KST ArcSense 33 en

KUKA System Technology
KUKA.ArcSense 3.3
For KUKA System Software 8.5 and 8.6
Issued: 15.01.2020
KST ArcSense 3.3 V1
KUKA Deutschland GmbH
KUKA.ArcSense 3.3
© Copyright 2020
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user
has no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and soft-
ware described. Nevertheless, discrepancies cannot be precluded, for which reason we are not
able to guarantee total conformity. The information in this documentation is checked on a regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub KST ArcSense 3.3 (PDF) en

PB14716
Book structure: KST ArcSense 3.3 V1.1

BS13283
Version: KST ArcSense 3.3 V1
2/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

KUKA.ArcSense 3.3
Contents
1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Industrial robot documentation.............................................................................. 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8
1.5 Licenses................................................................................................................. 8
2 Product description................................................................................. 9
2.1 Product description................................................................................................ 9
2.2 Overview of ArcSense........................................................................................... 9
2.3 General process conditions................................................................................... 13
2.4 Hardware components.......................................................................................... 14
2.4.1 KUKA ArcSense Shunt Box Basic........................................................................ 15
2.5 Intended use.......................................................................................................... 16
3 Technical data.......................................................................................... 19
3.1 KUKA ArcSense Shunt Box Basic and the connecting cables........................... 19
3.1.1 Hole pattern for shunt box.................................................................................... 20
3.1.2 Plates and labels................................................................................................... 20
4 Safety......................................................................................................... 23
4.1 Applied norms and directives................................................................................ 23
5 Planning.................................................................................................... 25
5.1 Dimensioning of the welding cable to the robot.................................................. 25
6 Start-up and recommissioning............................................................... 27

6.1 Installing and connecting the shunt box............................................................... 27
6.2 Overview of software start-up............................................................................... 27
7 Transportation.......................................................................................... 31
7.1 Transporting the shunt box................................................................................... 31
8 Installation................................................................................................ 33
8.1 System requirements............................................................................................. 33
8.2 Installation via WorkVisual.................................................................................... 33
8.2.1 Installing or updating KUKA.ArcSense 3.3........................................................... 33
8.2.2 Uninstalling KUKA.ArcSense 3.3.......................................................................... 34
8.3 Installation via smartHMI....................................................................................... 35
8.3.1 Installing or updating KUKA.ArcSense 3.3........................................................... 35
8.3.2 Uninstalling KUKA.ArcSense 3.3.......................................................................... 36
9 Operation.................................................................................................. 37
9.1 Operator control options in the event of an envelope violation........................... 37
9.1.1 Performing manual correction............................................................................... 37
9.1.2 Status keys for manual correction........................................................................ 38
9.1.3 Proceeding with welding after manual correction................................................ 39
9.2 Deactivating sensor guidance via status key....................................................... 39
KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 3/136

KUKA.ArcSense 3.3
10 Configuration............................................................................................ 41
10.1 Inserting the shunt box in a project...................................................................... 41
10.2 Opening the ArcTech Editor.................................................................................. 42
10.3 Configuring the inputs/outputs of the sensor....................................................... 42
10.4 Modifying General settings.................................................................................... 43
10.4.1 Envelope monitoring.............................................................................................. 44
10.4.2 Reaction to seam guidance errors....................................................................... 44
10.4.3 Height correction direction.................................................................................... 45
10.4.4 Calibration options................................................................................................. 46
10.4.5 Sensor signal type for seam tracking................................................................... 47
10.5 Expert configuration............................................................................................... 47
10.5.1 Correction variables............................................................................................... 47
10.5.2 Maximum correction per cycle.............................................................................. 47
10.5.3 Referencing variables............................................................................................ 48
10.5.4 Other variables...................................................................................................... 49
11 Programming............................................................................................ 51
11.1 Instructions on programming sensor guidance.................................................... 51
11.2 Determining the required vertical correction value............................................... 52
11.3 Activating sensor guidance with ARC ON............................................................ 53
11.3.1 Option window “Correction parameters” (ARC ON)............................................. 55
11.3.2 Option window “Weaving”..................................................................................... 57
11.4 Modifying sensor guidance with ARC SWITCH................................................... 58
11.4.1 Option window “Correction parameters” (ARC SWITCH).................................... 60
11.5 Deactivating sensor guidance with ARC OFF...................................................... 63
11.6 Activating sensor guidance with ARC SPLINE.................................................... 64
11.6.1 Option window “Correction parameters” (ARC SPLINE)...................................... 66
11.7 Modifying sensor guidance with ARC SWITCH in the ARC spline block........... 69
11.7.1 Option window “Correction parameters” (ARC SWITCH).................................... 71
12 Diagnosis.................................................................................................. 75
12.1 Recording sensor signals with the RSI monitor................................................... 75
12.2 ArcTech diagnosis editor....................................................................................... 75
12.2.1 Loading data from the robot controller into the editor......................................... 75
12.2.2 Loading locally saved data into the editor........................................................... 76
12.3 Configuring the display in the ArcTech diagnosis editor...................................... 76
12.3.1 Changing the signal display options..................................................................... 78
12.3.2 Overview of sensor signals................................................................................... 79
13 Maintenance.............................................................................................. 81
13.1 Shunt box maintenance........................................................................................ 81
14 Repair........................................................................................................ 83
14.1 Exchanging the shunt box.................................................................................... 83
15 Decommissioning, storage and disposal............................................. 85

15.1 Decommissioning the shunt box........................................................................... 85

KUKA.ArcSense 3.3
15.2 Storing the shunt box............................................................................................ 85

15.3 Disposal of the shunt box..................................................................................... 85
16 Messages.................................................................................................. 87
16.1 Information about the messages.......................................................................... 87
16.2 System messages from module: ARCS............................................................... 87
16.2.1 ARCS 30012.......................................................................................................... 87
16.2.2 ARCS 30016.......................................................................................................... 87
16.2.3 ARCS 30017.......................................................................................................... 89
16.2.4 ARCS 30018.......................................................................................................... 91
16.2.5 ARCS 30019.......................................................................................................... 93
16.2.6 ARCS 30020.......................................................................................................... 95
16.2.7 ARCS 30021.......................................................................................................... 96
16.2.8 ARCS 30022.......................................................................................................... 98
16.2.9 ARCS 30023.......................................................................................................... 100
16.2.10 ARCS 30024.......................................................................................................... 102
16.2.11 ARCS 30025.......................................................................................................... 104
16.2.12 ARCS 30026.......................................................................................................... 106
16.2.13 ARCS 30027.......................................................................................................... 107
16.2.14 ARCS 30028.......................................................................................................... 109
16.2.15 ARCS 30029.......................................................................................................... 111
16.2.16 ARCS 30030.......................................................................................................... 113
16.2.17 ARCS 30031.......................................................................................................... 115
16.2.18 ARCS 30032.......................................................................................................... 117
16.2.19 ARCS 30033.......................................................................................................... 118
16.2.20 ARCS 30034.......................................................................................................... 120
16.2.21 ARCS 30036.......................................................................................................... 122
16.2.22 ARCS 30037.......................................................................................................... 124
16.2.23 ARCS 30038.......................................................................................................... 126
16.2.24 ARCS 30039.......................................................................................................... 128
16.2.25 ARCS 30042.......................................................................................................... 129
16.2.26 ARCS 30043.......................................................................................................... 131
17 KUKA Service........................................................................................... 133

17.1 Requesting support............................................................................................... 133
17.2 KUKA Customer Support...................................................................................... 133
Index 135

KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• KRL programming skills

• Knowledge of the robot controller system
• Knowledge of arc welding
• Knowledge of weld power sources
For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2 (if used)
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts overview in KUKA Xpert
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.

Introduction KUKA.ArcSense 3.3
These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.
This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:
SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.
1.4 Terms used
Term Description
KUKA ArcSense KUKA ArcSense Shunt Box Basic contains a measuring shunt that
Shunt Box Basic can be used to measure the weld current values (measurement sig-
nals) for the arc sensor.
The short designation “shunt box” is usually used in this documenta-
tion.
Sensor error There is a sensor error if no sufficiently stable measurement signal
can be detected or if no control points can be determined when
teaching the sensor.
RS Revision level
RS number Number indicating the revision level of the shunt box
1.5 Licenses
The KUKA license conditions and the license conditions of the open-
source software used can be found in the following folders:
• Under .\LICENSE on the data storage medium with the installation
files of the KUKA software
• Under D:\KUKA_OPT\Option package name\LICENSE after installation
on the robot controller
• In the license folder under the name of the option package in the Op-
tions catalog after installation in WorkVisual
Further information about open-source licenses can be requested from

the following address: opensource@kuka.com

KUKA.ArcSense 3.3
Product description
2 Product description
2.1 Product description
Description
ArcSense is an add-on option package based on ArcTech Basic for sen-

sor-guided path correction.
The position of the seam and its path are not always identical from one
workpiece to the next. Correction of the original path is often necessary in
order to compensate for deviations in the shape or position of workpieces.
Using ArcSense, the original path can be corrected in such a way that the
robot finds the actual path of the seam. ArcSense enables both lateral
correction of the path in relation to the seam center and correction of the
standoff distance between the welding torch and the workpiece.
Functions
• Seam tracking using current or voltage curve signal with lateral and
vertical calibration
• Automatic calibration of the input signal for seam tracking without prior
start-up
• Support of analog and digital input signals for control
• Separate setting of lateral and vertical controller gain
• Vertical control without weave motion
• Search function for seam center at start of process
• Functionality for lateral offset (BIAS)
2.2 Overview of ArcSense
Base technology
The base technology for KUKA.ArcSense is KUKA.RobotSensorInterface

(RSI). The core function of RSI makes it possible to influence the robot
motion by processing sensor signals.
For seam tracking, RSI is used with the following configuration:
Correction type: Cartesian
Correction mode: relative
Sensor mode: #IPO_FAST
Further information about the processing of sensor signals via RSI can
be found in the documentation for KUKA.RobotSensorInterface.
Envelope monitoring
In order to ensure that the corrected path cannot deviate more than de-
sired from the original path, a protective envelope can be defined around
the original path.

Product description KUKA.ArcSense 3.3
Fig. 2-1: Envelope monitoring
1 Weave amplitude (deflection to one side from the path center)

2 Weave length
3 Maximum correction of the path (radius of the protective envelope)
Functional principle
The arc sensor uses the shunt box to determine the effective current dur-
ing welding. In combination with a weave motion, a deviation from the real
path center can be detected and corrected by ArcSense.
ArcSense regards each weld seam as a self-contained unit. As a result,
specific and non-retain controller values must be taught for every weld
seam.
Teaching the sensor (= calibration of the sensor) typically requires 5 com-
plete weave motions at the start of a weld seam. A weave motion
consists of one positive and one negative amplitude. The teaching phase
is limited in the system to a maximum of 15 weave motions. If required,
the sensor can also be retaught at the start of a new seam section.
Fig. 2-2: Teaching the sensor
1 Minimum distance for teaching the sensor

2 Maximum distance for teaching the sensor
3 Active seam tracking
During teaching, the parameters are determined that will be used for con-
trol over the further course of the weld seam. If no plausible parameters

KUKA.ArcSense 3.3
can be determined for the sensor, a sensor error results and the fault
Product description
strategy configured in WorkVisual is carried out.
ArcSense supports the Triangle weave pattern.
ArcSense supports 2 correction methods:
• If the welding task merely requires a vertical correction (= correction
along the tool direction), no weave motion may be executed.
• If weave motion is active, both vertical and lateral correction are auto-
matically carried out.
NOTICE
Loss of quality due to disrupted sensor signal
Production-related contamination of the weld seam preparation, such as
rolling skin, lubricants and other foreign matter, can have a disruptive ef-
fect on the sensor signal. This can have a negative effect on seam
guidance and thus on the welding quality.
• Check whether the system-side mechanisms for the attenuation and
filtering of sensor interferences are functioning.
• If necessary, ensure greater surface cleanliness.
Lateral bias
A lateral bias can be programmed for a seam or seam section in order to

offset the TCP sideways relative to the direction of travel:
• If the bias value is positive, the offset occurs to the right of the seam.
• If the bias value is negative, the offset occurs to the left of the seam.
The bias is relative to the located or calibrated seam center.
Fig. 2-3: Positive lateral bias
1 Lateral bias = 0
2 Lateral bias = positive value
3 Positive lateral bias = bias to the right in the direction of travel

Fig. 2-4: Negative lateral bias
1 Lateral bias = 0
2 Lateral bias = negative value
3 Negative lateral bias = bias to the left in the direction of travel
The lateral bias is set as a percentage value in the correction parameters.
The real lateral bias in mm resulting from the set value depends on sev-
eral process factors. The value that must be set in order to achieve the
desired bias can thus only be determined during optimization of the proc-
ess.
(>>> 11.3.1 "Option window “Correction parameters” (ARC ON)"
Page 55)
(>>> 11.4.1 "Option window “Correction parameters” (ARC SWITCH)"
Page 60)
(>>> 11.6.1 "Option window “Correction parameters” (ARC SPLINE)"
Page 66)
Arc types
ArcSense supports the following arc types for power sources with constant
voltage (CV) characteristics:
• Spray arc
Restriction:
‒ The functional capability of ArcSense may be restricted if regula-

tion of the welding current is active.
• Pulse arc
Restriction:

tion of the welding current and pulse form is active.
• Short arc
If using a short arc, we recommend thoroughly testing the sensor
guidance function in advance under real conditions.
Restriction:
‒ The functional capability of ArcSense may be restricted in the case

of strong or irregular short-circuit formation.
tion of the welding current is active.

KUKA.ArcSense 3.3
Product description
• No modified arc types
ArcSense does not support all arc types available on the welding mar-
ket:
• To receive information on the suitability of individual power sources
or arc types, please contact KUKA Customer Support. (>>> 17 "KU-
KA Service" Page 133)
• The general process conditions must also be taken into considera-
tion. (>>> 2.3 "General process conditions" Page 13)
Seam tracking depends, among other things, on the welding process

used and the characteristic curve. If necessary, a different welding proc-
ess or characteristic curve must be used.
ArcTech Advanced
ArcSense can used in conjunction with ArcTech Advanced.

It must be noted that the following ArcTech Advanced functions are deac-
tivated or may not be used when sensor guidance is activated:
• Sloping (deactivated)
• On-the-fly activation/deactivation of the arc (deactivated)
• Advanced Error Recovery strategy (do not use)
WorkVisual
The KUKA.WorkVisual software is required for configuring the sensor and

the sensor fault strategy.
2.3 General process conditions
Reliable and reproducible sensor guidance requires compliance with a

number of general conditions:
• The material thickness should be at least 3 mm.
• Only the weave pattern “Triangle” can be used for sensor guidance.
• The minimum weave amplitude should not be less than 1.5 times the
wire diameter.
• The welding torch must be positioned close to the center of the weld
seam at the start point of the weld. It may additionally be necessary to
use the KUKA.TouchSense option package.
• The actual course of the weld seam should deviate by less than a
10 degree rotation from the programmed weld seam, even if the sen-
sor signal is stable.
• A single-V butt weld should have a seam preparation with a constant
included angle. This should be in the range of 60 to 90 degrees. A
larger included angle may require a greater weave amplitude.
• A fillet weld should have a seam preparation with a constant included
angle of 90 degrees.
• During welding, the upper edge must not be melted; a residual depth
of penetration of 5 mm is recommended.
• Tack welds and depth of penetration should be less than or equal to
half the seam thickness and concave in profile.
• Tack welds must not be in the sensor calibration area.
• Sensor guidance requires a weld seam preparation without a root run
and with a constant gap.

• Sensor guidance is suitable in the welding positions PA (gravity posi-

tion) and PB (horizontal seam path).
• Base metals must be ferrous metals or have a greater resistance than
steel.
• We recommend using a shielding gas with only a low proportion of
CO2 (up to 20%).
• If using a shielding gas with 100% CO2, we recommend thoroughly
testing the sensor guidance function in advance under real conditions.
In this case, the welding process tends to be susceptible to strong
and irregular short-circuit formation, which can have a negative influ-
ence on the stability of seam tracking.
• If using filler wires, sensor guidance must be tested on a case-by-case
basis.
• If using the KUKA Shunt Box Basic, a welding characteristic curve
with a constant voltage characteristic must be used.
• If using a digital checkback signal via a field bus interface from the
power source, a signal must be used that is specifically suitable for
through-the-arc sensors.
• During programming, care must be taken to ensure a constant welding
torch position. A forehand welding torch position is to be used for pref-
erence.
• More stable seam tracking is achieved by setting an arc that is as free
as possible from short-circuits.
• The properties of the workpiece surface influence the stability of seam
tracking. It must be ensured that the surface characteristics are con-
stant along the weld seam.
• The component temperature should be as constant as possible
throughout the entire weld.
2.4 Hardware components
The following hardware components are optionally available:

• KUKA ArcSense Shunt Box Basic
• Lid for RDC box, cascadable
• Connecting cables:
‒ Welding cable 95 mm2 with reducer adapter (600 A –> 500 A)
‒ Data cable X21 - X31
‒ Shunt box ground conductor
A 95 mm2 welding cable is permissible up to a maximum weld current

strength of 500 A. It can be connected via the reducer adapter (600 A –
> 500 A).
Alternatively, without a reducer adapter, a welding cable with a cross-
section of 120 mm2 can be used.

KUKA.ArcSense 3.3
Product description
2.4.1 KUKA ArcSense Shunt Box Basic
Interfaces
Fig. 2-5: Shunt box interface
1 Data cable connection X31

2 Connection, ground conductor (M6)
3 Input for welding cable from power source (male connector)
4 Ouput for welding cable to robot (female connector)
Connecting cables
How the shunt box is connected depends on the hardware configuration.

If the robot used has an RDC interface, the shunt box is connected to this
RDC interface.
Fig. 2-6: Shunt box connection to robot (example)
1 Weld power source

2 Welding cable from the power source to the shunt box (positive po-
larity of the weld current circuit)
3 Shunt box
4 Welding cable to robot
5 Wire feeder
6 Robot
7 Cover for RDC box, cascadable (optional)
8 Data cable X21 - X31
9 Ground conductor
If the robot used has no RDC interface, the shunt box must be connected
to a control cabinet with an RDC interface.

Fig. 2-7: Shunt box connection to control cabinet (example)
1 Weld power source

2 Welding cable from the power source to the shunt box (positive po-
larity of the weld current circuit)
3 Shunt box
4 Welding cable to robot
5 Wire feeder
6 Robot
7 Data cable X21 - X31
8 Cover for RDC box, cascadable (optional)
9 Interface X21.1, 2nd RDC
10 Control cabinet
11 Ground conductor
Equipotential bonding (ground conductor) between shunt box and sys-

tem PE must be established. The user of the system is responsible for
ensuring that this is implemented correctly.
Further information about the installation of the lid for the cascadable
RDC box is contained in the assembly and operating instructions for the
External Cabling.
2.5 Intended use
Use
KUKA.ArcSense is intended exclusively for arc welding in an industrial en-

vironment. Using an arc sensor, the option package serves to correct the
path in accordance with the position and shape of a workpiece.
The option package must only be operated in compliance with the speci-
fied system requirements.
Operation in accordance with the intended use also requires compliance
with the start-up and configuration instructions in this documentation and
constant observance of the assembly and operating instructions for the
cell components used.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. KUKA Deutschland GmbH is not liable for any
damage resulting from such misuse. The risk lies entirely with the user.

KUKA.ArcSense 3.3
Examples of such misuse include:
Product description
• Use in a cell which does not conform to the applicable safety regula-
tions for arc welding
• Use in a non-industrial environment


KUKA.ArcSense 3.3
Technical data
3 Technical data
3.1 KUKA ArcSense Shunt Box Basic and the connecting cables
Basic data
Housing Metal
Dimensions 160 x 260 x 91 mm
Weight 2300 g
Permissible load cur- max. 600 A (120 mm2) / max. 500 A (95 mm2)
rent
Protection rating IP 23
Energy consumption approx. 4.8 W
Conformity CE
Ambient conditions
Operation +5 °C to +40 °C (278 K to 313 K)

Storage, transportation -20 °C to +55 °C (253 K to 328 K)
Air humidity max. 90% at +20 °C (293 K)
Connecting cables
Cable designation Connector designa- Connection

tion
Data cable X21 - X31 Harting connectors at
both ends, HAN 3A
Welding cable 95 mm2 IN - customer-specific Dinse DIX connectors
power source at both ends,
BKS 120 - SKK 95
Ground conductor, M6 ring cable lug at
10 mm2 both ends
Cable lengths
Data cable 3 m, 10 m, 20 m
Welding cable 1 m
Ground conductor 10 m
Fig. 3-1: Connecting cable, data cable X21 - X31

Technical data KUKA.ArcSense 3.3
Fig. 3-2: Connecting cable, wiring diagram, data cable X21 - X31
3.1.1 Hole pattern for shunt box
Fig. 3-3: Hole pattern for shunt box (wall mounting)
1 Holes for fastening (4x)
3.1.2 Plates and labels
The following plates and labels are attached to the shunt box. They must
not be removed or rendered illegible. Illegible plates and labels must be
replaced.

KUKA.ArcSense 3.3
Technical data
Overview
Fig. 3-4: Plates and labels
Item Designation
1 Identification plate
The RS number with the revision level of the shunt box can be
found at the top left of the identification plate.
2 Interface labelling
3 Ground symbol
4 Warning: High voltage warning sign (housing cover)

Technical data KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Safety
4 Safety
This documentation contains safety instructions which refer specifically to
the option package described here.
The fundamental safety information for the industrial robot can be found in
the “Safety” chapter of the Operating and Programming Instructions for
System Integrators or the Operating and Programming Instructions for End
Users.
Comply with safety-relevant information
The safe use of this product requires knowledge of and compliance with
fundamental safety measures. Death, severe injuries or damage to prop-
erty may otherwise result.
• The “Safety” chapter in the operating and programming instructions
of the KUKA System Software (KSS) must be observed.
4.1 Applied norms and directives
KUKA ArcSense Shunt Box Basic and the connecting cables fulfill the fol-
lowing norms and directives.
Name/Edition Definition
2014/35/EU:2014 Low Voltage Directive:

Directive of the European Parliament and the Council of 26 Febru-
ary 2014 on the harmonization of the laws of Member States relat-
ing to electrical equipment designed for use within certain voltage
limits.
2014/30/EU:2014 EMC Directive:

Directive 2014/30/EC of the European Parliament and of the Coun-
cil dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility
EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments
EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments
EN 60974-12:2011 Arc welding equipment:

Part 12: Coupling devices for welding cables (IEC 60974-12:2011)

Safety KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Planning
5 Planning
5.1 Dimensioning of the welding cable to the robot
The cross-section and length of the welding cable from the shunt box to
the robot must be dimensioned in accordance with the following guide val-
ues.
Cable cross-section
Cross-section 100% DC 60% DC

10 … 16 mm2 135 A 140 A
16 … 25 mm2 180 A 190 A
25 … 35 mm2 225 A 245 A
35 … 50 mm2 285 A 315 A
50 … 70 mm2 355 A 400 A
70 … 95 mm2 430 A 500 A
95 … 120 mm2 500 A 590 A
Cable length
Current
≤ 10 m > 10 m > 50 m > 100 m
strength
100 A 25 mm2 35 mm2 50 mm2 70 mm2
200 A 35 mm2 50 mm2 70 mm2 95 mm2
300 A 50 mm2 70 mm2 95 mm2 120 mm2
400 A 70 mm2 95 mm2 120 mm2 —
500 A 95 mm2 120 mm2 — —
600 A 120 mm2 — — —

Planning KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Start-up and recommissioning

6 Start-up and recommissioning
6.1 Installing and connecting the shunt box
Description
The shunt box is connected to the data bus (KCB) of the system. Start-up
is thus not completed until configuration in WorkVisual has been finished.
The robot cannot be moved until the configuration has been carried out
and the project with the configuration has been activated on the robot
controller.
Precondition
• The robot controller has been shut down with the following settings:
‒ Cold start
‒ Reload files
• The robot controller is switched off and secured to prevent unauthor-
ized persons from switching it on again.
• The power cable is de-energized.
NOTICE
Damage to property due to faulty installation
The shunt box must be installed in such a way that the connecting ca-
bles do not become kinked when connected. Damage to property may
otherwise result.
• The system user must ensure proper installation.
• Wall mounting with downward connector outlet is recommended.
Procedure
1. Fasten the shunt box between the power source and the manipulator
with 4 screws (M6 x 35/10). Hand-tighten the screws.
The precise positioning depends on customer-specific circumstances
in the system.
2. Connect the connecting cables.
(>>> "Connecting cables" Page 15)
3. Plug the ground conductor into the shunt box and connect it to the
system PE.
NOTICE
Damage to property due to incorrect routing of ground conductor
An improperly installed ground conductor can lead to inductive interfer-
ence, which adversely affects the function of sensors. This may result in
damage to property.
• Install the ground conductor correctly.
6.2 Overview of software start-up
The following is an overview of the tasks that are required for the
software start-up of the option package. Complete start-up of the robot
arm is assumed.
This overview also provides guidelines for the general software start-up,
as complete start-up is required in order to be able to use the option

KUKA.ArcSense 3.3
package. Further information is contained in the operating and program-

ming instructions for the System Software, WorkVisual and ArcTech Basic.
System Software
Step Description
1 Switching on the robot controller with the kinematic system for the first time
2 Performing general robot start-up
• Start-up wizard
• Mastering
• Software limit switches
• Performing TOOL calibration
• Load data determination
• Performing BASE calibration
WorkVisual
Step Description
3 Establishing a connection to the robot controller
4 Transferring and activating a project
• Loading the project from the robot controller

• Assigning the robot controller to the real robot controller
5 Performing the configuration in WorkVisual
• Cell configuration
• Editing the local safety configuration
• Configuring the field buses
• Definition of long texts
6 Transferring the project to the robot controller
ArcTech Basic
Step Description
7 Installing or updating ArcTech Basic

KUKA.ArcSense 3.3

Step Description
9 Configuring ArcTech Basic in WorkVisual
• Adding the power source to the project

• Configuring the weld power source in the ArcTech Editor:
‒ Define the general parameters of the power source.
‒ Configure the power source I/Os.
‒ Optional: create the task-specific data sets on the basis of the standard da-
ta sets.
• Changing the process options in the ArcTech Editor(optional).

• Optional: configuring the ignition and weld fault strategies in the ArcTech Edi-
tor.
ArcSense
Step Description
11 Installing or updating ArcSense
(>>> 8.2.1 "Installing or updating KUKA.ArcSense 3.3" Page 33)

13 Configuring ArcSense in WorkVisual
• If the shunt box is being used, insert the shunt box into the project.
(>>> 10.1 "Inserting the shunt box in a project" Page 41)
• Configure the inputs/outputs of the sensor in the ArcTech Editor.
(>>> 10.3 "Configuring the inputs/outputs of the sensor" Page 42)
• Configure general settings in the ArcTech Editor:
‒ Envelope monitoring
‒ Reaction to seam guiding errors
‒ Tool direction
‒ Calibration options
‒ Sensor signal type for seam tracking
(>>> 10.4 "Modifying General settings" Page 43)
15 Programming with inline forms

Start-up and recommissioning KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Transportation
7 Transportation
7.1 Transporting the shunt box
Before transportation, the shunt box must be removed. The shunt box
must be packaged in ESD protection foil for transportation. Care must be
taken to ensure that the shunt box does not come into contact with hu-
midity.

Transportation KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Installation
8 Installation
The option package can either be installed on the robot controller via the
smartHMI or via WorkVisual.
8.1 System requirements
Hardware
• KR C4 robot controller
Software
Robot controller:
• KUKA System Software 8.6
• KUKA.ArcTech Basic 3.3
• KUKA.RobotSensorInterface 4.1
Or:
• KUKA System Software 8.5
• KUKA.ArcTech Basic 3.3
• KUKA.RobotSensorInterface 4.0
Laptop/PC:
• WorkVisual 6.0
Compatibility
• KUKA.ArcSense 3.3 can be installed on a robot controller together

with the following option packages:
‒ KUKA.ArcTech Advanced 3.3
‒ KUKA.ArcTech Multilayer 3.3
‒ KUKA.ArcTech ArcLink® XT 3.3
‒ KUKA.ArcTech AdaptiveWelding 3.3
‒ KUKA.TouchSense 3.2
‒ KUKA.RoboTeam 3.1
• KUKA.ArcSense 3.3 is not downwards compatible with KUKA.ArcTech
Basic 3.2.
8.2 Installation via WorkVisual
8.2.1 Installing or updating KUKA.ArcSense 3.3
Description
The option package is installed in WorkVisual and added to the project.

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

Installation KUKA.ArcSense 3.3
Precondition
• User group “Expert”

• T1 or T2 mode
• No program is selected.
• Network connection to the robot controller
• The option package is available as a KOP file.
Procedure
1. Only for an update: Uninstall the previous version of the KUKA.Arc-

Sense 3.3 option package in WorkVisual.
2. Install the KUKA.ArcSense 3.3 option package in WorkVisual.
3. Load the active project from the robot controller.
4. Insert the KUKA.ArcSense 3.3 option package into the project.
5. Configure the option package in WorkVisual as required.
6. Deploy the project from WorkVisual to the robot controller and activate
it.
7. The request for confirmation Do you want to activate the project […]?
is displayed on the smartHMI. The active project is overwritten during
activation. If no relevant project will be overwritten: Answer the query
with Yes.
8. An overview with the changes and a request for confirmation are dis-
played on the smartHMI. Answer this with Yes. The option package is
installed and the robot controller carries out a reboot.
Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.
LOG file
A LOG file is created under C:\KRC\ROBOTER\LOG.
8.2.2 Uninstalling KUKA.ArcSense 3.3
Description
The option package can be uninstalled via WorkVisual.

It is advisable to archive all relevant data before uninstalling a software
package.
Precondition
• User group “Expert”

• T1 or T2 mode
Procedure
1. Load the project from the robot controller.

2. Remove the KUKA.ArcSense 3.3 option package from the project. A
window with modifications is displayed.
3. Deploy the project from WorkVisual to the robot controller and activate
it.
4. Answer the request for confirmation Do you want to activate the
project […]? on the smartHMI with Yes.

KUKA.ArcSense 3.3
Installation
played on the smartHMI. Answer this with Yes. The option package is
uninstalled and the robot controller carries out a reboot.
Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.
LOG file
8.3 Installation via smartHMI
8.3.1 Installing or updating KUKA.ArcSense 3.3
It is advisable to archive all relevant data before updating a software

package.
Precondition
• User rights: Function group General configuration

But at least the user group “Expert”
• T1 or T2 mode
• USB stick with the option package (KOP file)
NOTICE
Data loss due to USB sticks from third-party manufacturers
Data may be lost if USB sticks from manufacturers other than KUKA
are used for activities on the robot controller.
• For activities on the robot controller requiring a USB stick, use a
KUKA stick.
The KUKA sticks are validated for use with the robot controller.
Procedure
1. Connect the USB stick to the robot controller or smartPAD.

2. In the main menu, select Start-up > Additional software.
3. Press New software: The entry “KUKA.ArcSense 3.3” must be dis-
played in the Name column and drive E:\ or K:\ in the Path column.
If not, press Refresh.
4. If the specified entries are now displayed, continue with step 5.
Otherwise, the path from which the software is to be installed must be
configured first:
a. Press the Configure button.
b. Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwrit-
ten.
c. Press Path selection. The available drives are displayed.
d. If the stick is connected to the robot controller: On E:\, select the
directory in which the software is located.
If the stick is connected to the smartPAD: K:\ instead of E:\
e. Press Save. The Installation paths for options area is displayed
again. It now contains the new path.

Installation KUKA.ArcSense 3.3
f. Mark the line with the new path and press Save again.
5. Set the check mark at “KUKA.ArcSense 3.3” and press Install. Con-
firm the installation query with OK.
is displayed. The active project is overwritten during activation. If no
relevant project will be overwritten: Answer the query with Yes.
played. Answer this with Yes. The option package is installed and the
robot controller carries out a reboot.
8. Remove the stick.
LOG file
8.3.2 Uninstalling KUKA.ArcSense 3.3
It is advisable to archive all relevant data before uninstalling a software

package.
Precondition

• T1 or T2 mode
Procedure

2. Activate the check mark at KUKA.ArcSense 3.3 and press Uninstall.
Answer the request for confirmation with Yes.
project […]? with Yes.
played. Answer this with Yes. The option package is uninstalled and
the robot controller carries out a reboot.
LOG file

KUKA.ArcSense 3.3
Operation
9 Operation
9.1 Operator control options in the event of an envelope violation
If the envelope monitoring is active and the maximum permissible correc-

tion is exceeded (envelope violation), the robot is stopped, the process
switched off and a dialog message displayed. Operators are asked how
they would like to proceed.
The following operator control options are available:
• Cancel
This option is to be selected if the program is to be canceled, e.g. in
order to start welding a new workpiece.
The operator must reset or deselect the program.
• Proceed
This option is to be selected if visual inspection of the workpiece re-
veals that the executed sensor correction is OK and welding can pro-
ceed without any loss of quality.
The configured weld fault strategy is automatically executed and the
sensor is retaught. The sensor offset is also retained.
• Manual correction
The operator has the option of manually moving and repositioning the
welding torch via the status keys in T1. Status keys for manual correc-
tion are automatically displayed.
(>>> 9.1.1 "Performing manual correction" Page 37)
Once correction has ended, welding may proceed.
(>>> 9.1.3 "Proceeding with welding after manual correction"
Page 39)
9.1.1 Performing manual correction
Precondition
• The Manual correction option is activated.

• T1 mode
Procedure
1. Press and hold down the Start key.

2. Press and hold down the enabling switch.
3. Move the welding torch into the position where welding is to be re-
sumed using the status keys.
(>>> 9.1.2 "Status keys for manual correction" Page 38)
4. Once the welding torch is in the desired position, end manual correc-
tion using the related status key.
The status keys for manual correction can no longer be activated. This
is only possible after the next envelope violation.

Operation KUKA.ArcSense 3.3
Example
Fig. 9-1: Manual correction following envelope violation
1 Envelope violation 2 Manual correction
9.1.2 Status keys for manual correction
Description
If the Manual correction option is activated following an envelope viola-

tion, the status keys are automatically displayed.
Status key Description
Correction direction ±YTTS
The welding torch is moved in the weave plane (at right
angles to the weld path).
• Arrow pointing left = correction direction +YTTS

• Arrow pointing right = correction direction -YTTS
Switches to the correction direction ±ZTTS.
Correction direction ±ZTTS

The welding torch is moved at right angles to the weave
plane (vertically upwards/downwards).
• Arrow pointing upwards = correction direction +ZTTS

• Arrow pointing downwards = correction direction -
ZTTS
Switches to the correction direction ±YTTS.
Terminates manual correction.

The status keys for manual correction can no longer be
activated. Welding can proceed.
If other status keys were displayed before the envelope
violation and the activation of manual correction, these
keys will automatically be displayed again.

KUKA.ArcSense 3.3
Operation
Precondition
The status keys are active if the following conditions are met:
• T1 mode
• Start key is pressed.
• Enabling switch is pressed.
• Submit interpreter is running.
Procedure
Displaying the status keys:

• In the main menu, select Configuration > Status keys > ArcSense >
Motion.
9.1.3 Proceeding with welding after manual correction
Precondition
• Manual correction has been completed.

• T1, T2 or AUT mode
CAUTION
Risk of injury in case of unexpected welding restart
Welding is resumed immediately after the manual correction has ended.
Failure to take this into account may result in injuries.
• Wear the personal protective equipment (e.g. safety goggles, protec-
tive clothing) during welding in T1.
Procedure
• T1 or T2 mode: Press and hold down the Start key.

• AUT mode: Press the Start key.
9.2 Deactivating sensor guidance via status key
Description
Sensor guidance is typically deactivated in order to create and optimize

the process without sensor guidance.
The status key is grayed out and inactive, e.g. because
an automatic mode is set.
Sensor guidance is activated.
Sensor guidance is deactivated.
Precondition
The status key is active if the following conditions are met:

Operation KUKA.ArcSense 3.3
• T1 or T2 mode
• User group “Expert” or higher
Procedure
Display status key:

• In the main menu, select Configuration > Status keys > ArcSense >
Deactivation.

KUKA.ArcSense 3.3
Configuration
10 Configuration
10.1 Inserting the shunt box in a project
Description
The ArcSense option offers different shunt box devices in WorkVisual, as

there may be different configurations depending on the control cabinet and
the revision level of the shunt box.
The RS number with the revision level of the shunt box can be found on
the identification plate of the shunt box. (>>> 3.1.2 "Plates and labels"
Page 20)
Topology
The topology of the KUKA Controller Bus (KCB) must be manually correc-
ted via WorkVisual in individual cases:
• If several RDCs are used, the shunt box must be the last device on
one of the two KUKA Controller Bus (KCB) branches.
• If the shunt box is connected to the data cable between the manipula-
tor and robot controller X21, there must be a connection to the RDC
of the robot.
• If a connection to the RDC of the robot is not possible, the shunt box
must be connected to the second data cable between the RDC box
(cascadable) and robot controller X21.1. In this case, the shunt box
may be the only device.
• If a cascadable RDC box is used, the shunt box must be connected
after it.
The shunt box is displayed with the name EK1100 EtherCAT coupler
(2A E-Bus) in the topology tree. The shunt box may have a different
address from one project to another.
Information about the topology of the drive bus and editing the connec-
tions is contained in the WorkVisual documentation.
Precondition
• The project is open.

• The controller has not been set to active.
Procedure
1. Select the Hardware tab in the Project structure window.

2. Right-click on the robot controller and select Add… in the context
menu.
3. Select the Options tab and mark the appropriate shunt box for this
project.
The following must be taken into consideration when selecting the
shunt box:
• Is the shunt box (or will it be) physically connected to the control
cabinet or robot base?
• What is the revision level RSx of the shunt box? (Observe the
identification plate.)
4. Add the shunt box to the project by means of Drag&Drop. A dialog in-
dicates that the ArcSense option must also be added.

Configuration KUKA.ArcSense 3.3
5. Confirm the dialog with OK. The shunt box and option are added.
6. Configurations are already stored in the shunt box. Respond to the
query asking whether these configurations are to be imported with
Yes.
7. The Adjust signal connections window opens.
If the sensor signal to which the shunt box is to be mapped in accord-
ance with its default settings is already mapped in the current project,
this is shown in the Current conflicts: area.
8. If there is a conflict, enter the number of the input to which the sensor
signal should be mapped in the Analog inputs box.
The input set here must also be configured in the ArcTech Editor.
9. If a conflict is no longer displayed in the Current conflicts: area, click
on OK.
10.2 Opening the ArcTech Editor
Precondition
• The project is open.

• The power source is inserted in the project.
Procedure
1. Select the power source in the project (Hardware tab).

2. Select the menu sequence Editors > Options packages > Open Arc-
Tech Editor.
Alternative procedure
• Click on the button in the menu bar, or double-click on the power

source in the project (Hardware tab).
10.3 Configuring the inputs/outputs of the sensor
Description
An analog or digital input can be configured for the sensor signal. The sig-
nal type to be configured depends on the power source.
Outputs can also be configured to send an error signal to the higher-level
controller in the event of a sensor error or an envelope violation.
Preparation
WorkVisual does not indicate a double assignment of inputs/outputs or an

overlap of the configured signal ranges.
• For configuration of analog inputs/outputs: Check whether the desired
inputs/outputs have already been assigned by ArcTech Basic.
• For configuration of a digital sensor signal: Check whether the desired
signal range overlaps with a signal range that has already been con-
figured for ArcTech Basic.
Precondition
• ArcTech Editor is open.

KUKA.ArcSense 3.3
Configuration
Procedure
1. Select the I/O definition tab.

2. Configure the inputs/outputs of the sensor on the Inputs or Outputs
tab as required.
3. Save the project to accept the changes made.
Inputs
The following input signals for the welding equipment are available:
Parameter Description
Seam tracking sensor Use of the shunt box is intended for evaluation of an analog
sensor signal.
(If sensor signal type for
seam tracking is Analog) Enter the number of the analog input to which the sensor sig-
nal is mapped.
• 1 … 32
Default: 15
Note: If the default input is already assigned, a different ana-
log input can be configured. The number of the input that was
previously specified when inserting the shunt box into the
project must be entered.
Seam tracking sensor The digital sensor signal is transferred directly from the power
source by means of a field bus signal. The signal must meet
(If sensor signal type for
the specific requirements.
seam tracking is Digital)
Enter the start and end values for the signal width of the sen-
sor signal.
Signal width: max. 32 bits
Note: The signal range configured for the sensor must not
overlap with the signal ranges configured in ArcTech Basic.
WorkVisual does not indicate a range overlap.
Outputs
The following bits for outputs can be configured for the PLC:
Sensor error (ArcSense) Enter the number of the output that is used to report errors
that arise while teaching the sensor.
Envelope monitoring error Enter the number of the output that is used to report an enve-
(ArcSense) lope violation.
10.4 Modifying General settings
Description
The general settings for ArcSense can be modified:

• Envelope monitoring
• Reaction to seam guiding errors
• Height correction direction
• Calibration options:
‒ Calibration type
‒ Activation delay for seam calibration

‒ Height correction
Precondition
• ArcTech Editor is open.
Procedure
1. Select the General settings tab.

2. Make the required settings on the Process settings tab under Arc-
Sense options.
3. Save the project to accept the changes made.
10.4.1 Envelope monitoring
NOTICE
Risk of collision due to absence of envelope monitoring
Without envelope monitoring there is a risk of the robot colliding with
the weldment, e.g. due to a sensor error. Using envelope monitoring
can also detect if the parts to be welded are in significantly faulty posi-
tions. Damage to property may result without envelope monitoring.
• It is recommended to always use envelope monitoring.
Envelope monitoring Envelope monitoring is activated as standard (= On).
Envelope monitoring can be deactivated (= Off), but this is
not recommended. No value can then be entered for the max-
imum sensor correction in the programming.
10.4.2 Reaction to seam guidance errors
NOTICE
Risk of collision due to fault strategyContinue without sensor
In the Continue without sensor fault strategy, sensor guidance is de-
activated. This can lead to a collision with the part and cause damage
to property.
• Bear in mind that the robot moves along the taught path without tak-
ing obstacles into account.
The following strategies are available for responding to seam guidance er-
rors:

KUKA.ArcSense 3.3
Configuration
Reaction to seam guiding Stop and execute the fault strategy (default)
errors
The weld fault strategy configured in ArcTech Basic is used.
The following fault strategies from ArcTech Basic are suppor-
ted by ArcSense:
• KeepOnPosition
• MoveBackward
The distance on the path over which a backward move-
ment is possible is limited to 100 mm when sensor guid-
ance is activated.
• MoveUpAndStop
• MoveForward
As soon as the fault strategy has been carried out and weld-
ing can proceed, the sensor is retaught and welding resumes
with activated sensor guidance.
Continue without sensor
The robot continues to the next weld command, e.g. to the
next ARC SWITCH, without sensor guidance. Program execu-
tion then proceeds as programmed.
Further information about the fault strategies can be found in the Arc-
Tech Basic documentation.
10.4.3 Height correction direction
NOTICE
Risk of collision due to incorrect direction of the height correction
If the direction of the height correction has been entered incorrectly, an
incorrect vertical control reaction will occur. This can lead to a collision
with the weldment and cause damage to property.
• Check the entry under Height correction direction
Height correction direction The direction of the height correction configured for the tool
used must be specified here.
• Positive: This is the default setting.

Leave this setting if the direction of height correction for
the tool lies in the positive X or Z axis of the TOOL coor-
dinate system (in the direction of the free wire end).
• Negative: Select this setting if the direction of height cor-
rection for the tool lies in the negative X or Z axis of the
TOOL coordinate system (away from the free wire end).
Height correction direction Negative
The direction of the height correction must be set as negative in the fol-
lowing cases:
• If using weld programs that have been taught with a negative tool di-
rection
If the tool direction lies in the positive X or Z axis of the TOOL coordi-
nate system (in the direction of the free wire end), it is configured cor-

KUKA.ArcSense 3.3
rectly. This is specified in the operating and programming instructions

Configuration
for the System Software and for ArcTech Basic.

If the tool direction, contrary to this requirement, lies in the negative X
or Z axis of the TOOL coordinate system (away from the free wire
end) and welding programs have been taught with this tool, then these
welding programs may not be used with ArcSense without taking fur-
ther action. Risk of collision!
In order to be able to use welding programs taught with the negative
tool direction, the negative tool direction must be set.
• Vertical control with voltage signal
If there is a signal (measured value) available whose value is exactly
indirectly proportional to the length of the arc, this signal can be used
for vertical control. The precondition here is that the weave function is
not used. Such a voltage measurement signal is generally available in
the case of TIG and plasma power sources.
In order for ArcSense to be able to work with this signal, the tool di-
rection must be exactly the opposite to the real programming.
The sensor signal expected by ArcSense is indirectly proportional to
the length of the arc (distance signal). If the distance gets smaller, the
signal value (measured value) increases and if the distance gets larg-
er, the signal value (measured value) decreases. An example of a di-
rectly proportional signal would be a voltage signal whose signal value
(measured value) increases with increasing distance and decreases
with decreasing distance (e.g. in the case of plasma cutting).
10.4.4 Calibration options
The following parameters are available:

Calibration type Method used for teaching the sensor signal at the start of the
welding process
• Seam center
During teaching, ArcSense attempts to detect and track
the center of the weld seam preparation.
• As taught (default)
The sensor signal is taught dependent on the current sig-
nal that ArcSense finds in the programmed position at the
start of the welding process.
• Selection in ILF
The user can set the method for teaching the sensor sig-
nal in the inline form ARC ON or ARC SPLINE.
Activation delay for seam Teaching of the sensor signal starts with the ignition of the
calibration arc. In this case, the system attempts to generate sufficient
control points from the outset.
Teaching can also be delayed, e.g. if the current signal after
ignition is unstable.
• None (default)
Teaching commences at the start of the ignition process.
The user can set the teaching delay in the inline form
ARC ON or ARC SPLINE.

KUKA.ArcSense 3.3
Configuration
Height correction The value sets a correction of the welding task in the tool di-
rection.
• Calibration
The value for the vertical correction is calibrated at the
start of the weld seam.
The value for the vertical correction can be set via an in-
line form.
10.4.5 Sensor signal type for seam tracking
Sensor signal type for The option package requires an input signal for seam detec-
seam tracking tion which is used for control. This parameter can be used to
set whether the signal is analog or digital.
• Automatic detection
This is the default setting. ArcSense automatically detects
if the input signal is analog or digital.
• Analog
Select this if a KUKA shunt box is used
• Digital
Select this if the sensor signal is provided by the power
source (e.g. as weld current or voltage value)
10.5 Expert configuration
10.5.1 Correction variables
Variable and lateral correction can be activated and deactivated via global
BOOL variables:
Variable Description
gArsHeightControlOn If the variable is set to the value TRUE, vertical correction is
active. Setting the variable to FALSE deactivates vertical cor-
rection.
Default: TRUE
gArsSideControlOn If the variable is set to the value TRUE, lateral correction is
active. Setting the variable to FALSE deactivates lateral cor-
rection.
Default: TRUE
10.5.2 Maximum correction per cycle
The maximum correction per cycle can be limited using global REAL vari-
ables. These variables can be set using the variable display:

gArsMaxCorrWeaveSide Limitation in mm for lateral correction
Even if the determined correction per amplitude exceeds this
value, the actual lateral correction that is executed will be
limited to this value. Only change this value if the lateral cor-
rection is no longer sufficient.
gArsMaxCorrWeaveHeight Limitation in mm for vertical correction (tool direction)
Even if the determined correction per amplitude exceeds this
value, the actual vertical correction that is executed will be
limited to this value. Only change this value if the vertical cor-
rection is no longer sufficient.
10.5.3 Referencing variables
If a command is executed, new correction parameters are determined by

referencing. The following variables can be used to influence the referenc-
ing:
gArsSwiDontChangeParam If the variable is set to the value TRUE, no new referencing
is performed for ARC SWITCH if weld parameters change.
Data type: BOOL
Default: FALSE
gArsPeriodsCorrSlow Cycles for calculating the correction, when locating the seam
center or in the case of changes in lateral offset (BIAS)
Data type: INT
Default: 10
gArsSigQualSensitivity Sensitivity for referencing:
• 0: Without checking
• 1: High sensitivity
• 2: Low sensitivity
• 3: Lowest sensitivity
Data type: INT
Range of values: 0-3
Default: 2
gArsMinRefCycleOn Minimum number of weave patterns required for referencing
in the case of ignition.
Data type: INT
Default: 5
gArsMinRefCycleSwi Minimum number of weave patterns required for referencing
in the case of ARC SWITCH.
Data type: INT
Default: 3

KUKA.ArcSense 3.3
Configuration
gArsNrCycRefMidVal Number of cycles before referencing which are to be used to
calculate the average value for the correction.
Data type: INT
Default: 4
gArsMidValRefPercent Gain factor for the correction during re-referencing
Data type: INT
Default: 100
10.5.4 Other variables
The behavior of the application can additionally be influenced by the fol-

lowing REAL variables:
gArsSideDelay Wait time in milliseconds after the amplitude of the motion
was achieved.
gArsMinInputValue Threshold value for input signals
Input signals whose value is higher are taken into considera-
tion.


KUKA.ArcSense 3.3
Programming
11 Programming
11.1 Instructions on programming sensor guidance
ArcSense data set
The weld instructions from ArcTech Basic are used for ArcSense.
ArcSense provides an additional data set in the weld instructions for pro-
gramming the sensor guidance. This ArcSense data set can be inserted
or deleted using the ArcSense On/ArcSense Off button.
The parameters set in the ArcSense data set for sensor guidance are
automatically saved in the weld data set of the corresponding weld in-
struction of ArcTech Basic, e.g. with the name WDAT1. The weld data
set with the sensor guidance parameters can be reused with the saved
name in subsequent weld instructions.
Without spline
The following weld instructions are required for a single seam:

• ARC ON
• ARC OFF
The following weld instructions are required for a seam that is divided into
several seam sections:
• ARC ON
• ARC SWITCH
• ARC OFF
NOTICE
Material damage due to missing ArcSense data set
If sensor guidance is used for a seam, the ArcSense data set must be
used in all weld instructions programmed for this seam. If this data set
is missing in any of the inline forms, the robot may carry out unexpec-
ted motions. This may result in damage to property.
• Ensure that the relevant ArcSense data set is used for all weld in-
structions of a seam.
ARC spline block
The following weld instructions are required for a seam that is to be exe-
cuted as a spline motion:
• ARC SPLINE
‒ ARC ON
‒ ARC SWITCH
Only required if a seam is to be divided into several sections.
‒ ARC OFF
When using the ARC spline block, the ArcSense data set is only required
in ARC SPLINE and ARC SWITCH and is only available in these instruc-
tions.
General information
• It is advisable to optimize the weld parameters for the application first,

and then to program the sensor guidance. As long as the application

KUKA.ArcSense 3.3
is set without ArcSense, sensor guidance must be deactivated by

Programming
means of the corresponding status key.

(>>> 9.2 "Deactivating sensor guidance via status key" Page 39)
• Slight deviations when teaching the sensor can strongly affect the sen-
sor signal and thus the position of the weld seam. The start of a seam
and the start of a seam section at which the sensor is retaught must
therefore be taught precisely.
11.2 Determining the required vertical correction value
Description
The vertical correction can be carried out using the voltage or current
strength present during the welding process.
If the voltage or current strength necessary for the required application is
not known, it can be determined in the following manner.
Precondition
• The value Selection in ILF is set for the parameter Height

correction in WorkVisual.
• Vertical correction is deactivated.
Procedure
1. Teach motion points for the weld.

2. Perform weld with vertical correction deactivated.
Repeat the process, manually correcting the height until the desired
welding result is achieved.
3. Determine the preset value for vertical correction. This is possible in
two ways:
Reading the system variables
• Select the menu sequence Display > Variable > Single.
The Variable display – Single window opens.
• Enter the name of the variable $SEN_PREA[3] in the Name box
and confirm with the Enter key.
The input value for the current or voltage value used for vertical
control is displayed.
Fig. 11-1: Display of the variables for the input value
Reading from the ArcTech diagnosis editor

KUKA.ArcSense 3.3
Programming
• Open the display of the sensor signals in the RSI monitor.
(>>> 12.1 "Recording sensor signals with the RSI monitor"
Page 75)
• Perform weld and save file.
• Display the signal InSignalFilter in the ArcTech diagnosis editor.
(>>> 12.3 "Configuring the display in the ArcTech diagnosis editor"
Page 76)
The mean value of the displayed signal corresponds to the input
value for the current or voltage value used for vertical control.
Fig. 11-2
11.3 Activating sensor guidance with ARC ON
Description
Sensor guidance is activated with the ARC ON instruction. The correction

parameters for the seam can be defined.
Precondition
• Program has been opened.
Procedure
1. Select the menu sequence Commands > ArcTech > ARC ON.
2. Press ArcSense On to insert the ArcSense data set in the inline form.
3. Set the sensor guidance parameters as required in the inline form.
4. Press Cmd OK to save the instruction.

Programming KUKA.ArcSense 3.3
Inline form
Fig. 11-3: Inline form “ARC ON” with ArcSense
Item Description
1 Name of the ignition and weld data set and of the data set con-
taining the end crater parameters. The ArcSense data set is al-
so saved with this name.
The system automatically generates a name. The name can be
overwritten.
If sensor guidance is used, the configurable weave parameters
are modified.
Touch the arrow to edit the parameters. The corresponding op-
tion window is opened.
2 Name for the ArcSense data set. The system automatically gen-
erates a name. The name cannot be overwritten.
(>>> 11.3.1 "Option window “Correction parameters” (ARC ON)"
Page 55)
3 If sensor guidance is used, this is indicated by TRACK in the
program code.

KUKA.ArcSense 3.3
Programming
11.3.1 Option window “Correction parameters” (ARC ON)
Fig. 11-4: Option window “Correction parameters” (ARC ON)
Item Description
1 Lateral controller gain
• 0 ... 100%
The greater the value, the quicker the sensor responds to de-
tected lateral changes in position of the weld seam. The lower
the value, the slower the reaction.
If the value “0” is set, there is no lateral correction.
2 Vertical controller gain
• 0 ... 100%
tected changes in position of the weld seam in the tool direction
of the welding torch. The lower the value, the slower the reac-
tion.
If the value “0” is set, there is no vertical correction.
3 Maximum correction (= radius of the protective envelope)
This box is only displayed if the envelope monitoring has been
activated in WorkVisual.
• 1 … 300 mm
The maximum expected correction must be set.
4 Activation delay for seam calibration
This box is only displayed if the value Selection in ILF has
been set for the parameter Activation delay for seam calibra-
tion in WorkVisual.
• 0 … 10 s
As standard, teaching of the sensor signal starts with the igni-
tion of the arc (activation delay = 0 s). The start of teaching can
be delayed.

Item Description
5 Check box Find seam center
This box is only displayed if the value Selection in ILF or
Seam center has been set for the parameter Calibration type
in WorkVisual.
• Check box active: during teaching, ArcSense attempts to

detect and track the center of the weld seam preparation.
The maximum correction of the seam center search de-
pends on the magnitude of the programmed weave width,
as the controller has to work with a minimal checkback sig-
nal from both side walls of the seam.
• Check box not active: ArcSense tracks the position of the
welding torch relative to the seam located at the start of the
welding process.
6 Lateral bias
in WorkVisual.
The box is locked if the seam center search is deactivated
(Find seam center check box not activated).
• -100 ... 100%

The parameter can be used to offset the TCP laterally relative
to the direction of travel. If the value is positive, the bias occurs
to the right of the seam. If the value is negative, the bias oc-
curs to the left of the seam.
The real lateral bias in mm resulting from the set value
depends on several process factors. The value that must be set
in order to achieve the desired bias can thus only be deter-
mined during optimization of the process.
7 Vertical correction value
This value sets a correction of the welding task in the tool di-
rection. If the required value is not known, it must first be deter-
mined: (>>> 11.2 "Determining the required vertical correction
value" Page 52)
been set for the parameter Height correction in WorkVisual.
If the value Calibration is set for the parameter Height correc-
tion, the box is not displayed.

KUKA.ArcSense 3.3
Programming
If the value for the controller gain is set too high, the system may over-
react, resulting in a wavy line. If, on the other hand, the value is too
low, the system may, under certain circumstances, not respond quickly
enough to changes.
It is advisable to set a higher value for the controller gain initially and to
reduce it gradually in order to determine the optimal value empirically.
NOTICE
Risk of collision if correction not sufficiently taken into account
The maximum correction of the taught path by ArcSense is limited to
300 mm. It is recommended to set the maximum expected correction.
Otherwise, damage to property may result.
• To avoid collisions with the weldment or system components, set the
maximum expected correction.
11.3.2 Option window “Weaving”
If sensor guidance is activated, the configurable weave parameters are

modified.
Fig. 11-5: Option window “Weaving”

Item Description
1 If sensor guidance is activated, the following weave patterns are
available:
• ArcSense - Triangle
Triangle weave pattern
• None
No weaving is carried out. Suitable if the welding task only
requires a vertical correction and not a lateral correction.
Note: If sensor guidance is not activated, the weave patterns
that were configured for the selected data set in WorkVisual re-
main available.
Note: If weave patterns are already preset when sensor guid-
ance is activated, the behavior is as follows:
• If the preset weave pattern is not supported by ArcSense,

weaving is automatically deactivated (= None).
• If the preset weave pattern is supported by ArcSense, the
setting is retained.
2 Only available if a weave pattern has been selected.
Weave length (= 1 oscillation: length of the path from the start
point to the end point of the pattern)
Lateral deflection (= height of the weave pattern)
Angle (= rotation of the weave plane)
• -179.9° … +179.9°
If the weld or weave parameters are modified at the start of a new

seam section, the sensor is retaught automatically. This applies even if
it is defined in the correction parameters that the sensor is not to be re-
taught at the start of the new seam section. (>>> 11.4.1 "Option window
“Correction parameters” (ARC SWITCH)" Page 60)
11.4 Modifying sensor guidance with ARC SWITCH
Description
As standard, the correction parameters programmed with ARC ON are

valid for the entire seam. The ARC SWITCH instruction can be used to
assign other correction parameters to individual seam sections. These val-
ues then apply only to this seam section:
• The existing sensor offset can be retained in a new seam section or
eliminated.
• The sensor can be retaught at the start of a new seam section.
• Sensor guidance can be deactivated for individual seam sections.
Precondition
Procedure
1. Select the menu sequence Commands > ArcTech > ARC SWITCH.

KUKA.ArcSense 3.3
Programming
Inline form
Fig. 11-6: Inline form “ARC SWITCH” with ArcSense
Item Description
1 Name for the weld data set. The ArcSense data set is also
saved with this name.
overwritten.
are modified.
(>>> 11.4.1 "Option window “Correction parameters” (ARC
SWITCH)" Page 60)
program code.

11.4.1 Option window “Correction parameters” (ARC SWITCH)
Fig. 11-7: Option window “Correction parameters” (ARC SWITCH)
Item Description
1 Check box Control activated
• Check box active: sensor guidance is activated in the new

seam section.
• Check box not active: sensor guidance is deactivated in the
new seam section.
If sensor guidance is deactivated, only the Keep offset
check box remains available in the option window. All other
parameters are hidden since they are no longer relevant.
2 Check box Keep offset
• Check box active: the existing sensor offset is retained in

the new seam section.
• Check box not active: the existing sensor offset is not re-
tained in the new seam section, but rather reduced to zero
over a distance depending on the offset.
If the sensor offset has been eliminated, the sensor must be
retaught at the start of the new seam section. For this rea-
son, the Teach new check box is automatically activated
and locked for the user.
3 Check box Teach new
• Check box active: the sensor is retaught at the start of the

new seam section.
• Check box not active: the sensor is not retaught at the start
of the new seam section.

KUKA.ArcSense 3.3
Programming
Item Description
• 0 ... 100%
• 0 ... 100%
tion.
• 1 … 300 mm
7 Lateral bias
• -100 ... 100%

value" Page 52)

enough to changes.
NOTICE
NOTICE
Risk of collision due to unchecked sensor offset
Depending on the system configuration, proceeding with the sensor off-
set or proceeding without it for a new seam section and reteaching the
sensor can lead to a collision with the weldment or system components.
This may result in damage to property.
• For each new seam section, check whether the sensor offset can be
retained.


modified.

KUKA.ArcSense 3.3
Programming
Item Description
available:
• None
main available.

• -179.9° … +179.9°

11.5 Deactivating sensor guidance with ARC OFF
Description
Sensor guidance is deactivated with the ARC OFF instruction.
Precondition
Procedure
1. Select the menu sequence Commands > ArcTech > ARC OFF.

NOTICE
Material damage due to missing ArcSense data set
The ARC OFF inline form does not have any additional parameters. It is
nevertheless absolutely essential to end sensor guidance. Otherwise,
unexpected reactions and thus damage to property may result.
• Insert the ArcSense data set into the inline form
Inline form
Fig. 11-9: Inline form “ARC OFF” with ArcSense
Item Description
1 Name of the data set containing the end crater parameters. The
ArcSense data set is also saved with this name.
overwritten.
2 Name for the ArcSense data set (no parameters can be de-
fined)
The system automatically generates a name. The name cannot
be overwritten.
program code.
11.6 Activating sensor guidance with ARC SPLINE
Description
Sensor guidance is activated in the ARC spline block with the ARC
SPLINE instruction. The correction parameters for the seam can be de-
fined.
Precondition
Procedure
1. Select the menu sequence Commands > ArcTech > ARC SPLINE.

KUKA.ArcSense 3.3
Programming
Inline form
Fig. 11-10: Inline form “ARC SPLINE” with ArcSense
Item Description
1 Weld parameters
are modified.
SPLINE)" Page 66)
program code.

11.6.1 Option window “Correction parameters” (ARC SPLINE)
Fig. 11-11: Option window “Correction parameters” (ARC SPLINE)
Item Description
• 0 ... 100%
• 0 ... 100%
tion.
• 1 … 300 mm
4 Activation delay for seam calibration
been set for the parameter Activation delay for seam calibra-
tion in WorkVisual.
• 0 … 10 s
As standard, teaching of the sensor signal starts with the igni-
tion of the arc (activation delay = 0 s). The start of teaching can
be delayed.

KUKA.ArcSense 3.3
Programming
Item Description
5 Check box Find seam center
in WorkVisual.
• Check box active: during teaching, ArcSense attempts to

detect and track the center of the weld seam preparation.
The maximum correction of the seam center search de-
pends on the magnitude of the programmed weave width,
as the controller has to work with a minimal checkback sig-
nal from both side walls of the seam.
• Check box not active: ArcSense tracks the position of the
welding torch relative to the seam located at the start of the
welding process.
6 Lateral bias
in WorkVisual.
The box is locked if the seam center search is deactivated
(Find seam center check box not activated).
• -100 ... 100%

value" Page 52)

enough to changes.
NOTICE

modified.

KUKA.ArcSense 3.3
Programming
Item Description
available:
• None
main available.

• -179.9° … +179.9°

11.7 Modifying sensor guidance with ARC SWITCH in the ARC spline block
Description
As standard, the correction parameters programmed with ARC SPLINE

are valid for the entire seam (ARC spline block). The ARC SWITCH in-
struction can be used to assign other correction parameters to individual
seam sections (spline segments). These values then apply only to this
seam section (this spline segment):
• The existing sensor offset can be retained in a new seam section or
eliminated.
• The sensor can be retaught at the start of a new seam section.
• Sensor guidance can be deactivated for individual seam sections.
Precondition

• Sensor guidance for ARC spline block is activated.
• ARC spline block fold is open.

Procedure
• Select the menu sequence Commands > ArcTech > ARC SWITCH.
• Set the sensor guidance parameters as required in the inline form.
• Press Cmd OK to save the instruction.
Inline form
Fig. 11-13: Inline form “ARC SWITCH” in the ARC spline block with
ArcSense
Item Description
1 Name for the weld data set. The ArcSense data set is also
saved with this name.
overwritten.
are modified.
SWITCH)" Page 71)
program code.

KUKA.ArcSense 3.3
Programming
11.7.1 Option window “Correction parameters” (ARC SWITCH)
Fig. 11-14: Option window “Correction parameters” (ARC SWITCH)
Item Description
1 Check box Control activated
• Check box active: sensor guidance is activated in the new

seam section.
• Check box not active: sensor guidance is deactivated in the
new seam section.
If sensor guidance is deactivated, only the Keep offset
check box remains available in the option window. All other
parameters are hidden since they are no longer relevant.
2 Check box Keep offset
• Check box active: the existing sensor offset is retained in

the new seam section.
• Check box not active: the existing sensor offset is not re-
tained in the new seam section, but rather reduced to zero
over a distance depending on the offset.
If the sensor offset has been eliminated, the sensor must be
retaught at the start of the new seam section. For this rea-
son, the Teach new check box is automatically activated
and locked for the user.
3 Check box Teach new
• Check box active: the sensor is retaught at the start of the

new seam section.
• Check box not active: the sensor is not retaught at the start
of the new seam section.

Item Description
• 0 ... 100%
• 0 ... 100%
tion.
• 1 … 300 mm
7 Lateral bias
• -100 ... 100%

value" Page 52)

KUKA.ArcSense 3.3
Programming
enough to changes.
NOTICE
NOTICE
Risk of collision due to unchecked sensor offset
Depending on the system configuration, proceeding with the sensor off-
set or proceeding without it for a new seam section and reteaching the
sensor can lead to a collision with the weldment or system components.
This may result in damage to property.
• For each new seam section, check whether the sensor offset can be
retained.


modified.

Item Description
available:
• None
main available.

• -179.9° … +179.9°


KUKA.ArcSense 3.3
Diagnosis
12 Diagnosis
12.1 Recording sensor signals with the RSI monitor
If ArcSense does not function as intended, the sensor signals can be dis-
played, recorded and saved in a file using the RSI monitor. It is advisable
to compress the recorded data in the diagnosis package KRCDiag and
send them to KUKA for error analysis.
Additionally there is an ArcTech diagnosis editor available in WorkVisual
that can be used to display the sensor signals recorded with the RSI mon-
itor.
(>>> 12.3.2 "Overview of sensor signals" Page 79)
Further information about the RSI monitor can be found in the KU-
KA.RobotSensorInterface documentation.
Further information about the diagnosis package KRCDiag can be found

in the operating and programming instructions for the System Software.
12.2 ArcTech diagnosis editor
There is an ArcTech diagnosis editor available in WorkVisual that can be

used to display the sensor signals recorded with the RSI monitor. The re-
corded data can be loaded from the robot controller or locally from a data
storage medium, e.g. USB stick or network drive.
Fig. 12-1: ArcTech diagnosis editor
1 Legend for signals 2 Arrow button

The arrow button on the right-hand side of the editor can be used to open
a configuration window in which the display of the data can be custom-
ized.
12.2.1 Loading data from the robot controller into the editor
Precondition

Diagnosis KUKA.ArcSense 3.3
• Robot controller and KUKA smartHMI are running.

• There is at least one RSI monitor file with recorded data present on
the robot controller.
• The Programming and diagnosis workspace has been opened in
WorkVisual.
Procedure
1. Right-click on the robot controller of the desired cell in the Cell view
window and select ArcTech diagnosis. The ArcTech package win-
dow opens.
2. Select the desired file and click on OK. The editor opens and loads
the data from the selected file.
12.2.2 Loading locally saved data into the editor
Precondition
• At least one RSI monitor file with recorded data has been saved local-
ly.
• The Programming and diagnosis workspace has been opened in
WorkVisual.
Procedure
1. Select the menu sequence Editors > Options packages > ArcTech
diagnosis.
Alternatively: Click on the Open ArcTech diagnosis editor button in
the button bar.
2. Navigate to the desired file, select it and click on Open. The editor
opens and loads the data from the selected file.
12.3 Configuring the display in the ArcTech diagnosis editor
Description
The display in the ArcTech diagnosis editor can be configured:

• Signals that are to be displayed in the editor can be selected.
• Signals that are no longer to be displayed in the editor can be re-
moved again.
• For each signal, it is possible to set how it is to be displayed in the
editor, e.g. in which color.

KUKA.ArcSense 3.3
Diagnosis
Fig. 12-2: Configuration window in the editor
1 Configuration menu
• Load configuration
Loads a saved configuration containing all the settings in the
configuration window.
• Save configuration
Saves each individual configured setting in the configuration
window.
• Restore default configuration
Restores the last saved configuration.
2 Opens the display options
3 Closes the display options
4 Open display options
5 Adds a signal to the editor
6 Closes the configuration window
7 Removes signal from the editor
Precondition
• RSI monitor file is open in the editor.
Procedure
1. Move the mouse pointer to the arrow on the right-hand side of the ed-
itor. If there is a circle enclosing the arrow, the button is active.
2. Click on the button. The configuration window with the available sig-
nals opens.

3. Add or remove signals as required.

(>>> 12.3.2 "Overview of sensor signals" Page 79)
4. Modify the display options as required and save the configuration:
• Open configuration menu
• Save configuration
(>>> 12.3.1 "Changing the signal display options" Page 78)
5. To close the configuration window, move the mouse pointer to the cen-
tral left-hand area of the window until a semicircle becomes visible (=
button for closing the window).
6. Click on the button. The configuration window closes.
12.3.1 Changing the signal display options
Description
The following display options can be modified for each signal:

• Name: name under which the signal is displayed in the editor
• Color: color in which the signal is displayed in the editor
• Thickness: line thickness with which the signal is displayed in the ed-
itor
• Y offset: offset in the Y axis with which the signal is displayed in the
editor
Fig. 12-3: Display options for signals
1 Closes the display options

2 Buttons only visible after modification in display options
Button Description
Saves the changes in the display options
Rejects the changes in the display options and restores

the previous settings.
Precondition
• RSI monitor file is open in the editor.

• Configuration window is open in the editor.

KUKA.ArcSense 3.3
Diagnosis
Procedure
1. Move the mouse pointer to the signal for which the display options are
to be modified.
2. Click on the button with the arrow that is now displayed on the right-
hand side next to the signal. The display options are shown.
3. Make the desired settings and confirm the changes with the green but-
ton.
4. To close the display options, click on the arrow that is displayed on
the right-hand side next to the signal.
12.3.2 Overview of sensor signals
The sensor signals that can be recorded with the RSI monitor and dis-
played in the ArcTech diagnosis editor are described here. Each sensor
signal is assigned a number in the RSI monitor and a name in the diag-
nosis editor.
No. Name Description
1 TTS-PosAct-Y Position of the TCP relative to the taught path (X+) Y axis
2 TTS-PosAct-Z Position of the TCP relative to the taught path (X+) Z axis
3 InSignalFilter Filtered sensor signal
4 InSignalMulti Normalized sensor signal
5 SigQualReady Signal quality check has issued an enable signal (controller
start)
6 SigQualState Information about the status of the signal quality check
7 SigQualDebug Information about errors in the signal quality check
8 ControllerNGY Controller output, Y axis
9 ControllerNGZ Controller output, Z axis
10 ControllerNGY_Int Controller output, Y axis (integrated to controller cycle)
11 ControllerNGZ_Int Controller output, Z axis (integrated to controller cycle)
12 PosCalcSentOffsetInt Established sensor offset, Y axis
13 PosCorrZ Established sensor offset, Z axis
14 ControllerNGCleanPo- Corrected weave signal, Y axis
sIN
15 PosCorrY Overall correction frame, Y axis
16 ControllerNGUDZHeight Upper hysteresis barrier, vertical controller
17 ControllerNGLDZHeight Lower hysteresis barrier, vertical controller
18 ControllerNGState Internal states of the controller state machine
19 ControllerNGError Coded error output of the controller (type: INT, bit-coded)
20 ControllerNGTrigger Trigger window for measured value generation and refer-
ence value information
21 ControllerNGMidVal- Measured mean values of the controller
Meas
22 ControllerNGActSideRa- Current measured value, lateral controller
tio
23 ControllerNGUDZSide Upper hysteresis barrier, lateral controller
24 ControllerNGLDZSide Lower hysteresis barrier, lateral controller


KUKA.ArcSense 3.3
Maintenance
13 Maintenance
13.1 Shunt box maintenance
If used correctly, the shunt box is maintenance-free. Visual inspections of

the cabling are recommended in order to be able to detect changes in
good time. If damaged, exchange the complete shunt box.

Maintenance KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Repair
14 Repair
14.1 Exchanging the shunt box
Description
The new shunt box may have a different revision level from that of the ex-
isting shunt box, e.g. RS1 instead of RS0. If this is the case, the existing
shunt box must be removed from the WorkVisual project and replaced
with the new shunt box.
Precondition

Procedure
1. Disconnect the shunt box from the power source.

2. Unplug the connecting cables.
3. Disconnect the ground conductor.
4. Unscrew the shunt box.
5. Screw on the new shunt box.
6. Plug in the connecting cables on the shunt box.
7. Plug in the ground conductor on the shunt box.
8. Connect the new shunt box to the power source.
9. If the exchanged shunt boxes have different revision levels:
• Remove the existing shunt box from the WorkVisual project and in-
sert the new shunt box into the project.
(>>> 10.1 "Inserting the shunt box in a project" Page 41)

Repair KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Decommissioning, storage and disposal

15 Decommissioning, storage and disposal
15.1 Decommissioning the shunt box
Precondition

Procedure
1. Disconnect the shunt box from the power source.

2. Unplug the connecting cables.
3. Disconnect the ground conductor.
4. Unscrew the shunt box.
5. Prepare the shunt box for storage or transportation.
15.2 Storing the shunt box
Description
If the shunt box is to be put into long-term storage, the following points
must be observed:
• The place of storage must be as dry and dust-free as possible.
• Avoid temperature fluctuations.
• Avoid condensation.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the packaging materials cannot be
damaged.
• Only store the shunt box indoors.
Procedure
• Cover the shunt box with ESD protection foil and seal it against dust.
15.3 Disposal of the shunt box
When the shunt box reaches the end of its useful life, dispose of it as
electrical scrap without disassembling.

Decommissioning, storage and disposal KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Messages
16 Messages
16.1 Information about the messages
The “Messages” chapter contains selected messages. It does not cover all
the messages displayed in the message window.
16.2 System messages from module: ARCS
16.2.1 ARCS 30012
Message code ARCS 30012

Message text Caution! Sensor will be activated!!!(RSI-Arcsense).
Message type Error message
Possible cause(s) Cause: Motion with active sensor guidance started (>>> Page 87)
Solution: Avoid injuries (>>> Page 87)
Cause: Motion with active sensor guidance started
Description
A seam is executed in test mode with active sensor guidance. It is possi-

ble that the robot may correct the path, thereby executing unexpected mo-
tions.
Solution: Avoid injuries
Description
As the path to be executed may not be as expected, keep a sufficient dis-

tance from the robot.
16.2.2 ARCS 30016

Message text Unable to deploy part geometry of control (RSI-Arcsense).
Possible cause(s) Cause: Changes have been made to the KUKA standard settings
(>>> Page 88)
Solution: Uninstalling and reinstalling the option package
(>>> Page 88)

KUKA.ArcSense 3.3
Cause: Changes have been made to the KUKA standard settings

Messages
Description
Predefined KUKA standard parameters, settings or program sections have

been modified or deleted. User-specific adaptations may only be made in
the USER areas provided for this purpose.
Example of a USER area provided specially for user-specific adaptations:
...
;FOLD INI
;FOLD BASISTECH INI
GLOBAL INTERRUPT DECL 3 WHEN $STOPMESS==TRUE DO
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;ENDFOLD (BASISTECH INI)
;FOLD USER INI
;Make your modifications here
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...
Checking instructions
• Check whether all user-specific adaptations have been made exclu-

sively in the USER areas.
Description
Uninstall the option and re-install the software after a cold start. It is ad-
visable to archive all relevant data before uninstalling a software package.
If a KUKA USB Recovery Stick is used to provide the software for the
automatic update, it is essential that the stick is removed after the copy-
ing operation and before rebooting the controller. Otherwise, the control-
ler attempts to boot from the stick.
Precondition

• T1 or T2 mode
Procedure

2. Activate the check box next to the option package and press Unin-
stall. Answer the request for confirmation with Yes.

KUKA.ArcSense 3.3
Messages
7. Press New software: The name of the option package must be dis-
configured first:
ten.
d. If the stick is connected to the robot controller: select E:\.
9. Activate the check box next to the option package and press Install.
Confirm the installation query with OK.
relevant project will be overwritten: answer the query with Yes.
16.2.3 ARCS 30017

Message text Unable to set AccWindow of signal quality for trapezoid (RSI-Arc-
sense).
(>>> Page 89)
(>>> Page 90)
Description


Messages KUKA.ArcSense 3.3
...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure

configured first:

KUKA.ArcSense 3.3
Messages
ten.
16.2.4 ARCS 30018

Message text Unable to set AccWindow of signal quality for triangle (RSI-Arc-
sense).
(>>> Page 91)
(>>> Page 92)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI

;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

KUKA.ArcSense 3.3
Messages
16.2.5 ARCS 30019

Message text Unable to set amplitude of control (RSI-Arcsense).
(>>> Page 93)
(>>> Page 94)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...


KUKA.ArcSense 3.3

Messages
Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

KUKA.ArcSense 3.3
Messages
16.2.6 ARCS 30020

Message text Unable to set amplitude of ReduceCorr (RSI-Arcsense).
(>>> Page 95)
(>>> Page 95)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description

Precondition

• T1 or T2 mode
Procedure

configured first:
ten.
16.2.7 ARCS 30021

Message text Unable to set amplitude of signal generator (RSI-Arcsense).

KUKA.ArcSense 3.3
Messages
(>>> Page 97)
(>>> Page 97)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode

Procedure

configured first:
ten.
16.2.8 ARCS 30022

Message text Unable to set index of analog input signal (RSI-Arcsense).
(>>> Page 99)
(>>> Page 99)

KUKA.ArcSense 3.3
Messages
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure



configured first:
ten.
16.2.9 ARCS 30023

Message text Unable to set index of digital input signal (RSI-Arcsense).
(>>> Page 100)
(>>> Page 101)
Description

...
;FOLD INI

KUKA.ArcSense 3.3
Messages
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure

configured first:

KUKA.ArcSense 3.3
Messages
ten.
16.2.10 ARCS 30024

Message text Unable to set data size of digital input signal (RSI-Arcsense).
(>>> Page 102)
(>>> Page 103)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

KUKA.ArcSense 3.3
Messages

Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

16.2.11 ARCS 30025

Message text Unable to set frequency of control (RSI-Arcsense).
(>>> Page 104)
(>>> Page 105)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...


KUKA.ArcSense 3.3
Messages
Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

16.2.12 ARCS 30026

Message text Unable to set input index of Sen_PINT variable (RSI-Arcsense).
(>>> Page 106)
(>>> Page 106)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description

KUKA.ArcSense 3.3
Messages
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.
16.2.13 ARCS 30027

Message text Unable to set mode of control (RSI-Arcsense).

(>>> Page 108)
(>>> Page 108)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode

KUKA.ArcSense 3.3
Messages
Procedure

configured first:
ten.
16.2.14 ARCS 30028

Message text Unable to set mode of control for NONE (RSI-Arcsense).
(>>> Page 110)
(>>> Page 110)

KUKA.ArcSense 3.3

Messages
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure


KUKA.ArcSense 3.3
Messages
configured first:
ten.
16.2.15 ARCS 30029

Message text Unable to set output index of Sen_PINT variable (RSI-Arcsense).
(>>> Page 111)
(>>> Page 112)
Description

...
;FOLD INI

;FOLD BASISTECH INI

IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure

configured first:

KUKA.ArcSense 3.3
Messages
ten.
16.2.16 ARCS 30030

Message text Unable to set period of signal generator (RSI-Arcsense).
(>>> Page 113)
(>>> Page 114)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...


Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

KUKA.ArcSense 3.3
Messages
16.2.17 ARCS 30031

Message text Unable to set amplitude of control (RSI-Arcsense).
(>>> Page 115)
(>>> Page 116)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...


KUKA.ArcSense 3.3

Messages
Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

KUKA.ArcSense 3.3
Messages
16.2.18 ARCS 30032

Message text Unable to set amplitude of control for NONE (RSI-Arcsense).
(>>> Page 117)
(>>> Page 117)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description

Precondition

• T1 or T2 mode
Procedure

configured first:
ten.
16.2.19 ARCS 30033

Message text Unable to set SQMode of signal quality for NONE (RSI-Arcsense).

KUKA.ArcSense 3.3
Messages
(>>> Page 119)
(>>> Page 119)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode

Procedure

configured first:
ten.
16.2.20 ARCS 30034

Message text Unable to set SQMode of threshold (RSI-Arcsense).
(>>> Page 121)
(>>> Page 121)

KUKA.ArcSense 3.3
Messages
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure



configured first:
ten.
16.2.21 ARCS 30036

Message text Unable to set SQMode of signal generator for triangle (RSI-Arc-
sense).
(>>> Page 122)
(>>> Page 123)
Description


KUKA.ArcSense 3.3
Messages
...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure

configured first:


ten.
16.2.22 ARCS 30037

Message text Unable to set type of signal generator for trapezoid (RSI-Arcsense).
(>>> Page 124)
(>>> Page 125)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI

KUKA.ArcSense 3.3
Messages
;ENDFOLD (USER INI)
;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

16.2.23 ARCS 30038

Message text Unable to set type of signal generator for triangle (RSI-Arcsense).
(>>> Page 126)
(>>> Page 127)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...


KUKA.ArcSense 3.3
Messages
Description
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.

16.2.24 ARCS 30039

Message text Unable to set tool direction (RSI-Arcsense).
(>>> Page 128)
(>>> Page 128)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description

KUKA.ArcSense 3.3
Messages
Precondition

• T1 or T2 mode
Procedure

configured first:
ten.
16.2.25 ARCS 30042

Message text Error setting parameter: {0}

(>>> Page 130)
(>>> Page 130)
Description

...
;FOLD INI
;FOLD BASISTECH INI
IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;FOLD USER INI
;ENDFOLD (USER INI)

;ENDFOLD (INI)
...

Description
Precondition

• T1 or T2 mode

KUKA.ArcSense 3.3
Messages
Procedure

configured first:
ten.
16.2.26 ARCS 30043

Message text Path correction via status key deactivated. (RSI-Arcsense)
Possible cause(s) Cause: Sensor guidance not activated (>>> Page 132)
Solution: Activate sensor guidance via status key (>>> Page 132)

KUKA.ArcSense 3.3
Cause: Sensor guidance not activated

Messages
Description
No path correction can be carried out, as sensor guidance is deactivated.

The procedure for checking the state of the sensor guidance is as
follows:
• Check the Sensor guidance status key:

The status key is grayed out and inactive, e.g. because
an automatic mode is set.
Sensor guidance is activated.
Sensor guidance is deactivated.
Solution: Activate sensor guidance via status key
Description
Activate sensor guidance via the status key Teaching activated.
Precondition
• Operating mode T1 or T2.
Procedure
1. Keep the enabling switch held down.

2. Press the Teaching activated status key:

KUKA.ArcSense 3.3
KUKA Service
17 KUKA Service
17.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
17.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KUKA.ArcSense 3.3

KUKA.ArcSense 3.3
Index Height correction direction.......................43, 45

Hole pattern, shunt box................................. 20
2014/30/EU:2014............................................ 23
2014/35/EU:2014............................................ 23
I
A Identification plate...........................................21
Inputs/outputs, configuring............................. 42
Amplitude.....................................58, 63, 69, 74
Installation.......................................................33
Arc types.........................................................12
via smartHMI............................................. 35
Arc welding equipment...................................23
via WorkVisual...........................................33
ArcTech Advanced..........................................13
Intended use...................................................16
ArcTech diagnosis editor................................ 75
Interface.......................................................... 15
ArcTech Editor, opening................................. 42
Introduction....................................................... 7
B K
Base technology............................................... 9
Knowledge, required.........................................7
KUKA ArcSense Shunt Box Basic............ 8, 15
KUKA Customer Support............................. 133
C KUKA Service...............................................133
Calibration options..........................................46
Compatibility................................................... 33
Configuration...................................................41
Connecting cables.......................................... 19
L
Licenses............................................................8
Connecting cables, cable lengths..................19
Low Voltage Directive.....................................23
Correction variables........................................47
D M
Maintenance................................................... 81
Decommissioning............................................85
Manual correction, performance.................... 37
Diagnosis........................................................ 75
Manual correction, proceeding with welding. 39
Dimensioning, welding cable..........................25
Maximum correction per cycle.......................47
Directives........................................................ 23
Messages........................................................87
Disposal.......................................................... 85
Misuse.............................................................16
Documentation, industrial robot....................... 7
E N
Norms............................................................. 23
Electromagnetic compatibility (EMC)............. 23
Electromagnetic compatibility (EMC):............ 23
EMC Directive.................................................23
EN 60974-12:2011..........................................23 O
EN 61000-6-2:2005........................................ 23 Open source..................................................... 8
EN 61000-6-4:2007 + A1:2011...................... 23 Operation........................................................ 37
Envelope monitoring............................9, 43, 44 Overview, ArcSense......................................... 9
Envelope violation.......................................... 37
Expert configuration........................................47
P
Planning.......................................................... 25
F Plates and labels............................................20
Functional principle.........................................10 Process conditions, general........................... 13
Product description...........................................9
Programming.................................................. 51
G Programming instructions...............................51
Global settings, modifying.............................. 43
R
H Reaction to seam guidance errors................ 44
Recommissioning............................................27
Hardware components................................... 14

KUKA.ArcSense 3.3
Repair............................................................. 83 Weave pattern, length.................58, 63, 69, 74

RS..................................................................... 8 Weave plane............................... 58, 63, 69, 74
RS number.......................................... 8, 21, 41 WorkVisual...................................................... 13
RSI.................................................................... 9
RSI monitor.....................................................75
S
Safety..............................................................23
Safety instructions............................................ 7
Sensor error......................................................8
Sensor guidance, activating (ARC ON).........53
Sensor guidance, activating (ARC SPLINE). 64
Sensor guidance, deactivating (ARC OFF)...63
Sensor guidance, modifying (ARC SWITCH in
the ARC spline block).................................... 69
Sensor guidance, modifying (ARC
SWITCH).........................................................58
Shunt box, exchanging.................................. 83
Shunt box, hole pattern................................. 20
Shunt box, inserting in project.......................41
Shunt box, installingShunt box, connecting.. 27
Start-up........................................................... 27
Status key, deactivating sensor guidance..... 39
Status keys, manual correction..................... 38
Storage........................................................... 85
Support request............................................ 133
System requirements......................................33
Hardware................................................... 33
Software.....................................................33
T
Target group..................................................... 7
Technical data.................................................19
Terms used....................................................... 8
Terms, used...................................................... 8
Training............................................................. 7
Transportation................................................. 31
U
Uninstalling
via smartHMI............................................. 36
via WorkVisual...........................................34
Updating
via WorkVisual...........................................33
Updating via smartHMI...................................35
Use, intended................................................. 16
V
Variables......................................................... 49
W
Warnings........................................................... 7
Weave length.............................. 58, 63, 69, 74
Weave pattern, height.................58, 63, 69, 74

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KUKA System Technology

Publication: Pub KST ArcSense 3.3 (PDF) en

Book structure: KST ArcSense 3.3 V1.1

Version: KST ArcSense 3.3 V1

2/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

6 Start-up and recommissioning............................................................... 27

KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 3/136

15 Decommissioning, storage and disposal............................................. 85

4/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

15.2 Storing the shunt box............................................................................................ 85

17 KUKA Service........................................................................................... 133

KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 5/136

6/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

1.1 Target group

This documentation is aimed at users with the following knowledge and

• KRL programming skills

For optimal use of KUKA products, we recommend the training courses

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 7/136

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

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

Procedures marked with this warning must be followed exactly.

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

1.4 Terms used

Further information about open-source licenses can be requested from

8/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

2.1 Product description

ArcSense is an add-on option package based on ArcTech Basic for sen-

2.2 Overview of ArcSense

The base technology for KUKA.ArcSense is KUKA.RobotSensorInterface

KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 9/136

Fig. 2-1: Envelope monitoring

1 Weave amplitude (deflection to one side from the path center)

Fig. 2-2: Teaching the sensor

1 Minimum distance for teaching the sensor

10/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

A lateral bias can be programmed for a seam or seam section in order to

Fig. 2-3: Positive lateral bias

KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 11/136

Fig. 2-4: Negative lateral bias

‒ The functional capability of ArcSense may be restricted if regula-

‒ The functional capability of ArcSense may be restricted if regula-

‒ The functional capability of ArcSense may be restricted in the case

12/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

Seam tracking depends, among other things, on the welding process

ArcSense can used in conjunction with ArcTech Advanced.

The KUKA.WorkVisual software is required for configuring the sensor and

2.3 General process conditions

Reliable and reproducible sensor guidance requires compliance with a

KST ArcSense 3.3 V1 | Issued: 15.01.2020 www.kuka.com | 13/136

• Sensor guidance is suitable in the welding positions PA (gravity posi-

2.4 Hardware components

The following hardware components are optionally available:

A 95 mm2 welding cable is permissible up to a maximum weld current

14/136 | www.kuka.com KST ArcSense 3.3 V1 | Issued: 15.01.2020

Fig. 2-5: Shunt box interface