Industrial Robot Application-

MIG Welding
KUKA ArcTech Diagnosis &
Appendix

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Displaying the diagnostic data of the ArcLink XT driver

• The diagnostic data can also be displayed in WorkVisual

Name Description
Running: A connection has been established with the power source.
Driver state Waiting for Connection: A connection has not been established with
the power source.
IP address The IP address of the power source configured in WorkVisual.
1: Power source is ready.
Welding controller ready
0: Power source is not ready.
1: Wire drive is ready.
Wire drive ready
0: Wire drive is not ready.

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 Messages
No. Message Cause/remedy
Cause:
• Fault in welding periphery or weld power source
Maximum number of
• Number of ignition attempts after ignition fault too low.
10200 ignition attempts reached at
Remedy:
seam: {0}
• Check welding periphery and weld power source. Eliminate the error.
• Change the ignition fault strategy. Increase the permitted number of ignition attempts.
Cause: Ignition fault strategy was unsuccessful.
• Fault in the welding periphery
Maximum number of
• Number of repetitions of the fault reaction too low.
ignition attempts reached.
10201 Remedy:
Continue without welding!
• Check the welding periphery and eliminate the fault.
{0}
• Change the ignition fault strategy. Increase the number of repetitions of the fault
reaction.
The SPS.SUB or submit Cause: Welding is not possible as the submit interpreter was stopped or deselected.
interpreter must be Remedy: Start the submit interpreter manually (precondition:
10206
activated for the welding user group “Expert”, operating mode T1 or T2):
process! {0} • In the main menu, select Configuration > SUBMIT interpreter > Select/Start.

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 Messages
No. Message Cause/remedy
A signal of the input group Power source ready input group is missing.
Cause:
Weld controller not
10210 • The weld power source is not switched on.
ready: input {0}
• The connecting cables are defective or not correctly connected.
• The weld power source is defective.
Cause:
• The welding wire is not yet separated from the part at the end of the welding process
Welding wire is in (burnfree is not configured).
10215 contact with the • The welding wire could not be burned free (burnfree is configured).
workpiece: input {0} Remedy:
• Remove the welding wire from the part.
• Recommendation: Configure ignition parameters for burnfree.
Cause: A weld fault occurred on the seam and the robot completed the path without welding.
(Message only occurs if the weld fault strategy ContinueWithoutRetry is configured.)
The seam was not
10237 Remedy:
welded completely
• Check welding periphery and weld power source. Eliminate the error.
• Recommendation: If the application allows, change the weld fault strategy.

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Process-independent Digital Inputs
Input Description
This input can be used to monitor whether the welding process has been enabled
externally (e.g. via a keyswitch).
Weld keyswitch Note: For weld enable, either the state of the keyswitch or the state of the status key
may be relevant. This is dependent on the operating mode and the configuration of
this input.
This input can be used to monitor whether the welding wire is still in contact with the
component at the end of the welding process. If this is the case and ignition
Wire free signal
parameters for burnfree have been configured, an attempt is made to burn the
welding wire free.
Gas flow This input can be used to monitor whether gas is flowing.
Collision monitoring This input can be used to monitor whether a collision has occurred.
This input is used to determine the procedure once the maximum number of ignition
Continuation after faults or welding interruptions has been reached. If the input is set by the higher-level
maximum errors controller, the welding process is to be continued. If the input is not set, the robot is
to continue the weld path without welding.
Apply continuation If this input is set by the higher-level controller, the procedure determined by the
selection input Continuation after maximum errors is executed.

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Signal Groups for Digital Inputs

• Power Source Ready Input Group

• Power source ready = True
• Communication ready = True
• Welding Periphery Ready Input Group
• Power source ready = True
• Gas pressure = True
• Cooling = True
• Wire supply = True
• Collision protection device = True

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Signal Groups for Digital Inputs

• Motion start input group

• Current present = True
• Power source ready = True
• Gas flow = True
• Cooling = True
• Wire supply = True
• Weld process active = True

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Signal Groups for Digital Inputs

• Weld motion monitoring input group

• Current present = True
• Main current = True
• Power source ready = True
• Gas flow = True
• Wire supply = True
• Collision protection device = True
• Seam end input group
• Current present = False
• Main current = False
• Weld process active = False

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 Process-independent Digital Outputs

Input Description
Wire feed Set when the welding wire is moved forward using the status key for wire feed.
Wire retract Set when the welding wire is retracted using the status key for wire feed.
Set cyclically and indicates that the submit interpreter is running (= life sign from the submit
Life bit output
interpreter).
Set in the event of a burnfree fault. (Maximum number of ignition attempts to burn the wire free was
Burnfree fault
exceeded.)
Set if the weld path is completed without welding due to too many ignition faults. (Maximum number of
Critical ignition
ignition attempts and fault reaction repeats
error
was exceeded.)
Set if the weld path is completed without welding due to too many seam faults. (Maximum number of
Critical seam error
weld faults on a seam was exceeded.)
Collision detection Activated if a collision has been detected.
This output is set if, due to too many ignition faults or welding interruptions, it is necessary to decide
Process continuation
whether the welding process is to be continued or whether the robot is to continue the weld path without
requested
welding. (Maximum number of ignition faults or welding interruptions has been reached.)

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Signal Groups for Digital Outputs

• Gas preflow output group

• Gas flow = True
• Weld start output group
• Start welding = True
• Ignition fault output group
• Start welding = False
• Gas flow = False
• Ignition faults = True
• Group welding error = True

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Signal Groups for Digital Outputs

• Weld fault output group

• Start welding = False
• Gas flow = False
• Seam monitoring error = True
• Group welding error = True
• Acknowledge fault output group
• Acknowledge power source = True
• Ignition faults = False
• Group welding error = False
• Seam monitoring error = False
• Burnfree fault = False

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Signal Groups for Digital Outputs

• Weld end output group

• Start welding = False
• Group welding error = False
• Gas postflow output group
• Gas flow = False
• Output group before leaving weld seam
• Burnfree fault = False
• Ignition faults = False
• Seam monitoring error = False
• Group welding error = False

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Thank You