KR C2 KR C3 Operator Control

SOFTWARE
KR C2 / KR C3
Operator Control
KUKA System Software (KSS)

Release 5.2
Issued: 26 Sep 2003
Version: 00
BedienungBH5.2 09.03.00 en
1 of 163
e Copyright
KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
PD Interleaf
2 of 163
Contents
1
Running up / shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Operator control elements on the KR C2 control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Operator control elements on the KR C3 control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Running up the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
Shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
1.5
1.5.1
1.5.2
1.5.2.1
1.5.2.2
1.5.2.3
1.5.2.4
1.5.3
Controller response when switched back on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power failure with the system running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power failure during a cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power failure during a restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting external power supply and user outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
12
12
12
12
13
1.6
Battery charge monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
The KUKA Control Panel (KCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
2.1
Operator control elements of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
2.2
The rear of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
Graphical user interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Settings for brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUI elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/output windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
24
25
26
28
29
30
Coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
3.1
Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
3.2
WORLD coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
3.3
BASE coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
3.4
TOOL coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
3.5
ROBROOT coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Jogging the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
4.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
4.2
Selecting the jog mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
4.3
Selecting the kinematic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
4.4
Selecting the coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
4.5
Jog override (jog velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
4.6
Moving the robot with the Space Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
3 of 163
Operator Control
4.6.1
4.6.2
4.6.2.1
4.6.2.2
4.6.2.3
4.6.3
4.6.3.1
4.6.3.2
Mouse position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Degrees of freedom of the Space Mouse (mouse configuration) . . . . . . . . . . . . . . . . . . . . . .
Motion of the main axes (translational motions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion of the wrist axes (rotational motions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unlimited functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dominant axis of the Space Mouse (mouse configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dominant axis activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dominant axis not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
45
45
46
46
47
48
48
4.7
4.7.1
4.7.2
4.7.3
Moving the robot with the jog keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coordinate systems TOOL, BASE, WORLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incremental jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
49
50
51
Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
5.1
5.1.1
5.1.2
5.1.3
5.1.3.1
5.1.3.2
5.1.3.3
5.1.4
5.1.4.1
5.1.4.2
5.1.5
5.1.6
5.1.6.1
5.1.6.2
5.1.6.3
5.1.6.4
Graphical user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Directory structure, attributes display, selection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Directory structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attributes display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Directory and file list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pop--up menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
53
55
55
55
56
58
59
60
61
61
62
63
66
66
67
5.2
5.2.1
5.2.1.1
5.2.1.2
5.2.2
5.2.2.1
5.2.2.2
5.2.2.3
5.2.3
5.2.3.1
5.2.3.2
5.2.4
5.2.4.1
5.2.4.2
5.2.4.3
5.2.4.4
5.2.4.5
5.2.4.6
5.2.5
5.2.5.1
5.2.5.2
5.2.5.3
5.2.5.4
File menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Create directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Create module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
File/Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Log Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
68
69
70
70
71
72
72
72
72
73
73
74
74
74
74
74
75
75
76
76
76
4 of 163
5.2.5.5
5.2.5.6
5.2.6
5.2.7
5.2.8
History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rename . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Format floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attributes/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
77
78
79
80
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.7.1
5.3.7.2
5.3.8
5.3.9
Edit menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Without parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cancel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
81
81
81
82
82
83
84
84
85
85
85
5.4
Monitor menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
5.5
5.5.1
5.5.2
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyboard assignment of the Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default settings at User and Expert levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
86
88
Executing, stopping and resetting a program . . . . . . . . . . . . . . . . . . . . . .
91
6.1
6.1.1
6.1.2
Selecting and opening a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols in the program window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program status line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
92
94
6.2
Program velocity (Programm override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
Stop reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp--down braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Path--maintaining Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short--circuit braking (dynamic braking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
95
95
96
96
97
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
Manual program execution (jog mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program run mode Go, Single Step or I--Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Executing individual program lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program start backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting a program (Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
98
98
102
103
104
106
106
106
6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
Automatic program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BCO run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting a program (Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
107
107
107
108
108
6.6
Deselecting a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
7.1
Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
5 of 163
Operator Control
7.1.1
7.1.2
7.1.3
7.1.4
7.1.4.1
7.1.4.2
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog inputs/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
112
113
115
115
116
7.2
7.2.1
7.2.2
7.2.3
7.2.4
Rob. Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cartesian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis--specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incremental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master/Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
118
119
119
119
7.3
7.3.1
7.3.2
7.3.2.1
7.3.2.2
7.3.2.3
7.3.3
7.3.4
7.3.5
7.3.6
Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edit Configmon.ini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cyclic Flags (Notice) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
120
122
122
123
123
123
124
124
125
7.4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
7.5
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
7.6
Hardware Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
7.7
7.7.1
7.7.2
7.7.3
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Online help -- Contents/Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
127
130
132
Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
136
8.1
File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
8.2
8.2.1
8.2.2
8.2.3
Program/Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Edit menu in Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Program menu at programming level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Program menu in the editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
141
143
145
8.3
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147
8.4
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
151
8.5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155
8.6
Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161
8.7
Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
162
8.8
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163
6 of 163
Running up / shutting down the controller
Running up / shutting down the controller

The KR C... series control cabinets contain the power and control electronics for the robot.
Apart from the main switch, all the operator control elements of the controller are located on
the KCP (KUKA Control Panel).
Running up the controller presupposes that the initial start--up procedure has been carried
out correctly and that the system is set up ready for production.
1.1
Operator control elements on the KR C2 control cabinet

Main switch
The robot system and controller are switched on
and off with the main switch.
A padlock fitted to the main switch can be used
to prevent it reliably from being switched on accidentally (e.g. during maintenance work on the
robot system).
Options
If the control cabinet is equipped with extra
options, their status is indicated by the
LEDs.
Cabinet lock
The cabinet lock is protected by a cover,
which also serves as the door handle.
Computer drives
With the cabinet door open,
a CD--ROM drive and a
floppy disk drive are accessible.
CD--ROM drive
Floppy disk drive
7 of 163
Operator Control
It is also possible to connect a standard serial mouse to the computer systems COM1 port.
This can even be connected and disconnected during operation without having to reboot the
system. For this reason, COM1 is automatically used by the mouse driver.
Applications and functions that access the COM1 port must be reconfigured to a different
COM port.
The temporary connection of a keyboard to the corresponding DIN or PS/2 port is also
possible.
The KR C2 control cabinet door may only be opened by a skilled and appropriately trained
electrician for the purpose of service work. The KR C2 cabinet door must be closed again
immediately after service work, otherwise the cooling effect of the internal airflow is lost.
Failure to do so can cause the controller to overheat and fail.
1.2
Operator control elements on the KR C3 control cabinet
KCP connection
Status indication
The cable of the KCP (KUKA Control

Panel) is connected to this socket.
The first LED shows whether or not

the system is switched on. The
second indicates that the computer
unit hard drive is being accessed.
8 of 163
Running up / shutting down the controller (continued)
CD--ROM drive
Floppy disk drive
IUPS
On/off switch
Reset
The entire robot system is switched on

and off with this switch.
This button is used to reset the computer

(warm start) without having to switch the
system off and back on again.
Both doors on the control module must be kept shut in order to keep dirt out.
1.3
Running up the controller

After the robot system has been switched on using the main switch on the control cabinet,
the computer begins to run up (load) the operating system and the control software.
The display then shows the main menu for program creation, selection and execution.
9 of 163
Operator Control
If the machine data loaded do not match the robot type, a corresponding error
message is generated when the controller is booted. The robot must not be moved
in this case.
If the robot controller logs onto the network, this has a significant effect on the time the
controller takes to boot.
1.4
Shutting down the controller

After the robot system has been switched off using the main switch on the control cabinet,
the controller shuts down its own software and the operating system.
10 of 163
1.5
Controller response when switched back on

The controller offers two system boot variants:
1.5.1
Warm start (default setting)
Cold start
Warm start
A warm start is intended to keep production downtimes to a minimum in the event of a power
failure. Once the system has booted, the status reached immediately before the power failure is restored. The outputs that were set at the time the system was switched off are set
again when the system reboots, the field buses are reset (also in the event of a fault). The
processing of the program can then be resumed from the point that had been reached in the
program. In most cases it is no longer necessary to move the cell free.
Before restarting the system, you must decide whether it is still sensible to resume
program execution given that the outputs will be reset or restored.
The next time the system is booted, the initial state of the user interface is restored. If, for
example, forms were open or a program was loaded into the editor before the power failure,
they will not be displayed after the restart.
The state of the kernel system, including programs, block pointer, variable contents, outputs,
status messages and acknowledgement messages, is completely restored.
In the case of a restart after software problems, program resumption is only possible in
isolated cases.
All outstanding changes that have not yet been saved are lost after a shutdown.
Further information on the setup and configuration of the warm restart can be found in the
Programming Handbook in the main chapter [Configuration], chapter [Configuring
the system].
1.5.2
Cold start
No program is selected when the system has booted and the user outputs are set to FALSE.
This response can be activated via the corresponding menu command.
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
The menu command Force cold start is not

retained as a default setting, i.e. it must be
activated each time a cold start is required.
Force cold start

Disable PowerOff Delay
In Automatic Externalmode, the program CELL is automatically selected and executed.
11 of 163
Operator Control
1.5.2.1
Hardware requirements
All peripheral devices which can trigger potentially dangerous movements in the
cell must be designed using pulse valve technology. This prevents unintentional
movements from occurring when the power supply is switched off or back on.
1.5.2.2
Power failure with the system running

In the event of a power failure during normal operation, the robot is stopped by short--circuit
braking (dynamic braking). A corresponding message is generated in the message window.
It makes no difference whether the power failure was caused by failure of the mains supply
or by pressing the main switch during program execution.
All kernel system files are backed up on the hard disk. Once the files are saved, the system
waits until the PowerOff delay has elapsed. This is then followed by one of two eventualities:
G
Power is restored before the PowerOff delay has elapsed

The robot system is not shut down, but an acknowledgment message is generated
which must be acknowledged. Work can then be resumed.
Power is still absent when the PowerOff delay has elapsed

The status of the kernel system is backed up on the hard disk and the controller is shut
down, in a controlled manner, by the battery back--up. The control system is then
switched off.
If the battery back--up is not sufficient, in exceptional circumstances files could be

destroyed. In this case, a cold start is carried out.
Loss of mastering may occur if the battery voltage fails before the mastering data
are saved.
When power is restored the controller is automatically run up and selects the program that
was previously running. Program execution can be resumed at the point at which the program was interrupted. Once again, there are two ways of doing this:
1.5.2.3
If the robot is located on its programmed path (e.g. ramp--down braking), the program
can be started using the start continue function.
If the robot has left its programmed path (e.g. short--circuit braking), a BCO run may,
under certain circumstances, be necessary at the point where the path was left (RET
position).
Power failure during a cold start

The system boot--up is aborted. In some cases a processor reset may be triggered and a
cold start carried out once the power has returned.
1.5.2.4
Power failure during a restart

The control software is completely restarted. The subsequent sequence of events then
corresponds to that described in Section 1.5.2.2.
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1.5.3
Setting external power supply and user outputs

External power supply
The computer unit in the robot controller can be supplied separately by an external power
supply (option). A power source is required here, which works independently of the normal
power supply. In the event of a mains power failure, the computer unit is not shut down.
Deactivating the user outputs
In the event of a power failure with a functioning external power supply, the user outputs are
not deactivated as standard. If the system is configured accordingly, however, the user
outputs are restored when power returns.
1.6
Battery charge monitoring

Normally, when the system is shut down, or in the event of a power failure, the robot system
data are automatically backed up. The batteries used for backing up the computer system
are accommodated in the control cabinet.
If the battery voltage drops too far during the backup procedure (below 22 V), an error
message is generated in the message window.
If this message is generated during normal operation, a short--circuit has occurred

in the battery.
The current state of the batteries is saved at the end of the backup procedure. Next time the
system is booted, a corresponding message is generated:
G
Voltage below 22 volts

There was sufficient voltage to back up the system data.
Voltage below 19 volts

Operating system or robot system data may have been damaged as the computer was
switched off before completion of the backup procedure. The system is switched off in
order to protect against an exhaustive discharge (and thus destruction) of the batteries.
These messages can have the following causes:

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Operator Control
Cause
Remedy
The batteries are not fully charged.
Leave the robot controller running for at least 10

hours to recharge the batteries.
If this does not help, one of the batteries is presumably defective.
One or both batteries defective.
Replace both batteries immediately, WITHOUT

switching off the robot controller (could result in
faulty files or damage to the operating system).
Use only batteries that have been explicitly approved by KUKA.

The message in the message window can be neither deleted nor acknowledged. This
message is deleted automatically, but not until the next battery backup procedure has been
successfully completed.
14 of 163
The KUKA Control Panel (KCP)
The KUKA Control Panel (KCP)
KCP2
E--STOP
The KUKA Control Panel, referred to hereafter as KCP, forms the human--machine interface and is used for easy operation of the KR C... robot controller. All elements required
for programming and operator control of the robot system, with the exception of the main
switch, are located directly on the KCP. The LCD screen is used to visualize operator and
programming actions.
2.1
Operator control elements of the KCP

EMERGENCY STOP button
The red button is pressed in emergencies; the
robot drives are immediately deactivated.
The EMERGENCY STOP button must be
released before the drives can be switched
back on. Turn the button in the direction
indicated by the arrows until it audibly unlocks.
The corresponding EMERGENCY STOP
message in the message window must then
be acknowledged. This is done by pressing
the softkey Ackn..
Pressing the EMERGENCY STOP button
activates path--oriented braking.
Before the EMERGENCY STOP button is released, the situation that caused the stop
to be triggered, and if necessary its consequences, must first be rectified.
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Operator Control
Drives ON
Pressing this button activates the robot drives.
These can only be switched on under normal
operating conditions (e.g. no EMERGENCY
STOP button pressed, safety gate closed,
etc.).
Drives OFF
Pressing this button deactivates the robot
drives. The brakes of the motors are also applied after a slight time delay and hold the
axes in position.
Drives OFF activates dynamic braking.
Mode selector switch

Using this keyswitch you can switch between
the different operating modes.
The current setting of the mode selector
switch is displayed in the status line.
Operating
mode
Jogging
Program mode
(Test 1)
Jog velocity
Keep enabling switch held down
Press jog key or Space Mouse
Jog velocity
Keep Start key held down
(Test 2)
Jog velocity
Press jog key or Space Mouse
Programmed velocity
Keep Start key held down
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(Automatic)
(Automatic
External)
The KUKA Control Panel (KCP) (continued)
Not possible
Programmed velocity
Drives ON
Press Start key briefly
Not possible
Programmed velocity
Drives ON
External start
If the operating mode changes while the program is running, dynamic braking is activated.
Automatic operation is only possible with the safety circuit closed.
Enabling switches
For certain actions, such as jogging the
robot, one of the enabling switches must be
held down.
The enabling switches are situated on the
back of the KCP and on one of the holding
domes.
They are all designed as two--position
buttons. For program execution, a button
must be held in the middle position.
Releasing the button or pressing it hard
triggers dynamic braking.
Space Mouse
This is used for manually--controlled motion
of all 6 axes (degrees of freedom) of the
robot. The amount of deflection of the Space
Mouse influences the velocity of the robot.
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Operator Control
ESC key (Escape)
An action that has been started can be
aborted at any time using the Escape key.
This includes, for example, open inline forms
and status windows.
Menus opened by mistake can also be
closed again, one by one, by pressing this
key.
ESC
Window selection key

This key can be used to toggle between
program, status and message windows,
insofar as these are available.
The window that is currently active is
highlighted in color.
This activation is called focus.
Program STOP
Pressing this button stops a program that is
running.
Path--maintaining braking is carried out and
this can be acknowledged in automatic
mode.
To resume a program that has been stopped,
press the Program start forwards or
Program start backwards key.
STOP
Program start forwards

Pressing this button starts a program that
has been selected.
The start is only possible if the drives have
been switched on and there is no EMERGENCY
STOP situation.
Releasing the Program start forwards key
in mode T1 or T2 triggers path--maintaining
braking.
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There is an additional Program start
forwards key located on the holding dome.
Program start backwards

By pressing this key, the motion blocks of the
selected program are executed step by step
towards the beginning of the program.
The robot is thus moved in reverse direction
along the path originally programmed.
Releasing the Program start backwards key
triggers path--maintaining braking.
This function is only available in modes T1
and T2.
Enter key
This key is used to confirm entries or to
complete commands.
Arrow keys
The arrow keys are used to
-- move the focus
-- change the position of the edit cursor
-- toggle between the boxes in inline forms and
parameter lists.
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Operator Control
Menu keys
These are used to open the corresponding
menus
You can select from the menu that is opened
as follows:
-- by using the (# ") arrow keys, which
highlights the selected menu item in color
-- by entering the number preceding the
menu item.
A menu can be closed one step at a time by
pressing the ESC key.
Status keys
--
The status keys are used for selecting

operating options, switching individual
functions and setting values.
The relevant function is represented graphically by means of corresponding icons in the
satus key bars.
Softkeys
These are used for selecting the functions
displayed in the softkey bar.
The functions available are dynamically
adapted, i.e. the assignment of the softkey
bar is altered.
Numeric keypad
Numbers are entered using the numeric
keypad. At a second level, the numeric
keypad has cursor control functions.
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2
HOME
Jumps to the beginning
of the line in which the
edit cursor is positioned.
LDEL
Deletes the line in
which the edit cursor
is positioned.
TAB
Tabulation
UNDO
Cancels the last entry (not
yet implemented).
PGDN
Scrolls one screen
towards the end of the
file.
END
Jumps to the end of the
line in which the edit cursor is positioned.
INS
Switches between insert and
overwrite modes.
PGUP
Scrolls one screen
towards the start of the
file.
CTRL
Control key, e.g. for
program--specific
commands.
DEL
Deletes the character to
the right of the edit cursor.
Arrow z
Backspace key; deletes
the character to the left
of the edit cursor.
Keyboard
Used for entering letters and other
characters.
NUM key
Allows you to switch between entry of
numbers or control characters via the
numeric keypad. You can switch between
these functions by pressing the NUM key
briefly.
Numeric entry
Cursor control functions
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Operator Control
ALT key
This is used in keyboard shortcuts. In this
way, menus can be opened and certain
actions can be executed.
The ALT key remains activated for one
keystroke. In other words, it does not need
to be held down.
SHIFT key
For switching between lower--case and
upper--case letters.
If the shift key is pressed once, the next
character will be typed in upper case. To
type upper--case characters, the shift key
must be held down while the characters
are entered. It is also possible to switch to
continuous upper--case characters using
the keyboard shortcut SYM+SHIFT.
Lower--case letters
UPPER--CASE LETTERS
SYM key
Used for entering special characters
depicted on the letter keys.
The SYM key remains activated for one
keystroke. In other words, it does not need
to be held down.
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2.2
The rear of the KCP
Enabling
switch
Enabling
switch
Space Mouse
Enabling
switch
Program start
forwards
Rating plate
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Operator Control
2.3
Graphical user interface (GUI)

The display of the KUKA Control Panel is subdivided into several areas with various functions. During operation, the individual user interface elements are dynamically adapted to the
current action.
These are illustrated below on the basis of examples. The assignment of the menu, status
and softkey bars depends on the applications installed.
2.3.1
Settings for brightness and contrast

To adapt the GUI to different ambient conditions, both the brightness and contrast of the LCD
display can be adjusted.
The jog function must be switched
off first; only then are the status keys
for brightness and contrast activated.
The brightness and contrast values
can be adjusted between 0 and 15
using the corresponding +/-- status
key.
2.3.2
GUI elements
Keys
Monitor
Expert
These include menu keys, status keys and

softkeys. Simply press the corresponding
operator control element on the KCP or click
on the icon using the mouse.
Windows
These include, for example, status and
message windows.
The window selection key is used to toggle
between the individual windows in the GUI.
Within the individual windows, the focus can
be moved using the arrow keys.
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Selection lists
These are used for selecting predefined
values.
Position the focus on the selection list using
the arrow keys or the TAB key. Then open the
list using the keyboard shortcut ALT+ # and
select the desired entry. Confirm the selection
by pressing the Enter key.
Input boxes
These are used for entering values or texts.
Position the focus on the input box using the
arrow keys or the TAB key. Then enter the
desired characters.
Parameter boxes
Selection of a specific value from a predefined
range.
Set the desired value using the corresponding
status key. Alternatively, the value can be
entered in the input box.
Focus
The desired object can be selected using the
arrow keys. Commands and options will then
refer to this object.
2.3.3
Function keys
Menu bar
Robot controller functions are grouped
together in the menu bar.
These groups must be opened using the
menu keys in order to select the entries
contained therein.
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Operator Control
Status key bars
The individual status keys provide access to
robot controller functions. The assignment of
the softkey bar changes according to the
specific requirements.
Softkey bar
The softkey bar, which adapts itself dynamically, offers functions that can be selected
using the relevant softkeys.
2.3.4
Input/output windows
Program window
The contents of the selected program are
displayed in the program window. If no
program is selected, a list of all the available
programs is displayed.
Located between the line number and the text
of the instruction is a yellow arrow pointing
right, the block pointer. It is positioned in the
program line that is currently being executed.
Block pointer (program pointer)
Another mark in this window is the edit

cursor, represented as a vertical red line.
The edit cursor is located at the start of the
line that is currently being edited.
Edit cursor
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Status window
The status window is displayed as required.
It contains information about the status of
certain components, e.g. inputs/outputs.
The focus can be moved to the desired

position using the arrow keys or the numeric
keypad.
Form
The form is displayed as required. Data
required by the controller are entered here.
This is the case, for example, with tool
calibration.
The focus is moved to the desired position
using the arrow keys or the TAB key.
Parameter list
This is used for entering values from a range
of values.
The focus is moved to the desired position
using the arrow keys or the TAB key.
Message window
The controller communicates with the
operator via the message window.
Notification, status, acknowledgement, wait
and dialog messages are displayed here.
Each type of message has a specific symbol

assigned to it.
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Operator Control
Inline form
Some of the program functions require values
to be entered.
These values are entered in an input mask
(inline form) or selected from selection boxes.
In this way, you ensure that the programmed
instructions always have the correct format.
2.3.5
System status
Status line
Information regarding important operating
states is grouped together and displayed in
the status line.
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2.3.6
Messages
Notification messages contain information or indicate operator actions, programming
errors and operator errors. They are purely for information purposes and do not interrupt
program execution.
Start key required
This message appears after a program has been selected.
Status messages indicate the status of the system. They are also informational in character
and can interrupt the application program to a certain extent. Status messages are automatically deleted when the status that triggered them is no longer applicable.
EMERGENCY STOP
This message is generated if, for example, the EMERGENCY STOP button has been
pressed or a safety gate opened.
Acknowledgement messages frequently appear following a status message (e.g.
EMERGENCY STOP) and must be explicitly confirmed. They indicate disruption to program
execution.
Confirm EMERGENCY STOP
Acknowledgement messages stop robot operation until the cause of the error has been
eliminated and the message confirmed.
Wait messages are generated if a program is running and a wait condition is being executed.
WAIT FOR $IN[1]==TRUE
The robot controller is stopped until the condition is fulfilled or the program reset. In this
example the system is waiting for a signal at input 1.
The operator must respond to dialog messages. The result is stored in the relevant variable.
The program is stopped until the message is acknowledged, and subsequently resumed.
Do you want to touch point P1?
The yes and no softkeys are now offered in the softkey bar. When one of the two softkeys
is pressed, the message is deleted from the message window.
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Operator Control
2.3.7
Status bar
The numeric keypads number keys are activated.

The numeric keypads cursor control functions are activated.
UPPER--CASE LETTERS.
UPPER-- and lower--case letters are active.
Gray:
The Submit interpreter has been deselected.
Green:
The Submit interpreter is running.
Red:
The Submit interpreter has been stopped.
Green:
Drives are ready.
Red:
Drives are not ready.
Gray:
No program is selected.
Yellow:
The block pointer is situated on the first line of the

selected program.
Green:
A program has been selected and is currently being

executed.
Red:
The selected and started program has been stopped.
Black:
The block pointer is situated on the last line of the

selected program.
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This box indicates the name of the selected program.
The block number of the program line that is currently being executed
is indicated here.
Operating mode T1 (manual mode/jog mode).

Operating mode T2 (manual mode/jog mode).
Operating mode in which a host computer or PLC assumes control
of the robot system (Automatic External).
Operating mode (Automatic)
The program override
The name of the robot is displayed here.
The current system time
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32 of 163
Coordinate systems
Coordinate systems
In jog mode, the robot is moved in accordance with the selected coordinate system.
Joint coordinate system
WORLD coordinate system

BASE coordinate system
TOOL coordinate system

As jog mode, select jog keys or Space Mouse. Then use the +/-- status key to select the
desired coordinate system.
Further information on jogging with the Space Mouse and jog keys can be found in the
chapter [Jogging the robot].
3.1

In the joint coordinate system, each robot axis can be individually moved in
positive or negative axis direction. This can be done using the jog keys or the
Space Mouse, the Space Mouse allowing 3 or 6 axes to be moved simultaneously.
--
--
--
--
--
--
Jog keys
Space Mouse
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Operator Control
3.2

The WORLD coordinate system is a stationary, Cartesian coordinate system. It
serves as the root coordinate system for the BASE and ROBROOT coordinate
systems.
--
--
--
--
--
--
Jog keys
Space Mouse
The World coordinate system only corresponds with that of the Space Mouse if the
operator with the KCP is standing directly in front of the robot.
Position of
operator
Robot
As standard, the origin of the WORLD coordinate system is located at the center of the
robot base.
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3.3
Coordinate systems (continued)

The BASE coordinate system is a Cartesian coordinate system which is calibrated
in such a way that the origin is located in or at a workpiece or fixture.
--
--
--
--
--
--
Jog keys
Space Mouse
On delivery, the origin of the BASE coordinate system is located in the base of the robot.
The BASE coordinate system is relative to the WORLD coordinate system.
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Operator Control
3.4

The TOOL coordinate system is a Cartesian coordinate system which is
calibrated in such as way that the origin is located in the tool.
Example: servo gun
--
--
--
--
--
--
Jog keys
Example: torch
Space Mouse
The TOOL coordinate system is generally orientated in such a way that its X axis is identical
to the working direction of the tool (tool direction).
On delivery, the origin of the TOOL coordinate system is located at the flange centerpoint.
The TOOL coordinate system is relative to the BASE coordinate system.
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Coordinate systems (continued)
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Operator Control
3.5
ROBROOT coordinate system

The origin of the ROBROOT coordinate system is always located in the base of the robot
and is relative to the WORLD coordinate system. This allows the definition of an offset of the
robot relative to the WORLD coordinate system.
On delivery, the origin of the ROBROOT coordinate system is identical to that of the
WORLD coordinate system and is located in the base of the robot.
Detailed information on the subject ROBROOT may be found in the Programming
Handbook, in the main chapter [Expert Programming], chapter [Motion programming].
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Jogging the robot
4.1
General
Jogging the robot
Jogging is used for manually controlled movement of the robot. The standard robot has a
total of six axes, which are defined as follows:
Overview:
Position and direction of rotation of the robot
axes
To jog the robot, the mode selector switch must be set to Jog mode
(T1 or T2).
The robot can be jogged only if there is no EMERGENCY STOP situation.
If a robot axis runs against one of its software limit switches, it is immediately switched off.
The robot can then be moved out of this position manually in the joint coordinate system.
The other axes remain unaffected.
If one or more of the robot axes hits its end stop without being braked and at a
velocity in excess of the jog velocity set by the manufacturer, the buffer concerned
must be replaced immediately.
If this happens to axis 1 of a wall--mounted robot, its rotating column must be
replaced.
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Operator Control
4.2
Selecting the jog mode

The following modes are available for jogging the robot:
Jogging switched off
Only for program execution or Automatic mode.
Moving the robot with the Space
Mouse
Simultaneous movement of 3 or 6
axes, depending on the number of
degrees of freedom.
Moving the robot with the jog keys
In order to move each axis individually.
To get a better overview of the robot movement, the positions of the axes can be shown
in a status window.
Monitor
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
4.3
Cartesian
Axis specific
Incremental
Master/Slave
Selecting the kinematic system

The jog keys can be used to move both the standard robot axes and external axes, as well
as any external kinematic systems which have been configured.
The type and number of options available depend on your system configuration.
Robot
Only the 6 robot axes A1...A6 (joint coordinate system) or X, Y, Z, A, B, C
(reference coordinate system) can be moved.
External axes
Here you can move only the external axes (E1...E6).
40 of 163
Jogging the robot (continued)
Robot and external axes

The main axes of the robot (A1...A3 or X,Y,Z) and the first 3 external axes (E1...E3)
can be moved.
The main axes (A1...A3 or X,Y,Z) and the external axes (E4...E6) can be moved.
If the robot is moved using the Space Mouse (axes A1...A6 or X, Y, Z, A, B, C), the
external axes (E1...E6) can be moved using the status keys.
Further information about external axes can be found in the separate documentation
[External axes].
4.4
Selecting the coordinate system

Select the reference coordinate system to be used for moving the robot.
In the wrist singularity (A4 and A6 parallel), there is the danger that an external
energy supply system (if present) may be wound around the wrist axis.
Further information on moving the wrist axes can be found in the main chapter [User
Programming], in the chapter [Program commands], section [Motion] under
Infinitely rotating axes.
Information on the wrist axis singularity and the extended position may be found in the
Programming Handbook, in the main chapter [Expert Programming], chapter [Motion
programming], section [Motion commands] under Singularities.
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4.5
Jog override (jog velocity)

In some cases, it is of vital importance to reduce the velocity of the robot. Only in this way
is it possible to address points precisely and avoid collisions between the workpiece and the
tool.
The jog override value can be
modified using the +/-- status
key. The current setting is
displayed above the symbol.
...
In modes T1 and T2, the jog override can also be altered during program execution.
Depending on the configuration, the HOV value last used is restored when the system is
switched to T1 mode.
With the Space Mouse, the jog velocity can be further decreased by reducing the deflection
of the mouse (velocity proportional to the deflection).
The jog override increment can be increased. To do this you must activate the option Jog
OV Steps on/off in the Configure --> Jogging menu. The value is then no longer altered
in increments of 1% but changes between 1, 3, 10, 30, 50, 75 and 100 per cent of the value
defined in the machine data.
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
Program OV Steps
Jog OV Steps
Mouse position
Mouse configuration
If you have selected the joint coordinate system as the reference coordinate system the
jog override refers to the specific axis.
If a rectangular coordinate system is set (e.g. WORLD coordinate system) the jog override
refers to the axis with the longest trajectory (leading axis). The motions of all other axes
are synchronized with the leading axis.
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4.6
Moving the robot with the Space Mouse

If you have selected the Space Mouse as the operator control element using the
status key Jog mode, you can move the robot in 3 or 6 axes (degrees of freedom)
at the same time. The Space Mouse is assigned a coordinate system that stays
the same in all reference coordinate systems.
If you pull the Space Mouse towards you in the positive X direction, for example, the robot
axes will likewise move in the positive X direction in the reference coordinate system. This
also applies to the Y and Z axes.
Turning the Space Mouse about its X axis, for example, likewise causes the tool center point
to rotate about the X axis of the set reference coordinate system. This again applies equally
to the Y and Z axes.
For certain applications, e.g. fine positioning or tool calibration, it is useful not to move the
robot in all 6 axes simultaneously. For this reason, the aids Degrees of freedom and
Dominant axis are available to reduce the number.
4.6.1
Mouse position
In order to ensure intuitive operator control when traversing the robot using the Space
Mouse, the operator can inform the controller of his position.
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
Program OV Steps
Jog OV Steps
Mouse position
Mouse configuration
The default setting for the mouse position is 0 degrees. The robot thus moves in the positive
X direction. To ensure that the deflection of the Space Mouse corresponds to the motion
direction, the operator should stand in front of the robot.
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Operator Control
If the operator stands to the left of the robot and wishes to move the robot back towards
himself, he no longer has to rethink what he is doing. The mouse position is simply set to 90
degrees. This causes the world coordinate system to be rotated by 90 degrees in the robot
controller.
The same Space Mouse motion as before will move the robot towards the operator.
You can change the position of the 6D mouse by pressing the corresponding softkeys. Each
time the softkey + is pressed, the world coordinate system is rotated an additional 45
degrees in a clockwise direction. The softkey -- rotates the coordinate system in a
counterclockwise direction.
The KCP symbol in the status window also moves each time the softkey is pressed, and thus
always indicates the current position.
Close
The softkey Close accepts the current mouse position and closes the status window.
When switching to AUT (Automatic) or EXT (Automatic External) mode, the mouse
position is automatically reset to 0 degrees.
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4.6.2
Degrees of freedom of the Space Mouse (mouse configuration)

The number of axes which can be moved simultaneously using the Space Mouse can be limited.
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
Program OV Steps
Jog OV Steps
Mouse position
Mouse configuration
A status window opens in which you can set the degrees of freedom.
Degrees of freedom of the Space Mouse:
Axis selection
all Axis (6D)
Unlimited functionality
Motion of the wrist axes

Dominant mode
Motion of the main axes
4.6.2.1
Motion of the main axes (translational motions)

The functionality of the Space Mouse is here restricted to motion of the
main axes A1, A2 and A3, or translational motions. Only pulling or
pushing the Space Mouse results in corresponding motion of the robot.
How the robot moves depends on the reference coordinate system of the
robot that has been set.
In a Cartesian coordinate system, you can only move the robot rotationally about the X,
Y and Z coordinate axes. Several axes usually move synchronously in this case. If, on the
other hand, you have selected the joint (axis--specific) coordinate system, you can only
move the robot axes A1, A2 and A3 directly.
Joint reference coordinate system:
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Operator Control
4.6.2.2
Motion of the wrist axes (rotational motions)

The functionality of the Space Mouse is restricted here to motion of the
wrist axes, or rotational motions. Only rotating the Space Mouse moves
the robot. Here too, the type of movement depends on the reference
coordinate system of the robot that has been set.
In a Cartesian coordinate system, you can only move the robot rotationally about the X,
Y and Z coordinate axes. Several axes can also move simultaneously in this case too.
If, on the other hand, you have selected the joint (axis--specific) coordinate system, you
can only move the robot axes A4, A5 and A6 directly.
4.6.2.3
Unlimited functionality
With this setting, all 6 axes of the robot can be moved simultaneously. In
a Cartesian coordinate system, pushing or pulling the Space Mouse
along its X, Y or Z axis causes the robot to be correspondingly moved
along the X, Y or Z axis of the set reference coordinate system. Rotating
the Space Mouse about its X, Y or Z axis similarly causes the tool center
point to be correspondingly rotated about the X, Y or Z axis.
In the joint coordinate system, you can specifically move the robot axes A1 to A6: Pushing
or pulling (translational motions) along the X, Y and Z coordinate axes of the Space Mouse
moves the robot axes A1, A2 and A3. If, on the other hand, you turn the Space Mouse about
its X, Y and Z coordinate axes, you can move the wrist (robot axes A4, A5 and A6).
46 of 163
You can use the settings described above to reduce the number of degrees of freedom from
6 to 3, but it is not possible to move just one single axis with the Space Mouse.
It is, however, possible to define a so--called dominant axis in order to permit operation with
only one axis if required.
4.6.3
Dominant axis of the Space Mouse (mouse configuration)

For various applications, it is useful to limit the function of the Space Mouse to one robot axis,
the so--called dominant axis. When this function is switched on, only the coordinate axis
with the greatest deflection of the Space Mouse is moved.
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
Program OV Steps
Jog OV Steps
Mouse position
Mouse configuration
A status window opens in which you can specify whether only the dominant axis will be
moved.
Axis selection
all Axis (6D)
Dominant axis:
Dominant axis activated

Dominant mode
Dominant axis not activated
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Operator Control
The command Dominant axis can also be switched on and
off using the corresponding status key. This status key is only
available in the jog mode Space Mouse.
4.6.3.1
Dominant axis activated

For moving the robot, the coordinate axis of the Space Mouse that is
currently given the greatest deflection is relevant.
In this diagram, the relative deflections of

the Space Mouse for axes A1--, A2+ and
A3-- are represented by different arrow
lengths.
As can be seen, the deflection for A2+ is
greatest in this example.
Axis 2 is thus the dominant axis, and only
axis 2 is moved.
Deflections
of the Space Mouse
4.6.3.2
As soon as another axis registers a

greater deflection, this in turn becomes
the dominant axis.
Dominant axis not activated

Either 3 or all 6 axes can be moved depending on the setting of the degrees
of freedom. This is known as a so--called superposed motion. Jogging of
3 or 6 axes simultaneously should primarily be left to experienced users.
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4.7
Moving the robot with the jog keys

If, using the status key Jog mode, you have selected the jog keys as the input medium and
have also selected the desired reference coordinate system, you can move the robot by
pressing the +/-- status key.
Joint
WORLD
BASE
TOOL
With some robot models, the user interface may vary slightly from the standard interface.
With a palletizing robot in joint (axis--specific) jog mode, for example, axes A4 and A5 are
not available, and in Cartesian jog mode, angles B and C are not available.
It is only possible to jog the robot if you first hold down one of the enabling switches and
then press the desired jog key. If either the enabling switch or the jog key is released, the
robot is stopped immediately.
4.7.1

If you have selected the joint (axis--specific) coordinate system, the main and
wrist axes A1 to A6 will be displayed in the right--hand status key bar as soon as
you press one of the enabling switches (on the back of the KCP). Pressing one
of the +/-- status keys moves the corresponding axis.
Positive direction of motion
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4.7.2
Coordinate systems TOOL, BASE, WORLD

If you have selected one of the coordinate systems TOOL, BASE or WORLD, the main
axes X, Y and Z, and the wrist axes A, B and C are displayed. Several axes are usually moved
synchronously.
In the world coordinate system, the jog keys are assigned the axis designations depicted
below. Here, too, the arrows indicate the positive axis directions.
Positive direction of motion
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4.7.3
Incremental jogging
A motion command can be executed step by step using incremental jogging. Each motion
command is then executed step by step in accordance with the increment setting.
The positioning of equidistant points is significantly accelerated using this function.
In the event of an error it enables the user to move the robot a defined distance or orientation
away from the component. The robot can then be moved step by step back to the previous
position.
Incremental jogging switched off
Increment set to 100 mm linear (X, Y, Z)
or 10 degrees orientation (A, B, C)
or 3 degrees orientation (A, B, C)
or 1 degree orientation (A, B, C)
Increment set to 0.1 mm linear (X, Y, Z)
or 0.005 degrees orientation (A, B, C)
To jog the robot using the jog keys, you must hold down one of the
enabling switches and then press the jog key of the desired axis. The --
key toggles to the next value down while the + key toggles to the next
value up. The robot keeps moving as long as the jog key remains
pressed, and stops by itself after the preset distance or number of
degrees has been reached. The status key must then be released and
pressed again.
In the case of an interruption, e.g. Emergency Stop, change of operating mode, releasing
the jog key or enabling switch, the robot stops. This terminates the incremental motion that
was begun.
The increments are executed relative to the coordinate system selected.
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Operator Control
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Navigator
Navigator
The Navigator is a so--called file manager which the operator can use to navigate through
the drives and directory structures. The Navigator can be used to create, select, copy, save,
delete and open files.
5.1
Graphical user interface
5.1.1
Fundamentals
The Navigator consists of the following four areas:
Header
Directory structure,
attributes display or
selection list
(templates and filters)
Directory or file list
Status line
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The following icons and symbols are used in the Navigator:
Drives
Icon
Type
Default path
Robot
KRC:\
Floppy disk
A:\
Unknown drive (e.g. unavailable network drive)

Hard disk *1
e.g. KUKADISK (C:\) oder KUKADATA (D:\)
CD--ROM *1
E:\
Mapped network drive *1
F:\ , G:\ , ...
Backup drive
Archive:\
*1:These symbols are not shown in the user group User.

*2: If a network connection fails during operation, the Navigator is blocked by the operating
system until the network error is detected. Operator actions (e.g. select/open program) are
not possible during this time.
Directories and files

Icon
Type
Meaning
Directory
Normal directory
Directory open
Open directory
Archive
ZIP file (compressed directory)
Read directory
The contents of the directory are being read
Module
Program at user level (*.src, *.dat, *.sub)
Module containing
errors
Program at user level which must be corrected

before being run in the editor
Src file *1
Program file at expert level
Src file *1
Subprogram at expert level
Src file containing errors Program file at expert level which must be
*1
corrected before being run in the editor
Dat file *1
Data list at expert level
Dat file containing errors Data list containing errors

*1
ASCII file *1
File that can be read using any editor
Other files *1
Binary files which cannot be read in the text editor
Integrated file
The file is integrated into the system (e.g. a

selected program)
*1: These symbols are not shown in the user group User.
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5.1.2
Navigator (continued)
Header
The left side of the header shows the filter or the templates that are available for selection.
The right side shows the folder and/or file path.
The filter setting and template selection are not available in the user group User.
Filter
The current filter setting is

displayed above the directory
structure.
The filter can be set
Modules or Detail view.
The current drive or directory is displayed

in the directory or file list.
to
Information on the user group Expert can be found in the Programming Handbook in
the main chapter [Configuration], chapter [Configuring the system].
Template
The template selection is displayed

above the directory structure.
The current drive or directory is displayed

in the directory or file list.
5.1.3
Directory structure, attributes display, selection list
5.1.3.1
Directory structure
By default, the Navigator displays the directory structure of the current drives or directories.
Focus
The current directory structure is normally shown on the

left--hand side of the Navigator. This display varies
according to the filter that has been set.
The contents of the drive or directory highlighted in color
(focus) are then displayed as a file list on the right--hand
side of the Navigator.
To select a drive or directory, move the focus
to the desired symbol using the or
arrow key.
To open or close a directory level, press the

Enter key.
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Operator Control
Further drives and directories are available at expert
level.
Here too you can use the --, -- arrow keys or the
Enter key.
To switch between the directory structure and the file list, use the or
arrow key.
5.1.3.2
Attributes display
Display and modification of options relating to individual files or directories.
The attributes display is opened by first
selecting a file or directory.
File
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
General
Name of the selected file (in this case a module
comprising one src and one datfile).
Information about the file type ((Dir, Archive,
Bin, Text, Module, VirtualDir and Unknown),
its path and the total amount of memory occupied.
Date and time of file creation, change and most
recent access.
Display of the Windows file attribute which can be
changed at expert level.
The current edit mode (Free, Full, ProKor or
ReadOnly).
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Module info
Information about the release, the src and dat files
and the file type (RobotSRC, SubmitSub or
None).
Status of the file in the Submit interpreter and in the
robot interpreter (possibilities: Unknown, Free,
Selected or Active).
Switching of the kernel system attribute Visible.
User name, max. 30 characters.
Additional comment which can be scrolled using the
and arrow keys if required.
Parameter
Any desired additional information can be anchored
in KRL modules. This can be information about the
version or the template name, for example.
Parameter Template and associated information.
Name of the parameter.

Associated parameter values.
The arrow keys and can be used to move the focus to one of the boxes
in order to enter text or select an option (space bar).
To move the cursor within an input box, use the ! or z arrow keys. On
the Parameter page, you can access the individual parameter values
directly by pressing one of these keys.
Tab +
NUM
ESC
Tab +
The softkey Tab+ can be used to switch between the General, Module
info and Parameter tabs. If you want to use the numeric keypad, the
NUM display in the status line must be switched off.
OK
Cancel
Using the softkeys OK or Cancel, you can confirm the changes made or cancel the action.
Alternatively, you can use the Enter or ESC keys.
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5.1.3.3
Selection list
At present, Filter and Templates are available in selection lists.
Filter
The men command Filter offers the following filter types for selection:
This setting affects the output in the file window
The appearance of the file list changes depending on the filter that is set.
Filter Module
Filter Detail
The arrow keys and can be used to move the focus to the desired filter.
You can use the softkey bar to switch on the selected filter or cancel the action.
OK
Cancel
Template
At expert level, the softkey New opens a window and offers one of the following templates:
Which of the templates shown here will be offered

depends on the directory in which the program is to be
created. For example, a CELL program can only be
created in the directories R1 and Program.
Here again you have the option of accepting the relevant setting or canceling the action.
OK
Cancel
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5.1.4
Directory and file list

The contents of the current drive or directory are displayed as a file list on the right--hand side
of the Navigator.
To select a directory or file,
move the focus to the desired
symbol using the or
arrow key.
To open or close a directory

level or select a program,
press the Enter key.
To switch between the directory structure and the file list, use the or
arrow key.
The space bar can be used to select several files permanently or to cancel selections.
To do so, move the focus to the desired file using the or
arrow key and press the space bar. The file in question is now
selected.
Press the space bar again and the selection is canceled.
Alternatively, several consecutive files can be selected using
the keyboard shortcut Shift+ or Shift+.
The ESC key cancels the selection of all the files highlighted.
Using the filter option Detail at expert level, the same file list has the following appearance:
The contents of the file window can be

moved left or right using the keys Alt +
or Alt + in order to enable the
desired information to be seen.
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5.1.4.1
Pop--up menu
For each selected object (e.g. program list or data list, etc.) a pop--up menu can be opened
as an alternative to the pull--down menus and softkeys. Only those commands are available
for selection which can actually be executed at a given moment.
The menu can be opened in one of the following ways:
Pressing the ! arrow key;
Pressing the right mouse button (if a computer mouse is connected);
Pressing the application key (if a corresponding keyboard is connected to

the system).
Select
Open
Archive
Cut
Copy
Delete
Rename
Duplicate
Attributes
Without parameters
With parameters
The pop--up menu opens. This menu only offers those

functions that are actually available.
File/Folder
Data list
Error list
Move the focus to the previous/next menu item using the " and # arrow keys. You can
open a submenu using ! or the Enter key and close it again using z or the ESC key.
Alternatively, you can select a command by pressing the corresponding number on the
numeric keypad. The NUM display must be activated in order to do this. The numbers
preceding the individual commands are fixed, i.e. the commands are not dynamically
renumbered. Thus the experienced user need only remember the numbers relevant to him.
In some circumstances, the pop--up menu cannot be opened. This is the case, for example,
when the attributes display is open.
The pop--up menu can also be used in conjunction with multiple directories or files selected
at the same time.
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5
5.1.4.2
Additional information
The following information is available to the operator:
The title bar gives details about the type of information displayed.
Directory or file name
File extension, e.g. SRC, SUB, UPG etc.
The first 10...15 characters of the comment
The existing operating system and kernel system attributes
File size in kilobytes
Number of changes made to the file
Date and time of the last change
Creation date including time
5.1.5
Status line
Information about the number of files, their size, path, progress and other status messages
are displayed in the status line of the Navigator.
Contents display (turquoise)
Selection information (turquoise)
Action information (turquoise)
Process cancelled
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User dialog (yellow)
User entries (green)

These are confirmed with the Enter key or canceled by pressing the ESC key.
Request for confirmation (gray)
When a request for confirmation is made, a corresponding line is generated,
which must be answered via the softkey bar.
5.1.6
Error display
This option is used for error diagnosis and elimination. When the contents of a directory are
read, the program or module, etc., is checked for syntax errors. If any are found, the files
containing errors are highlighted accordingly.
Module containing errors
If the focus is moved to a file marked as containing errors, the appearance of the softkey bar
changes as follows:
New
Error list
Open
Data list
Delete
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5
5.1.6.1
Error list
This softkey opens the error display.
Additional information concerning the errors that have occurred is listed in the error list.
Title bar with the name of the file
Short description
Error number
Line and column in which the error occurs
Source text line in which the error occurs
The arrow keys and can be used to select the desired error.
The following commands are available in the softkey bar:
Show
Refesh
Close
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Show
This command opens the editor on the left--hand side.
In order for the line numbers in the error list to correspond to those in the editor, the options
-- All FOLDs open and
Edit
-- Detail view
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
FOLD
Copy
Paste
Cut
Delete
Find
Replace
Close
Current FOLD open/close

All FOLDs open
All FOLDs close
Language
Change password
Editor
Office option
Monitoring working env.
Reinitialization
Cycle Time Optimizer
PlugIn Configuration
Event planner
Def--line
ASCII Mode
Linebreak
must be activated. These functions are not available as standard in the user group User.
With open folds and ASCII mode activated, the entire contents of the program are displayed:
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The line/column numbers in the error list now correspond to those in the editor, which makes
fault location significantly easier.
If the error is in a closed fold, the edit cursor is positioned on this closed fold.
When the file is closed, a request for confirmation is generated asking if the file should really
be saved to the hard disk.
Date Wednesday, 30 July 2003 14:51:53
Source: XEdit
No.: 19
KRC:\R1\PROGRAM\PROG_04.SRC Save changes?
Cancel
The changes are not saved, but the program window remains open for
further editing.
Yes
The softkey Yes saves the changes and closes the program window.
No
Pressing No rejects the changes and closes the program window.
Once the file has been successfully saved, you can verify in the message window whether
the error has been successfully corrected.
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Refresh
The error display window is updated.
Close
The error list is closed.
5.1.6.2
Open
This command opens the file selected in the file list. This can be either a SRC file or a DAT
file.
Further information about the Open command can be found in Section 5.2.2.
5.1.6.3
Data list
The DAT file belonging to the program is loaded for editing. The data list can then be
modified.
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5.1.6.4
Delete
The description of this command can be found in Section 5.3.5.
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5.2
File menu
File
New
Open
File/Folder
Data list
Error list
Print
Current selection
Log book
Archive
All
Applications
Machine data
Configure
Log Data
Current selection
*1
All
Applications
Machine data
Configure
Current selection
*1
Restore
Rename
Format floppy disk
Attributes
Filter
*1:
5.2.1
*1
Drivers
I/O Longtexts
KUKA TechPack
Drivers
I/O Longtexts
KUKA TechPack
Not available in the user group User.
New
To be able to create a folder or module at all, the program window must first be active, i.e.
highlighted in color. If it is not, press the Window selection key until the program window
is activated.
The directory or module name can be entered in the input line. This name can have a
maximum of 24 characters. In the case of programs, a comment may optionally be entered.
The icon next to the input line indicates whether a folder or a file is being created.
Directory
NUM
Module
Numbers for directory and program names are entered using the numeric keypad on
the KCP. To do this, the NUM display in the status line must be deactivated.
The menu command New is also available in the softkey bar.

New
Select
Duplicate
Archive
Delete
Open
If a program has already been selected or there is a program in the editor, you must first
toggle to the Navigator. No new program can be created until this is done.
5.2.1.1
Create directory
To do this, the focus must be located in the directory structure.
Focus
File
Then select the command New under the menu File, or press the corresponding softkey. Enter the desired name of the directory in the input line.
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Create folder
Folder name
OK
5.2.1.2
To create the directory, press the softkey OK or the Enter key. The desired
file is automatically saved on the hard disk and displayed shortly afterwards
in the file window.
Create module
To do this, the focus must be located in the file list.
Focus
File
Then select the command New under the menu File, or press the corresponding softkey. Enter the desired name of the module in the input line.
Create module
Module name
Comment
A comment can be entered along with the module name for the purpose of
easier identification. The relevant input box in the form is accessed using the
arrow key. The first 15 characters of the comment, at most, are displayed
in the file list.
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OK
To create the module with the corresponding comment, press the softkey
OK or the Enter key. The desired file is automatically saved on the hard disk
and displayed shortly afterwards in the file window.
By following this procedure, a so--called skeleton program will be created, the program
name being shown in the file list.
If a module with this name already exists, a corresponding message is generated in the
message window.
Source: FILEHANDLER
No.: 17
Replace file?
Yes
No
The softkey Yes overwrites the existing file.

No will reject the current program creation and close the input line.
At expert level, in addition to modules other program files can be created. For this purpose,
when the command New is selected, instead of an input line a window is opened offering
a selection of the various templates available.
Where possible, create user programs in the directory R1\PROGRAM, in order to ensure
that they are automatically saved via the menu item File --> Archive --> Applications.
5.2.2
Open
File
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
File/Folder
Data list
Error list
The selected program or Folge is

loaded for editing in the editor.
Once the submenu Open has been selected, the following options are available:
5.2.2.1
File/Folder
For this option, a directory or file must be selected.
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While a program is being edited, the robot can at the same time be executing another
program in the background.
Example of an SRC file
The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars is altered at the same time.
If you have opened a program which has so far only been initially created, the so--called
skeleton program is displayed in the programming window. The following screenshot
shows such a skeleton program.
5.2.2.2
Data list
Example of a DAT file
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Operator Control
5.2.2.3
Error list
Example of an error list
5.2.3
Print
File
5.2.3.1
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
Current selection
Log book
You can use this command to create

printouts of the current selection and the
logbook. This can take some time,
depending on the amount of data to be
printed.
Current selection
The selected files are sent to the printer.
5.2.3.2
Log book
This command sends the logbook, which can be viewed via the menu Display -->
Diagnosis --> Logbook, to the printer.
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5.2.4
Archive
This function allows you to save important data to floppy disk. With Navigator, the user can
see what is stored in these archives.
File
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
All
Applications
Machine data
Configure
Log Data
Current selection
Drivers
I/O Longtexts
KUKA TechPack
A request for confirmation is generated which must be answered before the saving process
is carried out.
Source: FILEHANDLER
No.: 35
Do you really want to archive the selected file(s)?
Yes
The selected files are archived.
No
The selected files are not archived.
If you try to insert a file in an existing archive, the robot name is checked. The robot name
in the archive is compared with the name that is set in the controller. If the two names are
different, a request for confirmation is generated asking if you really wish to overwrite the
existing archive.
Date Monday, 4 August 2003 11:42:29
Source: C3ARC
No.: 0
Wrong robot archive: Archive: RName System: Rob--1
Ignore
The selected files are added to the archive.
Cancel
The selected files are not added to the archive.
The status line of the Navigator indicates the current status:

Source: FILEHANDLER
No.:
8
Save files...
Cancel
5.2.4.1
The archiving can be terminated at any time by pressing the ESC key or
the softkey Cancel.
All
All data, with the exception of log files, are loaded from the floppy disk back onto the hard
disk.
KRC:\
C:\KRC\Data\
C:\KRC\Roboter\Init\
C:\KRC\Roboter\IR_Spec\
C:\KRC\Roboter\Log\
C:\KRC\Roboter\Template\
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The menu command File --> Archive --> All is also offered in the softkey bar.
Restore
Restr. All
Open
Save all
Following reinitialization, the user interface must be reloaded using the command
Configure --> Miscellaneous --> Reinit --> BOF Reinitialization in order to ensure that
changes to the menu structure (MenuKeyUser.ini) are displayed correctly.
5.2.4.2
Applications
All programs in the listed folders will be saved:
KRC:\R1\Program\
KRC:\R1\System\
KRC:\Steu\$Config.dat
5.2.4.3
Machine data
The following files and folders can be selected:
KRC:\R1\MaDa\
KRC:\Steu\MaDa\
C:\KRC\Roboter\Ir_Spec\
5.2.4.4
Configure
The configurations of the following technologies are available:
I/O drivers
I/O long texts
KUKA TechPack
5.2.4.5
C:\KRC\Data\Kuka_Con.mdb\
The corresponding registry entries are saved here.
Log Data
The logbook data, which can be viewed using the diagnostic logbook function, are written
to the hard disk.
C:\KRC\Roboter\Log\
Log data
5.2.4.6
Current selection
The selected files are saved on the floppy disk in drive A:\.
The menu command File --> Archive --> Current selection is also available in the softkey bar.
New
Select
Duplicate
Archive
Delete
Open
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5.2.5
Restore
This command allows you to restore archives.
File
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
All
Applications
Machine data
Configure
Current selection
Drivers
I/O Longtexts
KUKA TechPack
This function is particularly useful, for example, if programs on the hard disk have become
damaged or if you wish to return a program to its original state after substantial changes have
been made to it. The files on the hard disk are hereby overwritten. A request for confirmation
is thus generated which must be answered before the files are restored.
Source: FILEHANDLER
No.: 34
Do you really want to restore the selected file(s)?
Yes
The selected files are restored.
No
None of the selected files is restored.
The action will then be displayed in the message window:
After a short wait time the end of the operation is shown:

Restoring succeeded
In the event of a version conflict between the archive files and the system files, an error
message is generated. Depending on the configuration, it may still be possible to copy the
affected files.
5.2.5.1
All
All data, with the exception of log files, are loaded from the floppy disk back onto the hard
disk.
KRC:\
C:\KRC\Data\
C:\KRC\Roboter\IR_Spec\
The I/O drivers are also reconfigured. The user interface is then reinitialized in order to update any changes, e.g. to the menu structure (MenueKeyUser.ini).
Depending on the configuration, the directory R1, including all files and subdirectories, can
be deleted before the files are restored. The request for confirmation before the R1 directory
is deleted also depends on the configuration. The directory structure and files are restored
exactly as they were when they were originally archived.
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Date Friday, 1 August 2003 11:02:13

Source: C3ARC
No.:
Delete folder R1 before restore?
No
The directory R1 is not deleted; the existing programs are overwritten

individually during the restore function.
Yes
Before the files are restored, the directory R1, including all files and
subdirectories, is deleted.
The menu command Restr. All in the softkey bar has the same function as the menu
command File --> Restore --> All.
Restore
5.2.5.2
Restr. All
Open
Save all
Applications
The following directories and files are written back on to the hard disk:
KRC:\R1\Program\
KRC:\R1\System\
5.2.5.3
Machine data
Only machine data are loaded from the floppy disk.
KRC:\R1\MaDa\
KRC:\Steu\MaDa\
C:\KRC\Roboter\Ir_Spec\
To restore individual files from the floppy disk, move the focus to the Archive:\ symbol and
open the directory Disk (corresponds to drive A:\). Then switch to the data list, locate the
desired files and paste them using the edit functions (Program menu).
5.2.5.4
Configure
Only the selected data are restored:
I/O drivers
I/O long texts
KUKA TechPack
UserTech
C:\KRC\Data\Kuka_Con.mdb\
The corresponding registry entries are saved here.
C:\KRC\Roboter\Init\MenueKeyUser.ini
C:\KRC\Roboter\Init\SoftKeyUser.ini
Once the long text database (Kuka_Con.mdb) has been written back onto the hard drive,
the restored version is immediately available.
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5
5.2.5.5
Current selection
Only the selected files or directories in the drive Archive:\Disk\ are written back to the hard
disk.
The menu command File --> Restore --> Current selection has the same function as
the corresponding softkey.
Restore
Restr. All
Open
Save all
The floppy disk drive A:\ can be accessed directly at expert level:
5.2.5.6
History
Depending on the configuration, every time files are archived to floppy disk, a backup copy
of the relevant system files is also made in a certain directory on the hard drive. This backup
copy can be used to restore the system to its current state. The entry Archive --> History
is available for this in the Navigator.
Time
Date
Robot name
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The backup copy required for restoring the system can be selected from the file list. The
archive name comprises the name of the robot, and the date and time the archive is saved.
As well as a complete restoration, it is also possible to restore selected files and directories.
This is done using the arrow keys and the Enter key.
Restore
Restr. All
Restores the selected files/directories following a request for confirmation.

Performs a complete restoration from the floppy disk. Once again, a request
for confirmation is generated, which must be answered.

Source: FILEHANDLER
No.: 34
Do you really want to restore the selected file(s)?
5.2.6
Yes
The selected files are restored.
No
None of the selected files is restored.
Rename
The command Rename allows you to change the name or the comment line of a program.
Certain directories cannot be renamed, depending on the particular configuration. In this
case, the menu command and the corresponding softkey cannot be selected.
In the right--hand Navigator window, select the file or directory that you would like to rename.
File
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
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Make the desired changes. You can move to the next input box in the form
using the arrow key.
Then confirm the action using the softkey OK or the Enter key, or cancel
the action by pressing the softkey Cancel or the Escape key.
OK
Cancel
At expert level the file extension (SRC, DAT or SUB) is shown.
The renamed file is automatically saved on the hard disk. If a name is entered which already
exists, a corresponding error message is displayed in the message window and the action
is canceled.
5.2.7
Format floppy disk

The contents of a 1.44 MB floppy disk in drive A:\ are deleted using Quickformat.
File
New
Open
Print
Archive
Restore
Rename
Format floppy disk
Attributes
Filter
After the menu item has been selected, a request for

confirmation is generated in the message window, which
must be answered.

Source: FILEHANDLER
No.: 33
Do you really want to format the inserted disk?
Yes
Deletes the contents of the floppy disk.
No
Cancels the action without formatting the floppy disk.
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Operator Control
Once the formatting has been completed, a corresponding output is generated in the
message window.
The floppy disk must not be removed from the disk drive until this message has
appeared in the message window and the LED on the disk drive is no longer lit.
Otherwise the disk drive and/or the floppy disk could suffer irreparable damage.
5.2.8
Attributes/Filter
Further information about the attributes display can be found in Section 5.1.3.2, while the
topic Filter is described in detail in Section 5.1.3.3.
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5.3
Edit menu
Edit
Select all
Copy
Paste
Cut
Delete
Duplicate
Select
Cancel program
Reset program
*1:
5.3.1
Without parameters
With parameters
*1
Not available at user level
Select all
All directories and files in the file
list are selected for editing.
The selection of directories or files can only be canceled if

G
another directory is selected in the directory tree,
the space bar is pressed when the focus is located on the desired symbol in the file list,
or
G
5.3.2
the ESC key is pressed.
Copy
Selected directories and files are first copied to the clipboard. The copied directories and files
can then be pasted in a different position.
5.3.3
Paste
Folders and files from the clipboard are inserted at the current position (Copy), or moved
there (Cut). If one of the files to be inserted already exists, this prompts a request for
confirmation.
Source: FILEHANDLER
No.: 12
File ... already exists.
Do you want to overwrite?
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Operator Control
Yes
Pastes the next selected file or directory.
No
Does not paste the next file or directory.
Yes All
No All
Cancel
Pastes all selected files or directories.

Pastes no file or directory.
Terminates the action.
This command is only available if there are data in the clipboard.
5.3.4
Cut
Selected directories are first copied to the clipboard. When this is done, the icons of the
selected directories will appear dimmed.
The copied directories and files can then be pasted in a different position.
After being inserted, the directories and files are deleted from their original locations.
5.3.5
Delete
The selected files and directories are irrevocably deleted from the hard disk following a
request for confirmation. If you want to delete a program, it must not be currently selected
or being edited. You might first have to deselect the program or close the editor.
Certain directories cannot be deleted, depending on the particular configuration. In this
case, the menu command and the corresponding softkey cannot be selected.
Use the arrow keys to select the program you want to delete, then press the menu command
Edit --> Delete. A request for confirmation appears in the message window.
Source: FILEHANDLER
No.: 32
Do you really want to delete the selected file(s)?
Yes
No
If you press the softkey Yes, the program is deleted. It is then no longer
displayed in the list of programs available.
If you press the softkey No, the program remains unchanged.
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The menu command Delete is also available in the softkey bar.

New
5.3.6
Select
Duplicate
Archive
Delete
Open
Duplicate
The option Duplicate creates a copy of a program. For this purpose, a form is then opened
in which the name of the selected file is offered as a suggestion.
Program name
Comment
On the left--hand side of this inline form is the input box Name. Here you can enter a name
for your program, up to 24 characters long. This name must begin with a letter.
You can additionally enter a text for this program. To do so, press the arrow
key to position the edit cursor in the box Comment and enter the desired
comment.
The entries are saved and the form is closed by pressing the Enter key. The desired
program is then created and displayed on the screen.
If you have entered a program name that already exists, an error message is displayed in
the message window:
The menu command Duplicate is also available in the softkey bar.

New
Select
Duplicate
Archive
Delete
Open
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Operator Control
5.3.7
Select
Edit
Select all
Copy
Paste
Cut
Delete
Duplicate
Select
Cancel program
Reset program
Without parameters
With parameters
A selected program can continue to run in the background while at the same time another
program is being processed in the editor.
5.3.7.1
Without parameters
The desired program is displayed in the program window. The assignment of the menu key,
softkey and status key bars changes at the same time, in order to make functions available
which are necessary for programming the robot.
If you have opened a program which has so far only been initially created, the so--called
skeleton program is displayed in the programming window.
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The menu command Select without parameters is also available in the softkey bar.
New
5.3.7.2
Select
Duplicate
Archive
Delete
Open
With parameters
At expert level, the entry of parameters is also possible. For this purpose the following form
is opened in which the relevant data can be entered:
Additional parameters are necessary if a program requires further entries to be able to run.
If, for example, the program Test.SRC contains the header
DEF TEST(INT :IN, BOOL :OUT)
an integer value and a Boolean value are transferred when the program is called.
Further information about the program window can be found in the documentation [User
Programming] in the chapter [Program editing].
5.3.8
Cancel program
A program that has previously been selected, i.e. one that is ready for execution, can be
canceled via the Navigator. A different program can then be loaded for editing.
5.3.9
Reset program
A program selected in the background can be reset via the Navigator. In this way the program
can be brought back to the initial state it had immediately after it was loaded.
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Operator Control
5.4
Monitor menu
Monitor
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
NAVIGATOR
PROGRAM
EDITOR
You can use the submenu

Windows to toggle between
the Navigator, a selected
program, and the editor.
It is also possible to switch between the Navigator, the program and the editor using the
corresponding softkey.
NAVIGATOR
PROGRAM
5.5
Appendix
5.5.1
Keyboard assignment of the Navigator
EDITOR
The keys of the KCP for controlling the Navigator are assigned in such a way that selection
of files and folders can be carried out using one hand.
Key
Effect
Function
General
Toggle between directory list and file list
windows
Toggle numeric keypad to enter either
numbers or control characters
Used for entering special characters on the
KCP keypad
Key for special functions in conjunction with
the Windows operating system
Directory structure
Select drive/directory
Open/close drive or directory

File list
Select directory/file
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Open directory
Select/edit/display module
Edit text file
Select a number of adjacent directories or

files
Select individual directories/files

Cancel a selection
ESC
Cancel all selections
Open pop--up menu
Keyboard shortcuts
Copy
Cut
Paste
The keys SHIFT and SYM remain activated for one keystroke.
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5.5.2
Default settings at User and Expert levels

Visibility of drives and directories
User
Expert
User
Expert
User
Expert
KRC:\
R1
MaDa
Program
System
TP
Steu
MaDa
Floppy disk (A:\)
Hard disk (C:\)
CD--ROM
Network drive
Archive:\
User privileges when creating

directories
KRC:\
R1
MaDa
Program
System
TP
Steu
MaDa
Filter
Detail
Modules
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5
Templates
User
Expert
Cell
Module
Submit
Expert module
Expert Submit
Function
Standard directories
Available templates
Cell, Expert, Expert Submit, Function, Module,
Submit
R1
MaDa
Program
System
TP
Steu
No
Cell, Expert, Expert Submit, Function, Module,
Submit
Exp., Exp. Submit, Function, Module, Submit
Exp., Exp. Submit, Function, Module, Submit
No
MaDa
No
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90 of 163
Executing, stopping and resetting a program
Executing, stopping and resetting a program

A precondition for program execution is that the controller is switched on and the graphical
user interface (GUI) is active.
6.1
Selecting and opening a program

In order to be able to select a program, the corresponding window must be active
in the Navigator. To ensure this, press the window selection key.
Select
Using the arrow keys and , select the desired program and confirm your selection with
the softkey Select or the Enter key. The selected program is then displayed in the program
window.
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6.1.1
Symbols in the program window

Various symbols are used in the program window. These include the block pointer, the edit
cursor, the direction indicator and the line break symbol.
The block pointer indicates which line of the program is currently being executed. It is shown
as either a yellow or a red arrow. The block pointer is only available when a program has been
selected, not in the editor.
Current program line

Line Sel.
If you want to place the block pointer on a particular line, first move the edit cursor to the
desired position using the arrow keys " or #. Then press the softkey Line Sel.. The block
pointer is then placed on the selected line.
The appearance of the block pointer changes according to the situation.
L--shaped arrow (yellow):
The motion instruction is being executed in the forward direction, but has not yet been
completed.
L--shaped arrow (yellow) with plus sign:
Here the block pointer is positioned on a closed fold. The motion instruction is being
executed in the forward direction and has not yet been completed. This display is not
available in the user group User.
Normal arrow (yellow):
The robot has completed the specified motion instruction in the forwards direction
Normal arrow (yellow) with plus sign:
Here, too the block pointer is positioned on a closed fold. The motion instruction has
been completed. This display is also not available in the user group User.
L--shaped arrow (red):
The motion instruction is being executed backwards, but has not yet been
completed.
L--shaped arrow (red) with plus sign:
Here the block pointer is positioned on a closed fold. The motion instruction is being
executed backwards and has not yet been completed. This display is not available
in the user group User.
Normal arrow (red):
The robot has completed the specified motion instruction in the backwards direction
Normal arrow (red) with plus sign:
Here, too the block pointer is positioned on a closed fold. The motion instruction has
been completed. This display is also not available in the user group User.
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Executing, stopping and resetting a program (continued)
Edit cursor (Input mark)

The blinking edit cursor indicates the position in the program where changes are being made.
Edit cursor
Characters are inserted or deleted at this position. New commands, on the other hand, are
inserted below the edit cursor.
Direction indicator
This symbol is displayed if the block pointer is not visible in the program window.
Direction indicator
The symbol indicates the required direction for scrolling to get back to the program pointer.
Double arrow (black) pointing up:
The block pointer is located higher up. Use the arrow key " or PGUP to scroll up.
Double arrow (black) pointing down:
The block pointer is located lower down. Use the arrow key # or PGDN to scroll
down.
Linebreak
If the command line does not fit in the program window, a line break will be made automatically. This will be marked by a small black L--shaped arrow.
Line breaks
You can prevent the line break at expert level by activating the option Configure -->
Miscellaneous --> Editor --> Linebreak ON/OFF.
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6.1.2
Program status line

The status line of a program which has been selected or which is in the editor shows the
operator additional information about the program.
Program path and name
Line/column
Symbol
Program name
The path and the program name of the program which has been selected
or is in the editor.
Line/column
The current line and column position at which the edit cursor is located.
Characters entered will, if possible, be inserted at this position.
Symbol
Here the operator can obtain additional information about the loaded program or about
program editing.
Padlock:
The file has been opened in write--protected mode. This means that no changes will
be saved. A selected program, for example, cannot at the same time be processed
in the editor.
Likewise, no changes can be made if the opened file has been given the attribute
ReadOnly. If you nevertheless want to make corrections to the file, first remove
the attribute ReadOnly. To do this, use the option File --> Attributes.
Chain:
The file indicated is selected or integrated into the selected program.
Clipboard:
Data have been copied to the clipboard; they can be inserted at another location.
Copy functions are available only at the Expert user level and above.
ABC with check mark:
The option Configure --> Miscellaneous --> Detail view is activated. This
function is not available in the user group User.
PTP:
An existing inline form has been opened by pressing the softkey Change.
PTP with star:
A new inline form has been opened.
Crossed--out (green) Start key:
The start interlock is active, i.e. the selected program cannot be started. This is the
case for example when a motion command is being inserted or modified.
Question mark:
A query dialog in the message window must be responded to. For example, deletion
of a block must first be confirmed by the operator.
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6.2
Program velocity (Programm override)

In some cases, e.g. when testing programs, it is of vital importance to reduce
the velocity of the robot. The Program override function, for which a key can
be found in the right--hand status key bar, can be used for this purpose. The
value can be increased or decreased using the +/-- key.
It is possible to alter the POV value not only in increments of 1%, but also directly between
values of 1, 3, 10, 30, 50, 75 and 100 per cent.
Configure
I/O
I/O Driver
SUBMIT Interpreter
Statuskeys
Jogging
User group
Cur. tool/base
Tool definition
On/Off Options
Miscellaneous
Program OV Steps
Jog OV Steps
Mouse position
Mouse configuration
Depending on the configuration, the program override is automatically set to 10 percent

when the mode selector switch is switched to T2. If the mode is changed back to T1,
the last value used for T1 is restored.
6.3
Stop reactions
If a running program is stopped, the EMERGENCY STOP button pressed or a safety gate
opened, the robot is stopped. The controller distinguishes here between various states.
In order to protect the brakes against overheating, the braking energy is calculated along
with an associated cooling time. If the braking energy exceeds a certain value, the drives
are locked and a status message is generated in the message window.
The message cannot be acknowledged until the motor brakes have cooled, and only then
can the robot motion can be resumed.
6.3.1
Ramp--down braking
The robot is stopped with a normal braking ramp and remains on its programmed path. This
occurs if...
6.3.2
the Program start forwards or Program start backwards key has been released in
jog mode, or
the Stop key has been pressed in Automatic or Automatic External mode (passive
stop);
the driving condition is no longer present;
Path--maintaining Emergency Stop

The controller attempts to brake the robot on the path with a steeper braking ramp. This
occurs if...
G
the Emergency Stop button has been pressed in Automatic mode;

if the Emergency Stop ramp cannot be completed, short--circuit braking occurs.
the enabling switch has been released;

if the path can no longer be held, the controller switches automatically to the maximum
braking state.
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Operator Control
6.3.3
the safety gate to the work cell or the operator safety has been opened in automatic
mode;
braking state.
the drives have been switched off during program execution;

braking state.
the operating mode has been changed during program execution;

braking state.
Maximum braking
The robot is no longer on its path. This occurs if...
G
an axis exceeds its command velocity or acceleration (the command velocity is lower
in jog mode T1 than in T2 or automatic mode);
a software limit switch has been reached or a command value has been exceeded.
6.3.4
Short--circuit braking (dynamic braking)

The robot is no longer on its programmed path and may have left its positioning window. This
occurs if...
G
the Emergency Stop button has been pressed in jog mode (T1 or T2);
there is an encoder error;
the controller is switched off or there is a power failure;
the line between DSE and RDC has been interrupted;
In the event of short--circuit braking or dynamic braking, the holding brakes of the individual
axes are applied while the motion is still in progress. If this happens frequently while the
robot is still moving it leads to significantly increased wear on the holding brakes.
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6.3.5
Warning and safety instructions

When safety devices are being used with path--maintaining braking, it must be
ensured that no--one enters the working range of the robot while the drives are on.
The optional function path--maintaining braking in event of operator safety
violation cannot be used in systems where there is a risk of people being situated
in the working range of the robot during the deceleration time. (These include, for
example, light curtains in loading stations).
Before using the function Path--maintaining braking in event of operator safety
violation, the user must carry out a danger analysis and a risk assessment for
every eventuality.
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6.4
Manual program execution (jog mode)

Select a program and set the mode selector switch to mode T1 or T2.
The robot can be moved manually and programs started only if there is no EMERGENCY
STOP situation and -- in the Automatic mode -- the drives are switched on.
If the option AutoAck has been activated, all the acknowledgeable messages displayed
are acknowledged the first time the Start key is pressed. These include all the actions which
trigger the message Active commands inhibited (e.g. moving the robot with the jog keys
or the Space Mouse).
Depending on the configuration, the program override is automatically set to 10 percent
when the mode selector switch is switched to T2. If the mode is changed back to T1,
the last value used for T1 is restored.
6.4.1
Program run mode Go, Single Step or I--Step

If you want to execute a program fully, select the setting Go. Then hold down one
of the enabling switches and press the Program start forwards key. The program
is executed until either the Start key or the enabling switch is released.
If you want to execute a program step by step, choose the setting Single Step.
Hold down one of the enabling switches and press the Program start forwards
key. Once the motion block has been completely executed, the Start key must be
released and pressed again. The next motion block is then executed.
In expert mode, the option Incremental Step is also available. In this mode a
program is executed one line at a time (this also applies for closed folds, although
at first glance nothing appears to be happening in such a case). In order to
advance through the program the Program start forwards key must be released
and pressed again at each step.
This symbol indicates backward motion using the Program start backwards key.
This function cannot be switched manually but appears automatically when the
Program start backwards key is pressed. Here again the Program start
backwards key must be pressed after every motion command.
6.4.2
Block selection
Within a selected program or subprogram, it is possible to select a program line and begin
program execution at this point. To do this, move the edit cursor to the desired program line
in the selected program using the " and # arrow keys.
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Line Sel.
Pressing the softkey

Line Sel. moves the
program pointer to the
line in which the edit
cursor is currently
positioned.
Any line in the current program or subprogram can be selected, provided it contains a KRL
instruction that can be executed. Variables and declarations of procedures or functions do
not fall into this category and cannot be selected using the block selection function.
Once a program has been selected, its initialization section should be run first. The
variables are initialized here. Block selection should only be carried out after this
initialization process.
A number of additional functions are available for use with subprograms.
Block selection in local subprograms
Local subprograms are located in the same file as the main program from which they are
called.
A local subprogram can be selected directly without the need to start the corresponding main
program. This subprogram need not necessarily be located in the caller stack of the main
program. Following a jump to a subprogram, further motion blocks in this subprogram can
be selected by means of block selection.
If a subprogram has been started by means of block selection and the Program start key has
subsequently been pressed, it is no longer possible to jump to another subprogram using
direct block selection. In this case, you have the following options:
G
The selected subprogram must be executed completely;
You can jump back to the main program by means of a direct block selection. From the
main program, you can jump into any subprogram.
When the end of a local subprogram is reached an advance run stop is triggered. The block
pointer is positioned at the point in the main program or subprogram from which the jump
occurred. The program is stopped at this point and may be restarted by pressing the Program
start key.
In the first example, a subprogram is being called.
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Operator Control
DEF PROG_1()
INI
PTP HOME Vel= 100 % DEFAULT
...
SP_1()
...
SP_2()
...
PTP HOME Vel= 100 % DEFAULT
END
DEF SP_1()
...
LIN P1 Vel= 2 m/s CPDAT1 Tool[1] Base[1]
...
END
PROG_1.SRC
DEF SP_2()
...
(1)
The local subprogram SP_1 is called.
(2)
On completion of the subprogram, the main program is resumed from the point at which
the jump to the subprogram was made.
The second example shows the possible actions within subprograms.
100 of 163
1
2
3
1
6
7
8
12
13
14
17
18
19
24
25
28
29
30
5
33
34
37
38
39
45
DEF
INI
PTP
...
PTP
LIN
LIN
...
PTP
END
PROG_1()
PROG_1.SRC
HOME Vel= 100 % DEFAULT

P1 Vel= 100 % PDAT1 Tool[1] Base[1]
P2 Vel= 2 m/s CPDAT2 Tool[1] Base[1]
HOME Vel= 100 % DEFAULT
DEF SP_1()
...
SP_3()
3
...
END
DEF
...
PTP
LIN
PTP
...
END
SP_2()
DEF SP_3()
...
PTP P21 Vel= 100% PDAT21 Tool[1] Base[1]
WAIT For IN 5 Periphery State= TRUE
PTP P22 Vel= 100% PDAT22 Tool[1] Base[1]
...
END
(1)
In the program PROG_1, the line PTP P1... has been selected. The caller stack is
currently empty.
(2)
The operator performs a block selection in the local subprogram SP_1. The caller
stack is still empty.
(3)
The subprogram is started, thereby placing SP_1 in the caller stack.

=>Caller stack: PROG_1 --> SP_1
(4)
While subprogram SP_1 is being executed, SP_3 is called.

=>Caller stack: PROG_1 --> SP_1 --> SP_3
(5)
Block selection to subprogram SP_2 is not permissible as SP_2 is not in the caller
stack.
(6)
Block selection in SP1 is possible, however, as this subprogram is in the caller stack.
(7)
Block selection in the main program PROG_1 is also possible as this program is also
in the caller stack.
A line selected in the subprogram is integrated into the program sequence in the same way
as an interrupt program.
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6.4.3
BCO run
For the purpose of ensuring that the robot position corresponds to the coordinates of the
current program point, a so--called BCO run (block coincidence) is executed. This is carried
out at reduced velocity. The robot is moved to the coordinates of the motion block in which
the block pointer is situated.
This is done...
G after a program reset by means of a BCO run to the home position;
G after block selection to the coordinates of the point at which the block pointer is situated;
G after selection of the CELL program before the Automatic External mode can be started;
G after a new program has been selected
G after modifying a command
G after manual traversing in programming mode
A BCO run is also necessary if the tool center point is located outside the positioning window.
The following examples are intended to illustrate this:
The tool center point is still located on the programmed path after the robot has stopped.
A BCO run is not therefore required.
Tool center point
Programmed
path
P5
PTool P6
Positioning window
The tool center point is situated within the positioning window. A BCO run is not required
here either.
Tool center point
PTool
Programmed
path
P5
P6
Positioning window
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The robot has left the positioning window. A BCO run must be carried out.
Tool center point
Tool center point
PTool
PTool
P5
Programmed
path
P6
BCO run to P6
P6
P5
Positioning window
If a CIRC motion is left (e.g. through dynamic braking) the necessary BCO run is carried
out directly to the next point.
Tool center point
PTool
PTool
BCO run
P5
P5
P6
P6
A BCO run always takes place by the direct route from the current position to the
destination position. It is therefore important to make sure that there are no
obstacles on this path in order to avoid damage to components, tools or the robot!
6.4.4
Executing individual program lines

First of all, ensure that the mode selector switch is in the test mode position
(T1 or T2).
Edit cursor
Line Sel.
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Program execution starts at the line indicated by the block pointer on the left. For the purpose
of selecting a particular block in the program, move the edit cursor to the desired program
line with the aid of the arrow keys. Then press the softkey Line Sel.. The block pointer now
jumps to the selected line.
Now start the program from the selected line. Press one of the enabling switches
and the Program start forwards key. During program execution, the program
pointer moves to the line that is currently being executed.
The first program step usually consists of a BCO run and must be triggered by pressing
an enabling switch and the Start key. When block coincidence is reached a corresponding
message is generated. At the start of the actual program, release the Start key briefly and
press it again.
The Program start forwards key must be held down while the robot is moving, otherwise
the program will be interrupted.
6.4.5
Program start backwards

Using the Program start backwards key, a program can be executed in the reverse
sequence.
For backward motion, only the operating modes Test (T1/T2) are available.
When the Program start backwards key is pressed, all outputs, flags and cycflags are
handled according to the configuration.
If a program is executed using the
Program start forwards key, the yellow
block pointer indicates the last motion
block addressed.
When the Program start backwards key
is pressed, the Program run mode status
key switches to backward motion. The
block pointer, which is now red, then
indicates the last motion block addressed
backwards.
Once the corresponding motion block has been reached, the Program start backwards key
must be released and pressed again. The next motion block is then addressed.
Forward and backward motion are only possible if BCO (block coincidence) exists.
In the case of backward motion, all programmed points are addressed with exact positioning.
Approximate positioning is not possible here.
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If the robot is moved backwards inside an approximate positioning range, the exact positioning point of the approximate positioning range is addressed.
P2 (exact positioning point)

Approximate positioning
range
Robot position
at change of direction
P1
P3
Forward direction
Overlapping motions, e.g. weaving or sensor corrections, are not supported during backward
motion.
Loss of BCO (caused, for example, by jogging the robot) causes the next reverse motion
to be executed automatically as a BCO run.
P2
P4
P3
P1
Forward direction
P2
P3
P1
Current
position
Programmed
path reached
(BCO)
BCO run
backwards
P4
Current
position
The backward motion function cannot be carried out in the following cases:
Backward motion not possible because...
Error message
...no points have been processed forwards;
No recording available
...all recorded points have been processed;
Recording already processed
...the completed subprogram cannot be processed Subprogram completed

backwards;
...the trace buffer has been discarded (e.g. Recording deleted, backward
program reset);
motion no longer possible
...this function has been deactivated
Backward motion not activated
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6.4.6
Stopping program execution

To stop a program in test mode, release the Start key. The program will then be stopped
immediately.
If the enabling switch is released, dynamic braking is activated. Under certain circumstances a new BCO run must then be carried out.
6.4.7
Continuing a program
A program that has been stopped or interrupted can be continued by holding
down an enabling switch and pressing the Start key.
6.4.8
Resetting a program (Reset)

Program
FOLD
Copy
Paste
Cut
Delete
Find
Replace
Cancel program
Reset program
Modify
A program that has been stopped or interrupted

can be returned to the initial state it had immediately after it was selected.
The yellow block pointer then jumps to the first instruction that can be executed in the
indicated program. The selected program can subsequently be restarted.
Reset program resets all the outputs.
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6.5
Automatic program execution

In manufacturing processes, programs or program sections are often executed cyclically.
For example, if the end of the program has been reached, the program can be executed
again.
To start automatic program execution, select a program and then switch the
robot drives on.
When a program is running, the menu commands Configure --> I/O Driver --> I/O Driver
Reset and I/O Reconfigure cannot be executed.
6.5.1
BCO run
A BCO run is now necessary. Press the Program start forwards key.
6.5.2
Complete program execution

Set the mode selector switch to Automatic or Automatic External
mode. The status line then changes for automatic mode as follows:
In Automatic mode, press the Program start forwards key.

In Automatic External mode, a PLC assumes control of the system.
6.5.3
Stopping program execution

STOP
A program can be stopped by pressing the Program stop key. The program and
the robot are then stopped.
Quitt
C... Time
In Automatic External mode, the acknowledgement message Passive

STOP is displayed in the message window. This message must be
acknowledged before the program can be resumed.
No.
11:09:16 209
11:09:16 1370
Source
Message
KCP
Passive STOP KCP

Passive STOP
If the drives of the robot have been switched off by means of the Drives OFF
key, the robot stops and the brakes of the axes are engaged.
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6.5.4
Continuing a program
If the drives of the robot have been switched off by means of the Drives OFF key,
the drives must first be switched on again before the program can be restarted.
This is done by pressing the Drives ON key.
In Automatic mode, press the Program start forwards key.
In Automatic External mode, a PLC assumes control of the system.
It may be necessary to carry out a BCO run at this point. This always takes place
by the direct route from the current position to the end position. It is therefore
important to make sure that there are no obstacles on this path in order to avoid
damage to components, tools or the robot!
6.5.5
Resetting a program (Reset)

If you wish to reset a program, ensure first of all that the mode selector
switch is in the T1, T2 or Automatic position
Program
FOLD
Copy
Paste
Cut
Delete
Find
Replace
Cancel program
Reset program
Modify
The yellow block pointer then jumps to the first instruction that can be executed in the
indicated program. The selected program can subsequently be restarted.
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6.6
Deselecting a program
If you wish to deselect a program, select the corresponding menu command.
Program
FOLD
Copy
Paste
Cut
Delete
Find
Replace
Cancel program
Reset program
Modify
Alternatively, the softkey deselect is available in the Navigator.

To check that the program has been deselected, please ensure that the name of the
previously selected program is no longer displayed in the status line.
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Monitor
A wide range of functions are grouped together under the menu item Monitor giving you
an overview of operating states and settings of the robot system.
Monitor
Digital Inputs
Digital Outputs
Analog I/O
Automatic External
I/O
Rob. Position
Single
Overview
Cyclic Flags
Flags
Counter
Timer
Variable
Diagnosis
*2
Windows
Hardware Info
*1:
*2:
7.1
Oscilloscope
Log book
CROSS Log book
Caller Stack
Interrupts
Securitycircuit
Web Diagnosis
Cartesian
Axis specific
Incremental
Master/Slave
Display
*1
Configure
Edit CONFIGMON.INI
*1
Display
Configure
Display
Configure
NAVIGATOR
PROGRAM
EDITOR
Not available in the user group User

In the Electrical Servicing handbook
Inputs/Outputs
The available inputs and outputs can be viewed and their long texts can be altered via the
menu item I/O.
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
Digital Inputs
Digital Outputs
Analog I/O
Automatic External
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7.1.1
Monitor (continued)
Digital Inputs
Once this option has been selected a status
window is opened, displaying the signal
states of the robot controllers inputs,
including the long texts.
There are normally 1024 inputs available, but it is also possible to use 2048 or 4096 inputs
(depending on the configuration).
Outputs
Name
You can open the status window for displaying the 1024 outputs with the aid
of the softkey Outputs. When you have pressed the softkey, its label and
function change. You can return to the status window for displaying inputs by
pressing it again.
The name of an input can be changed by pressing the softkey Name. This
information is saved in the long text database and is thus available again next
time the status window is opened.
The number of the desired entry can also be entered directly using the numeric keypad.
The focus is then positioned on the corresponding entry in the status window. To do this,
the function NUM must be activated in the status line.
Inputs can be simulated, i.e. set to fixed values, for the purposes of commissioning or in the
event of errors arising. This makes it possible to test robot programs even if the connected
peripheral equipment is not (yet) operational. This function can only be configured at Expert
level.
The designation SIM identifies simulated

inputs which may be either set or not set.
The designation SYS identifies inputs

whose value are saved in a system
variable.
Further information...
...on simulation of inputs and outputs can be found in the Programming Handbook in the
main chapter [Configuration], chapter [Configuring the system, Expert].
...on the subject of system variables can be found in the Programming Handbook in the
documentation [Expert Programming], chapter [Variables and declarations].
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7.1.2
Digital outputs
When this option has been selected, a status window is opened, displaying the signal states
of the robot controllers inputs.
When this option has been selected, a status
window is opened, displaying the signal states
of the robot controllers inputs.
The red LED symbols indicate that these

outputs are set.
There are normally 1024 outputs available, but it is also possible to use 2048 or 4096
outputs (depending on the configuration).
Inputs
Value
Name
You can open the status window for displaying the 1024 inputs with the aid
of the softkey Inputs. When you have pressed the softkey, its label and
function change. You can return to the status window for displaying outputs
by pressing it again.
By pressing the softkey Value, you can toggle the value of the selected
output between TRUE and FALSE. This softkey can only be used as long
as one of the enabling switches is held down. This softkey is not available in
Automatic mode.
The name of an input can be changed by pressing the softkey Name. This
information is saved in the long text database and is thus available again next
time the status window is opened.
The number of the desired entry can also be entered directly using the numeric keypad.
The focus is then positioned on the corresponding entry in the status window. To do this,
the function NUM must be activated in the status line.
Outputs can be simulated, i.e. set to fixed values, for the purposes of commissioning or in
the event of errors arising. This makes it possible to test robot programs even if the
connected peripheral equipment is not (yet) operational. This function can only be configured
at Expert level.
The designation SIM identifies simulated

outputs which may be either set or not set.
The designation SYS identifies outputs

whose value are saved in a system
variable.
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Monitor (continued)
Further information...
...on simulation of inputs and outputs can be found in the Programming Handbook in the
documentation [Configuration], chapter [Configuring the system, Expert], section
[Simulated inputs/outputs].
...on the subject of system variables can be found in the Programming Handbook in the
documentation [Expert Programming], chapter [Variables and declarations], section
[System variables and declarations].
7.1.3
Analog inputs/outputs
After this option has been selected a status window is opened, displaying the values of the
32 analog inputs.
The input values (ranging from --10 V to
+10 V) and their long texts are displayed in
the boxes. The values of these inputs cannot
be changed.
Tab +
You can open the status window for displaying the 32 outputs using this
softkey.
The output values (ranging from --10 V to
+10 V) and their long texts are displayed in
the boxes.
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Tab +
You can return to the status window for displaying the 32

inputs by pressing the softkey Tab+ again.
If the name of an input or output or the value of an output is selected using

the arrow keys, it can be edited by pressing the Enter key.
Enter the new value by means
of the keyboard or numeric
keypad.
Accept the modified value by pressing the Enter key again.
ESC
Pressing ESC rejects the change and closes the status

window.
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7.1.4
Monitor (continued)
Automatic External
When this option has been selected, a status window is opened, displaying the signal states
of the Automatic External interface.
7.1.4.1
Inputs
Status gray: No signal present at this input

(FALSE)
Status red:
(TRUE)
Signal present at this input
The input in question
Configure
Outputs
Details
Switches to the configuration page of the Automatic External interface.

The softkey Outputs takes you to the corresponding status window.
The softkey Details changes to a different status window displaying more
information: the type, the name of the variable and the channel number or
value.
The type can be a variable (yellow) or an input (green).
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Operator Control
The variable or system variable ($...) or the name of the
input.
The value of the input or the channel number.
Normal
Close
7.1.4.2
Normal switches back to the original display.

The status window is closed by means of the softkey Close.
Outputs
Start conditions
This page contains all the status information relevant to the start.
Status gray: No signal present at this output (FALSE)

Status red:
(TRUE)
Signal present at this output

The output in question
Configure
Inputs
Switches to the configuration page of the Automatic External interface.

You can open the status window for displaying the inputs with the aid of the
softkey Inputs.
Tab --
Scrolls back to the previous outputs page.
Tab +
Scrolls to the next outputs page.
Details
The softkey Details changes to a different status window displaying more

information: the type, the name of the variable and the relevant input.
Output (green).
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Monitor (continued)
The variable or system variable ($...).

The value of the output being used.
Normal
Close
Normal switches back to the original display.

The status window is closed by means of the softkey Close.
Program status
This page contains all the variables that are relevant to the program state.
Robot position
Here you will find a list of robot positions including, for example, the various HOME positions.
Operating mode
The operating mode currently active is displayed on the last page.
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Operator Control
7.2
Rob. Position
The menu item Rob. Position offers various display modes for the robot position.
Monitor
Cartesian
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
Axis spec.
Cartesian
Axis specific
Incremental
Master/Slave
Increment
Mas./Slave
You can switch between the different coordinate specifications at any time by pressing the
softkeys Cartesian, Axis spec., Increment and Mas./Slave.
Close
The status window display is terminated using the softkey Close.
If one of these status windows remains open, you can constantly monitor the position of
the robot while it is in motion.
7.2.1
Cartesian
This status window displays the current position of the robot in Cartesian mode.
Cartesian display
With this display mode, the position of the tool center
point (TCP) is displayed in relation to the WORLD
coordinate system in the base of the robot and the
rotational offset between the two coordinate systems.
The entries for Status and Turn are also displayed.
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7.2.2
Monitor (continued)
Axis--specific
This status window displays the current position of the robot in joint (axis--specific) mode.
Axis--specific display
The rotational offset of each robot axis is displayed
here in relation to its zero position determined during
mastering.
7.2.3
Incremental
This status window displays the current position of the robot in increments.
Incremental display
Values for the increments delivered by the axis
drives are displayed here.
7.2.4
Master/Slave
Master/slave display
The angular momentum of the master/slave

drives is shown in this status window.
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The softkey Mas./Slave and the associated status window are only displayed if the
corresponding options are installed.
7.3
Variable
The menu items Variable -- Single and Overview are available in conjunction with the
variable overview (variable correction display).
Monitor
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
Single
Overview
Cyclic Flags
Flags
Counter
Timer
Display
Configure
Edit CONFIGMON.INI
*1
*1
*1: Not available in the user group User
7.3.1
Single
After this option has been selected a status window is opened, in which the values of the
variables are displayed and can be altered.
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7
Name
Monitor (continued)
To change the value of a variable, first press the softkey Name to position
the cursor in the corresponding input box. Then enter the desired name and
press the Enter key.
As long as the cursor remains in
the box Name, the arrow keys
and can be used to scroll
through the list of variables being
edited and/or displayed.
The value the variable had when

you pressed the Enter key is
displayed in the box Actual
Value.
New Value
Now press the softkey New Value to position the cursor in the corresponding
input box. Enter the new value for the variable and confirm this by pressing
the Enter key.
As long as the cursor remains in

the box New Value, the arrow
keys and can be used to
scroll through the list of values
that have been entered.
Once your entry has been accepted by the controller, the new value is
displayed in the box Current value. If this is not the case, please check the
messages in the message window.
In the basic setting, the search for the specified variable begins in the program
currently selected. If it is not found here, all global data lists are searched.
Module
If you wish to search for the variable in a program other than the one currently
selected, you need to press the softkey Module. The input box of the same
name is opened. Enter the file path here for the program you wish to search.
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Operator Control
7.3.2
Overview
7.3.2.1
Display
After this option has been selected a status window is opened.
The groups of variables entered in
the file CONFIGMON.INI are displayed
here.
The box Status indicates whether or not the line is updated automatically.
This symbol is displayed if the display is updated automatically.
The name of the input or output is displayed in the box Name.
If the box Variable exists, the name of the corresponding system variable
is displayed.
Value gray:
No signal present at the input or output (FALSE)
Value red:
Signal present at the input or output (TRUE)
The arrow keys can be used to select a specific element in the group and
make certain modifications. This is done by pressing the softkey Change.
It is possible to see from the tabs at the bottom of the status window whether
or not further display groups are available.
Configure
The softkey Configure, which is not available in the user group User,
enables the configuration of individual groups.
Tab +
If there is at least one other group available, you can toggle to this page using
the softkey Tab+.
Refresh all
The softkey Update all is used to update the display.
The softkey Info start. activates the automatic updating of the selected
element. Cancel Info. can be used to deactivate the continuous automatic
Cancel Info updating function.
Start info
Edit
OK
Cancel
Close
Elements selected using the arrow keys can be modified by pressing the
softkey Edit. This applies to the names of inputs/outputs and the setting of
outputs to TRUE or FALSE.
The softkey OK is used to accept the changes that have been made.
The softkey Cancel is used to reject the changes.
Pressing Close saves the current changes in the file CONFIGMON.INI and
closes the status window.
The values of write--protected variables cannot be changed.

122 of 163
7.3.2.2
Monitor (continued)
Configuration
This menu item is not available in the user group User.
Information on this command can be found in the Programming Handbook in the main
chapter [Configuration], chapter [Configuring the system, Expert].
7.3.2.3
Edit CONFIGMON.INI
This menu item is also not available in the user group User.
Information on this command can be found in the Programming Handbook in the main
chapter [Configuration], chapter [Configuring the system, Expert].
7.3.3
Cyclic Flags (Notice)

After this option has been selected a status window is opened, displaying the signal states
of the 32 cyclical flags, also called Merker.
Gray: The cyclical flag is not set.

Red: The cyclical flag is set.
The number of the cyclical flag in
question is displayed in the box No.
A description of the cyclical flag is
displayed in the box Name.
The text stored for this cyclical flag is
displayed in the lower section of the
window.
Name
The name of the cyclical flag selected using the arrow keys can be modified
by pressing the softkey Name; up to 40 characters are permitted here.
OK
Cancel
The softkey OK is used to accept the changes that have

been made.
More detailed information on the use and programming of cyclical flags can be found in the
Programming Handbook, in the main chapter [Expert Programming].
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Operator Control
7.3.4
Flags
After this option has been selected a status window is opened, displaying the states of all
999 flags.
Gray: The flag is not set.
Red: The flag is set.
The number of the flag in question is
displayed in the box No.
The name of the flag is displayed in the box
Name.
Value
You can switch the flag on which the focus is located by pressing the softkey
Value.
Name
The name of the flag selected using the arrow keys can be modified by
pressing the softkey Name, up to 40 characters are permitted here.
OK
Cancel

been made.
More detailed information on the use and programming of flags can be found in the
Programming Handbook, in the main chapter [Expert Programming].
7.3.5
Counter
After this option has been selected a status
window is opened, displaying the values of
the counters already configured.
Value
After pressing the softkey Value, you can enter a new value for the selected
counter using the numeric keypad.
OK
Cancel
Name

been made.
The name of the counter can be modified using the softkey Name. The
name may consist of a maximum of 40 characters.
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7
OK
Cancel
Monitor (continued)

been made.
If you close the status window without having pressed the softkey OK beforehand, the
changes will not be saved.
More detailed information on the use and programming of counters can be found in the
Programming Handbook, in the main chapter [Expert Programming], in the chapter
[Variables and declarations], section [Boxes].
7.3.6
Timer
After this option has been selected a status window is opened, displaying the values and
operating states of all 10 timers.
Red: This timer is deactivated and set
to a value 0.
Red with check: This timer is deactivated and set to a value > 0.
Green: This timer is activated and
running in the range 0.
Green with check: This timer is activated and running in the range > 0.
Start/Stop
Value
This softkey starts the selected timer or stops one that is running.
After pressing this softkey, you can enter a new value for the selected timer
using the numeric keypad.
OK
Cancel
Name

been made.
The name of the timer can be modified using the softkey Name. The name
may consist of a maximum of 40 characters.
OK
Cancel

been made.
If you close the status window without having pressed the softkey OK beforehand, the
changes will not be saved.
More detailed information on the use and programming of timers can be found in the
Programming Handbook, in the main chapter [Expert Programming], in the chapter
[Variables and declarations].
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Operator Control
7.4
Diagnosis
A description of these functions may be found in the Electrical Servicing handbook.
7.5
Windows
Monitor
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
NAVIGATOR
PROGRAM
EDITOR
When Navigator, Program or Editor is selected, the corresponding window will be brought
to the foreground. If no program is selected, or nothing is present in the editor, these items
will be shown as inactive in the upper menu.
7.6
Hardware Info
Monitor
I/O
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
The operator can use the command Hardware Info to obtain further information about the
individual components of the robot system.
Refresh
Refreshes the display.
Export
Outputs the hardware information as an XML file.
Close
Exits the Hardware Info display.
The following hardware components can be displayed:

126 of 163
7
Cabinet
Monitor (continued)
Robot
PC
1st RDC/1st PM
MFC
2nd RDC/2nd PM
1st DSE
2nd DSE
1st KPS
1st KSD
...
8th KSD
2nd KPS
1st KSD
...
8th KSD
7.7
Help
Help
Online help
Online help -- Contents/Index
Info
The function of the window selection key is disabled while the online help is displayed.
If an external keyboard is connected, you can also call the online help function by pressing
function key F1.
7.7.1
Online help
Online help is available for individual elements of the user interface. These include
messages, logbook entries, inline forms and the error display.
If the window containing the desired element is not active, this
window must be selected using the window selection key. The
element in question is then selected using the arrow keys.
Help
Online help
Info
When the online help function is called, additional

information about the selected element is
displayed.
If the contents of the help window do not all fit in the window,
you can use the arrow keys to move the information or page
through it.
Close
Press the softkey Close to end the online help function and return
to normal operation.
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Operator Control
Message window
Once the desired message has been selected and the online help function has been called,
the corresponding window is opened.
Log book
Once the desired logbook entry has been
selected and the online help function has been
called, the corresponding window is opened.
128 of 163
Monitor (continued)
Inline forms
Once the desired inline form has been
selected and the online help function has been
called, the corresponding window is opened.
Error display
Once the desired error message has
been selected and the online help
function has been called, the corresponding window is opened.
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Operator Control
7.7.2

Here you can make targeted searches for information in the table of contents or index of the
online help function. In the index, all information is listed in alphabetical order.
Help
Online help
Info
After this option has been selected the corresponding window appears on the user interface.
The left--hand side of the window shows a list of contents or the index, while the right--hand
side displays the corresponding help messages. The following navigation options are
available:
The arrow keys " and # can be used to select a subject, or to page through
the help messages.
The arrow keys ! and z or the Enter key can be used to open or close a
subdirectory.
Once you have selected a subject, press the Enter key to display the
corresponding help page.
130 of 163
<---->
Index
Monitor (continued)
Use this softkey to switch between Contents/Index and the corresponding

help page. You can then use the arrow keys to page through the subjects
and/or help messages.
Pressing the softkey Index brings you to the overall index of the online help
function. Typing one or more letters in the input line will cause the list to be
scrolled forward immediately to the appropriate location.
To avoid having to type in the entire term, you can use the arrow
keys to scroll the focus up or down a line at a time.
Once you have found the desired term, press the Enter key or the
Monitor button. The help page will then appear on the right--hand
side of the display.
Contents
Close
Pressing the softkey Contents takes you to the table of contents which is
displayed by default when the online help function is started.
Press the softkey Close to end the online help function and return to normal
operation.
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Operator Control
7.7.3
Info
Help
Online help
Info
This command displays the following

version information:
Controller type
General version number
GUI version
Kernel system version

User text
Manufacturer
Tab +
The softkey Tab+ opens the Robot page.
Robot name
Robot type and configuration
List of external axes

showing axis number and
name (if available)
Machine data version
Tab +
Displays the System page.
132 of 163
Monitor (continued)
Computer name
System version information
Memory information
Tab +
Pressing this softkey again opens the page listing additionally installed
options, such as MeasureTech and LaserCut.
Tab +
Additional comments are displayed in the next page.
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Operator Control
Space for additional comments
Tab +
Switches to the next page, Modules.
Versions of the modules

present
Tab +
Save
The last page, Virus scanner, provides additional information about the Ikarus virus scanner.
The softkey Save allows you to save the module information in the text
fileC:\KRC\ROBOTER\LOG\OCXVER.TXT.
134 of 163
Monitor (continued)
Tab +
Switches to the first page, Info.
Export
The softkey Export allows you to send the information to a text file. By default, this file is C:\KRC\ROBOTER\LOG\VIRUSINFO.XML.
Close
The Info display is closed by pressing the softkey Close.
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Operator Control
Menu structure
The menus provided by the KUKA System Software can be opened by pressing the
corresponding menu key.
Menu bar
Menu key
The following commands are available in the menu bar:

File
Program
Configure
Monitor
Setup
Commands Technology
Help
Menu key
Options
File
File operations and display
8.1
Program
Commands relating to program creation and editing
8.2
Configure
Inputs/outputs and system settings
8.3
Monitor
Monitor functions for inputs/outputs, position, counters,

variables, etc.
8.4
Setup 1)
Mastering, calibration and service functions
8.5
Commands 2)
Motion and logic commands
8.6
Technology 2)
Technology commands
8.7
Help
Version information and online help
8.8
1)
2)
Section
No program may have been selected or loaded into the editor

This function is only available within a program
Whether or not specific submenus and commands can be accessed depends on the user
group that is being used.
136 of 163
8.1
Menu structure (continued)
File
User group Expert
New
Open
File/Folder
Data list
Error list
Print
Current selection
Log book
Archive
All
Applications
Machine data
Configure
Log Data
Current selection
Restore
Rename
Format floppy disk
All
Applications
Machine data
Configure
Current selection
Drivers
I/O Longtexts
KUKA TechPack
Drivers
I/O Longtexts
KUKA TechPack
Attributes
Filter
User group User

New
Open
File/Folder
Data list
Error list
Print
Current selection
Log book
Archive
All
Applications
Machine data
Configure
Log Data
Current selection
Restore
Rename
Format floppy disk
All
Applications
Machine data
Configure
Current selection
Drivers
I/O Longtexts
KUKA TechPack
Drivers
I/O Longtexts
KUKA TechPack
Attributes
Filter
137 of 163
Operator Control
New
Creation of new files and subdirectories1)

1)
MC [Operator control],
Ch. [Navigator]
Open
File/Folder
Data list
Error list
File/Folder
Opens the selected directory.
Ch. [Navigator]
Loads the source file of a selected module (*.SRC) into the
editor.
Data list 1)
Opens the data list (*.DAT) of a selected file in the editor.
Error list
Opens a list of errors that have been detected in the selected
file.
1)
Print
Current selection
Log book
Current selection
The selected files are printed
Ch. [Navigator]
[
g
]
Log book
The logbook entries are printed.
Archive
All
Applications
Machine data
Configure
Log Data
Current selection
Drivers
I/O Longtexts
KUKA TechPack
All
All files are saved to floppy (Ini, MaDa, etc.)
Ch. [Navigator]
[
g
]
Applications
Saves the applications (*.SRC and *.DAT) to floppy.
Machine data
Only saves the machine data to floppy.
138 of 163
Configure 1)
Drivers
Saves the drivers to floppy.
I/O Longtexts
Saves the long text database.
KUKA TechPack
Saves certain registry entries to floppy.
Ch. [Navigator]
Log Data
Saves the logbook files to floppy disk.
Current selection
Saves selected files and directories to floppy.
1)
Restore
All
Applications
Machine data
Configure
Current selection
Drivers
I/O Longtexts
KUKA TechPack
All
All files, with the exception of log files, are loaded from the Ch. [Navigator]
floppy disk (Ini, MaDa, etc.).
Applications
The saved applications are loaded back from the floppy disk
onto the hard disk (*.SRC, *.DAT).
Machine data
Only machine data are loaded from the floppy disk to the
controller.
Configure 1)
Drivers
Only the I/O drivers are loaded from the floppy disk.
I/O Longtexts
The I/O list is loaded from the floppy disk.
KUKA TechPack
Restores certain registry entries.
Current selection
Selected files are loaded back onto the hard disk.
1)
Rename
The name of the selected file can be altered.
Ch. [Navigator]
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Operator Control
Format floppy disk
The floppy disk in the disk drive is formatted.
Attributes
Ch. [Navigator]
2)
Details about type, path, size, creation, attributes, edit mode and MC [Operator control],
comment for the selected file.
Ch. [Navigator]
2)
Not available for program editing
Filter
1) 2)
Display variants for file components.

1)
2)
Ch. [Navigator]

Not available for program editing.
140 of 163
8.2
Program/Edit
The Program/Edit menu appears differently at the Navigator, Programming and Editor
levels.
8.2.1
The Edit menu in Navigator

User group Expert
User group User
Select all
Select all
Copy
Copy
Paste
Paste
Cut
Cut
Delete
Delete
Duplicate
Duplicate
Select
Without parameters
With parameters
Select
Cancel program
Cancel program
Reset program
Reset program
Without parameters
With parameters
Select all
All files in the selected folder are highlighted
Copy
1)
Selected files are copied to the clipboard

1)
Ch. [Navigator]
Paste
2)
Files from the clipboard are inserted at the current position

2)
Ch. [Navigator]
Ch. [Navigator]
Only available if a file or directory has been copied or cut.
141 of 163
Operator Control
Cut
The selected files are deleted from their original position and MC [Operator control],
copied to the clipboard
Ch. [Navigator]
Delete
All selected files are permanently deleted after a request for MC [Operator control],
confirmation
Ch. [Navigator]
Duplicate
The selected file is copied into the current directory under a MC [Operator control],
different name
Ch. [Navigator]
Select
Without parameters
With parameters
Without parameters
The program is selected without function parameters.
Ch. [Navigator]
[
g
]
With parameters
The function parameters are transferred when the program is
selected.
Cancel program
3)
The selected program is closed

3)
Only available if a program has been selected
Reset program
3)
The initial state of the program after loading is restored.

3)
Ch. [Navigator]
Ch. [Navigator]
142 of 163
8.2.2
The Program menu at programming level

User group Expert
User group User
FOLD

All FOLDs open
All FOLDs close
Copy
FOLD
Copy
Paste
Paste
Cut
Cut
Delete
Delete
Find
Find
Replace
Replace
Cancel program
Cancel program
Reset program
Reset program
Point
Modify
FOLD
1)
Modify
All FOLDs open

All FOLDs in the selected program are opened.
All FOLDs close
All FOLDs in the selected program are closed.
1) 2)
Selected lines are copied to the clipboard.
Ch. [Navigator]

Not available if a program is selected.
Paste
1) 2)
Data from the clipboard are inserted at the current position

1)
2)
HB Programming
Handbook
MC
Expert Programming
Ch.
[General information
on KRL programs]
Copy
1)
2)
Point

All FOLDs open
All FOLDs close

The FOLD in the current program line is opened or closed.
1)
Current FOLD op./cl.

All FOLDs open
All FOLDs close
Ch. [Navigator]

143 of 163
Operator Control
2)
Cut
The selected data are deleted from their original position and MC [Operator control],
copied to the clipboard
Ch. [Navigator]
2)
Delete
After a request for confirmation, the line in which the edit cursor MC User Programming
is situated is deleted.
Ch. [Program editing]
Find
It is possible to search the current program for a search string MC User Programming
Replace
1)
This function allows you to search for one search string and MC User Programming
replace it with another
1)
3)
Cancel program
The selected program is closed

3)
3)
Reset program
The initial state of the program after loading is restored.

3)
MC User Programming
MC User Programming
1)
Modify
Point
Point
HB Programming HandVarious online modification options for programs and motion book
commands.
MC
Expert Programming
Ch. [External editor]
1)
144 of 163
8.2.3
The Program menu in the editor

User group Expert
FOLD
User group User

All FOLDs open
All FOLDs close
Copy
FOLD
Copy
Paste
Paste
Cut
Cut
Delete
Delete
Find
Find
Replace
Replace
Close
Close
FOLD
1)

All FOLDs open
All FOLDs close

The FOLD in the current program line is opened or closed.
All FOLDs open
Opens all FOLDs of the program loaded in the editor.
All FOLDs close
All FOLDs in the program loaded in the editor are closed.
1)
Current FOLD op./cl.

All FOLDs open
All FOLDs close
HB Programming
Handbook
MC
Expert Programming
Ch.
on KRL programs]
Copy
1)
The program line selected via the edit cursor is copied to the clip- HB Programming Handboard.
book
MC
Expert Programming
Ch.
on KRL programs]
1)
Paste
1)
Data from the clipboard are inserted at the current position.
1)
HB Programming Handbook
MC
Expert Programming
Ch.
on KRL programs]
145 of 163
Operator Control
1)
Cut
The program lines selected by means of the edit cursor are HB Programming Handdeleted from their original position and copied to the clipboard. book
MC
Expert Programming
Ch.
on KRL programs]
1)
Delete
After a request for confirmation, the line in which the edit cursor MC User Programming
is situated is deleted.
Find
Search the current program for a specified search string.
Replace
1)
Search and replace program sections in the editor.
1)
MC User Programming
MC
Expert Programming
Ch.
on KRL programs]
Close
The editor is closed.
MC User Programming
146 of 163
8.3
Configure
I/O
I/O Driver
SUBMIT Interpreter
Status keys
User group Expert
Automatic External
Start / select
Stop
Cancel
Jogging
Program OV Steps on/off

Jog OV Steps on/off
User group
Mouse position
Mouse configuration
Edit I/O Config

I/O Driver Reset
Reconfigure I/O Driver
I/O State
Serial Communication
Serial Logging
Serial Reset
Cur. tool/base
Tool definition
Tool type
Base type
Force cold start
On/Off options
Miscellaneous
Language
Change password
Editor
Office option
DEF--line
ASCII Mode
Line breaks
Mon. working envelope
Reinitialization
Event planner
I/O
Status keys
Jogging
User group
Start / select
Stop
Cancel
Override
Configure
User group User
Automatic External
I/O Driver
SUBMIT Interpreter
BOF Reinitialization
Edit I/O Config

I/O Driver Reset
I/O State
Serial Logging
Serial Reset

Jog OV Steps on/off
Mouse position
Mouse configuration
Cur. tool/base
Tool definition
Tool type
Base type
Force cold start
On/Off options
Miscellaneous
Language
Change password
Editor
Office option
DEF--line
ASCII Mode
Line breaks
Reinitialization
Event planner
Override
Configure
147 of 163
Operator Control
I/O
Automatic External
Automatic External
Settings for the Automatic External interface
I/O Driver
Edit I/O Config

I/O Driver Reset
I/O State
HB Programming
Handbook
MC Configuration
Ch. [Configuring the
system]
Serial Logging
Serial Reset
Edit I/O configuration 1)

Opens the file IOSYS.INI
I/O Driver Reset
Resets the peripheral interfaces.
Reconfigure I/O Driver 1)
The inputs/outputs are reconfigured.
MC Configuration
C fi
ti
system]
I/O State
The current state of the I/O system is displayed in a log file.
Serial Communication 1)
Serial Logging
The serial communication is recorded in a log file.
Serial Reset
The serial channels are reset.
1)
SUBMIT Interpreter
Start / select
Stop
Cancel
Start / select
Start/select Submit interpreter
Stop
Stop Submit interpreter
Cancel
Deselect Submit interpreter
MC Configuration
C fi
ti
system]
Status keys
Status keys for optional technology packages
Relevant technology
148 of 163
8
Jogging

Jog OV Steps on/off
Mouse position
Mouse configuration
Program OV Steps
Switches program override on/off
Jog OV Steps
Switches manual (jog) override on/off
Mouse position
Definition of the spatial relationship between the 6D mouse
and the robot.
MC Configuration
C fi
ti
system]
Mouse configuration
Axis selection and dominant mode
User group
Access to defined user groups
MC Configuration
system]
Cur. tool/base
Selection of the desired tool, base or kinematic system.
Tool definition
MC Configuration
system]
Tool type
Base type
Tool type
Display saved calibration data for the tool type
Base type
Display saved calibration data for the base type.
MC Configuration
system]
149 of 163
Operator Control
On/Off Options
Force cold start

Force cold start

HB Programming HandThe next time the controller is run--up, a complete restart book
without selection of any programs will be forced.
MC Configuration
Ch [Configuring the
Ch.
1)
system]
Delay before the system can be rebooted.
1)
Miscellaneous
Language
Change password
Editor
Office option
Def--line
ASCII Mode
Line breaks
Reinitialization
Event planner
Language
Changes the language used in the graphical user interface.
Change password
Change the password for a user group
Editor 1)
Def--line
Displays the DEF lines in a program.
ASCII Mode
The program is displayed in KRL code.
Linebreak
Activates/deactivates line breaks in the program window.
Override
Configure
MC Configuration
C fi
ti
system]
Office option
Additional operator control elements on the GUI for mouse
operation.
Work envelope monitoring 1)
Override
Overrides the monitoring of the work envelope.
Configure
Definition of the workspaces
Reinitialization 1)
The GUI (graphical user interface) is reinitialized without
rebooting the system.
Cycle Time Optimizer 1)
HB Programming HandAdaptation of the maximum possible acceleration to various book
MC Configuration
different technology packages.
Ch [Configuring the
Ch.
2)
system]
Selection and setting of the modules used by KSS.
150 of 163
Event planner
HB Programming HandCarries out an action at a predefined time or when a specified book
event occurs.
MC Configuration
system]
1)
2)
8.4

Not available in the user groups User or Expert.
Monitor
I/O
Digital Inputs
Digital Outputs
Analog I/O
Automatic external
Rob. Position
Variable
Diagnosis
Windows
Hardware Info
I/O
Single
Overview
Cyclic Flags
Flags
Counter
Timer
Oscilloscope
Log book
CROSS Log book
Caller Stack
Interrupts
Securitycircuit
Web Diagnosis
Diagnosis
Windows
Hardware Info
Cartesian
Axis specific
Incremental
Master/Slave
Display
Configure
Edit ConfigMon.ini
Display
Configure
Display
Configure
NAVIGATOR
PROGRAM
EDITOR
Digital Inputs
Digital Outputs
Analog I/O
Automatic external
Rob. Position
Variable
User group Expert
Single
Overview
Cyclic Flags
Flags
Counter
Timer
Oscilloscope
Log book
CROSS Log book
Caller Stack
Interrupts
Securitycircuit
Web Diagnosis
User group User

Cartesian
Axis specific
Incremental
Master/Slave
Display
Configure
Edit ConfigMon.ini
Display
Configure
Display
Configure
NAVIGATOR
PROGRAM
EDITOR
151 of 163
Operator Control
I/O
Digital Inputs
Digital Outputs
Analog I/O
Automatic external
Digital Inputs
Assignment of the digital inputs
Ch. [Monitor]
[
]
Digital Outputs
Assignment of the digital outputs
Analog I/O
State of the analog inputs/outputs
Automatic external
Assignment of the Automatic External interface
Rob. Position
Cartesian
Axis specific
Incremental
Master/Slave
Cartesian
Current position of the TCP with respect to the world coordinate Ch. [Monitor]
system with the components Position, Orientation, Status
and Turn of the standard axes and the configured external
axes.
Axis specific
Current, axis--specific position of the standard axes and the
configured external axes
Incremental
Current position of the robot axes in increments
Master/Slave
Current position of the master and slave axes in increments
Variable
Single
Overview
Cyclical flags
Flags
Counter
Timer
Monitor
Configure
Edit CONFIGMON.INI
Single
Display and modification of individual variable values.
Ch. [Monitor]
Overview
Display
Displays the groups of variables in ConfigMon.ini.
Configure *1
Settings for the variable group Monitor.
Edit ConfigMon.ini *1
Editing the file ConfigMon.ini
Ch. [Monitor]
HB Programming
Handbook
MC [Configuring the
system, Expert]
152 of 163
Cyclic Flags (Notice)

Signal states of the Merker (notices)
Ch. [Monitor]
[
]
Flags
Signal states of the flags
Counter
Display of the counter values
Timer
Values and operating states of the timers
*1
Diagnosis
Oscilloscope
Log book
CROSS Log book
Caller Stack
Interrupts
Securitycircuit
Web Diagnosis
Display
Configure
Display
Configure
Oscilloscope
Display
View and analyze saved traces.
Configure
Setting of the oscilloscope functions
HB
Electrical Servicing
Log book
Display
Displays logged operator actions
Configure
Configuration of the logbook function
CROSS Log book 1)
Log program KUKA--CROSS
Caller Stack 1)
Displays the order in which programs and subprograms are
called.
Interrupts1)
List of the interrupts.
Securitycircuit
Displays the safety circuit of the robot.
Web Diagnosis
Starts the internal Web browser which can be used to display
predefined pages.
*1
153 of 163
Operator Control
Windows
NAVIGATOR
PROGRAM
EDITOR
NAVIGATOR
Displays the Navigator in the user interface
PROGRAM 2)
Switches the user interface to the selected program
EDITOR 3)
Displays the program that is loaded in the editor
2)
3)
Ch. [Monitor]
Only available if a program has been selected.

Only if there is a program in the editor.
Hardware Info
Displays information about the control cabinet and robot and MC [Operator control],
their components.
Ch. [Monitor]
154 of 163
8.5
Setup
User group Expert
Measure
Master
Tool
Base
Fixed tool
Supplementary load data
External kinematic
Measurement Points
Tolerances
Dial
EMT
UnMaster
Software Update
Automatic
Service
DSE--RDW
Load data determination
External Editor
Axisconfigurator
Long text
Robot Data
X Y Z -- 4--Point
X Y Z -- Reference
A B C --2--Point
A B C -- World
Numeric Input
Payload data
3--Point
Indirect
Numeric Input
Root point
Root point (numeric)
Offset
Offset (numeric)
Workpiece
Tool
Offset external kinematic
Numeric Input
Tool type
Base type
External Axis
Direct measuring
Indirect measuring
Standard
With load corr.
Set mastering
Check mastering
First mastering
Teach offset
Master load
With offset
Without offset
155 of 163
Operator Control
User group User
Measure
Master
Tool
Base
Fixed tool
External kinematic
Measurement Points
Tolerances
Dial
EMT
UnMaster
Software Update
Automatic
Service
DSE--RDW
External Editor
Axisconfigurator
Long text
Robot Data
X Y Z -- 4--Point
X Y Z -- Reference
A B C --2--Point
A B C -- World
Numeric Input
Payload data
3--Point
Indirect
Numeric Input
Root point
Offset
Offset (numeric)
Workpiece
Tool
Numeric Input
Tool type
Base type
External Axis
Direct measuring
Indirect measuring
Standard
With load corr.
Set mastering
Check mastering
First mastering
Teach offset
Master load
With offset
Without offset
Only KR3...
Measure
Master
UnMaster
Software Update
Service
Robot Data
Robot mastering
Commutation
Alter factory mastering
Drives diagnosis
External Editor
Axisconfigurator
Long text
156 of 163
Measure
Tool
Base
Fixed tool
External kinematic
Measurement Points
Tolerances
X Y Z -- 4--Point
X Y Z -- Reference
A B C --2--Point
A B C -- World
Numeric Input
Payload data
3--Point
Indirect
Numeric Input
Root point
Offset
Offset (numeric)
Workpiece
Tool
Tool type
Base type
External Axis
Direct measuring
Indirect measuring

Numeric Input
Tool
MC [Start--up],
Calibration programs for position, orientation and structural Ch. [Calibration]
calculations for a tool mounted on the robot wrist.
X Y Z -- 4--Point
Moving the robot to a fixed reference point
X Y Z -- Reference
Moving the robot with a known reference tool to a reference
point
A B C -- 2--Point
Moving the robot to 2 points with orientation data
A B C -- World
Positioning perpendicular to the world coordinate system
Numeric Input
Entering the tool data
Tool load data
Entering the mass, center of mass and mass moment of
inertia
Base
Calibration programs to determine workpiece position and
orientation.
3--Point
Moving to the reference point of a workpiece
Indirect
Entering the inaccessible reference point of a workpiece
Numeric Input
Entering a reference point manually
Fixed tool
Calibration programs to define an external fixed tool.
Workpiece
Moving with a workpiece mounted on the robot flange
Direct measuring
Robot must be moved to TCP.
Indirect measuring
TCP is entered numerically.
Tool
Moving the robot to a fixed tool
157 of 163
Operator Control
Moving the robot to a fixed tool on an external machine
Numeric Input
Entering a fixed tool manually
MC [Start--up],
Ch. [Calibration]

Entry of data for a supplementary load on the robot
External Machine
MC [Start--up],
Ch. [Calibration -- Ex Root point
Moving the distance from the world coordinate system to the ternal kinematics]
external machine
Entering the distance from the world coordinate system to
the external kinematic system manually
Offset
Moving the distance from the external machine to the workpiece
Offset (numeric)
Entering the distance from the external machine to the workpiece manually
Measurement Points
Tool type
Display saved calibration data for the tool type
Base type
Display saved calibration data for the base type
External Axis
Display saved calibration data for the external machine
MC [Start--up],
Ch. [Calibration]
Tolerances 1)
Entry of tolerance limits for tool calibration
1)
Master
Dial
EMT
Standard
With load corr.
Set mastering
Check mastering
First mastering
Teach offset
Master load
Master
Robot mastering
Commutation
Alter factory mastering
With offset
Without offset
158 of 163
Dial
Mastering with a mechanical dial gauge
MC [Start--up],
Ch. [Robot mastering/
unmastering]
EMT
MC [Start--up],
Mastering with the electronic measuring tool
unmastering]
Standard
Set mastering
The robot is mastered in the mechanical zero position with
or without a payload.
Check mastering
Checks the mastering
With load correction
First mastering
The robot is mastered in the mechanical zero position with
or without a payload
Teach offset
The robot is mastered with a payload and the encoder
offset relative to the first mastering is calculated for this
payload
Master load
With offset
This function is used to check the mastering of a payload
mounted on the robot, that has previously been
mastered with Teach offset.
Without offset
Mastering of the robot with any load; the difference from
the first mastering is calculated
Robot mastering *1
Robot mastering following successful first mastering.
Commutation *1
Synchronization between the motor and the encoder.
Alter factory mastering *1
First mastering of the KR 3...
*1
This selection is only available for the robot type KR3....
UnMaster
Unmastering of selected axes
Software Update
MC [Start--up],
unmastering]
Automatic
Automatic
Load new version of program from CD--ROM
MC [Start--up],
Ch. [Software Update]
159 of 163
Operator Control
Service
DSE--RDW
External editor
Axisconfigurator
Long text
DSE -- RDW
HB
Displays for the Digital Servo Electronics and Resolver-- Electrical Servicing
Digital Converter
Determination of the load data
See additional package

[Load data determination]
External Editor 1)
HB Programming HandExternal program for editing application programs at GUI and book
MC Expert ProgramKRL levels.
ming
Ch. [External editor]
Axisconfigurator *1
Setting up of external axes
See documentation
[External Axes]
Long text *1
Names of inputs/outputs
MC Configuration
system]
*1
Robot Data
Change the robot name and display additional information about MC Start--up
the robot.
Ch. [Robot data]
160 of 163
8.6
Commands
User groups Expert and User
Last Cmd
Motion
PTP
LIN
CIRC
Moveparams
Torquemon.
Logic
WAIT
WAITFOR
OUT
IBUS Segment on/off
Analog output
Static
Dynamic
Comment
Normal
Stamp
OUT
PULSE
SYN OUT
SYN PULSE
Last Cmd
Repeats the last command executed
Motion
MC
[User Programming],
Ch.
[Program commands]
PTP
LIN
CIRC
PTP
Point--to--point motion command
LIN
Linear motion command
CIRC
Circular motion command
Moveparams
Torquemon.
Collision monitoring call
MC
[User Programming],
Ch.
[Program commands]
Torquemon.
MC
[User Programming]
Ch.
[Program commands]
161 of 163
Operator Control
Logic
WAIT
WAITFOR
OUT
IBUS Segment on/off
OUT
PULSE
SYN OUT
SYN PULSE
WAIT
Time--dependent wait function
WAITFOR
Signal--dependent wait function
MC
[[User Programming]
g
g]
Ch
Ch.
[Program commands]
OUT
OUT
Simple switching function
PULSE
Simple pulse function
SYN OUT
Path--dependent switching function
SYN PULSE
Path--dependent pulse function
IBUS Segment on/off
Coupling and decoupling an Interbus segment
Analog output
Static
Dynamic
Static
MC
Setting of analog outputs under program control to a fixed [User Programming]
value
Ch.
[P og a commands]
[Program
co
a ds]
Dynamic
Setting of analog outputs under program control to a fixed
value that is dependent on the velocity or the specific
technology package
Comment
Normal
Stamp
Normal
Inserts a comment line into a program
Stamp
Comment line with the date and time in a program
8.7
MC User Programming
Ch.
[P
[Program
commands]
d ]
Technology
This menu is reserved for optional technology packages.
162 of 163
8.8
Help
User groups Expert and User
Online help
Contents/Index
Help
Online help
Starts context--specific online help for the topic currently MC [Operator control],
selected
Ch. [Monitor]
Complete index of the online help function
Ch. [Monitor]
Help
Provides version information

(GUI / kernel system / system data)
Ch. [Monitor]
NOTES:
163 of 163
Index
Numbers
Computer drives, 7
ConfigMon.ini, 122
3--Point, 157
Configure, 136, 147

Continuing a program, 106, 108
Contrast, 24
Control cabinet, 7
A B C -- World, 157
A B C --2--Point, 157
ALT key, 22
Alter factory mastering, 159
Analog outputs, 113, 152
archiving, 73
Arrow key, 21
Arrow keys, 19
ASCII Mode, 150
Attributes, 61, 80, 140
Attributes display, 53, 56
Aut, 31
Automatic External, 115, 148
Automatic program execution, 107
Axis--specific, 119, 152
Axisconfigurator, 160
Coordinate systems, 33, 41

Coordinate systems TOOL, BASE, WORLD,
50
Copy, 81
Counter, 153
Coupling and decoupling an IBUS segment,
162
Cross logbook, 153
CTRL key, 21
Current selection, 138
Current value, 121
Cut, 82
Cycle Time Optimizer, 150
Cyclical flags, 123, 153
B
Backward move, 98
Backwards key, 19
Base, 157
BASE coordinate system, 33, 41
Base type, 149, 158
BCO run, 102, 107
Block coincidence, 102
Block pointer, 26, 30, 92
BOF Reinitialization, 150
Braking ramp, 95
Brightness, 24
Data list, 66, 138

DEF--line, 150
Degrees of freedom of the Space Mouse, 45
DEL key, 21
Delete, 67, 82
Detail view, 55
Dial, 159
Digital Inputs, 152
Digital outputs, 152
Direction indicator, 93
Directory list, 53, 59
Directory structure, 53, 55
Disable PowerOff Delay, 150
C
Cabinet lock, 7
Caller Stack, 153
Cancel program, 109
Cartesian, 118, 152
CD--ROM drive, 7
Change password, 150
Check mastering, 159
CIRC, 161
Commands, 136, 161
Comment, 69, 83
Commutation, 159
Display, 136
Dominant axis, 47
Dominant axis activated, 48
Dominant axis not activated, 48
Drives, 54
Drives OFF, 16, 107
Drives ON, 16
DSE -- RDC, 160
Duplicate, 83
Dynamic, 162
Dynamic braking, 96
Index -- i
Index
G
Edit, 81
Edit cursor, 93
Edit I/O configuration, 148
Edit menu, 81
Edit mode, 140
Editor, 150
EMERGENCY STOP button, 15
EMT, 159
Enabling switch, 23
Enabling switches, 17
END key, 21
Enter key, 19, 83
Error diagnosis, 62
Error display, 62
Error list, 63, 138
ESC key, 18
Escape key, 18
Go, 98
Graphical user interface, 53
GUI, 24
Gun, 152
H
Header, 53, 55
Help, 127, 136, 163
HOME key, 21
I
I--Step, 98
I/O Driver Reset, 148
I/O State, 148
Icons, 54
Executing program lines, 103

Executing, stopping and resetting a program,
91
Expert level, 56
Ext, 31
External axes, 40
External axis, 158
External editor, 160
External kinematic systems, 40
External Machine, 158
Incremental, 119, 152

Incremental jogging, 51
Incremental Step, 98
Increments, 119
Indicator light, 151
Indirect, 157
Info, 132
Inline form, 28
Input mark, 93
Inputs/outputs, 110
INS key, 21
Interrupts, 153
File, 68, 136, 137, 138
File list, 53, 59
File manager, 53
File menu, 68
File name, 61
File operations, 136
Filter, 58, 80
First mastering, 159
Fixed tool, 157
Flags, 153
Floppy disk drive, 7
Folder, 138
Force cold start, 150
Form, 27
Format floppy disk, 79
Function parameters, 142
J
Jog keys, 40, 49
Jog mode, 31, 39, 40, 98
Jog OV Steps, 42, 149
Jog override, 42, 149
Jogging, 40
Jogging the robot, 39
Joint coordinate system, 33, 41, 49
K
KCP connection, 8
KCP, rear, 23
Keyboard, 21
Index -- ii
Index
O
Office option, 150
Offset external kinematic, 158
On/off switch, 9
Online help, 127, 130
Open, 66, 70
Operating mode, 31
Operator control elements, 15
Oscilloscope, 153
OUT, 162
Outputs, 111
Language, 150
LDEL key, 21
LIN, 161
Line breaks, 93, 150
Line/column, 94
Load correction, 159
Load data determination, 160
Log book, 138, 153
Log Data, 74
Long text, 160
Parameter, 57, 142

Parameter list, 27
Parameters, 84
Paste, 81
Path--maintaining braking in event of operator
safety violation, 97
Path--maintaining Emergency Stop, 95
PGDN key, 21
PGUP key, 21
PlugIn Configuration, 150
Point, 144
POV, 31
Power failure, 11
Print, 72
Program, 136
Program creation, 136
Program name, 94
Program OV Steps, 149
Program override, 31, 95, 149
Program pointer, 92
Program run mode, 98
Program start backwards, 98, 104
Program start backwards key, 19
Program start forwards key, 18, 23
Program stop key, 18
Program velocity, 95
Program window, 26, 92
Program/Edit, 141
PTP, 161
PULSE, 162
Main axes, 45
Main switch, 7
Manual mode, 31
Manual program execution, 98
Master load, 159
Master/Slave, 152
Master/slave display, 119
Maximum braking, 96
Measurement points, 158
Menu bar, 25, 136
Menu key, 136
Menu keys, 20
Menu structure, 136
Merker (notices), 123, 153
Message window, 27
Messages in the status bar, 30
Mode selector switch, 16, 39
Module, 121
Module info, 57
Modules, 55
Monitor, 86, 110, 136
Monitor menu, 86
Mouse configuration, 45, 47, 149
Mouse position, 43, 149
N
Name, 83, 121, 124
Navigator, 53
New, 58, 68
New Value, 121
NUM, 57
NUM key, 21
Numeric input, 157, 158
Numeric keypad, 20
R
Ramp--down braking, 95
Reactivation, 11
Reconfigure I/O Driver, 148
Index -- iii
Index
Reinit, 150
Release E--STOP, 15
Rename, 78
Reset, 9, 106, 108
Reset program, 106, 108
Restore, 75
Robot mastering, 159
Robot position, 118
Root point, 158
Running up the controller, 7, 9
Symbols in the program window, 92

SYN OUT, 162
SYN PULSE, 162
System time, 31
T
T1, 31, 39
T2, 31, 39
TAB key, 21
Teach offset, 159
Technology, 136, 162
Templates, 58
Timer, 153
Tolerances, 158
Tool, 157
TOOL coordinate system, 33, 41
Tool load data, 157
Tool type, 149, 158
S
Safety circuit, 153
Safety Instructions, 97
Select, 84, 91
Selecting and opening a program, 91
Selecting the kinematic system, 40
Selection list, 53, 58
Serial Communication, 148
Set mastering, 159
Setup, 136, 155
SHIFT key, 22
Short--circuit braking, 96
Shutting down the controller, 10
Signal states, 111, 112
Simultaneous motion, 33
Single Step, 98
Skeleton program, 70, 71
Softkey bar, 26
Softkeys, 20
Software limit switches, 39
Space Mouse, 17, 40, 43
Stamp, 162
START key, 18
Static, 162
Status bar, 30
Status key bars, 26
Status keys, 20
Status line, 16, 28, 53, 61, 94
Status window, 27, 40
STOP key, 18
Stop reactions, 95
Stopping program execution, 106, 107
Superposed motion, 48
Supplementary load data, 158
SYM key, 22
Symbol, 94
Symbols, 54
U
UNDO key, 21
User levels, 149
V
Variables, 121
W
WAIT, 162
WAITFOR, 162
Warning and safety instructions, 97
Web Diagnosis, 153
Window selection key, 18, 68
With offset, 159
Without offset, 159
Workpiece, 157
Workspace monitoring, 150
WORLD coordinate system, 33, 41
Wrist axes, 46
X
X axis, 36
X Y Z -- 4--Point, 157
X Y Z -- Reference, 157
Index -- iv

KR C2 KR C3 Operator Control

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KR C2 KR C3 Operator Control

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SOFTWARE

KUKA System Software (KSS)

Issued: 26 Sep 2003

KUKA Roboter GmbH

Running up / shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . .

Operator control elements on the KR C2 control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator control elements on the KR C3 control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running up the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller response when switched back on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery charge monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The KUKA Control Panel (KCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator control elements of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The rear of the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphical user interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joint coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WORLD coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BASE coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOL coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROBROOT coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jogging the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the jog mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the kinematic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jog override (jog velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving the robot with the Space Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving the robot with the jog keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphical user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Selecting and opening a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program velocity (Programm override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual program execution (jog mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running up / shutting down the controller

Running up / shutting down the controller

Operator control elements on the KR C2 control cabinet

Floppy disk drive

Operator control elements on the KR C3 control cabinet

The cable of the KCP (KUKA Control

The first LED shows whether or not

Running up / shutting down the controller (continued)

The entire robot system is switched on

This button is used to reset the computer

Running up the controller

Shutting down the controller

Running up / shutting down the controller (continued)

Controller response when switched back on

Warm start (default setting)

The menu command Force cold start is not

Force cold start

In Automatic Externalmode, the program CELL is automatically selected and executed.

Power failure with the system running

Power is restored before the PowerOff delay has elapsed

Power is still absent when the PowerOff delay has elapsed

If the battery back--up is not sufficient, in exceptional circumstances files could be

Power failure during a cold start

Power failure during a restart

Running up / shutting down the controller (continued)

Setting external power supply and user outputs

Battery charge monitoring

If this message is generated during normal operation, a short--circuit has occurred

Voltage below 22 volts

Voltage below 19 volts

These messages can have the following causes: