INIT_TOL_N[1] ... [6] REAL
Negative position tolerance for initialization
Default value: -5 mm
EG_INIT_TOL_P[1] ... [6] REAL
Positive position tolerance for initialization
Default value: 5 mm
EG_NON_KUKA_DRESS BOOL
 FALSE (default): Default sequence for tip dressing
 TRUE: Use a user-defined program EG_USERDRESS
for tip dressing
EG_OFFICE BOOL
Office mode
Default value: FALSE
EG_PART_CONTROL BOOL
Workpiece check
Default value: TRUE
EG_RESET_CHECK_VALUE REAL
Force check after sensor reset. If the value is < 1, the reset
is accepted.
Default value: 1
EG_SERVOGUN_EXAXIS[1] ... INT
[6]
Assignment of a gun to an external axis
Default value: 0
EG_TIMEOUT[4] REAL
Timeout for different types of error messages
Default value: (various)

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Variable Description
EG_TOUCH_DIFF[1] ... [6] REAL
Only relevant for EqualizingTech
When approaching weld spots and tip dressing points, the
robot maintains a certain distance from the workpiece so
that the fixed electrode does not scrape against the work-
piece. The variable defines the distance. The opening width
of the gun at the point is the sum of the taught opening
width and the distance.
Default value: 3 mm
EG_WEAR[1] ... [6] REAL
Current electrode wear (both electrodes)
Default value: 0 mm
EG_WEAR_MAX[1] ... [6] REAL
Maximum permissible electrode wear (both electrodes)
Default value: 8 mm
EG_WELD_DISTANCE[1] ... [6] REAL
Gun flexion calculated by EG_CAL
Default value: 20 mm
EG_WELD_TOL_N REAL
Negative position tolerance for the weld spot
Default value: -5 mm
EG_WELD_TOL_P REAL
Positive position tolerance for the weld spot
Default value: 5 mm
EG_WORN[1] ... [6] BOOL
Current electrode wear greater than max. permissible elec-
trode wear
Default value: FALSE

9.2 Important kernel system variables

Variable Description
$FORCE_ACT[7]...[12] REAL
Actual force on the force sensor
Default value: 0 N

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 10 Messages

10 Messages
s

10.1 Information about the messages

s

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

10.2 System messages from module: EGSPOT

10.2.1 EGSPOT 00101

Message code  EGSPOT 00101

Message text  The target force is lower than the switch-on threshold for force control!
Message type  Error message

Possible cause(s)  Cause: The closing force set in the inline form is too low. (>>> Page 95)
Solution: Change the value in the inline form. (>>> Page 95)

Cause: The closing force set in the inline form is too low.

Description The value set in the Force box (= closing force of the gun) of the inline form is
too low.
The value must not be less than the value set in the Force-control switch-on
in kN box in the configuration.
The procedure for checking what value is set in the Force-control switch-
on in kN box is as follows:

Inspection 1. In the main menu, select Configuration > ServoGun Force Control >
instructions Force control.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.

Recommendation: Do not change the value in the Force-control

switch-on in kN box. Always leave the default value.

Solution: Change the value in the inline form.

Precondition  Program is selected or open.

 T1, T2 or AUT mode

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

10.2.2 EGSPOT 00105

Message code  EGSPOT 00105

Message text  Command force is higher than maximum gun force

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Message type  Error message

Possible cause(s)  Cause: The closing force set in the inline form is too high.
(>>> Page 96)
Solution: Change the value in the inline form. (>>> Page 96)

 Cause: The value configured for the maximum force of the gun is too
low. (>>> Page 96)
Solution: Configure the correct value for the maximum force of the gun.
(>>> Page 96)

Cause: The closing force set in the inline form is too high.

Description The value set in the Force box (= closing force of the gun) of the inline form is
too high.
The value must not exceed the value set in the Maximum gun force in kN
box in the configuration.
The procedure for checking what value is set in the Maximum gun force
in kN box is as follows:

Inspection 1. For ServoGun TC: Select Configuration > ServoGun Torque Control
instructions > Calibration 5 P in the main menu.
For ServoGun FC: Select Configuration > ServoGun Force Control >
Force control in the main menu.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.

Solution: Change the value in the inline form.

Precondition  Program is selected or open.

 T1, T2 or AUT mode

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

Cause: The value configured for the maximum force of the gun is too low.

Description The value set in the Maximum gun force in kN box in the configuration is too
low.
This can be the case, for example, if the default value is left, although the gun
has a higher maximum force.

Solution: Configure the correct value for the maximum force of the gun.

Preparation  Consult the gun manufacturer’s data sheet to find out the value for the
maximum force of the gun.

Precondition  “Expert” user group

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 No program is selected.

Procedure 1. For ServoGun TC: Select Configuration > ServoGun Torque Control
> Calibration 5 P in the main menu.
For ServoGun FC: Select Configuration > ServoGun Force Control >
Force control in the main menu.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.
3. Enter the correct value in the Maximum gun force in kN box.
4. Press Save. The change is saved.
5. Close the screen via the Close icon.

10.2.3 EGSPOT 00107

Message code  EGSPOT 00107

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

Possible cause(s)  Cause: The gun has been decoupled by the software. (>>> Page 97)
Solution: If necessary, decouple the other gun. Couple the desired
gun. (>>> Page 97)

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 fol-
lows:

Precondition:  The total number of configured guns is known.

Inspection 1. Touch the message in the message window. The message window ex-
instructions 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). Mas-
tering 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.

Guns can be coupled and decoupled by means of status keys or pro-

gram instructions. Information about this can be found in the docu-
mentation of the ServoGun technology package.

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10.2.4 EGSPOT 00110

Message code  EGSPOT 00110

Message text  Incorrect gun position. Initialization, mastering, part thickness, repeat
point?
Message type  Error message

Possible cause(s)  Cause: The value set for the workpiece thickness in the inline form is
invalid. (>>> Page 98)
Solution: Change the value in the inline form. (>>> Page 98)

 Cause: The saved tip wear value does not correspond to the actual
wear. (>>> Page 98)
Solution: Initialize the tips. (>>> Page 98)

 Cause: The gun is not correctly mastered. (>>> Page 99)

Solution: Master the gun. (>>> Page 99)

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 measured
and is known.

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

Cause: The saved tip wear value does not correspond to the actual wear.

Description  Either: New tips have been fitted, without then carrying out first initializa-
tion.
 Or: Too much time has elapsed since cyclical initialization was carried out.

Solution: Initialize the tips.

Procedure  If new tips have been fitted, carry out first initialization.
 Otherwise, perform cyclical initialization.

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Depending on the technology package used, the initialization se-

quence may vary.
Information about initialization is contained in the documentation of
the relevant technology package.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is as

follows:

Precondition  Operating mode T1

 New electrode tips are fitted on the gun.

Inspection 1. In the main menu, select Display > Actual position. The Robot position
instructions 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.

The gun must not exert any force, otherwise it may be-
come damaged.

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 in-
correct.

Solution: Master the gun.

Depending on the technology package used, different mastering

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

10.2.5 EGSPOT 00112

Message code  EGSPOT 00112

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

Possible cause(s)  Cause: The value set for the workpiece thickness in the inline form is
too great. (>>> Page 100)
Solution: Change the value in the inline form. (>>> Page 100)

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 Cause: The saved tip wear value does not correspond to the actual
wear. (>>> Page 100)
Solution: Initialize the tips. (>>> Page 100)

 Cause: The gun is not correctly mastered. (>>> Page 100)

Solution: Master the gun. (>>> Page 101)

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

Description In the Part box (= workpiece thickness) in the inline form, a value has been set
that is greater than 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 measured
and is known.

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

Cause: The saved tip wear value does not correspond to the actual wear.

Description  Either: New tips have been fitted, without then carrying out first initializa-
tion.
 Or: Too much time has elapsed since cyclical initialization was carried out.

Solution: Initialize the tips.

Procedure  If new tips have been fitted, carry out first initialization.
 Otherwise, perform cyclical initialization.

Depending on the technology package used, the initialization se-

quence may vary.
Information about initialization is contained in the documentation of
the relevant technology package.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is as

follows:

Precondition  Operating mode T1

 New electrode tips are fitted on the gun.

Inspection 1. In the main menu, select Display > Actual position. The Robot position
instructions window is opened. The Cartesian actual position is displayed.
2. Press Axis-specific to display the axis-specific actual position.

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3. Close the gun manually with the jog keys until the electrodes are just
touching.

The gun must not exert any force, otherwise it may be-
come damaged.

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 in-
correct.

Solution: Master the gun.

Depending on the technology package used, different mastering

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

10.2.6 EGSPOT 00116

Message code  EGSPOT 00116

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

Possible cause(s)  Cause: The closing force set in the inline form is too low.
(>>> Page 101)
Solution: Change the value in the inline form. (>>> Page 102)

Cause: The closing force set in the inline form is too low.

Description The value set in the Force box (= closing force of the gun) of the inline form is
too low.
The value must not be less than the value set in the Force-control switch-on
in kN box in the configuration.
The procedure for checking what value is set in the Force-control switch-
on in kN box is as follows:

Inspection 1. In the main menu, select Configuration > ServoGun Force Control >
instructions Force control.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.

Recommendation: Do not change the value in the Force-control

switch-on in kN box. Always leave the default value.

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Solution: Change the value in the inline form.

Precondition  Program is selected or open.

 T1, T2 or AUT mode

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

10.2.7 EGSPOT 00117

Message code  EGSPOT 00117

Message text  Incorrect program number, repeat point?
Message type  Dialog message

Possible cause(s)  Cause: An incorrect program number is set in the inline form.
(>>> Page 102)
Solution: Change the value in the inline form. (>>> Page 102)

 Cause: The output range for transfer of the program number is too
small (>>> Page 103)
Solution: Configure a larger output range. (>>> Page 103)

Cause: An incorrect program number is set in the inline form.

Description The program number set in the inline form does not match the program num-
ber in the weld timer.

Inspection 1. Check which number is configured in the weld timer for the desired pro-
instructions gram.

Information can be found in the documentation of the weld timer man-

ufacturer.

2. Check in the ServoGun program whether this program number is entered

in the line with the corresponding ServoGun statement.

Depending on the technology package used, the number may be

specified differently:
The number can be specified using the parameter ProgNr.
 The number may be included in the point name. The parts of the name
that contain the program number depend on the configuration.
Information about this can be found in the documentation of the technology
package used.

Solution: Change the value in the inline form.

Precondition  Program is selected or open.

 T1, T2 or AUT mode

Procedure 1. Position the cursor in the line with the inline form that is to be modified.

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2. Press the Change button. The inline form is opened.

3. Modify the value.
4. Save the change by pressing Cmd Ok.

Cause: The output range for transfer of the program number is too small

Description The range set in the Program number box in the configuration is too small.

A range for the program number must also be configured when weld-
ing with the timer type TEST.

Solution: Configure a larger output range.

Description The required width of the output range depends on the program numbers to
be transferred.
The width must not exceed 32 bits.

Precondition  “Expert” user group

 No program is selected.
 The outputs that have not yet been used are known.

Procedure 1. For ServoGun TC: Select Configuration > ServoGun Torque Control
> Outputs in the main menu.
For ServoGun FC: Select Configuration > ServoGun Force Control >
Outputs in the main menu.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.
3. Define a larger output range in the Program number box.
4. Press Save. The change is saved.
5. Close the screen via the Close icon.

10.2.8 EGSPOT 00118

Message code  EGSPOT 00118

Message text  Error during first initialization. Tipwear is out of tolerance, repeat point?
Message type  Dialog message

Possible cause(s)  Cause: The variable EG_INIT_TOL_P and/or EG_INIT_TOL_N is in-

correctly configured. (>>> Page 104)
Solution: Change value of the variable (>>> Page 104)

 Cause: The tips are incorrect or of the wrong length. (>>> Page 104)
Solution: Use tips of the correct length; fit the tips correctly.
(>>> Page 104)

 Cause: The gun is not correctly mastered. (>>> Page 104)

Solution: Master the gun. (>>> Page 105)

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Cause: The variable EG_INIT_TOL_P and/or EG_INIT_TOL_N is incorrectly configured.

Description During first initialization, the robot controller compares the position of the gun
with the mastering position. A tolerance range is taken into consideration. It is
possible that the variables defining the tolerance range may have been con-
figured incorrectly.

Variable Description
EG_INIT_TOL_N[1] … Type: REAL
[6]
Negative position tolerance for initialization
Default: -5 mm
EG_INIT_TOL_P[1] … Type: REAL
[6]
Positive position tolerance for initialization
Default: 5 mm

Solution: Change value of the variable

Precondition  “Expert” user group

Procedure 1. In the main menu, select Display > Variable > Single.
The Variable display – Single window opens.
2. Enter the variable name in the Name box and confirm with the Enter key.
The current value of the variable is displayed.
3. Enter the new value in the New value box.
4. Press the Set value button. The new value is displayed in the Current val-
ue box.

Cause: The tips are incorrect or of the wrong length.

Description During first initialization, the robot controller compares the position of the gun
with the mastering position. A tolerance range is taken into consideration. The
tolerance range may have been exceeded for the following reasons:
 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 be-
neath 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  Operating mode T1

 New electrode tips are fitted on the gun.

Inspection 1. In the main menu, select Display > Actual position. The Robot position
instructions 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.

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The gun must not exert any force, otherwise it may be-
come damaged.

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 in-
correct.

Solution: Master the gun.

Depending on the technology package used, different mastering

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

10.2.9 EGSPOT 00119

Message code  EGSPOT 00119

Message text  Command force is higher than maximum gun force, repeat point?
Message type  Dialog message

Possible cause(s)  Cause: The closing force set in the inline form is too high.
(>>> Page 105)
Solution: Change the value in the inline form. (>>> Page 106)

 Cause: The value configured for the maximum force of the gun is too
low. (>>> Page 106)
Solution: Configure the correct value for the maximum force of the gun.
(>>> Page 106)

Cause: The closing force set in the inline form is too high.

Description The value set in the Force box (= closing force of the gun) of the inline form is
too high.
The value must not exceed the value set in the Maximum gun force in kN
box in the configuration.
The procedure for checking what value is set in the Maximum gun force
in kN box is as follows:

Inspection 1. For ServoGun TC: Select Configuration > ServoGun Torque Control
instructions > Calibration 5 P in the main menu.
For ServoGun FC: Select Configuration > ServoGun Force Control >
Force control in the main menu.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.

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Solution: Change the value in the inline form.

Precondition  Program is selected or open.

 T1, T2 or AUT mode

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

Cause: The value configured for the maximum force of the gun is too low.

Description The value set in the Maximum gun force in kN box in the configuration is too
low.
This can be the case, for example, if the default value is left, although the gun
has a higher maximum force.

Solution: Configure the correct value for the maximum force of the gun.

Preparation  Consult the gun manufacturer’s data sheet to find out the value for the
maximum force of the gun.

Precondition  “Expert” user group

 No program is selected.

Procedure 1. For ServoGun TC: Select Configuration > ServoGun Torque Control
> Calibration 5 P in the main menu.
For ServoGun FC: Select Configuration > ServoGun Force Control >
Force control in the main menu.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.
3. Enter the correct value in the Maximum gun force in kN box.
4. Press Save. The change is saved.
5. Close the screen via the Close icon.

10.2.10 EGSPOT 00125

Message code  EGSPOT 00125

Message text  Attention! Timer type is TEST, repeat point?
Message type  Dialog message

Possible cause(s)  Cause: Welding not possible due to weld timer type TEST
(>>> Page 106)
Solution: Configure a value other than TEST as the weld timer type
(>>> Page 107)

Cause: Welding not possible due to weld timer type TEST

Description The value TEST is set in the Timer type box. Welding cannot be carried out if
this value is set.

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Solution: Configure a value other than TEST as the weld timer type

Preparation  Cancel all selected programs.

Precondition  “Expert” user group

Procedure 1. In the main menu, select Configuration > ServoGun Torque Control or
ServoGun Force Control.
Then select Configuration.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.
3. Select a value other than TEST in the Timer type box.
4. Press Save. The change is saved.
5. Close the screen via the Close icon.

10.2.11 EGSPOT 00126

Message code  EGSPOT 00126

Message text  Caution! EG_OFFICE=TRUE; repeat point?
Message type  Dialog message

Possible cause(s)  Cause: Welding is not possible, as EG_OFFICE=TRUE is set.

(>>> Page 107)
Solution: Set the variable EG_OFFICE to FALSE in
EG_EXTERN.DAT. (>>> Page 107)

Cause: Welding is not possible, as EG_OFFICE=TRUE is set.

Solution: Set the variable EG_OFFICE to FALSE in EG_EXTERN.DAT.

Precondition  “Expert” user group

Procedure 1. In the Navigator, open the file EG_EXTERN.DAT in the directory

R1\TP\ServoGun_[…].
2. Open the fold timer type.
3. Set the variable EG_OFFICE to FALSE.
4. Close the file. Respond to the request for confirmation asking whether the
changes should be saved by pressing Yes.

10.2.12 EGSPOT 00151

Message code  EGSPOT 00151

Message text  Caution! EG_OFFICE=TRUE
Message type  Notification message

Possible cause(s)  Cause: Welding is not possible, as EG_OFFICE=TRUE is set.

(>>> Page 108)
Solution: Set the variable EG_OFFICE to FALSE in
EG_EXTERN.DAT. (>>> Page 108)

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Cause: Welding is not possible, as EG_OFFICE=TRUE is set.

Solution: Set the variable EG_OFFICE to FALSE in EG_EXTERN.DAT.

Precondition  “Expert” user group

Procedure 1. In the Navigator, open the file EG_EXTERN.DAT in the directory

R1\TP\ServoGun_[…].
2. Open the fold timer type.
3. Set the variable EG_OFFICE to FALSE.
4. Close the file. Respond to the request for confirmation asking whether the
changes should be saved by pressing Yes.

10.2.13 EGSPOT 00158

Message code  EGSPOT 00158

Message text  Programmed force not reached!
Message type  Error message

Possible cause(s)  Cause: The value set for the workpiece thickness in the inline form is
too great. (>>> Page 108)
Solution: Change the value in the inline form. (>>> Page 108)

 Cause: The saved tip wear value does not correspond to the actual
wear. (>>> Page 109)
Solution: Initialize the tips. (>>> Page 109)

 Cause: The gun is not correctly mastered. (>>> Page 109)

Solution: Master the gun. (>>> Page 109)

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

Description In the Part box (= workpiece thickness) in the inline form, a value has been set
that is greater than 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 measured
and is known.

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

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Cause: The saved tip wear value does not correspond to the actual wear.

Description  Either: New tips have been fitted, without then carrying out first initializa-
tion.
 Or: Too much time has elapsed since cyclical initialization was carried out.

Solution: Initialize the tips.

Procedure  If new tips have been fitted, carry out first initialization.
 Otherwise, perform cyclical initialization.

Depending on the technology package used, the initialization se-

quence may vary.
Information about initialization is contained in the documentation of
the relevant technology package.

Cause: The gun is not correctly mastered.

The procedure for checking whether the gun is correctly mastered is as

follows:

Precondition  Operating mode T1

 New electrode tips are fitted on the gun.

Inspection 1. In the main menu, select Display > Actual position. The Robot position
instructions 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.

The gun must not exert any force, otherwise it may be-
come damaged.

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 in-
correct.

Solution: Master the gun.

Depending on the technology package used, different mastering

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

10.2.14 EGSPOT 00170

Message code  EGSPOT 00170

Message text  Incorrect mastering following coupling

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Message type  Error message

Possible cause(s)  Cause: The gun was not opened the same amount during coupling and
decoupling. (>>> Page 110)
Solution: Master the gun. (>>> Page 110)

 Cause: The gun was decoupled in the mastering position.

(>>> Page 110)
Solution: Master the gun. (>>> Page 110)

Cause: The gun was not opened the same amount during coupling and decoupling.

Description When a mastered gun is coupled, the gun must have the same opening width
as when it was decoupled. If this is not the case, the mastering will be lost.
(When coupling a gun that has not yet been mastered, the opening width of
the gun is not relevant.)
This applies to uncoupling/coupling both by means of the status key and via
an instruction in the program.

Solution: Master the gun.

Depending on the technology package used, different mastering

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

Cause: The gun was decoupled in the mastering position.

Description When decoupling a mastered gun, the gun must not be in the mastering posi-
tion or closed to force, otherwise the mastering will be lost on recoupling.
This applies to uncoupling/coupling both by means of the status key and via
an instruction in the program.

Solution: Master the gun.

Depending on the technology package used, different mastering

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

10.2.15 EGSPOT 00182

Message code  EGSPOT 00182

Message text  The welding test is not possible because the timer type is “test”
Message type  Notification message

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Possible cause(s)  Cause: Weld test not possible due to weld timer type TEST
(>>> Page 111)
Solution: Configure a value other than TEST as the weld timer type
(>>> Page 111)

Cause: Weld test not possible due to weld timer type TEST

Description The value TEST is set in the Timer type box. Welding cannot be carried out if
this value is set, and thus the weld test cannot be carried out either.

Solution: Configure a value other than TEST as the weld timer type

Preparation  Cancel all selected programs.

Precondition  “Expert” user group

Procedure 1. In the main menu, select Configuration > ServoGun Torque Control or
ServoGun Force Control.
Then select Configuration.
2. If there is more than one gun configured: Select the relevant gun in the Se-
lected gun box.
3. Select a value other than TEST in the Timer type box.
4. Press Save. The change is saved.
5. Close the screen via the Close icon.

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 11 KUKA Service

11 KUKA Service
A

11.1 Requesting support

v

Introduction This documentation provides information on operation and operator control,

and provides assistance with troubleshooting. For further assistance, please
contact your local KUKA subsidiary.

Information The following information is required for processing a support request:

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 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 modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
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 hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

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

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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

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka-roboter.de

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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 Robotics 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

Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
info@kuka.co.jp

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
info@kukarobotics.com
www.kuka-robotics.com/canada

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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

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 Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
office@kuka-roboter.at
www.kuka.at

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Poland KUKA Roboter 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-roboter.de

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

Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
info@kuka-robotics.ru
www.kuka-robotics.ru

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 Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

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Spain KUKA Robots Ibérica, S.A.

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

South Africa Jendamark Automation LTD (Agency)

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 Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
info@kuka.com.tw
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz

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Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
info@kukarobotics.com
www.kukarobotics.com

UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk

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 Index

Index
A EG_THICK_MIN 42
Approximate positioning 82 EG_THICK_SCALE 42
EG_THICK_TMR_END_IN 42
B EG_THICK_TMR_START_IN 42
Burn-off 8, 58 EG_THICKTOL_MAX 42
EG_THICKTOL_MIN 42
C EG_THICKTOL_SCALE 42
Calibration 8, 48 EG_THICKTOL_TMR_END_IN 42
Calibration step 47 EG_THICKTOL_TMR_START_IN 42
Check, mastering 45 EG_TOUCH_DIFF 69, 84
Closing, gun 24 EG_TURN_ACTIVE 44
Collision detection 81 EG_TURN_COUNT 44
Communication principle 39 EG_TURN_FORCE 44
Compensation 8, 40 EG_TURN_IN 44
Compensator (status key) 24 EG_TURN_TESTMODE 44
Configuration 27 EG_WELDTIME_MAX 43
Configuration parameters 32 EG_WELDTIME_MIN 43
Configuration, displaying values 26 EG_WELDTIME_OFFSET 43, 82
Configuration, entering values 30 EG_WELDTIME_SCALE 43
Configuration, inputs 32, 41 EG_WELDTIME_TMR_END_IN 43
Configuration, loading 31 EG_WELDTIME_TMR_START_IN 43
Configuration, outputs 34 Electrical connections, motor 16
Configuration, start-up 27 EqualizingTech 19, 27, 40, 65, 94
Connecting cables 15 EqualizingTech, tip dressing 76
Connector X52 16 EqualizingTech, weld spot 68
Controller parameters, overview 59 Exchangeable gun 9
Couple (status key) 24
Coupling 25, 78, 79 F
Cyclical initialization 9 First initialization 8, 29, 58, 71
Cyclical initialization (status key) 24 First initialization (status key) 24
Force characteristic 50
D Force control 8, 14, 68, 70
Deactivation, EqualizingTech 80 Force gauge 8
Decouple (status key) 24 Force gauge, thickness 36, 46
Decoupling 25, 78 Force sensor 8, 14
Diagnosis 87 Force sensor, checking 87
Documentation, industrial robot 7 Force test 49
Dressing 8 ForceTimer 40
Dressing, programming 73, 76 Functional principle 14

E G
EG_CAL_F 49 Gear ratio 9, 45
eg_extern.DAT 39, 41, 43 Gun (status key) 24
eg_extern.DAT, variables 93 Gun flexion 9, 90
EG_FLEXXX 90 Gun flexion characteristic 50
EG_FORCE_F 49 Gun, fixed 65
EG_FORCE_MAX 41 Gun, sensitivity 79
EG_FORCE_MIN 41 Gun, stationary 65
EG_FORCE_SCALE 41
EG_FORCE_TMR_END_IN 41 H
EG_FORCE_TMR_START_IN 41 Hardware 21
EG_INIT_TOL_N 104
EG_INIT_TOL_P 104 I
EG_NON_KUKA_DRESS 74, 77, 83, 93 Initialization, cyclical 58, 71
EG_RECAL_F 49 Initialization, overview 58
EG_SET_FORCE_PARAM 60, 62 Initialization, programming 71
EG_SET_MOTOR_PARAM 60, 61 Initializing, EqualizingTech 79
EG_THICK_MAX 42 Inline forms, overview 65

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 KUKA.ServoGun FC 2.1

Installation 21 ServoGun options 38

Installation sequence 21 SetTip 72
Intended use 17 Software 21
Interpolation mode 81 Software limit switches, checking 53
Introduction 7 Software limit switches, setting 52
Spin time 40
K Start-up 27
KUKA Customer Support 113 Start-up, overview 27
Status keys 23
L Stiffness 83
Licenses 9 Subprograms, adaptable 83
Support request 113
M Switching off EqualizingTech 80
Mastering 8 System requirements 21
Mastering, check 45 System variables 93
Mastering, manual 44
Menus 23 T
Messages 95 T1, welding 65
Motor cable, connection 16 Target group 7
Motors 12, 13 TCP correction 36, 58
Terms used 8
N Thickness of parts 40
Name for gun, entering 31 Thickness, force gauge 46
Thickness, tip dresser 47
O Thickness, tolerance 40, 82
Open source 9 Thickness, workpiece 82
Opening, gun 24 ThicknessTimer 40
Operation 23 ThicknessTolTimer 40
Tip dresser, thickness 47, 75, 78
P Tip dressing 8, 73, 76
P_APPROX 84 Tip initialization, overview 58
P_WELD 84 Tip wear 36
Pneumatic (option) 40 Tip wear, compensation 36
Pole pair 8 Tips, pressing on 72
Position control 8, 14, 68, 70 Tolerance, thickness 40, 82
Product description 11 Tool direction 30, 35
ProgDigits 40 Trace 9, 60
Programming 65 Trademarks 8
Programming, tip dressing 73, 76 Training 7
Programming, weld spot 66, 68 Turning functionality 43
ProgSelect 40
U
R Uninstallation sequence 22
RDC 8 Uninstalling ServoGun FC 22
Required knowledge and skills 7 Use, intended 17
Reset 8
Reset, checking 87 V
Residual travel 9, 53 Variables, eg_extern.DAT 93
Resolver Digital Converter 8 Variables, kernel system 94
Resolver-sensor cable, connection 16
RoboSpin 27, 40 W
Warnings 7
S Water monitor 9
Safety 19 Weld controller 9
Safety instructions 7 Weld spot, programming 66, 68
SDC 9, 12, 13, 21 Weld timer 9
Sensor cable, connection 16 Welding cell 12
Service, KUKA Roboter GmbH 113 Welding force 40, 82
Servo Digital Converter 9 Welding process 14
Servo file 37 WeldTimeTimer 40
Servo gun 9 WorkVisual 11

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 Index

X
X52 16
XM7 16

Issued: 04.08.2017 Version: KST ServoGun FC 2.1 V2 123 / 125

 KUKA.ServoGun FC 2.1

124 / 125 Issued: 04.08.2017 Version: KST ServoGun FC 2.1 V2

 KUKA.ServoGun FC 2.1

Issued: 04.08.2017 Version: KST ServoGun FC 2.1 V2 125 / 125