1L21700E E 1 - SpotWelding PDF

No.
1L21700E-E-1
series
INSTRUCTION MANUAL
APPLICATION MANUAL
SPOT WELDING
■ Read and follow these instructions and all safety blocks carefully.
■ Have only trained and qualified persons install, operate, or service this unit.
■ Give this manual to the operator.
■ For help, call your distributor.

Be Sure to Read Instruction Manuals Before Use
Thank you for selecting DAIHEN arc welding robot Almega series.
Almega series are the robots with high performance and various functions developed by making full use of the
latest technology. Since the knowledge of welding peculiar to a welding machine maker is applied to both
hardware and software, we are sure that each user can be fully satisfied
In order to use the superior performance and the abundant functions safely and fully, be sure to read the
following instruction manuals including this manual and other attached documents, and understand the
knowledge of the machines, safety information, and notes thoroughly.
Instruction manuals related to the manipulator “V/B/H series”, and the robot control unit “FD11” are as follows.
■Standard Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
QUICK START Point on Safety, Transportation and Installation,
1L21700A
Turning the power on/off and manual operation, etc.
SETUP Safety precautions, installing & connecting method,
1L21700B starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE Specifications of controller, explanation of each parts
1L21700K
and maintenance, parts list, etc.
MANIPULATOR Specifications or maintenance of manipulator, parts
1L11130A
（NB4 / NB4L / NB15 / NV6 / NV6L / NV20 / NH5） list, etc.
1L11312A
（NV50） list, etc.
1L11306A
（NV166 / NV210） list, etc.
BASIC OPERATIONS Explanation of manual operation, teaching, automatic
1L21700C operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
EXTERNAL INPUT/OUTPUT Interfacing method with external control device, list of
1L21700H
I/O signals and start/halt the automatic operation, etc.
Software PLC Create program,Input/output relay lists,List of
1L21700J
command words, etc.
CONTROL AND MAINTENANCE Edit logging,User Check,Troubleshooting, etc.
1L21700L
FUNCTION
■Application Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700F
(ARC WELDING) technic, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21700E
(SPOT WELDING) technic, etc.
Instruction manuals are available other than the above for each optional function that you have purchased.
[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual
ones.
3. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do not take any
responsibility for damages resulting from neither direct nor indirect errors.
4. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.
5. No part of this manual may be reproduced without permission.
6. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.
The warranty does not cover any altered or remodeled products.
-1-
Notice
Notes on Safety
Before installation, operation, be sure to read "Chapter 1 Points on Safety" in SETUP manual and other attached
documents thoroughly and acquire all the knowledge of machines, safety information, and precautions.
Furthermore, before maintenance, inspection, and trouble scene, be sure to read CONTROLLER
MAINTENANCE manual and MANIPULATOR manual and other attached documents thoroughly and acquire all
the knowledge of machines, safety information, and precautions.
If operating machines in a wrong way, the accident resulting in various ranks of injury or death, or damage may
occur.
In order to call attention to wrong handling, the following four ranks of safety notes (“DANGER”, “WARNING”,
“CAUTION”, and “IMPORTANT”) are provided.
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury and where the degree of the urgency
(imminence) of the warning given for the danger to occur is at the high end of the
DANGER scale (including high-level danger).
the danger of death or serious injury.
WARNING
the danger of minor injuries or of property damage only.
CAUTION
The following symbol is also used for particularly important checkpoints:
This is a particularly important checkpoint.

IMPORTANT
Note that even the matters which are described as CAUTION can result in serious accident depending on the conditions.
Be sure to keep the safety notes since they describe very important matters.
The meanings of “Serious injury”, “Minor injury”, and “Damage” described above are as follows.
Serious injury ： Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.
Minor injury ： Injury which does not require either hospitalization or long-term treatment as an outpatient,
a burn (high temperature, low temperature), and an electric shock.
Damage ： Direct and indirect damage in connection with damage of property and equipment.
-2-
Table of Contents
Table of Contents
Chapter 1 Basic settings

1.1 Complete sequence of advanced setup work ..................................................................... 1-1
1.2 Basic welder and gun settings ............................................................................................ 1-2

1.2.1 Spot welder settings........................................................................................................ 1-4
1.2.2 Spot welding gun settings ............................................................................................... 1-5
1.3 Assignment of spot welding input/output signals ................................................................ 1-6
1.3.1 Spot welding input signal ................................................................................................ 1-6
1.3.2 Spot welding output signals ............................................................................................ 1-9
1.4 Expert settings for servo gun conditions ........................................................................... 1-12
1.5 Servo gun tip consumption detection Expert settings....................................................... 1-15
Chapter 2 Spot welding condition

2.1 Spot welding condition ........................................................................................................ 2-1
2.1.1 Welding conditions common to all welders..................................................................... 2-1
2.1.2 Individual welding conditions for each welder ................................................................ 2-1
2.2 Recording and manual spot welding conditions ................................................................. 2-3
2.3 Useful welding condition editing functions .......................................................................... 2-4

2.3.1 Copying the welding conditions ...................................................................................... 2-4
2.3.2 Listing the welding condition usage statuses ................................................................. 2-5
Chapter 3 Spot weld sequence

3.1 Spot weld sequence ............................................................................................................ 3-1
3.1.1 Welding sequences common to all welders ................................................................... 3-3
3.1.2 Individual welding sequence for each welder................................................................. 3-6
3.2 Recording and manual spot welding sequences ................................................................ 3-9
3.3 Useful welding sequence editing functions ....................................................................... 3-10
Chapter 4 Servo gun tip consumption measurements

4.1 Outline of tip consumption compensation ........................................................................... 4-1
4.2 Gun Search Function .......................................................................................................... 4-2

4.2.1 How to use gun search 1 (total tip consumption amount detection) .............................. 4-4
4.2.2 How to use gun search 2 (moving side tip consumption amount detection).................. 4-5
4.2.3 How to use gun search 3 (simplified tip consumption amount detection) ...................... 4-6
4.3 Teaching of tip consumption amount detection program .................................................... 4-7
4.4 Gun search reference write................................................................................................. 4-8
4.5 Executing gun search 2 first................................................................................................ 4-9

4.5.1 Designating by constants setting .................................................................................... 4-9
1
Table of Contents
4.5.2 Designating the execution sequence by function command .......................................... 4-9

4.6 Clearing tip consumption amounts.................................................................................... 4-10
4.6.1 How to clear the tip consumption amounts using an R code ....................................... 4-10
4.6.2 How to clear the tip consumption amounts by manual operation................................. 4-10
4.6.3 How to clear the tip consumption amounts using an external signal ........................... 4-10
4.6.4 How to clear the tip consumption amounts automatically ............................................ 4-10
4.7 Abnormal tip consumption amount detection.................................................................... 4-11
4.7.1 Tip consumption amount abnormality detection ........................................................... 4-11
4.7.2 Search 3 tip consumption change trouble detection .................................................... 4-11
4.7.3 Gun search stop trouble detection................................................................................ 4-11
4.8 Offset of Tip Consumption Amount Display and Error Detection Level....................................................... 4-12
4.8.1 Registration of Offset Value .......................................................................................... 4-13
Chapter 5 Welding program teaching

5.1 Basic operations for welding steps ..................................................................................... 5-1
5.2 Welding conditions and welding sequences during step recording ............................................................. 5-2
5.3 Welding step teaching ......................................................................................................... 5-3

5.3.1 Spot welding command recording .................................................................................. 5-3
5.3.2 Tip consumption compensation during welding point recording .................................... 5-6
5.4 CHECK GO/BACK for welding steps .................................................................................. 5-7
5.4.1 Non-continuous CHECK GO/BACK ............................................................................... 5-7
5.4.2 Permanent "pressurizing OFF" for CHECK BACK ......................................................... 5-8
5.5 Modifying welding steps ...................................................................................................... 5-9
5.5.1 Position modification....................................................................................................... 5-9
5.5.2 Overwriting...................................................................................................................... 5-9
5.5.3 Insertion .......................................................................................................................... 5-9
5.5.4 Deletion........................................................................................................................... 5-9
5.5.5 Affinity with jump call commands.................................................................................. 5-10
5.6 Checking the recording positions of the welding steps..................................................... 5-11
5.7 Setting of Clearance by Function Command ....................................................................5-12

5.7.1 Recording of equalization value setting command....................................................... 5-13
5.7.2 Recording the equalizing clear command ....................................................................5-16
5.7.3 Example of recording.................................................................................................... 5-17
Chapter 6 Useful functions

6.1 Gun lock (mechanism disconnection) ....................................................................................... 6-1
6.2 Short-cuts .................................................................................................................................. 6-2

6.2.1 R315 Welder select ........................................................................................................... 6-2
6.2.2 R339 Preset Tip Consumption Amounts ........................................................................... 6-2
6.2.3 R349 Calibrate servo gun.................................................................................................. 6-3
6.2.4 R376 Equalize confirmation / clear.................................................................................... 6-3
6.3 Spot welding monitor ................................................................................................................. 6-4
6.3.1 Servo gun data .................................................................................................................. 6-5
6.3.2 Welder I/O.......................................................................................................................... 6-9
6.3.3 Welding counter............................................................................................................... 6-10
6.4 Group Designation Type Welding Condition Setting Function ................................................ 6-12
6.4.1 Outline ............................................................................................................................. 6-12
6.4.2 Constant Setting .............................................................................................................. 6-13
2
Table of Contents
6.4.3 Spot Welding Condition Setting....................................................................................... 6-14

6.4.4 Welding Condition Group Designation Record ............................................................... 6-17
6.4.5 Spot Welding Monitor ...................................................................................................... 6-18
6.4.6 R371 Welding Condition Group Number Change ........................................................... 6-18
6.4.7 Troubleshooting ............................................................................................................... 6-18
6.5 Servo Gun Weld Stuck Detection ............................................................................................ 6-19
6.5.1 Setting the Error Code Output Format ............................................................................6-19
6.5.2 Allotting the Error Code Signal ........................................................................................ 6-19
6.5.3 Setting the Abnormal Tracking Detection Level .............................................................. 6-20
Chapter 7 Tip dressing

7.1 High-quality tip dressing using a servo gun ........................................................................ 7-1
7.2 Settings ............................................................................................................................... 7-2

7.2.1 Setting the tip dressing sequence .................................................................................. 7-2
7.2.2 Setting the input/output signals for tip dressing.............................................................. 7-5
7.3 Teach/playback.................................................................................................................... 7-9
7.3.1 Function command "TIPDRESS: Tip Dressing" (FN265)............................................... 7-9
7.3.2 Playback with welding OFF ............................................................................................ 7-9
7.3.3 Detection of trouble during tip dressing playback........................................................... 7-9
Chapter 8 Special servo gun functions

8.1 Functions using external signals ......................................................................................... 8-1
8.1.1 External wide open ......................................................................................................... 8-1
8.1.2 External small open ........................................................................................................ 8-1
8.1.3 External welding ............................................................................................................. 8-2
8.1.4 External manual pressurizing ......................................................................................... 8-2
8.1.5 Re-welding ...................................................................................................................... 8-2
8.1.6 Tip consumption amount reset ....................................................................................... 8-3
8.1.7 External gun search........................................................................................................ 8-3
8.1.8 External tip dressing ....................................................................................................... 8-3
8.1.9 Gun contact detection..................................................................................................... 8-3
8.2 Multi-step welding force control........................................................................................... 8-4
8.2.1 Outline of multi-step welding force control ..................................................................... 8-4
8.2.2 Setting the multi-step parameters................................................................................... 8-5
8.3 Gun change control............................................................................................................. 8-7
8.4 Double gun control .............................................................................................................. 8-8
8.5 Multi-gun simultaneous welding .......................................................................................... 8-9

8.5.1 What is multi-gun simultaneous welding ........................................................................ 8-9
8.5.2 Restrictions ..................................................................................................................... 8-9
8.5.3 Setting the simultaneous manual operations to be enabled ........................................ 8-10
8.5.4 Selecting the welder to be operated manually ............................................................. 8-11
8.5.5 Manual operation .......................................................................................................... 8-12
8.5.6 External operations....................................................................................................... 8-16
8.5.7 Recording SYNCSPOT (FN303): simultaneous spot welding function ........................ 8-18
8.5.8 Executing SYNCSPOT (FN303): simultaneous spot welding function......................... 8-23
8.5.9 Error detection of tip consumption amount difference.................................................. 8-25
Chapter 9 Special Air Gun Functions

9.1 Stroke Change by Function Command ............................................................................... 9-1
3
Table of Contents
9.1.1 Setting of stroke change by function command ............................................................. 9-1

9.1.2 GUNOPEN; Full/half gun open function (FN218)........................................................... 9-2
9.1.3 Spot welding sequence................................................................................................... 9-3
9.1.4 Example of behavior ....................................................................................................... 9-4
Chapter 10 Pressure direct weld function

10.1 Outline ............................................................................................................................... 10-1
10.1.1 FN268 function (Specified force weld)........................................................................ 10-1
10.1.2 Required settings........................................................................................................10-1
10.1.3 The difference of the welding motion and the gun axis motion .................................. 10-1
10.2 Settings ............................................................................................................................. 10-2
10.2.1 Enabling the FN268 function ...................................................................................... 10-2
10.2.2 The settings for function record and the manual weld operation ............................... 10-3
10.2.3 Recording FN268 function.......................................................................................... 10-5
10.2.4 Manual recording of FN268 function .......................................................................... 10-6
10.2.5 Automatic recording of FN268 function ...................................................................... 10-6
10.3 Special functions for Specified force weld function ........................................................... 10-7
10.3.1 <Cancel WI> operation is prohibited in motors OFF .................................................. 10-7
10.3.2 Gun axis pressure limitation for manual axis operation.............................................. 10-7
10.4 Pressure limitation............................................................................................................. 10-8
10.4.1 How to set the limitation values .................................................................................. 10-8
10.4.2 The pressure limit in the welding condition screen................................................... 10-10
10.4.3 The pressure limit in the [Spot Teach/Playback Condition] screen .......................... 10-10
10.5 Troubleshooting............................................................................................................... 10-11
4
Chapter 1 Basic settings
This chapter describes the advanced setup work, that is not described in Setup
Manual or Basic Operations Manual, for operators who uses this robot for spot
welding application.
Use the information contained in this chapter at times when, for instance, the system
configuration is to be changed after the robot has been installed.
1.1 Complete sequence of advanced setup work...........................................1-1

1.2 Basic welder and gun settings..................................................................1-2
1.2.1 Spot welder settings.........................................................................1-4
1.2.2 Spot welding gun settings ................................................................1-5
1.3 Assignment of spot welding input/output signals ......................................1-6
1.3.1 Spot welding input signal .................................................................1-6
1.3.2 Spot welding output signals .............................................................1-9
1.4 Expert settings for servo gun conditions.................................................1-12
1.5 Servo gun tip consumption detection Expert settings.............................1-15
1.1Complete sequence of advanced setup work
1.1 Complete sequence of advanced setup work

The figure below shows all the steps involved in the setup work for the spot welding application.
Spot welding setup start
Assignment of spot welding

input/output signals
Overall spot welding setup

Setup of each spot welding tool
(this work is inherent to servo guns)
Welder settings Mechanism machine constant settings
Spot welding tool settings Servo tuning Since the steps taken
in the shaded area are
Servo gun general characteristics normally performed
settings prior to shipment from
the factory, the user
Servo gun bending characteristics
need not take them.
settings
Servo gun welding force adjustment
Servo gun conditions settings
Servo gun tip consumption settings
Spot welding setup end
Fig. 1.1.1 Complete sequence of spot welding setup work
This section first explains the "Welder settings" and "Spot welding tool (gun) settings" which constitute
part of the shaded area in "Fig. 1.1.1 Complete sequence of spot welding setup work".
Furthermore, this chapter describes the settings for many of the spot welding input/output signals, the
servo gun conditions and the servo gun tip consumption amount detection so that spot welding with an
even higher quality can be achieved.
Details on the setup work from the "Mechanism machine constant settings" to the "Servo gun welding
force adjustment" on the right-hand side of the shaded area in "Fig. 1.1.1 Complete sequence of spot
welding setup work" will not be presented in this manual. A high level of knowledge relating to industrial
robots is required for this work, and details are given in a separate manual.
1-1
1.2Basic welder and gun settings
1.2 Basic welder and gun settings

The setup here involves such aspects as the number of spot welders to be used and their connection
methods as well as the control systems of the spot welding guns.
Up to six spot welders (welding controllers or timer contactors) can be connected. Numbers 1 to 6 are
assigned to the welding controllers, and it is these numbers that the spot welding commands specify for
recording. Up to 31 spot welding guns can be controlled.
This controller makes a clear distinction between welders and spot welding guns. For identification purposes,
"W" refers to the welders and "G" to the guns.
Welder #1 Welder #2 Welder #3 Welder #4 Welder #5 Welder #6
Fig. 1.2.1 Spot welder (timer contactor) connections
Robot controller
Welding controller
Spot welding gun
Multi-gun specification Gun change specification
Fig. 1.2.2 Spot welding tool (gun) connections
1-2
The setting menu is divided into two sets of settings: the "spot welder setting" and the "spot welding gun
settings." The operation method used is the same for both sets.
1 Select the teach mode.
2 Select <Spot Constant> f key. The same menu can be selected by pressing [8.
Spot Welding Application] from <Constant Setting> f key.
>>The constant setting menu used exclusively for spot welding such as the one
shown below now appears.
Menu items for title No.3 and following are displayed only when servo guns have
been already set.
3 Align the cursor with "Spot welder setting," and press the [Enter] key.
>>The setting screen such as the one shown below now appears.
Alternatively, align the cursor with "Spot welding gun setting," and press the
[Enter] key.
>>The setting screen such as the one shown below now appears. The menu items
proportionate to the number of welders defined by "Spot welder settings" are
displayed.
4 If there is an edit box, input the appropriate number, and press the [Enter] key.
1-3
With radio buttons (a horizontal row of selection fields), switch between them
＋ by pressing the [ENABLE] and [left or right cursor] key simultaneously.
With a combo box (a selection box with an arrow at the far right), align the
cursor, and begin by pressing the [Enter] key. A table with a list of selection
candidates now appears. Use the up or down cursor key to select the chosen
candidate, and press the [Enter] key again.
5 Upon completion of the settings, press <Complete> f key.

The settings are now written in the spot welding constants file.
1.2.1 Spot welder settings

The parameters in this section define the number of the spot welders connected and the method
used to connect them.
Table 1.2.1 Welder settings
Factory
Parameter Description of function
settings
Number of welder 1 This is used to set the number of spot welders (timer contactors)
which will be used. Up to six welders can be defined.
(Refer to "Fig. 1.2.1 Spot welder (timer contactor) connections")
Guns 0 This is used to specify the number of spot welding tools.

A value of 1 or more must be set without fail.
Welding control Standard This is used to specify the type of welding controller to be used.
interface A number of different kinds of spot welders are sold on the market
including the regular parallel I/O connection type, field bus
connection type and bus direct-coupled type.
Since these instructions assume that only the regular parallel I/O
connection type is used, "standard" is selected as the setting here.
Even when a multiple number of welders are used, there is only one
welder interface.
1-4
1.2.2 Spot welding gun settings

Table 1.2.2 Spot welding tool settings
Factory
settings
Driving source Air This is used to define the drive method and application of the spot
welding tool. Select one of the following.
Air Air-driven spot welding gun

GUN15AD Servo-driven spot welding gun. The name of the
(Example) mechanism which has been set is displayed
unchanged as the selection candidate.
Type Spot This parameter is used to select the application of the spot welding
gun concerned. At the "Stud" setting, special control is exercised to
raise the servo rigidity during pressure application.
Spot The gun is controlled as a spot welding gun.
Stud <Not supported at present time.>
Seam The gun is controlled as a seam welding gun.
Welder 1 This is used to set the number of the welder which is connected to
the spot welding gun concerned.
(1 to 6)
Tool 1 This is used to set the number of the tool which is used for the spot
welding gun concerned.
(1 to 32)
Parent mechanism Stationary This is used to select the method used to secure the spot welding
gun concerned.
Stationary The spot welding gun concerned is secured to
the ground and used for stationary welding.
SRA166-01+A The spot welding gun concerned serves as the
(Example) end effecter of the robot. Select the robot on
which the gun is to be installed from the list of
the mechanisms displayed.
1-5
1.3Assignment of spot welding input/output signals
1.3 Assignment of spot welding input/output signals

The commonly used input/output signals were already described in the "Spot welding setup" section of Setup
Manual. This section describes the input/output signals used to achieve more advanced spot welding.
1.3.1 Spot welding input signal

All the spot welding input signals, including the ones already described in the "Spot welding setup"
section of Setup Manual, are described.
The basic input signals (for standard uses) are not described.
Among the signals are the ones used with air guns only, the ones used with servo guns only, and
the ones used for both types of guns. The "" symbol in the table denotes the signal which is used
(or which can be used). "–" denotes a signal which is not used even if it has been assigned.
Table 1.3.1 Spot welding input signal

Factory
Basic input signal Air Servo
settings Description of function
designation Gun gun
input signal
Weld completed (WI) 26 This signal requests that the fact that the welding has been
(Connector completed be input from the welder (timer contactor). When
 
pin #34) this signal is input, the gun release is started in order for the
W2 to W6 0 gun to move to the next step.
Gun closed 0 Input this signal after detecting the fully closed position of
 –
the air gun using a limit switch, etc.
Gun half-opened 0 Input this signal after detecting the semi-open position of
 –
the air gun using a limit switch, etc.
Gun full-opened 0 Input this signal after detecting the fully open position of the
 –
air gun using a limit switch, etc.
Welder fault input 0  
Weld stuck input 0 Immediately after the welding finish (WI) signal is input, this  
controller checks whether any of these signals have been
Water flow sw. #1 0  
input, and if one of them has been set to ON, it displays the
Water flow sw. #2 0  
corresponding error message to suspend the playback
Thermo. Temp. fault 0 operation. It does not detect these signals when they have
 
Air pressure sw. 0 not been assigned.  
System fault 0  
Weld ON 27 Weld ON, weld OFF or pressurizing OFF is selected by
(Connector means of external signals. The combinations of these
pin #35) signals are presented below. For the individual statuses,
refer to the "Basic operations for spot welding" in the Basic
 
Operations Manual.
Weld ON and weld OFF can be switched by means of
external signals only when the "Weld ON/OFF" spot welding
condition has been set to "Input signal."
Pressurizing OFF 0 The pressurizing OFF status, however, is established
simply as a result of the input of the pressurizing OFF signal
regardless of this setting.
"Pressurizing
"Weld ON" input
OFF" input Status
signal
signal
 
ON ON →Pressurizing
OFF
ON OFF →Weld ON
OFF ON →Pressurizing
OFF
OFF OFF →Weld OFF
To use the input signals “Weld ON” and “Weld OFF,” determine the status of “Weld ON/OFF” at least
100msec before running the work program.
Even if the status of “Weld ON/OFF” is changed when running the program, such change may not
IMPORTANT be immediately incorporated in the program.
1-6
Factory
designation Gun gun
input signal
Servo gun touch 0 When the signal that indicates that the servo gun is
touching the work is input from an external source, the
– 
buzzer on the teach pendant sounds intermittently while the
signal is ON.
External wide release 0 The servo gun is set to wide release (position of the wide
release end default value) by means of an external signal.
It is valid only in the playback underway mode. The wide – 
release operation is initiated when the rise at which the
signal goes from OFF to ON is detected.
External narrow 0 The servo gun is set to narrow release (pressuring stroke
release position) by means of an external signal. It is valid only in
the playback underway mode. The narrow release – 
operation is initiated when the rise at which the signal goes
from OFF to ON is detected.
External welding 0 This is used for manual welding by means of external
signals.
It is valid only in the playback mode. The processing is – 
performed when the rise at which the signal goes from OFF
to ON is detected.
External pressurizing 0 This is used for manual pressurizing by means of external
signals.
It is valid only in the playback mode. The processing is – 
performed when the rise at which the signal goes from OFF
to ON is detected.
Re-welding 0 This is used for re-welding by means of external signals. It
is valid only in the playback mode.
The welding is executed under the welding conditions for – 
the welding that was executed immediately before when the
rise at which the signal goes from OFF to ON is detected.
Welding condition 0 This specifies the numbers of the welding conditions under
select which external welding or external pressurizing is to be
performed. – 
If the signal has not been allocated, the number designated
by the spot welding conditions is used.
Welding sequence 0 This specifies the numbers of the welding sequences in
select which external welding or external pressurizing is to be
performed. – 
If the signal has not been allocated, the number designated
by the spot welding sequence is used.
Reset consumption 0 This is used when the tip consumption amounts of the
moving side tip and settled side tip are to be reset together – 
by means of an external signal.
Moving side reset 0 This is used when the tip consumption amount of the moving
– 
consumption side tip is to be reset by means of an external signal.
Settled side reset 0 This is used when the tip consumption amount of the settled
– 
consumption side tip is to be reset by means of an external signal.
External gun search 1 0 <Not supported at present time.>
This is used when executing gun search 1 by means of an – 
external signal.
external signal.
external signal.
Gun search type 0 <Not supported at present time.>
This signal identifies whether the standard type or input
signal interrupt type is to be used when executing gun – 
search 2 by means of an external signal. Input this signal
when the input signal interrupt type applies.
Gun search interrupt 0 <Not supported at present time.>
This is used as the interrupt signal for executing gun search – 
2 which is the input signal interrupt type.
External tip dressing 0 <Not supported at present time.>
This executes the tip dressing function by means of an – 
external signal.
Tip dress condition 0 <Not supported at present time.>
select This is used to select the tip dressing conditions by means  
of an external signal.
1-7
Factory
designation Gun gun
input signal
Tip dress normal 0 This inputs the tip dresser status.
If this signal has not been input when the tip dressing
 
function is executed, trouble is detected, and the tip is not
dressed.
Tip dressing 0 Input this signal to forcefully abort tip dressing at any interim
complete point. When it is input while a dressing sequence is being
executed, the sequence is aborted, and the function is
 
completed. It need not be input when tip dressing has
ended normally.
One signal can be allocated per welder (total: 6 signals).
Simultaneous 0 This is used to select the discrete welders which are to
welding select perform the simultaneous welding. If, for instance, pressure
is to be applied with welders 1 and 2 simultaneously using
welder 1 as the master, the external pressure application
– 
signal of welder 1 will be input while simultaneous welding
select signals 1 and 2 of welder 1 are turned ON.
Six of these signals for each welder (making a total of 36
signals for all the welders) can be allocated.
Unit select 0 This is used to specify in binary format the unit to be
operated when a multi-unit system is used. – 
Four signals can be allocated per welder (total: 24 signals).
Servo gun number 0 This specifies the ID of the currently connected spot
welding gun discretely from 1 to 31 when servo gun – 
changing is performed.
Test weld 89 Used only when welder control interface = MEDbus (option) – 
Stepper reset 1 90 Used only when welder control interface = MEDbus (option)
– 
91
Stepper reset 2 0 Used only when welder control interface = MEDbus (option) – 
Isolation contact 93 Used only when welder control interface = MEDbus (option) – 
Isolation 1 95 Used only when welder control interface = MEDbus (option) – 
Isolation 2 96 Used only when welder control interface = MEDbus (option) – 
SCR thermal switch 119 Used only when welder control interface = MEDbus (option)
– 
120
Control stop 94 Used only when welder control interface = MEDbus (option) – 
External stroke 121 Used only when welder control interface = MEDbus (option)
– 
switching 122
Weld enabled 123 Used only when welder control interface = MEDbus (option) – 
Welding force 0 Used only when welder control interface = MEDbus (option) – 
Schedule in Progress 0 Used only when welder control interface = MEDbus (option) – 
Reset auto modify 0 Used only when welder control interface = MEDbus (option) – 
Extended input 0 Used only when welder control interface = MEDbus (option) – 
Unit select 0 <Not supported at present time.> – 
Welding condition 0 Used only when welder control interface = RWC3200
– 
compensation (option).
Manual weld enabled 0
1-8
1.3.2 Spot welding output signals

All the spot welding output signals, including the ones already described in the "Spot welding setup"
section of Setup Manual, are described.
The basic output signals (for standard uses) are not described.
Among the signals are the ones used with air guns only, the ones used with servo guns only, and
the ones used for both types of guns. The "" symbol in the table denotes the signal which is used
(or which can be used). "–" denotes a signal which is not used even if it has been assigned.
Table 1.3.2 Spot welding output signals

Factory
Basic output signal Air Servo
settings output Description of function
designation Gun Gun
signal
Pressurization 17 This is output when the step in which the spot welding
(Connector pin command (SPOT: FN119) has been recorded is played
#19) back. It is also output during manual pressurizing  
operations in the teach mode.
Only welder 1 (W1) is initially assigned.
Full open 18 This is the signal for opening the air gun fully. It is output
(Connector pin when fully open has been set with "Stroke" in the spot
 –
#20) welding sequence.
Only welder 1 (W1) is initially assigned.
Half open 0 This is the signal for opening the air gun halfway.
It is output when semi-open has been set with "Stroke" in  –
the spot welding sequence.
Weld start 0 This is output when the "Power-on signal" in the spot
welding sequence has been set to "Output provided" and
 
the spot welding command is played back in the Weld ON
status.
Welding condition 0 The "Welding condition output data" which has been set as
the spot welding conditions is output.  
The signal range from 1 to 16.
Pressure control 0 When air guns are used, the [Welding force control] data
specified in the spot welding conditions is output. Use this
when air guns that employ an electro-pneumatic  –
proportional valve, etc. to control the welding force are
used.
Weld warning 19 <Not supported at present time.>
(Connector pin  
#21)
Gun stuck alarm 0 This level signal is output when deposition is detected.  
Weld time 0 This is output when the welding finish (WI) signal is not
 
exceeded input even when the "Power-on wait time" has elapsed.
System fault 0 This is output when the "Peripheral device trouble" input
signal has been turned ON after the welding finish (WI)  
signal was input.
Weld ID# bits 0 The number recorded as the welding point of the spot
welding command is output in binary form if trouble has
 
occurred during welding. At which spotting point the trouble
has occurred can be pinpointed using this.
Weld count up 0 When the number of welding times indicated on the welding
counter has exceeded the count-up value which had been
set, this signal is output with a 0.3 sec. pulse every time a  
spot welding command is subsequently executed.
It is not output when the count-up value is not set.
Tip consumption 0 During a gun search, this signal is output when the moving
trouble side or settled side tip consumption amount has exceeded – 
the maximum tip consumption amount.
Moving side 0 During a gun search, this signal is output when the moving
tip consumption side tip consumption amount has exceeded the maximum – 
trouble tip consumption amount.
Settled side 0 During a gun search, this signal is output when the settled
tip consumption side tip consumption amount has exceeded the maximum – 
trouble tip consumption amount.
Tip consumption. 0 During a gun search, this signal is output when the moving
alarm side or settled side tip consumption amount has exceeded – 
the tip change tip consumption r amount.
Moving side tip 0 During a gun search, this signal is output when the moving
consumption side tip consumption amount has exceeded the tip change – 
Alarm tip consumption amount.
1-9
Factory
designation Gun Gun
signal
Settled side tip 0 During a gun search, this signal is output when the settled
consumption alarm side tip consumption amount has exceeded the tip change – 
tip consumption amount.
Tip consumption 0 An error is displayed and the robot is stopped when the
amount change difference between the tip consumption amount detected
trouble by search 3 and the total tip consumption amount detected
by the previous search 1 or search 3 has exceeded the
"Search 3 trouble tip consumption change amount" in the – 
servo gun conditions.
Trouble is not detected if "0" has been set for the "Search 3
trouble tip consumption change amount" in the servo gun
conditions.
Sheet thickness 0 This is output when the error in the sheet thickness
trouble detected at each welding point has exceeded the sheet – 
thickness trouble detection amount.
Servo gun 0 This is set to ON when pressurizing starts and to OFF when
squeeze the servo gun is released. – 
It is output while a welding command is being executed.
Gun search 0 This is set to ON when the gun search starts and to OFF
underway upon completion of the search.
It remains ON if stop, emergency stop, etc. was input – 
during the gun search and the gun search was not
completed.
Gun search finish 0 This is output upon completion of gun search execution. – 
Gun search 0 This is set to ON when gun search reference write has
– 
reference writing been set to valid.
Tip dressing 0 This signal is set to ON from the start to end of the
execution of the tip dressing function.
It is set to OFF if operation has stopped at an interim point  
when, for instance, the tip dress normal input signal has
been set to OFF.
Tip dress normal 0 This outputs the tip dress normal input signal status.  
Tip dress forward 0 This signal instructs the tip dresser to rotate in the forward
direction. Perform the connections in such a way that when
this signal has been set to ON, the tip dresser will rotate in
 
the forward direction.
The signal is set to OFF upon completion of execution or
after execution has stopped at an interim point.
Tip dress reverse 0 This signal instructs the tip dresser to rotate in the reverse
direction. Perform the connections in such a way that when
this signal has been set to ON, the tip dresser will rotate in
 
the reverse direction.
Tip dress rotation 0 Each of these signals instructs the tip dresser by dividing
 
1 up its speed into four settings. Perform the connections in
Tip dress rotation 0 such a way that when one of these signals is set to ON, the
 
2 tip dresser will rotate at the speed corresponding to the
Tip dress rotation 0 condition commensurate with the signal. At each setting,
the signals are set to ON at the following times.  
3
Tip dress rotation 0 Rotation Speed 1: During the tip dressing start time and
4 initial pressurizing time
Rotation Speed 2: During the pre-pressurizing time
Rotation Speed 3: During the main pressurizing time
 
Rotation Speed 4: During the finish pressurizing time and
tip dressing stop time
Stroke check 120 Used only when welder control interface = MEDbus (option)
– 
output 121
Stepper end 113 Used only when welder control interface = MEDbus (option) – 
1-10
Factory
designation Gun Gun
signal
Shunt trip 116 Used only when welder control interface = MEDbus (option) – 
Isolation contact 117 Used only when welder control interface = MEDbus (option) – 
Solenoid valve 118 Used only when welder control interface = MEDbus (option)
– 
119
Fault (Major fault) 114 Used only when welder control interface = MEDbus (option) – 
Alert (Minor fault) 115 Used only when welder control interface = MEDbus (option) – 
Weld error-out 126 Used only when welder control interface = MEDbus (option)
127
128 – 
129
130
Weld complete ack 122 Used only when welder control interface = MEDbus (option) – 
Weld ON 0 This outputs the current Weld ON or OFF status. This level
 
signal is set to ON in the Weld ON status.
With welding 123 Used only when welder control interface = MEDbus (option)  
Ready to weld 124 Used only when welder control interface = MEDbus (option) – 
Weld in progress 125 Used only when welder control interface = MEDbus (option) – 
Weld control 0 Used only when welder control interface = MEDbus (option) – 
Equalizer pressure 0 Used only when welder control interface = MEDbus (option) – 
Equalizer pressure flip 0 Used only when welder control interface = MEDbus (option) – 
Extended output 0 Used only when welder control interface = MEDbus (option) – 
Pressure select 0 Used only when welder control interface = MEDbus (option) – 
Welder mode 1 0 Used only when welder control interface = MEDbus (option) – 
Gun separation 0
Gun wide open 0
Gun small open 0
Visual teach correct 0
Resist. error 0
Electrode test 2 0
Dress current failed 0
Dress Len. failed 0
0 This level signal is set to ON when servo gun pressure
Servo gun prs adj.
adjustment is set to enabled.
1-11
1.4Expert settings for servo gun conditions
1.4 Expert settings for servo gun conditions

A description the servo gun conditions was already given in Setup Manual. This section describes all the
operating condition parameters including the more advanced parameters which are to be set by an operator
with the qualifications class of EXPERT or above. For details of operation, refer to Setup Manual.
Servo gun conditions (common data)
Table 1.4.1 Servo gun conditions (common data)

Factory
settings
Wire stick Disabled <Not supported at present time.>
detection This is for selecting whether gun deposition is to be detected upon completion of
the welding.
The commands in the next step are executed without checking
Disabled that the gun moves when it is released upon completion of the
welding.
The gun axis data is monitored during gun release upon
completion of deposition, and if the gun fails to move within the
Enabled specific time, this is detected as trouble, and the robot is stopped.
In this case, the cycle time is slightly longer than when deposition
is not detected.
Panel error type Information Sheet thickness trouble is detected when the difference between the sheet
thickness detected when the spot welding command (SPOT: FN119) has been
executed and the sheet thickness registered in the welding conditions has
exceeded the "Sheet thickness trouble detection amount," and this parameter
specifies how the trouble is to be handled.
A message is displayed, and then the playback operation is
Information
continued.
A message is displayed, and then the playback operation is
Alarm suspended.
Panel abnormal 0.0 mm This detects the alarm (or information) when the difference between the sheet
level thickness detected when the spot welding command (SPOT: FN119) has been
executed and the sheet thickness registered in the welding conditions has
exceeded the "Sheet thickness trouble detection amount." This check is not
performed when the overall total for the "Sheet thickness trouble detection amount"
or "Sheet thickness" in the welding conditions is zero.
Input range: 0.0 to 99.0 mm, 0.0 to 3.90 inches
Tool number Disabled This parameter sets whether or not to check during playback operations that the
check tool number registered in the movement command immediately before the spot
welding command (SPOT: FN119) matches the gun number used for the welder
specified by FN119.
This is valid only in the case of a mechanism change.
Disabled Matching of the tool number with the gun number is not checked.
If the gun number and tool number do not match, this is detected
Enabled
as an alarm, and the robot stops.
1-12
Factory
settings
Bend coef. at Low rigid This parameter sets the method by which "bending compensation" is implemented
record work piece during step recording. The bending compensation method differs depending on
how rigid the work to be welded is.
Low rigid During step recording, the position is compensated using the total
work piece bending amount.
Bending compensation is based on the setting for "Work rigidity
type" among the spot teach or playback condition menu items. If
Select. "Low work rigidity" is set, the bending is compensated by the total
bending amount; if "High work rigidity" is set, it is compensated by
the moving side bending amount.
Diff limit to weld 0.0 mm <This parameter must be set by an operator with the qualifications class of
sync EXPERT or above.>
This is used with simultaneous welding control over servo guns when an attempt is
to be made to initiate simultaneous welding when the tip consumption amount
difference is greater than the value which has been set here. When "0" has been
set, no trouble detection is performed.
Servo gun conditions (individual data)
Table 1.4.2 Servo gun conditions (individual data)

Factory
settings
Large opening end 50 mm This specifies the distance at which the
(Stroke 0) moving side tip e and settled side tip have
opened maximally during manual
opening/closing. This distance must be set
inside the soft limit. In the case of a gun
without a battery, the gun is set to this
position after returning to its home point.
Input range: 10 to 999 mm, 0.39 to 39.3
inches
Stroke 1 40 mm Since the gun axis is servo-controlled, the
gun can be stopped at any position but, with a
view to facilitating the teaching process, the
design enables stroke switching by a
Stroke 2 35 mm single-action operation.
When the [Stroke select] f key is pressed,
stroke switching operations can be performed
in one go for a total of four settings, namely,
Stroke 3 30 mm
stroke 1, stroke 2, stroke 3 and wide release
value.
Input range: 10 to 999 mm, 0.39 to 39.3
inches
Pressurizing stroke 20mm This parameter specifies the distance when Wide release Welding stroke
(Stroke 4) the moving side tip and settled side tip have default value
closed maximally during manual
opening/closing. A value lower than the wide
release end default value must be set without
fail.
Input range: 10 to 50 mm, 0.39 to 1.96 inches
1-13
Factory
settings
Clearance/move 10.0 mm This parameter specifies the distance between the moving (or settled) side
tip and the work immediately prior to pressurizing when the spot welding
command (SPOT: FN119) is played back.
Input range: Moving side 0 to 50 mm, 0 to 1.96 inches
Settled side 0 to 20 mm, 0 to 0.78 inches
Moving side Settled side

clearance clearance
Clearance/Settle 5.0 mm
Moving side
electrode
Settled side
electrode
Previous step Pressurizing Release Next step
Spot welding command Welding operation

(SPOT: FN119)
Clearance Limit/move 3.0 mm <This parameter must be set by an operator with the qualifications class of
EXPERT or above.>
If the moving or settled side clearance setting is less than the clearance limit
value, an alarm is detected, and the clearance can no longer be updated.
Clearance Limit/settle 2.0 mm Input range: Moving side 0 to 50 mm, 0 to 1.96 inches
Settled side 0 to 20 mm, 0 to 0.78 inches
Equalize at manu. weld Enable <This parameter must be set by an operator with the qualifications class of
EXPERT or above.>
This parameter sets whether the robot (settled side tip) is to be equalized or
not during manual welding.
During manual welding, the pressurizing operation is
Disabled performed for the gun axis (moving side tip) but the equalizing
operation is not performed for the robot (settled side tip).
During manual welding, the pressurizing operation is
Enabled performed for the gun axis (moving side tip), and the
equalizing operation performed for the robot (settled side tip)
1-14
1.5Servo gun tip consumption detection Expert settings
1.5 Servo gun tip consumption detection Expert settings

A description the servo gun tip consumption amount detection was already given in Setup Manual. This
section describes all the tip consumption amount detection parameters including the more advanced
parameters which are set by an operator with the qualifications class of EXPERT or above. For details of
operation, refer to Setup Manual.
Table 1.5.1 Expert settings for servo gun tip consumption amount detection
Factory
settings
(+) 0mm When the moving (or settled) side tip consumption amount detected by the
Move-tip gun search has exceeded the setting of this parameter, the "Moving side tip
(-) 0mm
consumption amount has exceeded the maximum tip consumption amount"
Max tip
(+) 0mm alarm error results, and the robot stops.
consumption
No trouble will be detected when "0" is set.
Settle-tip
(-) 0mm The + direction is the side subject to tip consumption. The - direction shows
a condition where the tip becomes longer than the standard.
(+) 0mm When the moving (or settled) side tip consumption amount detected by the
Move-tip gun search has exceeded these settings, the "Moving side tip consumption
(-) 0mm amount of the servo gun has exceeded the setting range" information is
Change
detected, and the operator is prompted to change the tip.
consumption (+) 0mm
No trouble will be detected when "0" is set.
Settle-tip The + direction is the side subject to tip consumption. The - direction shows
(-) 0mm
a condition where the tip becomes longer than the standard.
(+) 0mm
Welding (-) 0mm <Not supported at present time>
(+) 0mm When the difference between the total tip consumption amount detected by
Abnormal tip the gun search 3 and the total tip consumption amount detected by the gun
change search 1 is larger than the set value, the alarm "Search 3 tip consumption
change amount is abnormal." is detected, and the robot stops.
Search 3 (-) 0mm The case when the difference between the total tip consumption amount
detected by the gun search 3 and the total tip consumption amount detected
by the gun search 1 is larger than the set value becomes the + direction,
meanwhile, the case when it is smaller becomes the - direction.
When 0 is set, the error is not detected.
Move tip consump. rate 0% If the tip consumption amount is to be detected using gun search 1 alone or
using gun searches 1 and 3 together, only the "total tip consumption
amount," which is obtained by adding the moving side tip consumption
amount and settled side tip consumption amount, can be detected.
Using the value set here, the "total tip consumption amount" is divided into
two parts, the moving side tip consumption amount and the settled side tip
consumption amount.
(This parameter cannot be used with gun search 2.)
Gun search speed 0 mm/sec. This specifies the speed of the gun axis during gun searches.
With the initial value of "0," the "pressurizing speed" which was pre-set is
used.
1-15
1.5Servo gun tip consumption detection Expert settings
Factory
settings
Manual search pressure 0.00 kN This is used to specify the welding force used when a manual gun search is
performed.
Step fault waiting time 0 sec. During a gun search, the gun axis coming to a complete standstill is checked
in order for the correct tip consumption amount to be detected. However, if a
time limit is placed on the wait time for identifying the standstill and the gun
axis fails to stop even after this time limit has elapsed, the "Gun axis
encoder data is not stable" message will appear, and the robot will stop. The
time limit is set in this parameter. This trouble is not detected if the setting
remains at zero (factory setting).
Execution type Standard This parameter selects the format in which the tip consumption amount
detection is executed.
Both search 1 and search 2 are detected. Since, for this reason,
the tip consumption amount is not established until search 1
Standard
and search 2 are completed, tip consumption amount is not
detected until searches are completed.
This is selected when only search 1 is to be used. When the
Search 1
search is executed, tip consumption amount trouble is always
only
detected.
Execution order Normal This parameter sets the sequence in which search 1 and search 2 are to be
executed. If search 1 alone has been set as the execution format, this
setting is ignored.
The searches are executed in the sequence of search 1
Normal followed by search 2. Tip consumption amount is not detected
when search 1 is executed.
The searches are executed in the sequence of search 2
Reverse followed by search 1. Tip consumption amount is not detected
when search 2 is executed.
Function The sequence of the search order by using of FN229
Search Search 1 0.00 mm <This parameter must be set by an operator with the qualifications class of
base EXPERT or above.>
position This parameter establishes the reference position for detecting the total tip
consumption amount set by gun search 1 reference write. Input range:
-9999.999 to 9999.999 mm, -393.701 to 393.701 inches
Search 2 0.00 mm <This parameter must be set by an operator with the qualifications class of
EXPERT or above.>
This parameter establishes the reference position for detecting the moving
side tip consumption amount set by gun search 2 reference write.
Input range: -9999.999 to 9999.999 mm, -393.701 to 393.701 inches
Monitor Move-tip 0.00 mm <This parameter must be set by an operator with the qualifications class of
offset EXPERT or above.>
This displays the moving tip consumption amount and the standard position
of the tip consumption error detection level. The moving tip consumption
corrected amount - this set value is displayed as a tip consumption amount
on the servo gun monitor.
Settle-tip 0.00 mm <This parameter must be set by an operator with the qualifications class of
EXPERT or above.>
This displays the settled tip consumption amount and the standard position
of the tip consumption error detection level. The settled tip consumption
corrected amount - this set value is displayed as a tip consumption amount
on the servo gun monitor.
1-16
Chapter 2 Spot welding condition
This chapter describes the detailed settings of "spot welding conditions" data that
determine the welding current, welding force and other conditions of the spot welding
itself.
2.1 Spot welding condition ............................................................................. 2-1

2.1.1 Welding conditions common to all welders ..................................... 2-1
2.1.2 Individual welding conditions for each welder ................................. 2-1
2.2 Recording and manual spot welding conditions....................................... 2-3
2.3 Useful welding condition editing functions ............................................... 2-4
2.3.1 Copying the welding conditions....................................................... 2-4
2.3.2 Listing the welding condition usage statuses .................................. 2-5
2.1Spot welding condition
2.1 Spot welding condition

The spot welding conditions refer to the groups of data that determine the welding current, welding force and
other conditions of the spot welding itself. The spot welding conditions are completely separate from the work
programs, and they are stored on a one-file-per-welder basis. A file can contain groups of up to 255
conditions. During playback, the welding condition numbers written in this group of conditions are output to
the welding controller. The actual welding current and schedule must be taught ahead of time on the welding
controller side.
Robot controller
Welder
Gun Power-on based (Timer contactor)
on preset welding
conditions Welding condition number
(Electro-pneumatic Welding force

proportional valve) control condition Welding condition 1 data
Air Gun
Welding condition 2 data
•••
Welding condition W1 data
Welding force directly controlled using servo control Welding condition W2 data
Servo Gun
•••
Welding condition 255 data
Fig. 2.1.1 Spot welding condition
Exactly what is controlled differs according to the drive system used by the spot welding gun, as is shown in
the figure above. For this reason, the spot welding conditions settings for an air gun are slightly different from
those of a servo gun.
This section describes the contents of each setting data for the spot welding conditions. No details are
provided on how to perform the data editing operations so reference should be made to the Basic Operations
Manual instead.
2.1.1 Welding conditions common to all welders

There are no spot welding conditions which are common to all the welders.
2.1.2 Individual welding conditions for each welder
Spot welding condition editing screen Spot welding condition editing screen
(For each air gun/welder) (For each servo gun/welder)
2-1
2.1Spot welding condition
In the table, "" denotes a parameter that can be set.

"" denotes a parameter which is not displayed. Alternatively, it denotes a parameter which is not
used even though it is displayed.
Table 2.1.1 Spot welding condition

Factory Air Servo
settings Gun Gun
Condition# – This is the number of welding condition group data
displayed.
Numbers can be selected using the [Previous number] f9
 
key or [Next number] f10 key or the data number of the
welding condition group can be input here directly.
Input range: 1 to 255
Output value (Welding This sets the values which are output to the welder as the
condition welding conditions.
number) The factory settings are values that match the welding
 
condition numbers.
Input range: 0 to 15 (Discrete)
0 to 65535 (Binary)
Weld cnd. output Binary This specifies whether the welding condition output data is
type to be output in the binary format or discrete format. Sixteen
welding condition output signals are provided so the data  
can be output from 1 to 65535 for the binary for-mat and
from 1 to 16 for the discrete format.
Pressure control 0 This sets the values which are output to the welder for
controlling the welding force. Use this when air guns that
employ an electro-pneumatic proportional valve, etc. to
 
control the welding force are used.
The data is output in the discrete format.
Input range: 0 to 2
Pressure 1.00 kN This sets the welding force when a servo gun is used.
(102 kgf) Input range: 0 to 50.0 kN  
0 to 5099 kgf
Pressure multi Disabled For a servo gun, this enables the welding force to be varied
by dividing the pressurizing time into the four stages of the
initial pressurizing time, squeeze time, welding pressurizing
time and holding pressurizing time. This is known as
"multi-stage control," and the parameter sets this to either  
enabled or disabled.
At the disabled setting, the welding force is controlled in
such a way that it remains constant at all times. (For details,
refer to "Chapter 8 Special servo gun functions.")
Thickness 1 to 5 0.00 mm The thickness of the work is set in this parameter. Five
sheets on top of each other represent the maximum sheet
thickness which can be set.
To detect sheet thickness trouble in the servo gun, the
 
detected sheet thickness is compared with the total of the
values set here. If all the values have been set to "0," sheet
thickness trouble is not detected.
Input range: 0 to 3.00 mm
Initial pressurizing Welding force When multi-step welding force control is used, this
force already set parameter is used to specify the initial welding force.
 
on previous
page
Squeeze welding 0.00kN When multi-step welding force control is used, these
force and time 1 0.00 sec. parameters are used to specify the squeeze welding forces  
to 4 and times for up to 4 steps.
Welding force and 0.00kN When multi-step welding force control is used, these
time 1 to 4 0.00 sec. parameters are used to specify the actual welding forces  
and times for up to 4 steps.
Holding welding 0.00kN When multi-step welding force control is used, these
force and time 1 0.00 sec. parameters are used to specify the holding welding forces  
to 4 and times for up to 4 steps.
2-2
2.2Recording and manual spot welding conditions
2.2 Recording and manual spot welding conditions

The numbers of the spot welding conditions to be recorded must be specified ahead of time when the spot
welding command (FN119) is to be recorded at the same time as the spot position (movement command).
The numbers of the spot welding conditions to be used for manual welding must be specified ahead of time
also with manual welding.
This section describes the setting method. The same operations are performed whether an air gun or servo
gun is used.
1 Open the spot welding condition editing screen.
2 Whichever number editing screen is opened, two lines are displayed at the very
bottom of the dialog box:
"Welding condition number used when automatic recording" on the first line,
and "Welding condition number used at manual welding."
Align the cursor with one of these lines, input the applicable welding condition
number, and press the [Enter] key.

(To stop editing at any time, press the [Reset/R] key.)
2-3
2.3Useful welding condition editing functions
2.3 Useful welding condition editing functions

A number of useful functions are provided for editing the spot welding conditions.
The operating procedure of each function is described below.
2.3.1 Copying the welding conditions

This function enables the data groups of spot welding conditions to be easily copied on a condition
by condition basis.
Editing can be accomplished quickly when similar conditions are prepared by first copying the
conditions and then making changes to only those parts that are different.
1 Open the editing screen for the spot welding conditions to be edited.
2 Press <Copy> f8 key.

>> Specify the copy source by indicating which welding condition is to be copied. First,
the dialog box for specifying the welder number serving as the copy source
appears.
(This box does not appear if only one welder is used.)
3 Input the number of welder serving as the copy source, and press the [Enter]
key.
>> Next, the dialog box for specifying the welding condition number serving as the
copy source appears.
4 Input the welding condition number serving as the copy source, and press the
[Enter] key.
5 The data is copied altogether in a group from the welding conditions of the
specified welder, and the display is updated.
6 Modify the data as required, and after this, press <Complete> f12 key.
2-4
2.3.2 Listing the welding condition usage statuses

With the push of a key, this function enables the operator to determine by browsing which identical
spot welding condition numbers are being used in which steps of which program. It is helpful when
the data contents are to be modified since it makes it possible to easily examine what will be
affected by the modifications. To operate, follow the steps below.
1 Open the editing screen for the spot welding conditions to be edited.
2 Press <Weld Program List> f11 key.

>> In which step of which program the currently displayed spot welding condition is
used is searched, and the results are displayed on the pop-up window similar to the
one shown below.
3 If the results displayed do not fit on one screen, they can be scrolled using the
[up or down cursor] key.
Upon completion of the browsing, press the [Reset/R] key to clear the window.
2-5
NOTE
2-6
Chapter 3 Spot weld sequence
This chapter describes the detailed settings of the "spot welding sequence" data
which defines the I/O sequences, etc. between the robot controller and welder.
3.1 Spot weld sequence ................................................................................ 3-1

3.1.1 Welding sequences common to all welders .................................... 3-3
3.1.2 Individual welding sequence for each welder.................................. 3-6
3.2 Recording and manual spot welding sequences ..................................... 3-9
3.3 Useful welding sequence editing functions ............................................ 3-10
3.1Spot weld sequence
3.1 Spot weld sequence

A spot welding sequence refers to the data which defines the I/O sequences, etc. between the robot
controller and welder. The spot welding sequences are completely separate from the work programs, and
they are stored on a one file per welder basis. A file can contain up to 64 sequences per welder. During
playback, this controller controls the welding flow in accordance with these sequences.
The spot welding sequences do not determine the sequences of the welding itself such as its power-on cycle
and cooling cycle. The sequences of the welding itself must be taught ahead of time at the welder side.
Robot controller
Welder
(timer contactor)
Gun
Pressurizing valve Pressurizing command,

ON/OFF power-on command Welding sequence 1 data
Welding sequence 2 data
Welding completion •••
Stroke switching
Welding sequence S1 data
valve ON/OFF
Welding sequence S2 data
Stroke switching
Air Gun •••
Welding sequence 64 data
Stroke directly controlled using servo control
Servo Gun
Fig. 3.1.1 Spot weld sequence
Depending on the drive system (air or servo drive) of the spot welding gun, the settings of the spot welding
sequences are slightly different.
This section describes the contents of each setting data in the spot welding sequence. No details are
provided on how to perform the data editing operations so reference should be made to the "Basic
Operations Manual" instead.
3-1
The spot welding work is often executed in accordance with the time sequence shown in the figure below. A
spot welding sequence designs the ON/OFF execution timing of each signal.
Previously recorded point

passed through Welding recorded point Next step executed
Moving side
electrode
FN119 recorded Fully open
Semi-open
Settled side
electrode
Timing of stroke
(dur ing pressurizing)
Fully open signal
Semi-open signal Ti mi ng o f we ldi ng co ndi ti on si gna l

(duri ng we ldi ng ) + 0.02 sec.
Welding condition signal Stored

Timing of pressurizing
signal OFF
Pressure signal
Welding force control Timing of weld

signal command signal
Weld command
signal
Weld completed (WI) Timing of robot movement start
Timing of gun release Welding end wait time
Fig. 3.1.2 Air Gun Spot Weld Sequence
Previously recorded point Welding recorded Next recorded

passed through point point
FN119 recorded
Moving side
electrode
Stroke (af ter completion of
welding)
St roke (during pressurizing)
Moving side clearance
Fixed side clearance
Settled side
electrode
Fully open signal
Semi-open signal
Welding condition signal

0.02 sec.
fixed
Pressure signal
Welding f orce control

signal
Timing of weld command
signal
Weld command signal
Weld completed (WI)
Timing of gun release Timing of robot movement start

Welding end wait time
Fig. 3.1.3 Servo gun spot weld sequence
3-2
3.1.1 Welding sequences common to all welders

Spot welding sequence editing screen (common to all welders)
The setting items in the spot welding sequences common to all welders are displayed
on a multiple number of screen pages.
To scroll the pages, make the selection by pressing the [ENABLE] key and [Scroll
page] f9 or f10 key simultaneously.

Table 3.1.1 Spot Weld Sequence (common for all welders)

Factory Air Servo
settings Gun Gun
Weld cnd. 0.00 sec. This parameter sets the output time of the welding condition
signal signal. A level output is set with a "0" setting; a pulse output
for the specified time is set with any other setting. Power  
failures are not detected with the pulse output.
Input range: 0.00 to 9.99 sec.
Gun signal 0.00 sec. This parameter sets the output time of the pressurizing
signal. A level output is set with a "0" setting; a pulse output
for the specified time is set with any other set-ting. Power  
failures are not detected.
Welding 0.00 sec. This parameter sets the output time of the weld command
Signal signal. A level output is set with a "0" setting; a pulse output
for the specified time is set with any other setting. Power  
failures are not detected.
Full Open 0.00 sec. This parameter sets the output time of the fully open signal.
Signal A level output is set with a "0" setting; a pulse output for the
specified time is set with any other set-ting. Power failures  
are not detected with the pulse output.
Half Open 0.00 sec. This parameter sets the output time of the semi-open
Signal signal. A level output is set with a "0" setting; a pulse output
for the specified time is set with any other set-ting. Power  
failures are not detected with the pulse output.
Pressure 0.00 sec. This parameter sets the output time of the Welding force
Signal control signal. A level output is set with a "0" set-ting; a
pulse output for the specified time is set with any other
 
setting. Power failures are not detected with the pulse
output.
3-3
Factory Air Servo

settings Gun Gun
Abnormal 0.00 sec. This parameter sets the output time of the trouble signal
Signal (welding time expired, peripheral device trouble, etc.). A
level output is set with a "0" setting; a pulse output for the  
specified time is set with any other setting.
Gun Proc. 0.00 sec. If the interval between one welding session and another is
Interval too short, the signals may not be processed exactly as
specified. In a case like this, the time set between the
 
completion of the last pressurizing signal and the start of
the next pressurizing signal is forcibly opened up.
Reweld Count 0 This parameter sets the number of re-welding times.
Re-welding is retried up to the specified number of times
when the WI signal is not input even after the "power-on
wait time" has passed following the output of the
pressurizing signal.
When re-welding is executed, the pressurizing signal is first
set to OFF and then re-output at 0.5 sec. intervals if level
output is set for the pressurizing signal. When the pulse  
output is set, there are no 0.5 sec. intervals. It should
therefore be borne in mind that re welding will be executed
while the pressurizing signal is still output if the
"pressurizing signal output time" is longer than the
"power-on wait time."
Re-welding is not performed with step GO/BACK.
Input range: 0 to 3
When Wait This parameter sets the behavior of the robot when trouble
Abnormal has occurred during welding.
Alarm The robot continues to wait for the WI input
Wait
signal in the start status.
The robot continues to wait for the WI input  
Stop
signal in the stop status.
The robot stops and the WI input signal wait
Step- is released. When the robot is restarted,
Resume welding resumes from the step at which it
stopped.
Open of gun No This parameter sets the behavior of the gun when any
in abnormal trouble or robot shutdown trouble has occurred during the
WI wait.
The gun is not released when any trouble
No or robot shutdown trouble has occurred  
during the WI wait.
The gun is released when any trouble or
Yes robot shutdown trouble has occurred during
the WI wait.
Abnormal After WI This parameter specifies the timing at which the welding
Signal input trouble signal from the external source is read.
After WI The welding trouble signal is read after the
 
input WI input.
After The welding trouble signal is read after the
pressurizing pressurizing signal is output.
Common WI Individual This parameter selects whether the WI signals are to be
use used for individual guns or for all the guns together.
Regardless of this setting, the WI signal of one gun is
released each time the <Cancel WI> f key is pressed once.
The WI signals are used on a gun by gun
Individual basis. The parameter is normally used at
this setting.  
One WI signal is used for all the guns
together. In a case like this, the WI signal of
Common welder 1, which has been set by the
assignment of the input/output signals, is
used.
3-4
Factory Air Servo

settings Gun Gun
WI off check Before gun The next operation is initiated after checking that the WI
method signal signal has been set to OFF. If the WI signal is not set to
output OFF even after 5 seconds have elapsed since the checking
operation was initiated, an alarm is displayed, and the robot
is stopped.
The pressurizing signal is output after
checking that the WI signal has been set to
Before gun OFF before the pressurizing signal is
signal output output. ("Before gun signal output" signifies
immediately before the pressurizing signal
 
is output.)
The WI wait is performed after checking
After gun that the WI signal has been set to OFF
signal output following the output of the pressurizing
signal.
Absolutely no checks are performed to
verify that the WI signal has been set to
Disabled OFF. In a case like this, the WI wait is
performed 0.1 sec. after the output of the
pressurizing signal.
Welding Standard This parameter sets the timing at which the welding
condition condition signal is to be output.
output timing The signal is output at the timing which was
Standard
set in the welding sequence.
The welding condition signal is output at the  
Pressurizing timing at which the pressurizing signal is
output.
The welding condition signal is output at the
Power-on timing at which the weld command signal is
output.
WI input wait 0.10 sec. <This parameter must be set by an operator with the
delay qualifications class of EXPERT or above.>
This is the time elapsing until the WI input signal starts to be
inspected after the pressure application signal is output.  
Normally, in order to ensure that the previous WI signal will
not be read in error, do not change the factory setting.
3-5
3.1.2 Individual welding sequence for each welder
Spot welding condition editing screen Spot welding condition editing screen
(For each air gun/welder) (For each servo gun/welder)
The individual welder setting items in the spot welding sequences are displayed on a multiple number of screen
pages.
To scroll the pages, make the selection by pressing the [ENABLE] key and [Scroll page] f9 or f10 key simultaneously.

Table 3.1.2 Spot welding sequence (for each welder)

Factory Air Servo
settings Gun Gun
Sequence# 1 This is the welding sequence number which is displayed. It may be
selected using the [Prev No] f9 key or [Next No] f10 key or by inputting
 
the data number of the welding sequence group here directly.
Stroke No This parameter sets how the stroke signal (fully open signal and
(start) change semi-open signal) is controlled when starting movement to the position
(air) recorded by the spot welding command (FN119).
Neither the fully open signal nor semi-open signal is
None
or changed.
 
Half The semi-open signal is set to ON.
0.0mm Full The fully open signal is set to ON.
(servo) In the case of a servo gun, this parameter sets the stroke prior to
pressurizing directly as a distance.
Input range: 0.00 to 999.9 mm
Stroke None This parameter sets how the stroke signal (fully open signal and
(weld) 0.00 sec. semi-open signal) is controlled at that point in time when the
pressurizing signal is output. When a minus sign is assigned to the
timing, the stroke signal is executed sooner (ahead of the pressurizing
time).
None
changed.
The semi-open signal is set to ON.
The timing can be specified as a time. The signal is set  
Half to the first-out mode when a minus sign is assigned to
the timing.
Input range: –9.99 to 1.00 sec.
The fully open signal is set to ON.
The timing can be specified as a time. The signal is set
Full to the first-out mode when a minus sign is assigned to
the timing.
3-6
Factory Air Servo

settings Gun Gun
Stroke No This parameter sets how the stroke signal (fully open signal and
(finish) change semi-open signal) is controlled at that point in time when welding is
(air) completed or, in other words, when the WI input signal has been input.
None
or changed.
 
Half The semi-open signal is set to ON.
0.0mm Full The fully open signal is set to ON.
(servo) In the case of a servo gun, this parameter sets the release amount upon
completion of the welding directly as a distance.
Input range: 0.00 to 999.9 mm
Welding Enabled This parameter specifies whether to output the welding condition
condition 0.00 sec. number, which was specified by the spot welding command (FN119),
signal during welding. Alternatively, when it is output:
(Welding) Disabled The welding condition number is not output.
The welding condition number is output. If an air gun is
used, how far ahead of the pressurizing signal output  
the number is to be output is set as timing data.
Enabled The welding condition signal is output at the same time
as the movement starts if the movement time between
steps is shorter than the specified timing time.
Welding Off This parameter sets what status the welding condition signal is to be in
condition at that point when the WI input signal has been input.
signal The welding condition signal is set to OFF after the WI  
Off
(welding input signal has been input.
end) Preset The status of the welding condition signal is held.
Gun Signal Enabled This sets whether or not to output the pressurizing signal.
0.00 sec. Disabled The pressurizing signal is not output.
The pressurizing signal is output. If an air gun is used,
how far ahead of the time when the target position is
reached the signal is to be output is set as timing data.  
However, normally (with an "Enabled: 0.00 sec."
Enabled
setting), the signal is output 0.05 sec. after the step in
which the spot welding command has been recorded is
reached (coincidence of axes).
Welding Disabled This sets whether or not to output the welding force control signal.
condition Disabled The welding force control signal is not output.
signal The welding force control signal is output.  
(Welding) Enabled It is output at the same timing as the pressurizing
signal.
Weld Disabled This sets whether or not to output the weld command signal.
Signal 0.00 sec. Disabled The weld command signal is not output.
The weld command signal is output.
The weld command signal can be output  
simultaneously with the output of the pressurizing
Enabled
signal or at a timing after this signal equivalent to the
specified time.
Welding 0.00 sec. This parameter sets the wait time until the WI signal is input after the
Wait Time weld command signal (or pressurizing signal) has been output. If the WI
signal is not input even after this time has elapsed, the "Welding time
exceeded" alarm is displayed, the welding time expired signal is output
and, in accordance with the "Processing when welding trouble has
occurred" setting common to all sequences, either WI wait is
 
established (while the start status remains established) or the robot is
shut down.
When 0.00 is set, wait will continue until the WI signal is input; when a
value greater than zero is set, the wait time is set to 1.00 sec. regardless
of the set value.
Finish Wait 0.00 sec. This parameter sets the wait time until the check for trouble in the gun
Time and welder is performed (deposition, welder trouble, transformer
temperature trouble, etc.) after the pressurizing signal or weld command  
signal has been set to OFF following the input of the WI signal.
3-7
Factory Air Servo

settings Gun Gun
Robot 0.00 sec. This parameter sets the wait time until the robot moves after the welding
Delay Time operation has been completed and the fully open or semi-open signal
has been output.
If fully open or semi-open is detected during this wait time, the next
operation is initiated. If the fully open or semi-open detection signal is
not input even when this time has elapsed, an alarm such as "Gun is not  
set to the fully open status" or "Gun is not set to the semi-open status" is
displayed and, in accordance with the "When Abnormal Alarm" setting
common to all sequences, either WI wait is established (while the start
status remains established) or the robot is shut down.
Gun Open 0.00 sec. This parameter sets the wait time until the pressurizing signal, weld
Delay Time command signal, etc. are set to OFF after the WI signal has been input.
(This is the time during which the welding force is maintained after  
power-on.)
The figure below shows the spot welding sequence using the initial factory settings.
Axis coincidence at position where Welding

spot welding command is recorded completion
Welding condition
signal
Pressure signal
Weld completed (WI)
Detection of various
types of fault
Pressurizing signal is output with a delay of Start of movement to next

0.02 sec. after the welding conditions have step
been output.
Fig. 3.1.4 Spot welding sequence using the initial factory settings (for an air gun)
3-8
3.2Recording and manual spot welding sequences
3.2 Recording and manual spot welding sequences

The numbers of the spot welding sequences to be recorded must be specified ahead of time if the spot
welding command (FN119) is to be recorded simultaneously at the spot position (movement command).
Similarly, the numbers of the spot welding sequences to be used for manual welding must be specified
ahead of time also in the case of manual welding.
Details on the operations performed are omitted here since they are the same as those for the spot welding
conditions. For further details, refer to "Chapter 2 Spot welding condition."
3-9
3.3Useful welding sequence editing functions
3.3 Useful welding sequence editing functions

A number of useful functions are provided for editing the spot welding sequences.
Details on the operations performed are omitted here since they are the same as those for the spot welding
conditions. For further details, refer to "Chapter 2 Spot welding condition."
3-10
Chapter 4 Servo gun tip consumption measurements
This chapter describes the method used to measure the "tip (electrode) consumption
amounts" which must be done prior to teaching the work program when a servo gun
is to be used. By conducting these measurements properly, the pressurizing position
is automatically adjusted in accordance with the tip (electrode) consumption amounts
that are worn by the welding, and stable spot welding is assured.
4.1 Outline of tip consumption compensation ................................................ 4-1

4.2 Gun Search Function............................................................................... 4-2
4.2.1 How to use gun search 1 (total tip consumption amount detection) 4-4
4.2.2 How to use gun search 2 (moving side tip consumption amount detection)
4-5
4.2.3 How to use gun search 3 (simplified tip consumption amount detection)
4-6
4.3 Teaching of tip consumption amount detection program ......................... 4-7
4.4 Gun search reference write ..................................................................... 4-8
4.5 Executing gun search 2 first .................................................................... 4-9
4.5.1 Designating by constants setting..................................................... 4-9
4.5.2 Designating the execution sequence by function command ........... 4-9
4.6 Clearing tip consumption amounts ........................................................ 4-10
4.6.1 How to clear the tip consumption amounts using an R code......... 4-10
4.6.2 How to clear the tip consumption amounts by manual operation .. 4-10
4.6.3 How to clear the tip consumption amounts using an external signal4-10
4.6.4 How to clear the tip consumption amounts automatically.............. 4-10
4.7 Abnormal tip consumption amount detection..........................................4-11
4.7.1 Tip consumption amount abnormality detection .............................4-11
4.7.2 Search 3 tip consumption change trouble detection ......................4-11
4.7.3 Gun search stop trouble detection .................................................4-11
4.8 Offset of Tip Consumption Amount Display and Error Detection Level........................ 4-12
4.8.1 Registration of Offset Value .......................................................... 4-13
4.1Outline of tip consumption compensation
4.1 Outline of tip consumption compensation

Read this chapter only when the servo gun is to be used.
As welding is performed over and over again, tips (electrodes) gradually start to wear down, and their length
shortens. An equalizing function is not generally provided with servo guns. For this reason, when tips start to
wear down, the settled side tip is no longer pressed against the work, resulting in a deficient welding force on
the settled side and extra stress on the work, resulting also in a deterioration of the simultaneous arrival of
the top and bottom tips and an increase in the cycle time.
Therefore, in order to maintain the correct welding position, a "tip consumption compensation function" is
provided to shift the welding target point at the settled and moving sides by the distance equivalent to the
consumption amount.
Moving
side tip
Moving side tip
consumption amount
Settled Settled side tip

side tip consumption amount
(1) New tip (2) Worn tip
Fig. 4.1.1 Servo gun tip consumption
Pressurizing Pressurizing Pressurizing
New tip Worn tip Worn tip

(wi thout compensation) (with compensation)
Fig. 4.1.2 What happens when the tip consumption amount is compensated
In order for the tip consumption amount to be compensated, this amount has to be detected.
There are two main kinds of tip consumption amount detection: total tip consumption amount detection and
moving side tip consumption amount detection. Total tip consumption amount detection involves performing
a dry strike where nothing is sandwiched between the tips of the spot welding gun. The moving side tip
consumption amount is detected by performing the pressurizing operation on a standard plate which has
been fixed. If the total tip consumption amount and moving side tip consumption amount are known, the
settled side tip consumption amount can be obtained from the difference between them.
These tip consumption amount detection functions are called "gun search functions," and function
commands are used for them.
4-1
4.2Gun Search Function
4.2 Gun Search Function

The "gun search function" serves to detect the tip consumption amounts of the servo gun.
Once the tip consumption amounts have been detected, the welding position is then automatically
compensated for by the tip consumption amounts when the spot welding commands are executed, and the
position where contact is made with the work is corrected.
Three function commands—gun search 1, gun search 2 and gun search 3—are provided. The tip
consumption amounts are detected by using these commands independently or in combination.
Table 4.2.1 3 gun search commands

Function
Description of features
Command
Gun Total tip consumption amount detection
Search 1 The total tip consumption amount is measured and subdivided into the
settled side tip consumption amount and moving side tip consumption
amount according to a constant ratio. When gun search 1 is used
independently, there is no need for a reference stand, and the tip
consumption amount can be measured in a short period of time. On the other
hand, the measurement accuracy is not as good as when both gun search 1
and gun search 2 are performed.
Moving side Settled side tip

tip consumption amount
Total wear
amount
Moving side tip
consumption amount
Settled side
tip
(a) New tuip (b) Worn tip
Note: The dotted lines indicate the shapes of the tips which have not been worn.
Reference write is required.

Gun Moving side tip consumption amount detection
Search 2 This is used together with gun search 1.
The moving side tip consumption amount is measured. The settled side tip
consumption amount is calculated by subtracting the moving side tip
consumption amount from the total tip consumption amount obtained by gun
search 1. This has the highest measurement accuracy. It is necessary to
GSEA provide a reference stand.
(FN167)
Reference plate Moving side tip consumption
amount
(a) New tip (b) Worn tip

Note: The dotted lines indicate the shapes of the tips which have not been worn.
Reference write is required.

Gun Simplified tip consumption amount detection
Search 3 This is used together with gun search 1 and gun search 2. The total tip
consumption amount is measured. With gun search 3, tip consumption
amount can be compensated in a simplified way for the tip consumption after
gun search 1 and gun search 2 have been executed.
Generally, the gun search 1 and the gun search 2 are carried out after
exchange of tips whose tip consumption ratio cannot be forecasted,
meanwhile, the search 3 is carried out at every welding cycle whose tip
consumption ratio can be forecasted in some measure.
The measurement accuracy is not as good as when gun search 3 is
performed together with gun search 1 and gun search 2. However, its
advantage is that the search operation is completed in one go except when
the tips have been replaced.
Reference write is not required.
4-2
With gun search 1 or gun search 2, first the positions serving as the reference are registered using new tips.
Then, the same operations are performed using tips worn down during actual spot welding operations, and
the tip consumption amount is obtained from the difference between the two values. The "registration of the
positions serving as the reference using new tips" is referred to as "gun search reference write" when the
gun search function is involved.
Teach the program for measuring the

amount of wear.
Set to reference write <enabled>.

This work
When the program for measuring the must always
Gun be done with
search amount of wear is played back, the
reference position is registered. the new tip or
reference tips already
write installed.
Return to reference write <disabled>.
Teaching of
Teach the spot welding work program.
welding work
Play back the program for measuring the amount of wear

regularly, and obtain the amount of wear.
Auto
operation
Repeatedly run the spot welding work program.
Clear the amount of wear when a worn tip has been

replaced with a new tip.
Fig. 4.2.1 Gun search reference writing
The tip consumption amounts are detected using the three gun search function commands independently or
in combination.
How to combine the commands will be described next.
[Case 1] This is the simplest method for measuring the tip consumption amounts in a short period of time.
Use gun search 1 only.
Gun Search1 Welding
[Case 2] This is the most accurate method for measuring the tip consumption amounts.
Use both gun search 1 and gu n search 2. A reference stand is required.
Gun Search 1
+ Gun Search 2 Welding
[Case 3] At times other than tip exchange and tip dress, only one time of the search action is needed.
Use all the gun searches 1, 2 and 3.
The accuracy is better than [Case 1] and n ot as good as [Case 2].
Gu n Search 1
+ Gun Search 2 Welding Gun Search 3
4-3
4.2.1 How to use gun search 1 (total tip consumption amount detection)
With gun search 1, the total tip consumption amount is detected by executing a dry strike with the gun.
The total tip consumption amount is subdivided into the moving side tip consumption amount and settled
side tip consumption amount in accordance with the ratio set in the "Moving side tip consumption
amount/total tip consumption amount" item among the servo gun conditions.
In some cases, gun search 1 is used alone; in other cases, it is used together with gun search 2.
● Tip consumption amount when gun search 1 only is used
Moving side tip consumption amount = "Detected total tip consumption amount" x "moving side tip
consumption amount/total tip consumption amount"/100
Settled side tip consumption amount = "Detected total tip consumption amount" – "moving side tip
consumption amount"
Where the value of "moving side tip consumption amount/total tip consumption amount" is a fixed ratio
● Tip consumption amount when gun search 1 is used together with gun search 2
(→ 4.2.2How to use gun search 2 (moving side tip consumption amount detection))
Total detected tip consumption amount
Pressurizing
Moving Release
side tip
Settled
side tip
Gun Search1 Pressurizing Teach position

Teach position position
Position with Position with

playback playback
using new tips using worn tips
Fig. 4.2.2 Gun search 1 operation
As the position where the gun search 1 command is taught, teach any position where a dry strike is
permitted with the gun open by 20 to 30 mm. When gun search 1 is executed, the equalizing operation
(where the settled side is shifted toward the position where it makes contact with the work) is not performed.
4-4
4.2.2 How to use gun search 2 (moving side tip consumption amount detection)
With gun search 2, the tip consumption amount of the moving side tip is detected by pressing the moving
side tip against the reference stand.
Provide a reference stand which is anchored to the ground and is rigid enough not to be deformed by
pressurizing.
When gun search 2 is to be used, first record gun search 1. If gun search 1 has not been executed prior to
gun search 2, gun search 2 is not performed, and an alarm results.
Moving side tip consumption amount = "Moving side tip consumption amount detected by gun search 2"
Settled side tip consumption amount = "Total tip consumption amount detected by gun search 1" – "moving
side tip consumption amount"
Moving Pressurizing Release

side tip
Reference
stand
Settled
side tip
Gun Search 2 Pressurizing Teach
Teach position position position
Position with Position with

playback using new playback using
tips worn tips
When the gun search 2 command is executed, the gun (moving side tip) is pressed against the reference
stand.
Record the position where the gun search 2 command is to be taught in such a way that the settled side tip
is set to a position 4 to 5 mm away from the reference stand during pressurizing. Depending on the gun,
arm bending or some other factor may cause the settled side tip to come into contact with the reference
stand. Measurements cannot be performed accurately when the settled side tip comes into contact with the
reference stand. Record the position with a clearance left to establish a constant speed when the moving
side tip makes contact with the reference stand.
Moving side Teach position

tip
Leave a 4-5 mm
clearance so that the
Reference settled side tip does
stand not make contact
with the reference
Settled side stand.
tip
Fig. 4.2.4 Detail of gun search 2 recording position
When you want to carry out the search 2 first from the positional relation of the reference stand, the search
2 can be carried out first by constants setting or search execution sequence command. As for details, refer
to 4.5 Executing gun search 2 first.
4-5
4.2.3 How to use gun search 3 (simplified tip consumption amount detection)
Simplified tip consumption amount compensation can be provided by using gun search 3 in combination
with gun search 1 and gun search 2. Gun search 3 must always be used in combination with gun search 1
and gun search 2.
For instance, when gun search 1 and gun search 2 are executed after tip replacement or tip dressing and
gun search 3 is executed with each welding cycle, the detection accuracy will be slightly lower but the cycle
time will be shorter compared with executing gun search 1 and gun search 2 with each cycle.
Gun search 3 detects the total tip consumption amount by executing a dry strike. The robot operates in the
same way as with gun search 1, but the way in which the tip consumption amounts are obtained is different.
In order to improve the accuracy, the results of gun search 1 and gun search 2 are used to obtain the tip
consumption amounts as follows.
Moving side tip consumption amount = "Moving side tip consumption amount detected by gun search 2"
+ ("total tip consumption amount detected by gun search 3" – "total tip consumption
amount detected by gun search 1")
 "moving side tip consumption amount / total tip consumption amount"
Settled side tip consumption amount = "Total tip consumption amount detected by gun search 3" – "moving
side tip consumption amount"
Where the value of "moving side tip consumption amount/total tip consumption amount" is a fixed ratio
Pressurizing
Moving Release
side tip
Settled
side tip
Gun Search 3 Pressurizing Teach position

Teach position position
Position with playback Position with playback

using new tips using worn tips
As with gun search 1, teach any position where a dry strike is permitted with the gun open by 20 to 30 mm.
When gun search 3 is executed, the equalizing operation (where the settled side is shifted toward the
position where it makes contact with the work) is not performed.
4-6
4.3Teaching of tip consumption amount detection program
4.3 Teaching of tip consumption amount detection program

Read this section only when a servo gun is used.
The servo gun search command is a function command. As with the timer commands or input/output
commands, it can be recorded using the [FN] key.
Mnemonic Number Command
GSEA FN167 Servo gun search
Parameter Data Description, setting range

Parameter No.1 Gun number This specifies the number of the welder to which the servo
gun whose tip consumption are to be detected is connected.
(1 to 6)
Parameter No. 2 Gun search This parameter specifies the type of gun search. (1 to 3) 1:
number Gun search 1 = Total tip consumption detection
2: Gun search 2 = Moving side tip consumption detection
3: Gun search 3 = Total tip consumption detection (simplified
tip consumption detection)
Parameter No. 3 Pressure As the search welding force, this parameter sets welding
force [N] during the gun search in accordance with the gun
used. Normally, a force of 1.0 to 1.5 N (100 to 150 kgf) is
used. Execute gun search several times and set the welding
force with which the fluctuations in the search results are
minimal.
(0.5 to 10.0 kN)
(51.0 to 1020.0) kgf
The figure below shows an example of the teaching when the tip consumption amount is to be measured
with the highest accuracy using gun search 1 and gun search 2.
Gun search 2:
Rec ord in such a way that the settled
side electrode is posit ioned 4 t o 5
mm away from t he reference
st andard during pressurizing.
Depending on t he gun, arm bending
or some other factor may cause the Gun search 1: With the
settled side electrode to come into gun open by 20 to 30 mm,
contact with the ref erence s tand. For teach any position that
t he moving side electrode, t each t he Reference stand
position which is 20 to 30 mm away permits a dry strike.
anchored t o t he
f rom the referenc e stand. ground
1 REM [Search] FN99: comment

2 300 mm/s LIN A1 T1
4 G SEA[1,1,10] FN167: Servo gun s pot search

7 G SEA[1,2,10] FN167: Servo gun spot search

10 END FN99: End
Fig. 4.3.1 Example of tip consumption amount detection program
4-7
4.4Gun search reference write
4.4 Gun search reference write

This section describes the job of registering the reference position that will serve as the tip consumption
amount detection source before the welding work program is taught. This job is known as "gun search
reference write."
Before proceeding, new tips must be installed without fail.
The operation method is the same regardless of whether gun search 1 or gun search 2 is recorded in the tip
consumption amount detection program to serve as the gun search command.
Since the job of registering the position that will serve as the tip consumption amount detection source is an
important one, it must be performed by an operator with the qualifications class of EXPERT or above. For
details on the operator qualifications, refer to Setup Manual.
1 Select the playback mode.
2 Press <Spot Condition> f7 key.

>> The Spot Teach/Playback Condition setting screen used exclusively for spot welding
such as the one shown below now appears.
3 Align the cursor with "Servo gun search write," and select the "Enabled" radio
button setting using the [ENABLE] and left or right cursor keys.
4 Press <Complete> f12 key, and exit the spot welding condition setting screen.
>> This establishes the status in which the reference position is written when the gun
search commands are subsequently played back. The following indicator appears
on the status window to indicate that the gun search reference write mode is now
established.
While the above gun search standard writing indicator is displayed, do not carry
out the automatic operation for production. After completion of one cycle
operation for standard writing, make sure that the indicator display disappears,
and then carry out the production operation.
5 Proceed to operate by playing back in the 1-cycle mode for tip consumption
amount detection program taught in the previous section.
6 When the playback of the series of gun search commands is completed, the
reference position is registered.
>> Registration is a type of processing that is done inside the software. After the tip
consumption amount detection program has been played back, the reference
position is written automatically.
7 Upon completion of the playback, open the same menu as in 2, return the "Servo
gun search write" setting to "Disabled," and press <Complete> f12 key.
>> Do not forget to return this setting to "Disabled."
At the end, do not forget resetting the gun search standard writing mode to "Disabled." If the
automatic operation for production is carried out while the gun search standard writing mode
POINT is "Enable," even a worn tip is considered always as the latest tip (of zero tip consumption
amount) and the automatic operation is carried out. As a result, the tip consumption amount
correction function will not work properly, and the tip consumption amount warning message
may not be output, welding quality failure and so forth may occur.
4-8
4.5Executing gun search 2 first
4.5 Executing gun search 2 first

When to use both of the gun search 1 and the gun search 2, their execution sequence can be designated.
Designation of the execution sequence is made by constants setting or function commands.
In normal cases, designate it by constants setting. When to switch the execution sequence for some reason,
use the function commands.
4.5.1 Designating by constants setting

Designate the execution sequence in reverse order in the servo gun tip consumption screen.
4.5.2 Designating the execution sequence by function command

Set the execution sequence to the function in the servo gun tip consumption screen, and designate the
execution sequence by the following function command.

GSEA_ORDER FN229 This command specifies the servo gun search execution
sequence.
Parameter
Data Description, setting range
Parameter No. 1 Execution This parameter specifies the execution sequence of gun
sequence search 1 and gun search 2.
(0 to 1)
0: Gun search 1 is executed first followed by gun search 2.
1: Gun search 2 is executed first followed by gun search 1.
When executing in the sequence of When executing in the sequence of

gun search 1 followed by gun search 2 gun search 2 followed by gun search 1
1 REM[Search] FN99: comment 1 REM[Search] FN99: Comment
2 300 mm/s LIN A1 T1 2 300 mm/s LIN A1 T1

4 GSEA[1,1,10] FN167: Servo gun spot search
4 GSEA_ORDER[1] FN229; Servo gun search
5 300 mm/s LIN A4 T1 sequence specification
6 300 mm/s LIN A1 T1 5 GSEA[1,2,10] FN167: Servo gun spot search
7 GSEA[1,2,10] FN167: Servo gun spot search 6 300 mm/s LIN A4 T1
8 300 mm/s LIN A4 T1 7 300 mm/s LIN A1 T1

8 GSEA[1,1,10] FN167: Servo gun spot search
10 END FN99: End 10 300 mm/s LIN A1 T1
11 END FN99: End
Fig. 4.5.1 Teaching example of servo gun search execution sequence
If what has been specified in the search sequence and the gun search sequence differ, an alarm is detected
during playback, and the robot stops.
4-9
4.6Clearing tip consumption amounts
4.6 Clearing tip consumption amounts

When the gun welding tips have been replaced with new ones, the tip consumption amounts obtained by the
gun search and welding functions must be cleared (set to zero). This can be accomplished in a number of
ways.
4.6.1 How to clear the tip consumption amounts using an R code

Tip consumption amounts can be preset to the desired values by inputting the R339 short-cut (R code).
Following the message, input the gun number, tip type and tip consumption amounts. Select "0" for the tip
consumption amounts.
4.6.2 How to clear the tip consumption amounts by manual operation

When the servo gun monitor screen is opened, the current tip consumption amount values are displayed.
When the [EDIT] key is pressed to establish the edit enable mode, the values can be changed directly by
aligning the cursor. For details, refer to "Chapter 6 Useful functions" given later.
4.6.3 How to clear the tip consumption amounts using an external signal
Tip consumption amounts can be cleared to zero using an external signal. (They cannot be preset to the
desired values.)
With <External> set for start select:
• When the "Reset consumption" input signal is set to ON, the tip consumption amounts of the moving side
tip and settled side tip are both reset.
• When the "Moving side reset consumption" input signal is set to ON, the tip consumption amount of the
moving side tip only is reset.
• When the "Settled side reset consumption" input signal is set to ON, the tip consumption amount of the
settled side tip only is reset.
This function cannot be used when <Internal> has been set for start select. In the case of the gun changing
specifications, the tip consumption amounts are not reset when the guns are not connected.
Input a pulse of 300 ms or more.
These spot welding input signals are not assigned as standard factory settings. When they are to be used,
assign the spot welding input signals.
4.6.4 How to clear the tip consumption amounts automatically

Tip consumption amounts can be cleared to zero using a function command. (They cannot be preset to the
desired values.)
When tips are to be replaced automatically, record this function command in the tip replacement program.

SGTIPRST FN270 Tip consumption amount reset

Parameter No.1 Welder This specifies the number of the welder whose tip
number consumption amount is to be reset. (1 to 6)
Parameter No. 2 Tip selection This parameter specifies the tip whose tip consumption
amounts is to be reset. (0 to 2)
0: The tip consumption amount of only the moving side tip is
reset.
1: The tip consumption amount of only the settled side tip is
reset.
2: The tip consumption amounts of both the moving side and
settled side tip are reset.
4-10
4.7Abnormal tip consumption amount detection
4.7 Abnormal tip consumption amount detection

4.7.1 Tip consumption amount abnormality detection

Abnormalities in the detected tip consumption amounts can be detected at two levels: the alarm level and
the abnormal level. For each level, set the detection values for the directions in which the tip consumption
amount increases and decreases. Abnormalities are not detected when "0" is selected as the setting.
When the alarm level has been exceeded, the "Information" alarm is displayed. The robot operation is not
shut down, but the tip consumption alarm signal is output.
When the abnormal level has been exceeded, the "Alarm" trouble is displayed, and the robot during
playback stops then and there.
+ side abnormal level
+ side alarm level

Normal electrode Usable electrode
– side alarm level area
area
– side abnormal level Status of electrodes with reference
writing
Fig. 4.7.1 Tip consumption amount abnormality detection
Spot welding output signals:

"Tip consumption alarm", "Moving side tip consumption alarm," "Settled side tip consumption alarm,"
"Tip consumption trouble," "Moving side tip consumption trouble," "Settled side tip consumption trouble"
The error detection level is set by [maximum tip consumption amount] and [tip exchange tip consumption
amount] in the servo gun tip consumption screen.
4.7.2 Search 3 tip consumption change trouble detection

An error is displayed and the robot is stopped when the difference between the tip consumption amount
detected by search 3 and the total tip consumption amount detected by the previous search 1 or search 3
has exceeded the "Search 3 trouble tip consumption change amount" in the servo gun conditions. The
signal is also output if the change in the tip consumption amount has exceeded the trouble tip consumption
change amount when the tip consumption amount is detected at each welding point.
When 0 is set to the "search 3 abnormal tip consumption change amount" in the servo gun tip consumption
amount detection screen, the error detection is not carried out.
Spot welding output signal: "Tip consumption amount change trouble"
4.7.3 Gun search stop trouble detection

The software incorporates a function for checking that the "gun axis has come to a complete standstill" in
order for the correct tip consumption amounts to be detected by gun search. If the standstill criterion cannot
be satisfied due to defective servo tuning or some other cause, a situation arises in which the gun search
command fails to be completed indefinitely. To prevent this, a time limit is set for the wait time of the
standstill criterion, and if the gun axis fails to stop even after this wait time has elapsed, the "Unstable gun
axis encoder data" error is displayed, and the robot is stopped.
The time limit is set by the "stop error detection wait time" in the servo gun tip consumption amount
detection screen. If it is 0 second (factory shipment setting), the error detection is not carried out.
4-11
4.8Offset of Tip Consumption Amount Display and Error Detection Level
4.8 Offset of Tip Consumption Amount Display and Error Detection Level
Read this section only in the case of the servo gun.
Even when a new tip is attached, such as when welding tip and shank are changed, tip consumption amount
is detected. At that time, ideally setting is redone from the start, but it is necessary to correct the welding
program too.
However, it is necessary to carry out the gun search standard writing after change, and a difference in length
is detected by tip consumption amount measurement as tip consumption amount, therefore, welding work
can be carried out by tip consumption amount correction function without correcting the welding program.
(However, in the case of change in other direction than length direction, this measure is not available.)
In this case, because a difference in length is detected as tip consumption amount, the tip consumption
amount of actual welding tip does not coincide with the detected tip consumption amount. By registering this
difference in length as an offset value, it is possible to make the tip consumption amount of the actual
welding tip same as the tip consumption amount to be displayed on the monitor. And, the offset value is used
also at detection of tip consumption error, welding tip can be used efficiently. In tip consumption amount
correction, the detected value is used as it is.
Shank length change Tip consumption zero

= offset amount position at search
standard writing
Tip consumption zero
position at shank
length change
(a) At search standard writing (b) Shank length change
Fig. 4.8.1 Offset of tip consumption amount display (Settled tip)
When the gun search standard writing is carried out after welding tip and shank are
changed, the detected corrected tip consumption amount does not become the shift
amount of welding point with record point. Therefore, be sure to carry out the position
correction of welding program.
CAUTION Because the contact point to works changes, works may be deformed or the gun may be
destroyed.
Welding point position is corrected in the tip consumption amount correction, but in other
transfer commands, recorded position is played back as it is. Therefore, interference with
works or jigs may occur depending on the change length.
CAUTION Be sure to confirm the playback position by check go or the like.
INFO. In long term use of the spot welding gun, the shank may be pushed down in comparison
with a new one. In such a case too, this function is effective.
4-12
4.8.1 Registration of Offset Value

The method to register an offset value to make the tip consumption amount zero is explained.
This is an important work to register the value to become the source for tip consumption amount error
detection, and requires operator qualification of EXPERT or higher. As for details of operator qualification,
refer to Setup Manual.
As a result of tip consumption amount detection after attaching a new tip, the detected tip consumption
amount becomes the offset value. At that time, if the attachment of the tip is incomplete, attachment
shortage is detected as an error. Therefore, when to carry out tip consumption amount detection in
registration of offset position, attach the tip completely by manually pressurize it at maximum pressure.
1 Attach a new tip, playback the tip consumption amount detection program, and detect the
current tip consumption amount.
2 Press <Constant Setting> - [Spot welding application] - [Servo gun tip consumption].
>> The following screen is displayed.
First page Second page
3 Press the [Enable] key and <Register monitor offset> f11 key.
>> The following message is displayed.
4 If there is no problem for making the <Current tip consumption> displayed in the message,
select [Yes] by the cursor key and press the [Enter] key.
>> The current detected tip consumption amount (value used for correction) displayed in the
message is taken into the display offset parameter. The display offset parameter is displayed on
the second page.
At necessity, this value can be changed manually.
5 Press <Complete> f12 key and exit the servo gun tip consumption screen.
>>Then, the value of the monitor display and the tip consumption value at abrasion error detection
become the value obtained by subtracting the value registered against the actually detected
value.
When the tip consumption correction amount to become the standard has already been known by some
means, a value may be input directly without carrying out tip consumption amount detection.
4-13
The value to be registered as an offset value becomes the tip consumption correction
value to make the tip consumption amount of display and error detection zero.
The value of monitor display and tip consumption error detection becomes the value
POINT obtained by subtracting the value set against the detected tip consumption amount (tip
consumption correction amount).
For example, when the offset is registered as 2.0mm and the detected tip consumption
amount is 5.0mm, 3.0mm is displayed on the monitor. The tip consumption amount error
is detected by comparison of this 3.0mm and the error detection level.
When a wrong offset value is registered, error cannot be detected even if the welding tip
is worn over the permissible tip consumption amount, therefore, pay sufficient attention
to registration.
CAUTION
• When a new tip is attached and tip consumption amount is detected, if minus tip
consumption amount (tip has become long) is detected, a phenomenon where the error
cannot be detected even the welding tip is worn over the permissible tip consumption
INFO. amount. By making the minus side of tip consumption amount error detection level a
small value, a wrong setting can be detected as an error.
• When a new tip is attached and tip consumption amount is detected, if plus tip
consumption amount is detected, tip consumption amount of the welding tip even
below the permissible tip consumption amount is detected as an error.
4-14
Chapter 5 Welding program teaching
This chapter gives details on the spot welding program teach operations.
5.1 Basic operations for welding steps .......................................................... 5-1

5.2 Welding conditions and welding sequences during step recording ........................5-2
5.3 Welding step teaching ............................................................................. 5-3
5.3.1 Spot welding command recording ................................................... 5-3
5.3.2 Tip consumption compensation during welding point recording ...... 5-6
5.4 CHECK GO/BACK for welding steps ....................................................... 5-7
5.4.1 Non-continuous CHECK GO/BACK ................................................ 5-7
5.4.2 Permanent "pressurizing OFF" for CHECK BACK .......................... 5-8
5.5 Modifying welding steps........................................................................... 5-9
5.5.1 Position modification ....................................................................... 5-9
5.5.2 Overwriting...................................................................................... 5-9
5.5.3 Insertion .......................................................................................... 5-9
5.5.4 Deletion........................................................................................... 5-9
5.5.5 Affinity with jump call commands .................................................. 5-10
5.6 Checking the recording positions of the welding steps ...........................5-11
5.7 Setting of Clearance by Function Command ......................................... 5-12
5.7.1 Recording of equalization value setting command........................ 5-13
5.7.2 Recording the equalizing clear command ..................................... 5-16
5.7.3 Example of recording .................................................................... 5-17
5.1Basic operations for welding steps
5.1 Basic operations for welding steps

The spot welding command (SPOT: FN119) is recorded in the spot welding steps for both the air gun and
servo gun.
With the servo gun, since the position data of the servo gun axis (moving tip position) is recorded by pressing
the <O.WRITE / REC> key on the teach pendant as with the other axes, it is recorded in the welding steps as
the position where the moving side tip and settled side tip come into contact with the work.
When the spot welding command is played back for the servo gun, the flow of operations is as shown below.
Moving side tip
Clearance/move
Work
piece Elapsed
time
Clearance/settle
Settled side tip
Position of gun tips when FN119 With a servo gun, press the [RECORD] key
spot welding command has been where both the moving side tip and settled
recorded. side tip touch the work.
Fig. 5.1.1 Flow of servo gun pressurizing operations
1. While moving toward the recorded point, the servo gun axis (moving side tip) begins to move toward the
position which is distanced from the work by an amount equivalent to the "Moving side clearance" in the
servo gun conditions. The settled side tip moves toward the position which is distanced from the work by
an amount equivalent to the "Settled side clearance" in the servo gun conditions. After this, the moving
side tip moves by a distance equivalent to the "Moving side clearance" in the servo gun conditions while
the settled side tip also moves by a distance equivalent to the "Settled side clearance" in the servo gun
conditions, and they move to positions where both tips come into contact with the work.
2. Pressurizing is now performed with the set welding force. (The settled side tip and moving side tip move
in the pressurizing direction.)
3. When welding completion (WI signal) is input, the moving side tip returns as far as the amount equivalent
to the "Moving side clearance" in the servo gun conditions. The settled side tip returns as far as the
amount equivalent to the "Settled side clearance" in the servo gun conditions.
4. Operation moves onto the next step.
POINT The clearance position can be changed with the use of function command.
For detail, refer to information in “5.7 Setting of Clearance by Function Command”.
5-1
5.2Welding conditions and welding sequences during step recording
5.2 Welding conditions and welding sequences during step recording

The numbers of the spot welding sequences to be recorded must be specified ahead of time if the spot
welding command (FN119) is to be recorded simultaneously at the spot position (movement command).
This section describes the setting method. The same operations are performed whether an air gun or servo
gun is used.
1 Open the spot welding condition or welding sequence editing screen.
Spot welding condition
Spot weld sequence
2 Whatever the number of the editing screen that is opened, the following two
lines are displayed at the bottom of the dialog box:
"Condition (Sequence) No. (automatic recording)” and
"Condition (Sequence) No. (manual welding)"
Align the cursor here, input the number of the desired welding condition
(sequence), and press the [Enter] key.

5-2
5.3Welding step teaching
5.3 Welding step teaching
5.3.1 Spot welding command recording
Whether the tip is new or worn, the gun search must be implemented and tip
consumption amount measurement completed before the teaching work is
commenced.
POINT Bear in mind that if teaching is initiated while there is a significant discrepancy in the
tip consumption amount of the tip used and the amount stored in the robot,
pressurizing will be performed at a position differing from the taught pressurizing
position, making it impossible to obtain the proper welding force or possibly
deforming the work.
The spot welding command is a function command. As with the timer commands or input/output
commands, it can be recorded using the [FN] key.
Nemonic Number Command

SPOT FN119 Spot weld
(Common to both the air gun and servo gun)

Parameter Welder This parameter specifies the number of the first
No. 1 number welder for which the welding control signal is
output.
(1 to 6)
Parameter This parameter specifies the number of the
Welding
No. 2 welding condition that determines the welding
condition
force and welding condition signal.
number
(1 to 255)
Parameter Welding This parameter specifies the number of the
No. 3 sequence welding sequence that determines the timings at
number which the pressurizing signal, power-on signal
and stroke signal are to be output, etc.
(1 to 64)
Parameter Welding point Use this parameter when controlling the welding
No. 4 number points. The welding point numbers are output
when welding trouble has occurred to enable the
hitting points to be specified. Set this to "0" when
the welding point numbers are not going to be
used.
(0 to 16000)
Nevertheless, insofar as only the spot welding function is concerned, automatic recording of the
spot welding function at the same time as the movement commands are recorded is enabled in
order to improve the operational ease. Simply by moving the robot to the hitting point position and
pressing the [O.WRITE / REC] key, the two steps of recording the position concerned (movement
command) and recording the spot welding (function command) can be performed at the same time.
The procedure is described below. (To present the simplest scenario, the procedure is described
using only one welder.)
5-3
1 Move the robot close to the hitting point position.
2 In order to establish the FN119 (spot welding command) automatic recording

status, press the [CLAMP ARC] key on the teach pendant once.
>>A red circle appear in the application area (in the section enclosed by the red frame
immediately below the comment in the figure below) on the status window.
When a movement command is now recorded, the FN119 spot welding function will
be recorded at the same time.
In this status, the spot welding command is not recorded yet.
3 Move the robot to the exact hitting point position.

＋ With a servo gun, ensure that the settled side tip of the gun touches the work
("A" in the figure below) by using the axis operation keys while grasping the
enable switch.
Now ensure that the moving side tip also touches the work ("B" in the figure
below) by executing the manual pressurizing operation (by pressing the
[ENABLE] and [CLAMP ARC] keys together).
This is the hitting point position.
Moving sid e
e lectrode
Settled side
electrode
A B
Fig. 5.3.1 Servo gun hitting point teaching
4 Check whether the gun is pressurizing properly.
When recording and/or modifying the welding points

• Set the welding force to a level low enough not to cause the arm to bend.
• Then proceed with the pressurizing and recording or modifying by executing the
manual gun pressurizing operation.
When a high welding force is set and the "manual gun pressurizing" operation is
performed, the arm will bend, and the work will also bend in tandem. When a recording
and/or modifying operation is performed in this state, the correct position will not be
recorded.
When the teaching and/or modifying steps are played back in this way, pressurizing is
executed at the position where the work bends during playback as well. This may
cause the work to become deformed.
Fig. 5.3.2 Correct pressurizing position
5-4
5 If OK, press the [O.WRITE / REC] key.

>>The FN119 spot welding command is also recorded at the same time as the
movement command for the position concerned. In the example shown in the figure
below, the movement command has been recorded in step 3 and the spot welding
command has been recorded in step 4.
Step1: Move Command
Step 2: Move Command
Step 3: Move Command

Step 4: Spot welding command
Initial welding point
Fig. 5.3.3 Teaching spot welding commands
>> The welding command and welding sequence number now recorded are the ones
which were set in 0Welding conditions and welding sequences during step
recording.
6 The gun is opened by executing the manual pressurizing operation (by pressing
＋ the [ENABLE] and [CLAMP ARC] keys together) once again.
In addition, the settled side tip is also released and disengaged from the work
using the axis operation keys. (“C" in the figure below)
Moving sid e electrode
Settled side electrode
A B C
Fig. 5.3.4 Servo gun hitting point teaching
In the case of an air gun, release the settled side tip from the work by a manual
operation.
7 Press the [CLAMP ARC] key again to prepare for the recording of the next step.
>>The letters "REC" and the red circle in the application area are cleared.
From now on, the spot welding command will not be recorded simultaneously even
when a movement command is recorded.
When a hitting point is reached again, repeat the same operations starting with step
2.
5-5
5.3.2 Tip consumption compensation during welding point recording

With a servo gun, use tips which are not worn (new tips) for recording and/or modifying the recorded
positions.
Even when teaching using worn tips is unavoidable, it is possible to record the positions applying
when the tip consumption amounts have been compensated automatically and new tips have been
used. In this case, execute search 1 and search 2 to detect the correct tip consumption amounts,
and then proceed with the teaching work.
Bear in mind that, depending on the recording and/or modifying operation method, the tip
consumption amounts may or may not be compensated. If tip consumption amount compensation
is not executed, the work may be pushed up or down during pressurizing. To prevent this from
happening, make every effort to always execute position compensation for the movement
command immediately before the spot welding command (SPOT: FN119). If this is done, the
welding recorded points are recognized automatically, and the position is compensated to the
position where the tip consumption amounts have been compensated.
Welding step recording and Tip consumption

modifying operation method compensation
When the spot welding command (SPOT: FN119)
was recorded automatically
The position where the tip
When position compensation was executed for the
consumption amounts have
movement command immediately before the spot
been compensated are
welding command (SPOT: FN119)
recorded automatically.
When position compensation was executed by the
spot welding command (SPOT: FN119)
When the spot welding command was recorded
Tip consumption amount
using the [FN] key on the teach pendant
compensation is not
When the spot welding command was recorded
executed.
directly during screen editing
Moving side tip
Tip
consumption
amount
This position is recorded.
When the [RECORD] key is

pressed:
Fig. 5.3.5 Recording in which the tip consumption amounts have been compensated
5-6
5.4CHECK GO/BACK for welding steps
5.4 CHECK GO/BACK for welding steps

This section describes the CHECK GO/BACK functions for the spot welding command (SPOT: FN119).
5.4.1 Non-continuous CHECK GO/BACK

The steps can be played back one at a time during 1-step operation, step feed 1-cycle operation or
step feed continuous operation in the CHECK GO/BACK and playback mode. Because movement
commands and function commands are treated without distinction as "steps", commands are
played back one by one by above mentioned operation.
The same applies during CHECK BACK. Since regular function commands cannot be played back
during CHECK BACK, the SETM command in steps 6 and 10 shown in the figure below are not
played back.
Playback in forward direction Playback in reverse direct

Stroke
1 REM[Test] FN99: Comment Stroke
Operation A 2 10 % JOINT A1 T1
Operation A
3 100 % LIN A1 T1
Operation B 4 SPOT[1,1,1,0] FN119: Spot weld
Operation B
5 100 % LIN A4 T1
6 SETM[o48,1] FN105: Output ON/OFF 
7 100 % LIN A4 T1
8 100 % LIN A4 T1
Operation A
9 100 % LIN A1 T2 Operation A
10 SETM[o48,1] FN105: Output ON/OFF 
Operation B 11 SPOT[2,1,1,0] FN119: Spot weld
12 100 % LIN A1 T1 Operation B
13 END FN99: End
During CHECK BACK, the pressurizing operation is not performed by the

air gun or servo gun.
With an air gun With a servo gun

Operation A The gun performs the no change, The gun moves by the "stroke
(operation prior semi- open or fully open operation in (movement start)" setting in the
to pressurizing) accordance with the "stroke welding sequence or "moving side
(movement start)" setting in the clearance" setting in the servo gun
welding sequence. conditions, whichever is greater.
Operation B Welding start: The pressurizing Welding start: The pressurizing
(pressurizing signal is output, and the WI input signal is output, and the WI input
operation) wait status is established. (CHECK wait status is established. (CHECK
GO only) GO only)
Welding end: The gun performs the Welding end: The gun moves by the
no change, semi-open or fully open "stroke (welding end)" setting in the
operation in accordance with the welding sequence or "moving side
"stroke (welding end)" setting in the clearance" setting in the servo gun
welding sequence. conditions, whichever is greater.
Fig. 5.4.1 Non-continuous CHECK GO/BACK
5-7
5.4CHECK GO/BACK for welding steps
5.4.2 Permanent "pressurizing OFF" for CHECK BACK

With CHECK GO (forward direction playback), operation follows the "welding ON," "welding OFF"
and "pressurizing OFF" settings as during automatic operation. This is the status in which operation
can be checked or changed using the f1 key.
On the other hand, CHECK BACK (reverse direction playback) is performed always in the
"pressurizing OFF" status regardless of the above settings and air gun or servo gun settings. In this
case, the tips move as far as the clearance position but no further spot welding operations
(pressurizing operations, gun signal output, power-on signal output, WI wait, etc.) are performed.
This measure is taken to ensure safety and reduce the teaching time.
Moving side tip

Stroke length or
With the tips remaining at their clearance clearance,
positions, none of the operations such as whichever is
pressurizing operation, gun signal output, greater
power-on signal output or WI wait are
performed. Clearance
Settled side tip
Fig. 5.4.2 Permanent "pressurizing OFF" for CHECK BACK
Furthermore, in the case of regular function commands, whether these commands are to be
executed for CHECK GO/BACK can be specified using "Function playback during check = No
playback, all or I only" among the teach playback conditions.
Although the spot welding command (SPOT: FN119) is also a function command, this selection is
unrelated to whether the spot welding command can be executed or not.
5-8
5.5Modifying welding steps
5.5 Modifying welding steps
5.5.1 Position modification

To modify the position of a movement command, press the [ENABLE] and [MOD Position] keys
simultaneously while the movement command whose position is to be modified is designated by the
current step. An operating error results if this operation is conducted when the current step involves
a function command.
However, if the [ENABLE] and [MOD Position] keys have been pressed simultaneously when the
current step involves the spot welding command (SPOT: FN119), the movement command
immediately before this command is searched, and its position is modified. This is done in order to
make it easier to modify the position at the spot welding point. If the search fails to find a movement
command, the same operating error as the one mentioned above will result.
1 REM[Test] FN99: Comment

2 10 % JOINT A1 T1
3 100 % LIN A1 T1
4 SETM[o48,1] FN105: Output ON/OFF
5 100 % LIN A4 T1
6 100 % LIN A4 T1
"Position modify" 7 100 % LIN A4 T1
when the current
step is 8 8 SPOT[2,1,1,0] FN119: Spot weld
9 100 % LIN A1 T1
10 100 % LIN A1 T1
11 100 % LIN A1 T1
The position of step 7
which contains the 12 END FN99: End
movement command
immediately before is
modified.
Fig. 5.5.1 Modifying the welding step position
5.5.2 Overwriting
An operating error will result if the [ENABLE] and [O.WRITE / REC] keys have been pressed
simultaneously when the current step contains a spot welding command (SPOT: FN119). Proceed
with overwriting after step setting so that the current step will contain a movement commands.
If the example of the sample in "Fig. 5.5.1 Modifying the welding step position" applies, proceed
with overwriting after step setting in step 7.
5.5.3 Insertion
[Insert] operations are the same as for the regular function commands.
If the [ENABLE] and [INS] keys have been pressed simultaneously when the current step involves
the spot welding command (SPOT: FN119), a new step (movement command) is inserted between
steps 7 and 8 in the case of the example provided in "Fig. 5.5.1 Modifying the welding step
position."
With [Insert] operations in the welding command automatic recording status, the welding command
(SPOT: FN119) is recorded in the step following the movement command.
5.5.4 Deletion
[Delete] operations are the same as for the regular function commands.
If the [ENABLE] and [DEL] keys have been pressed simultaneously when the current step involves
the spot welding command (SPOT: FN119), only step 8 is deleted in the case of the example
provided in "Fig. 5.5.1 Modifying the welding step position."
5-9
5.5Modifying welding steps
5.5.5 Affinity with jump call commands

Any step (movement command or function command) can be specified as the jump destination of
the jump call command. This means that specifying the spot welding command (SPOT: FN119) as
the jump call destination is possible as far as teaching goes.
However, by design this kind of sequence is disabled to be played back, in order to eliminate the
danger that spot welding will be executed at an unacceptable position that is specified as a result of
modifying the teaching.
More specifically, if a function command of the jump call type was played back even once during the
period between the completion of the execution of a movement command and the execution of the
spot welding command (SPOT: FN119), the alarm of "A2003: Spot welding function cannot be
executed" is detected before command (SPOT: FN119) is attempted and the robot stops
immediately before the execution of the spot welding.
JMP to general function command JMP to SPOT command
1 REM[Test] FN99: Comment 1 REM[Test] FN99: Comment

2 10 % JOINT A1 T1 2 10 % JOINT A1 T1
3 100 % LIN A1 T1 3 100 % LIN A1 T1
4 JMP[9] FN20: Jump 4 JMP[9] FN20: Jump
5 100 % LIN A4 T1 5 100 % LIN A4 T1
6 100 % LIN A4 T1 6 100 % LIN A4 T1
7 100 % LIN A4 T1 7 100 % LIN A4 T1
8 100 % LIN A4 T2 8 100 % LIN A4 T2
9 SETM[o48,1] FN105 : Output ON/OFF 9 SPOT[2,1,1,0] FN119: Spot weld
10 100 % LIN A4 T2 10 100 % LIN A4 T2
11 100 % LIN A1 T1 11 100 % LIN A1 T1
12 END FN99: End 12 END FN99: End
Fig. 5.5.2 Jump call command and spot welding command
5-10
5.6Checking the recording positions of the welding steps
5.6 Checking the recording positions of the welding steps

Since tip consumption compensation is activated during CHECK GO or auto operations, both the gun axis
and robot body axis move to locations that deviate from the actual teach positions. For this reason, the
original recorded positions cannot be checked. Use of this function makes it possible to check the recorded
positions of the robot body axis in the steps where the spot welding command has been recorded but only
during CHECK GO.
When this function is set to "Enabled", only the robot body axis moves to the recorded position in the step
without performing the pressurizing operation when the spot welding command is played back with CHECK
GO. After this, the WI wait status is established. The gun signal and power-on signal are not output at this
time. Furthermore, when a step position is modified, the position is modified for all the axes except the gun
axis. This means that when modifying welding step positions, these positions can be modified simply by
teaching for the robot body alone.
1 Select the teach mode or playback mode.

However, settings cannot be performed while a playback operation is underway.
2 Press f7 <Spot Condition> key.

3 Align the cursor with "Servo gun teach check," and select the "Enabled" radio
button setting using the [ENABLE] and left or right cursor keys.
4 Press f12 <Complete> and exit the spot teach/playback condition setting screen.
>> From this point on until the setting is returned to "Disabled," the pressurizing
operation is not performed and only the robot body axis moves to the recorded
position in the step when the spot welding command is played back by CHECK GO.
5 The indicator shown below now appears to indicate that the recorded points of
the gun are now being checked.
CHECK GO operation
with
Clearance recorded point
ch eck "Disa bled"
Only the settled

side electrode
CHECK GO (robot body)
operation with moves to the
recorded positio n.
recorded point
check "Enabled"
Fig. 5.6.1 Checking the servo gun recorded position
5-11
5.7Setting of Clearance by Function
5.7 Setting of Clearance by Function Command

This setting function is only applicable to servo gun systems.
Normally, playing back the spot welding command will make the servo gun move as shown below.
Moving side
Clearance:
Moving side
Welding
WI
Clearance:
Fixed side
Settled side
Consequently, if even one welding position is located in a confined space, clearance should be made smaller
in order to prevent the servo gun from interfering with surroundings.
This presents the need to create a shelter step before and after the welding command in order to prevent the
servo gun from interfering with workpiece or protrusions.
Enabling changes of equalization of the welding command using the function command eliminates the need
to create the shelter step before and after the welding command.
If function command is recorded, playing back the spot welding command will make the servo gun move as
shown below.
Moving side
Finish equalization:
Start equalization:
Moving side
Moving side Welding
WI
Start equalization: Finish equalization:

Fixed side Fixed side
Settled side
5-12
5.7.1 Recording of equalization value setting command

Recording this function command will make changes to all subsequent spot welding
POINT commands. Record this command before a spot welding command to which you want
to make a change.
Data on this function command are cleared in Stop “0”.
The equalization value setting command is an function command, and thereby it can be recorded
using the [FN] key all the same as the timer command and I/O command.
1 Press [FN] and [2], [8], [7].

>> The Function list shown below will appear.
2 Press the [Enter] key.

EQUALIZE FN287 Equalize value
>> Make setting of the parameters listed in the table below.

Parameter Data Function/Setting range
Parameter 1 Welder No. To designate the welder number to which an
equalization value is set.
Input range : 1 to 6
Parameter 2 Equalize start To designate the equalization value (of moving
: Move-tip side) to start welding by distance.
Input range : Refer to following point
Parameter 3 Equalize start To designate the equalization value (of settled
: Settle-tip side) to start welding by distance.
Parameter 4 Equalize End To designate the equalization value (of moving
: Move-tip side) to finish welding by distance.
Parameter 5 Equalize End To designate the equalization value (of settled
: Settle-tip side) to finish welding by distance.
5-13
Input range of following parameter is limited by “large opening end” and

POINT “Clearance Limit” of “servo gun usage condition” setting screen.
Minimum value is limited by “Clearance Limit”. Maximum value is limited
in order that total amount of move-tip and settle-tip does not exceed “large
opening end”.
・Equalize start : Move-tip (2nd parameter)

・Equalize start : Settle-tip (3rd parameter)
・Equalize end : Move-tip (4th parameter)
・Equalize end: Settle-tip (5th parameter)
<input range to record function>

Data Minimum Maximum
Equalize start Clearance limit large opening end - Clearance
: Move-tip of move-tip limit of move-tip
Equalize start Clearance limit large opening end - inputted
: Settle-tip of settle-tip value of equalize start : move-tip
Equalize End Clearance limit large opening end - Clearance
: Move-tip of move-tip limit of move-tip
Equalize End Clearance limit large opening end - inputted
: Settle-tip of settle-tip value of equalize end : move-tip
<input range in the screen editor>

Data Minimum Maximum
: Move-tip of move-tip value of equalize start : settle-tip
: Settle-tip of settle-tip value of equalize start : move-tip
: Move-tip of move-tip value of equalize end : settle-tip
: Settle-tip of settle-tip value of equalize end : move-tip
For general function commands, whether or not to execute these commands while in
Check GO/BACK mode can be set with the parameter “Check with function 
POINT Disable/Enabled/I-Enabled” on the Teach/Playback Condition screen.
Equalization value setting command (EQUALIZE: FN287) is also function command,
but this command is executed without depending on such setting. (The execution
sequence becomes the same as that for the spot welding command.)
Data which is set by equalization value setting command (EQUALIZE: FN287) can be
monitored and edited in servo gun monitor.
Please refer to “Chapter 6 Useful functions” for the detail operation.
POINT
Equalization amount set in this monitor screen is kept enabled until the
following timing when equalization amount is modified to new one.
・Equalization value setting command (EQUALIZE: FN287) is executed
・Equalization value clear command (EQUALIZECLR：FN248) is executed
・Step 0 is executed
・Equalization value is cleared by shortcut R376 (Equalize confirmation / clear)
5-14
When spot welding function is executed in CHECK BACK operation,

equalization amount set in this monitor screen is not used.
While CHECK back, equalizing motion is determined by equalization value setting
command (EQUALIZE：FN287) recorded before the spot welding command.
If equalization value clear command (EQUALIZECLR：FN248) is recorded before the
spot welding command or if equalization value setting command (EQUALIZE：FN287)
is not recorded, equalizing motion is determined by the clearance amount set in
“Servo gun usage condition”.
Equalizing amount set by equalization value setting command (EQUALIZE：FN287)

POINT can be confirmed or cleared by shortcut R376 (Equalize confirmation / clear).
<In Teach mode>

When executing R376 (Equalize confirmation / clear) in Teach mode, current
equalizing amount is displayed as followed. If <yes> is selected, equalizing amount is
cleared.
If equalizing amount is cleared, robot trajectory may change when

executing spot welding command recorded later in step.
CAUTION
<in Playback mode>

When executing R376 (Equalize confirmation / clear) in Playback mode, current
equalizing amount is displayed as followed. In Playback mode, equalizing amount can
not be cleared. This is different from the operation in Teach mode.
5-15
When equalizing amount is set by equalization value setting command (EQUALIZE：

FN287), following icon is displayed.
POINT
In manual weld and external input weld, Equalizing amount is set by equalization value
POINT setting command (EQUALIZE：FN287) is not enabled.
In manual weld and external input weld, only “Clearance Limit” of “Servo gun usage
condition” setting screen is enabled.
5.7.2 Recording the equalizing clear command
If this command is recorded, equalizing amount set by equalization value setting

command (EQUALIZE：FN287) is cleared, and after here, clearance of the spot
POINT welding command is controlled as the value that is set in “servo gun usage condition”
setting screen. Record this command before the spot welding command which is
needed to be changed.
Equaling clear command is function command. Record this using [FN] key same as DELAY or I/O command.
１ Press [FN] and [2], [4], [8].

FN ≫ Following menu will appear.
２ Press [Enter].
pneumonic number name
EQUALIZECLR FN248 Equalize clear
≫ Following parameters should be set here.

Parameter Data Contents, input range
1st parameter Welder No. To designate the welder No. that equalizing
amount is needed to be cleared.
For general function commands, whether or not to execute these commands while in
Check GO/BACK mode can be set with the parameter “Check with function 
POINT Disable/Enabled/I-Enabled” on the Teach/Playback Condition screen.
Although Equalizing clear command (EQUALIZECLR ： FN248) is same kind of
function, this is executed irrelevant with this setting. (just same as spot welding
command)
5-16
5.7.3 Example of recording

Record the equalization value setting command before the spot welding command.
1 REM[TEST] FN99:COMMENT
In Steps 3 and 4, the servo gun
moves according to the clearance 2 10 % JOINT A1 T1
position (of 10 on the moving side
3 100 % LIN A1 T1
and 5 on the fixed side).
4 SPOT[2,1,1,0] FN119:SPOT WELD
5 100 % LIN A4 T1
moves according to the 6 EQUALIZE[-5,-5,-5,-5]
equalization value set in Step 6 (of 7 100 % LIN A4 T1
5 on the moving side and 5 on
the fixed side). 8 SPOT[2,1,1,0] FN119:SPOT WELD
9 EQUALIZE[-5,-5,-10,-5]
moves according to the 10 100 % LIN A1 T1
equalization value set in Step 9 (of 11 SPOT[2,1,1,0] FN119:SPOT WELD
5 on the moving side and 5 on
the fixed side in Step 10, and of 12 EQUALIZECLR[1]
10 on the moving side and 5 on 13 100 % LIN A1 T1
the fixed side in Step 11).
14 SPOT[2,1,1,0] FN119:SPOT WELD
15 100 % LIN A1 T1
moves according to the clearance 16 END FN99:End
amount (of 10 on the moving side
and 5 on the fixed side).
Fig. 5.7.1 Recording of Equalization Value Setting Command
5-17
NOTE
5-18
Chapter 6 Useful functions
This chapter describes for the benefit of operators who will be using the robot in spot
welding applications some functions which they will find useful to know for teaching.
6.1 Gun lock (mechanism disconnection) ......................................................... 6-1

6.2 Short-cuts ................................................................................................... 6-2
6.2.1 R315 Welder select............................................................................... 6-2
6.2.2 R339 Preset Tip Consumption Amounts ............................................... 6-2
6.2.3 R349 Calibrate servo gun ..................................................................... 6-3
6.2.4 R376 Equalize confirmation / clear ....................................................... 6-3
6.3 Spot welding monitor .................................................................................. 6-4
6.3.1 Servo gun data ..................................................................................... 6-5
6.3.2 Welder I/O............................................................................................. 6-9
6.3.3 Welding counter .................................................................................. 6-10
6.4 Group Designation Type Welding Condition Setting Function .................. 6-12
6.4.1 Outline ................................................................................................ 6-12
6.4.2 Constant Setting ................................................................................. 6-13
6.4.3 Spot Welding Condition Setting .......................................................... 6-14
6.4.4 Welding Condition Group Designation Record ................................... 6-17
6.4.5 Spot Welding Monitor.......................................................................... 6-18
6.4.6 R371 Welding Condition Group Number Change ............................... 6-18
6.4.7 Troubleshooting .................................................................................. 6-18
6.5 Servo Gun Weld Stuck Detection ............................................................. 6-19
6.5.1 Setting the Error Code Output Format ................................................ 6-19
6.5.2 Allotting the Error Code Signal............................................................ 6-19
6.5.3 Setting the Abnormal Tracking Detection Level .................................. 6-20
6.1 Gun lock (mechanism disconnection)
6.1 Gun lock (mechanism disconnection)

Read this chapter only when the servo gun is to be used.
This function enables the servo gun axis to be set never to move in spite of the axis operation the manual
open/close operations or manual pressurizing operations. Since the gun axis errors will not be checked
either, it is possible to operate the robot even when the gun is not ready or the gun cannot be operated.
This function is available not only for servo gun axes but also for positioner, travel device or other auxiliary
mechanism ("mechanism disconnection" function). It is called "gun lock" only when a servo gun serves as
the target of the isolation.
The function is executed by following the steps below.

However, settings cannot be performed while a playback operation is underway.
2 Press <Spot Condition> f7 key.

3 Align the cursor with "Mech. disconnection," and press "Enabled" + “1/ON”.
>> If plural servo guns are being used, select the desired gun before doing this.
4 Press <Complete> f12 key, and exit the spot welding condition setting screen.
>> This turns off permanently the servo power for the servo gun axis regardless of
whether the motor power is set to ON or OFF.
5 This turns off permanently the servo power for the servo gun axis regardless of whether
the motor power is set to ON or OFF.
If steps are recorded with the gun lock status still established, the current values applying at
the time will be recorded for the gun axis.
When steps are recorded while, for instance, the servo gun is not connected or trouble in the
position detector system remains unremedied, an unstable position outside the gun axis
operating range will be recorded. If gun lock is released without remedying the situations
CAUTION and playback is initiated, the gun may be damaged by mistake.
This point should be borne in mind during recording.
6-1
6.2 Short-cuts
6.2 Short-cuts
This section describes all the useful short-cuts (R codes) used exclusively for spot welding.
6.2.1 R315 Welder select

This short-cut is common to air guns and servo guns.
It is used with the multi-welder specifications. It is not used when only one welder is used. Use it to
declare the numbers of the welders in the spot welding commands or the numbers of the welders
targeted for stroke selection or other manual operations. Air guns and servo guns cannot be
selected simultaneously.
Shortcut Description
R315 Select welding controller

Parameter Welder number This parameter specifies all the numbers of the welders to
No.1 be selected. When a multiple number of guns are to be
selected at the same time, input all the numbers of
welders to be selected in succession.
(1 to 654321)
(Example) When to designate all the welding controllers 1
to 4, input "4321", "2341", "1234" and the like.
The numbers of the welders targeted for the current operation are displayed in the application area
on the status window. They are indicated by the bold numbers on the top row. In the example given
below, welders 1 and 2 are targeted. The '^' above the number 1 indicates that welder 1 serves as
the master for the multi-gun simultaneous welding function. (For details on the multi-gun
simultaneous welding function, refer to Chapter 8.)
6.2.2 R339 Preset Tip Consumption Amounts

This short-cut is used exclusively with servo guns.
It enables the current tip consumption amounts to be preset to any values.
R339 Preset consumption of tips

Parameter Gun number This parameter specifies the number of the gun whose tip
No.1 consumption amounts are to be changed. (1 to 31)
Parameter Chip kind This parameter specifies the tip to be preset. (0 to 2)
No. 2 0: Moving side tip
1: Settled side tip
2: Both moving side tip and settled side tip
Parameter Consumption Input the tip consumption amount of the tip to be preset. In
No. 3 the millimeter mode, input the amount in millimeters; in the
inch mode, input it in inches.
(0 to maximum tip consumption amount)
The tip consumption amount to be preset by this shortcut is detected tip consumption
POINT
amount (corrected amount). When tip consumption amount display offset value is set, the
value obtained by subtracting the offset value from the value set here is displayed on the
monitor.
6-2
6.2 Short-cuts
6.2.3 R349 Calibrate servo gun

This short-cut is used exclusively with servo guns.
(This function is not supported at present time.)
6.2.4 R376 Equalize confirmation / clear

Only for servo gun.
This can confirm and clear the equalize amount set by Function command EQUALIZE (FN287:
Equalize value).
R376 Equalize confirmation / clear
Data Description, setting range

Parameter Welder No. This parameter specifies all the welder No. which equalize
No.1 amount is confirmed or cleared. (1 to 6)
<In Teach mode>

When executing R376 (Equalize confirmation / clear) in Teach mode, current equalizing amount is
displayed as followed. If <yes> is selected, equalizing amount is cleared.
If equalizing amount is cleared, robot trajectory may change when executing the spot
welding command recorded later in step.
CAUTION
<in Playback mode>

When executing R376 (Equalize confirmation / clear) in Playback mode, current equalizing amount
is displayed as followed. In Playback mode, equalizing amount can not be cleared. This is different
from the operation in Teach mode.
6-3
6.3 Spot welding monitor

This controller comes with functions for monitoring many different statuses. One such function is the "Spot
welding monitor" which picks out only those monitoring functions related to spot welding. It can be selected
in single-touch operation using an f key.
The monitoring display is updated every 0.1 sec. but no display may appear depending on the input/output
timing, etc.
Presented below is a description of all the monitor data related to the spot welding monitor.

It does not matter if playback operation is underway.
2 Press <Spot Monitor> f3 key.

Alternatively, "3 (to 6) monitor 1 (to 4)" and "29 Spot Welding" may be selected
from service to achieve the same result.
>> A following list of the monitor menu items exclusively used for spot welding is now
displayed.
3 Select the desired monitor using the up or down cursor key, and press the
[Enter] key.
>> The monitor select menu is cleared, and the monitor screens which will be described
below are displayed. The figure below shows an example of the welder I/O monitor
display.(In the case of air gun)
4 Normally, there are more monitor data items than can be displayed on one
screen.
To scroll the screens, first press the [CLOSE/SELECT SCREEN] key to set this
monitor screen to the active status, and then press the up or down cursor key.
>>The active status is established when the title bar turns blue.
5 To close a monitor, set the spot welding monitor to the active status, and press
＋ the [ENABLE] and [CLOSE/SELECT SCREEN] keys simultaneously.
Once opened, a monitor screen remains displayed even if the mode is changed.
It must therefore be closed as soon as it is no longer required.
6-4
6.3.1 Servo gun data

This function can be selected only when a servo gun is used.
It is used when adjusting the welding force of the servo gun or ascertaining the current tip
consumption amounts.
Table 6.3.1 Data displayed by servo gun monitor

Display item Description
Position The current position of the servo gun axis and the position specified by the
command are displayed as encoder values.
Current The current value actually flowing to the servo gun axis and the current value
specified by the command are displayed as [Apeak].
Pressure The specified welding force and the welding force calculated by the feedback
current are displayed in [N] units.
Length The current position of the servo gun and the position specified by the
command are displayed as lengths in millimeter or inch units.
Tip consumption The current tip consumption amounts at the moving side and settled side are
displayed.
Total The tip consumption amount is detected at each hitting point, and the last five
detected values are displayed. This item is valid only when "Update" has
been selected as the "Update tip consumption amounts every time" setting.
Equalize FN exe. This item is turned ON while "FN287 EQUALIZE : Equalize value" function is
Value being used.
While executing the FN287
While not executing the FN287

Start:Move The equalize amount of a welding start is displayed. (moving side tip)
Start:Settle The equalize amount of a welding start is displayed. (settled side tip)
End:Move The equalize amount of a welding end is displayed. (moving side tip)
End:Settle The equalize amount of a welding end is displayed. (settled side tip)
In the edit screen, tip consumption amount can be preset. It is also possible to edit the equalize value.
When tip consumption amount display offset value is set, the displayed value is not the
detected tip consumption amount (corrected amount), but the value obtained by subtracting
the offset value from this abrasion corrected value.
POINT However, the tip consumption amount in the edit screen is tip consumption amount where
offset value is not subtracted.
In operator qualification of SPECIALIST or higher, tip consumption amount where offset
value is not subtracted is displayed in the normal screen as well.
The units of (pressurization) force and length, you can select among the following.
POINT Unit of (pressurization) force : [kN] or [kgf]

Unit of length : [m], [cm], [mm] or [inch]
Confirmation and setting in <Constant setting> -[2 display environment] - [3 unit selection].
6-5
How to edit the equalize value
1 Only while executing the "FN287 EQUALIZE : Equalize value" function, it

is possible to edit the equalization value.
>> If FN287 is not being executed, press <Equalize value> f key to make a
FN287 execution status and then edit the equalize value.
[When not executing the FN287]
Press <Equalize value> f key
[When executing the FN287]

>> f8 key changes to <Equalize clear>.
>> Now it becomes possible to edit the equalize value. The initial values are
the setting values of "Clearance move/settle" that are set in the [Servo gun
usage condition] screen.
2 Input the desired values to the equalize value edit boxes and then press
<Complete> f key.
>>The equalize values are modified to the inputted values.
>>If the operation is canceled on the way, the modified values are not saved.
6-6
The input range for the "Equalize value" is regulated via the "Clearance Limit" and the "Large
opening end" in the [6 Servo Gun usage condition] screen.
The minimum value is regulated by the "Clearance Limit". And the maximum value is
regulated so that the sum of the moving side and the settled (fixed) side does not exceed the
value of the "Large opening end".
Data Minimum value Maximum value
Moving side of "Large opening end"
POINT Start: Moving side
Clearance Limit - value of "Start : Settled side"
Settled side of "Large opening end"
Start: Settled side
Clearance Limit - value of "Start : Moving side"
Moving side of "Large opening end"
End: Moving side
Clearance Limit - value of "End : Settled side"
Settled side of "Large opening end"
End: Settled side
Clearance Limit - value of "End : Moving side"
The equalize values edited in the Servo gun data monitor window are effective until the
following timings when the equalize values are modified.
POINT - When the "FN287 EQUALIZE : Equalize value" function is executed.
- When the "FN248 EQUALIZECLR : Equalize clear" function is executed.
- When the step 0 is executed.
- When the shortcut code "R376 Equalize confirmation/clear" is executed.
When executing a spot welding function with a CHECK BACK operation, it is not possible to
make an equalize motion with the equalize values that are set in the servo gun data monitor.
In case of CHECK BACK, the equalize motion is made using the values that are set in the
POINT "FN287 EQUALIZE : Equalize value" function recorded before the spot welding function.
In case that "FN248 EQUALIZECLR : Equalize clear" is recorded before the spot welding
function or "FN287 EQUALIZE : Equalize value" is not recorded anywhere in the program,
the equalize motion is made using the Clearance value set in the [Servo Gun usage
condition].
6-7
How to clear the equalize value
1 Press <Equalize clear> f key.

>> <Equalize clear> f key is displayed while the "FN287 EQUALIZE : Equalize
value" function is being executed.
[When executing the FN287]
Press <Equalize clear> f key
[When not executing the FN287]

>> The f8 key turns to <Equalize value>.
>> In this status, the equalize values cannot be edited. And the equalize
values are initialized with the setting values of "Clearance move/settle" that
are set in the [Servo gun usage condition] screen.
2 Press <Complete> f key.

>> The equalize values are cleared.
>> If the operation is canceled on the way, the modified values are not saved.
6-8
6.3.2 Welder I/O

It picks out only those input/output signals related to spot welding from among the many
input/output signals provided, and displays them.
The display data differs slightly depending on whether an air gun or servo gun is used.
In case of air gun
Table 6.3.2 Data displayed by welder I/O monitor (air gun)

Out Weld condition (x16)
Press control (x3)
ON or OFF is displayed for the Press, Electric, Full (MX) and Half open.
ON is indicated by the yellow highlighting, and OFF or not used by the gray
highlighting.
In ON or OFF is displayed for the Completion, Full close, Full open, Half open,
Welding, Abnormal, Water 1, Water 2, Air press, and TR temp.
highlighting.
In case of servo gun
Table 6.3.3 Data displayed by welder I/O monitor (servo gun)

Out Weld condition (x16)
ON or OFF is displayed for the Press, and Electric.
highlighting.
In ON or OFF is displayed for the Completion, Welding, Abnormal, Water 1, Water
2, and TR temp.
highlighting.
6-9
6.3.3 Welding counter

A hitting point counter is provided for each welder. The hitting point counter counts up each time the
spot welding command (SPOT: FN119) is played back, and when the preset count-up value is
reached, the "Count-up signal" can be output to an external destination.
Up to six hitting point counters can be used at the same time. They are convenient when used to
ascertain the tip dressing and other timings.
As the factory settings, all the count-up values and assignment of the count-up signals are left at
zero. In this state, the count-up signals will not be output so perform these settings when the
function is to be used. Input the count-up values directly on this monitor screen.
The spot welding output signals must be assigned in the constant mode for the count-up signals.
1 To edit the data, set this monitor screen to the active status using the
[CLOSE/SELECT SCREEN] key, and press the [EDIT] key.
>>The title bar turns red, and the current screen is switched to the editing screen.
2 Move the cursor to the desired edit box, input the data, and press the [Enter] key.
>>The display changes, but the data has not been updated at this point in time.
3 Upon completion of the editing, press <Complete> f12 key.

>>The data is updated, and the original display screen is restored.
Table 6.3.4 Data displayed and edited on welding counter monitor

Welder# The number of the welder to be displayed or edited is specified here.
Input range: 1 to 6
Welding Comments can be set for each hitting point counter. The software keyboard is
counter started when the [ENABLE] and [EDIT] keys are pressed simultaneously.
Times num. This is the current count value.
All six hitting point counters are counted up each time welding is performed in
the "Weld ON" status. When the value reaches the count-up value, the count-up
signal is output at a 0.3 sec. pulse each time the spot welding command is
subsequently executed.
The number of welding times will not exceed the count-up value.
If a value is set here, this item can be preset to any number of welding times.
Count-up This item is used to set the count-up value.
Status When the number of welding times reaches the count-up value, "●" is
displayed; otherwise, "" is displayed. If the count-up value is zero, the number
of welding times remains "" even if it exceeds the count-up value. In this case,
the count-up signal is not output either.
The number of welding times is recorded in the welder counter file and, out of consideration for the
playback operation, the file is updated only after welding has stopped. This means that the latest
values will be lost if the power of the controller is turned off during robot playback. If this screen is
6-10
displayed during robot playback, the latest number of welding times at the time when this screen
was displayed appears. However, while it is displayed, the display is not updated even if some
points have been hit.
During manual pressurizing operations, count-up processing is not implemented immediately but by
the subsequent playback operation.
6-11
6.4 Group Designation Type Welding Condition Setting Function
6.4.1 Outline
1 to 255 kinds of welding conditions can be used per one welding controller, and by this function,
these welding conditions can be taught in division of 16 groups x 16 conditions. Welding condition
output data is set by divided welding conditions, and welding conditions (group number + welding
condition output data) are output to designated welding controller.
Conventional welding condition files are used as they are, and made into the following groups.
● Group 1 conditions 1 to 16: Areas 1 to 16 of conventional welding conditions are used.
* Only group 16 has 15 welding conditions.
Thereby, it is possible to make welding conditions into groups per work kind and they can be used.
In the case of use, welding controller number, group number, welding condition number are set.
6-12
6.4.2 Constant Setting

Constant setting necessary for use of this function is explained.
In advance, change the operator qualification to EXPERT or higher.
2 Press <Spot Constant> f key. Or press [8 spot welding application]

from <Constant setting> f key.
>> The following spot welding constant setting menu is displayed.
Menus of title No. 3 or after are displayed only when the servo gun setting
has been already made.
3 Place the cursor on [1 Spot Welder setting] and press [Enter] key.
>>he following setting screen is displayed.
4 Set the "Welding control interface" to "Standard", and press [Enter]

key once. A table listing selection candidates is displayed there, so
select the candidate you want to select by [up and down cursor] key,
and press [Enter] key once again.
>> In order to use this function, the welding controller interface must be set
to "standard".
5 Place the cursor on the "group designation type welding condition

＋ setting", and set the radio button to "Enable" by [Enable] + [left and
right cursor] key.
6 After completion of setting, press <Complete> f key.

Setting contents are written into the spot welding constant file.
6-13
6.4.3 Spot Welding Condition Setting

In the spot welding condition setting screen, it is possible to select group conditions and welding
condition numbers per welding controller, and set various welding conditions.
1 Set the operator level to USER or higher.
2 Press <Spot Weld. Cond.> f key..

>>The following setting screen is displayed.
(in case of air gun)
(in case of servo gun)
3 Set the welding condition group number to be used in each welding

controller to "group number".
Note) When the group number is set as "16" in welding condition number
"16", the welding condition number is automatically "15".
6-14
4 Position the cursor on the following "group", and set the welding
condition group number to be used at manual welding.
5 Press <Group copy> f key, all the welding conditions of other groups
are copied to the currently selected group.
>>In the case where there are 2 or more welding controllers, the following
input screen is displayed. Input the welding controller number to become
copy source and press [Enter] key.
Then, the following input screen is displayed.
Input the welding condition group number to become the copy source and
press [Enter] key.
Note) When group 16 is made copy source or copy destination, welding

conditions 1 to 15 are copied. In the case to copy among groups 1 to 15,
welding conditions 1 to 16 are copied.
6 Press <Previous No> <Next No> keys to switch welding condition group
numbers (1 to 16).
Note) When the group number is set as "16" in welding condition number
"16", the welding condition number is automatically "15", and welding
condition of group number "16" and welding condition number "15" is
displayed.
7 Press <Complete> key.

>>Data is saved.
6-15
The followings are parameters whose input range differs with enabled/disabled of this function.
 is not displayed. Or even if it is displayed, it is not used.
Table 6.4.1 Spot welding conditions

Factory
Air Servo
Parameter shipment Function description
Gun Gun
setting
Group number – This is the welding condition group number displayed.
It may be switched by f9 <previous number> f10 <next
number>, or by inputting welding condition group  
number directly here.
Welding condition – This is the data number of displayed welding condition
number group. Input the data number of welding condition
group directly here.
 
However, only in group number 16, input range is 1 to
15.
Welding condition Welding This sets the values to be output to the welding
output data condition controller as welding condition. Factory shipment
number setting is a numeric value corresponding to welding
 
condition number.
Input range : 0 to 2047 (welding condition output
for-mat does not matter)
Welding condition Binary When this function is enabled, binary is fixed, so data  
output format cannot be changed.
Condition No. – This is the welding condition number to be used at
(automatic recording) automatic record of welding command.  
Condition No. – This is the welding condition number to be used at
(at manual welding) manual welding.  
Group# – This is the group number to be used at manual
welding.  
6-16
6.4.4 Welding Condition Group Designation Record
The welding condition group designation command is an function command. It can be recorded by
use of the [FN] key in the same manners as timer command and input / output commands. Only
when this function is enabled, recording is available.
Pneumonic Number Japanese name

WELDGRP FN282 Weld condition with group
(Common to air gun and servo gun)
Parameter Data Contents, setting range

Parameter Welder number This designates the welding controller number of output
No.1 destination of welding control signal.
(1 to 6)
Parameter This designates the welding condition group number.
Group number
No.2 (1 to 16)
1 Before executing the welding command (FN119), record the welding condition
group designation function (FN282).
1 REM[Test] FN99: Comment

2 WELDGRP[1,2]
3 100 % LIN A1 T1
4 SPOT[1,1,1,0] FN119: Spot welding 4
5 100 % LIN A4 T1
6 100 % LIN A4 T1
7 WELDGRP[1,3]
8 100 % LIN A4 T1
9 SPOT[1,1,1,0] FN119: Spot welding
10 100 % LIN A1 T1
11 END FN9 9: End
The group number "2" designated at step 2 becomes enabled until step 6. From step 7
to step 11, the group number "3" becomes enabled.
■ Notes at check back

When check back is executed, played back welding condition group number may
differ, which please note.
● In the case of check go from step 0

Step 4 FN119 is executed by group number "2".
● In the case of check back from step 11

Step 4 FN119 is executed by group number "3".
The welding condition group number may be set by R371 too, so use it at necessity.
When welding command is executed without designating the welding condition group
designation function, "A2063: Welding condition group function is not set" is displayed,
and the robot stops. Before executing the welding command (FN119), record the
POINT welding condition group designation function.
As for the use method of spot welding function FN119, refer to "Chapter 5 Welding
Program Teaching". The setting range of the welding condition number (parameter
No.2) in the case of use by group designation is 1 to 16.
6-17
6.4.5 Spot Welding Monitor

When this function is enabled, the group number of current welding and welding condition number
are displayed on the welding spot monitor.
By setting the monitor to edit mode, welding controller numbers can be changed.
As for other display contents, refer to "6.3 Spot welding monitor".
6.4.6 R371 Welding Condition Group Number Change

The welding group number is set normally by the welding condition group designation function
(FN282), while in the case of temporary change of group number in the course of program for
welding adjustment or the like, group number is changed by use of R371.
Shortcut Explanation of contents

R371 Welding condition group
Parameter Data Contents, setting range

Parameter Welder number This designates the welding controller number of output
No.1 destination of welding control signal.
(1 to 6)
Parameter This designates the welding condition group number.
Group number
No.2 (1 to 16)
1. When stop the program and R371 set is carried out and restart it in the course of
POINT playback, thereafter welding is carried out by the group number designated here.
2. This group number is used until FN282 is played back next.
3. At start, R371 is not accepted.
6.4.7 Troubleshooting
Error codes concerning welding condition group destination are explained.
A2062 There is no welding condition.

[Cause] In group designation type welding condition setting, setting conditions are 1 to 16.
(1 to 15 for group 16) Welding condition number of other than setting range is
designated.
[Countermeasures] Designate the right condition number.
A2063 Welding condition group number is not set.

[Cause] Welding function (FN119 or FN303) has been executed without recording the
welding condition group designation function (FN282).
[Countermeasures] Before executing welding function (FN119 or FN303), record the welding
condition group designation function (FN282).
6-18
6.5 Servo Gun Weld Stuck Detection

How to detect the weld stuck after welding of servo gun is explained.
By use of “Error 21: Abnormal Servo Tracking", which always monitors the difference between the servo gun
axis command value and the current value and detects deviation over a specified value, this function
recognizes the weld stuck using of external logic in combination with error code output function.
There is no influence upon cycle time.
6.5.1 Setting the Error Code Output Format
2 Select [6 Signals] in constant setting mode.
3 Select [1 Condition setting].
4 The following screen is displayed.
As for detailed setting, refer to help messages.
6.5.2 Allotting the Error Code Signal
1 Select [6 Signals] in the constant setting mode.
2 Select [3 Output signal Assignment].
3 Select [1 Standard outputs].
4 Allot an arbitrary signal to the next signal.
Signal name Contents

Error code Error code number is output in one method of "2 division" or "continuous" or
"BCD".
At “Abnormal Servo Tracking”, error number "21" is output.
Error output select When the error code output method is "2 division", it is output for identifying
master/slave.
Error output STRB When the error code output method is "2 division", it is output for read timing.
Error mechanism The mechanism number with error occurrence is output in 4 bits.
number
When the servo gun mechanism number is 2, "2" is output in binary
manner.
Error axis number The axis number with error occurrence is output in 4 bits.
When error code = 21 and error mechanism number = servo gun, it can be judged as "Weld stuck
has occurred in servo gun."
6-19
6.5.3 Setting the Abnormal Tracking Detection Level

Operator must have qualification of EXPERT or higher.
The threshold value to detect an Abnormal Tracking is set here. Factory shipment setting is set to
"disabled", therefore set it at necessity.
1 Select [3. Machine Constants] in <Constant setting>.
2 Select [14. Servo Error].
3 Select "Servo gun" by mechanism key of teach pendant.
4 The following screen is displayed.
Parameters concerning Abnormal Tracking

Initial
Parameter Meaning and use
setting
Abnormal Tracking 0.00 Set 1.00. Small number will increase detection sensitivity.
Disabled Large number will decrease sensitivity. Change the setting at
necessity.
Abnormal Tracking 0.00 Leave it as the initial value (0.00).
Rev.
After setting the error detection parameter, make sure there is no mistake in detection in
normal operation.
IMPORTANT
Before detecting the Abnormal Tracking, chip may come out. In this case, it is difficult to
detect adhesion.
IMPORTANT
6-20
Chapter 7 Tip dressing
welding applications the sophisticated tip dressing function and how it is operated.
7.1 High-quality tip dressing using a servo gun................................................ 7-1

7.2 Settings ...................................................................................................... 7-2
7.2.1 Setting the tip dressing sequence ..................................................... 7-2
7.2.2 Setting the input/output signals for tip dressing ................................. 7-5
7.3 Teach/playback .......................................................................................... 7-9
7.3.1 Function command "TIPDRESS: Tip Dressing" (FN265) .................. 7-9
7.3.2 Playback with welding OFF ............................................................... 7-9
7.3.3 Detection of trouble during tip dressing playback .............................. 7-9
7.1High-quality tip dressing using a servo gun
7.1 High-quality tip dressing using a servo gun

After welding is repeated, gun tip will eventually wear down and their shape will change. Since the shape of
tips determines the current density of the current-carrying path, proper welding cannot be performed if tips
have worn down.
Therefore, before tip consumption amounts become significant and the welding quality is impaired, the tips
must be ground and reshaped. This work is known as “tip dressing”.
A machine called a “tip dresser” is used to dress the tips. It has a rotary blade matching the shape of tips.
The tips are ground by rotating the rotary blade while pressure remains applied to the blade by the spot
welding gun.
Normally, tip dressing is taught so that it is performed when the prescribed number of welding times or cycles
have been executed.
Rotary blade
Fig. 7.1.1 Tip dresser (Example)
The tips are generally dressed by executing welding operations in the welding OFF status. For the rotational
direction and speed of the dresser and the time to be controlled, an interface using I/O signals between the
robot controller and tip dresser is required.
This function, which utilizes the characteristics inherent to a servo gun, divides the tip dressing cycle into six
periods, two of which are the tip dressing start time and the initial pressurizing time. By specifying the servo
gun welding force and rotational speed of the tip dresser for each of these periods, the function achieves
high-quality tip dressing without using an external sequencer.
Furthermore, since a simple sequence can be executed with an air gun as well, the tip dressing command
can be used with the air gun as well.
Servo gun pressurizing force
Real pressure Finish

Initial Prelimi- pressure
pressurizing nary
force pressure Time
Number of tip dresser ro tations
Rotation speed 3
Rotation
Rotation speed 4
speed 2
Rotati on speed 1 Time
Dress start Initial time Prelimi- Main time Finishing Dress

time nary time time stop
time
Fig. 7.1.2 Tip dressing sequence
7-1
7.2Settings
7.2 Settings
7.2.1 Setting the tip dressing sequence

Set the tip dressing sequence (tip dressing time schedule).
Up to 8 patterns per welder can be registered as the tip dressing sequence.
2 Press <Service Utilities>, and [20 Spot Welding Application] → [3 Tip dress].
>> Following screen will appear. Setting items differ slightly depending on whether
servo gun or air gun.
(in case of servo gun)
(in case of air gun)
3 Press the [CLOSE/SELECT SCREEN] key to switch the welder.

To switch the tip dressing sequence number, either press the f9 & f10 <Scroll
page> keys or align the cursor with the tip dressing sequence number field,
input a number and press [Enter].
4 Refer to "Table 7.2.1 Tip dressing condition parameters," and input the
parameters required.
5 Upon completion of the settings, press <Complete> key.
6 If the contents are not to be rewritten, do not press <Complete> key but the
[Reset/R] key instead to exit the setting screen.
Table 7.2.1 Tip dressing condition parameters
7-2
7.2Settings
Factory Air Servo

settings gun gun
Ini. pressure 0.0 Kgf This is used to specify the pressurizing force during the initial
time. * 
Setting range: 51 to 1020
Pre. pressure 0.0 Kgf This is used to specify the pressurizing force during the
preliminary time. * 
Main pressure 0.0 Kgf This is used to specify the pressurizing force during the main
time. * 
Finishing 0.0 Kgf This is used to specify the pressurizing force during the finishing
pressure time. Setting range: 51 to 1020 * 
Dress start 0.0 sec This is used to set the time from the output of the rotation signal
time of the tip dresser to the start of the pressurizing operation.  
Setting range: 0.0 to 10.0 sec
Pressurizing 0.0 sec This is used to set the forward rotation time during which the
time forward rotation signal is output and the reverse rotation time
during which the reverse rotation signal is output for 4 times,
namely, the initial time, preliminary time, main time and finishing
time. Each pressurizing time is expressed by the equation
below.  
Pressurizing time
= Forward rotation time + reverse rotation time
If “0” is set for any of these times, no signals are output and no
other functions are executed during the time concerned.
Forward/rever For-> This is used to set the sequence in which the forward and
se sequence Rev. reverse output signals are output.
 
specification For->Rev.: The forward signal is output first.
R->F.: The reverse signal is output first.
Dress stop 0.0 sec This is used to set the time from the start of the open operation
time to the shutdown of the tip dresser.  
Rotate output 0.0 sec This is set for outputting the pulse signals for rotational speed
time output signals 1 to 4. This is used to specify the width of the
1 to 4 pulses to be output.
When “0” is set, the pulses are output until the pressurizing time  
ends, after which the output is set to off.
0.00 to 10.00
Press value 5.0 mm In the case of a servo gun, the command value must represent
a position where the gun will be placed when it is pushed in
beyond the contact position in order to obtain the pressurizing
force. It is the distance between this position and the contact
position, that is to say, the push-in amount, which is set here.
– 
When “0” has been set, the value of the command value offset
among the servo gun characteristics is used. This means that
the operation is performed with the same push-in amount as for
the spot welding function.
Setting range: 0.0 to 20.0 mm
Press speed 30.0 This is used to set the pressurizing speed of the servo gun.
mm/ sec When “0” has been set, pressurizing is performed at the
pressurizing speed among the servo gun characteristics. This
– 
means that the operation is performed at the same pressurizing
speed as for the spot welding function.
Setting range: 0.0 to 200.00 mm/sec
7-3
7.2Settings
Setting items indicated with an asterisk (*) in the air gun field are as follows for an air gun.
Factory Air Servo
settings gun gun
Ini. pressure 0 This is used to specify the pressurizing force control
signal during the initial time.  –
Pre. pressure 0 This is used to specify the pressurizing force control
signal during the preliminary time.  –
Main pressure 0 This is used to specify the pressurizing force control
signal during the main time.  –
Finishing 0 This is used to specify the pressurizing force control
pressure signal during the finishing time.  –
7-4
7.2Settings
7.2.2 Setting the input/output signals for tip dressing

Set the input/output signals which are to be used for tip dressing.
Tip dressing is executed by transferring the input/output signals to and from the tip dresser.
Tip dressing parameters
Init ial, preliminary, main and finishing

pressure
Init ial, preliminary, main and finishing time
Dress start /stop time
Dressing speed sig nal pulse time
Push-in amount
Press s peed
Tip dress normal
I signal FN265
Tip dressing
Tip dresser function
O signal Pressuri zing
&
Pressuri zing
Tip dress forward
Tip dress reverse force change
Tip dress rot
Tip dressing
Tip dress no rmal
Fig. 7.2.1 Input/output signals for tip dressing
Since these signals are not allocated at the time of shipment, steps must be taken to allocate them
without fail.
1 Press <Constant Setting>.
2 To allocate the input signals,

press [6 Signals] → [2 Input Signal Assignment] → [2 Spot Inputs].
To allocate the output signals,
press [6 Signals] → [2 Output Signal Assignment] → [3 Spot Outputs].
3 Refer to "Table 7.2.2 Tip dressing dedicated input signals" and "Table 7.2.3
Tip dressing dedicated output signals," and set the input/output signals.
5 If the contents are not going to be rewritten, do not press <Complete> key
but the [RESET/R] key instead to exit the setting screen.
When the input signal or output signal assignment has been changed, go to the trouble
of turning off the power of the controller and then turning it back on.
This must be done to initialize the status signals.
CAUTION If operation is continued without turning off the power, the status signals may not be input
or output properly.
7-5
7.2Settings
Table 7.2.2 Tip dressing dedicated input signals

Factory Air Servo
settings gun gun
Tip dress normal 0 Input the tip dresser status.
The tip dressing function can be executed only while this
signal is ON. If the signal is set to OFF while the function
 
is being executed, the function is shut down and an error
is output.
Tip dress finished 0 Input this signal to forcefully abort tip dressing at any
interim point. When it is input while a dressing sequence
is being executed, the sequence is aborted, and the
 
function is completed. It need not be input when tip
dressing has ended normally.
Table 7.2.3 Tip dressing dedicated output signals

Factory Air Servo
settings gun gun
Tip dress forward 0 This signal is output to rotate the tip dresser in the
forward direction.
It is set to OFF when the tip dressing function ends (or is  
shut down at an interim point).
Tip dress reverse 0 This signal is output to rotate the tip dresser in the
reverse direction.
It is set to OFF when the tip dressing function ends (or is  
shut down at an interim point).
Tip dress rot 1 to 0 These signals enable the rotational speed conditions to
4 be divided into 4 steps and output to the tip dresser.
(Level/ pulse output enabled)
Rotation speed 1: Dress start time + initial time
Rotation speed 2: Preliminary time
Rotation speed 3: Main time  
Rotation speed 4: Finishing time + dress stop time
These signals are set to OFF when the tip dressing
function ends (or is shut down at an interim point).
Four signals can be allocated per welder (total: 24
signals).
Tip dressing 0 This signal is output while the tip dressing function is
being executed. It is set to OFF when the tip dressing
 
function ends (or is shut down at an interim point).
Tip dress normal 0 This signal outputs the status of the signal which has
been input from the tip dresser.  
7-6
7.2Settings
Pressurizing force
Initial
pressure Real pressure Finish
Prelimi- pressure
nary Time
pressure
Number of tip dresser rotations
Rotation speed 3
Rotation
Rotation
Rotation speed 1 speed 2 speed 4 Time
Dress start Initial Prelimi- Main Finishing Dress

time time nary time time stop
time time
Output signal
Tip
dressing
Rotation
speed 1
Rotation
speed 2
Rotation
speed 3
Rotation
speed 4
• The tip dressing signal is set to ON from the dress start time to the dress stop time.
• The rotational speed 1 signal is set to ON during the dress start time and initial time.
• The rotational speed 2 signal is set to ON during the preliminary time, and the rotational speed 3
signal is set to ON during the main time.
• The rotational speed 4 signal is set to ON during the finishing time and dress stop time.
(In the case of an air gun, the pressurizing force itself may be treated as the output data of the
pressurizing control signals.)
Fig. 7.2.2 Timing of tip dressing dedicated output signals
In the case of forward  reverse In the case of reverse  forward

Initial time Initial time
Dress start Initial forward Ini tial reverse Dress start Initial reverse Initial forward
time time time time time time
Tip dress Tip dress

forward forward
The start time also
Tip dress becomes a forward Tip dress
reverse rotation command. reverse The start time also
become s a reverse
rotation command .
Forward Reverse Reverse Forward
Fig. 7.2.3 Timing of initial time
7-7
7.2Settings

Preliminary & real time Preliminary & real time
Preli minary & main Prelimina ry & main reverse Preliminary & main reverse Preliminary & ma in
forward rotation time rotation time rotation time forward rotation time
Tip dress Tip dress

forward forward
Tip dress Tip dress

reverse reverse
Fig. 7.2.4 Timing of preliminary time and main time

Finishing time Finishing time
Finishing forward Finishing reverse Dress Finishing reverse Finishing forward Dress
rotation time rotation time stop time rotatio n time rotation time stop time
Tip dress
Tip dress
forward forward
The stop ti me also
Tip dress Tip dress becomes a forward
reverse rotation co mmand.
reverse
The stop time also
becomes a re verse
rotation command.
Fig. 7.2.5 Timing of finishing time
7-8
7.3Teach/playback
7.3 Teach/playback
7.3.1 Function command "TIPDRESS: Tip Dressing" (FN265)

Tip dressing uses the function command in the same way as with spot welding.

TIPDRESS FN265 Tip Dressing

Parameter Welder number This is used to specify the number of the tip
No. 1 dressing welder.
(1 to 6)
Parameter Tip dressing This is used to specify the sequence
No. 2 sequence number to be used for tip dressing.
number (1 to 8)
Teaching Proceed with the same teaching as for the spot welding function.
Record the positions where contact has been made on the tip dresser at both the moving
and settled sides, and record the tip dressing function TIPDRESS (FN265) in the step
concerned.
Playback Basically, operation is the same as for the spot welding function.
The pressurizing operation is performed once the “dress start time” has elapsed after the
clearance position is reached.
The execution of the tip dressing sequence is commenced as described in "Fig. 7.1.2 Tip
dressing sequence."
The gun open operation is performed after the “finishing time”.
The next step is executed once the “dress stop time” has elapsed after the gun starts the
open operation.
7.3.2 Playback with welding OFF

If the tip dressing command has been executed during welding OFF, the pressurizing operation of
the servo gun is not performed in order to ensure safety. However, the signal output is executed.
7.3.3 Detection of trouble during tip dressing playback

If the “tip dress normal input signal” is set to OFF immediately before the tip dressing function is
executed or while it is being executed, the following alarm is detected, and the playback operation of
the robot is shut down.
Code A2657
Message Trouble has occurred in the tip dresser.
Details This error results when the normal input signal from the tip
dresser has been set to OFF while the tip dressing function
is being executed.
Countermeasure Check the normal input signal from the tip dresser.
7-9
7.3Teach/playback
NOTE
7-10
Chapter 8 Special servo gun functions
welding applications the gun changing specifications and other special servo gun
control features.
8.1 Functions using external signals.............................................................. 8-1

8.1.1 External wide open .............................................................................. 8-1
8.1.2 External small open ............................................................................. 8-1
8.1.3 External welding................................................................................... 8-2
8.1.4 External manual pressurizing............................................................... 8-2
8.1.5 Re-welding ........................................................................................... 8-2
8.1.6 Tip consumption amount reset ............................................................. 8-3
8.1.7 External gun search ............................................................................. 8-3
8.1.8 External tip dressing............................................................................. 8-3
8.1.9 Gun contact detection .......................................................................... 8-3
8.2 Multi-step welding force control ............................................................... 8-4
8.2.1 Outline of multi-step welding force control ........................................... 8-4
8.2.2 Setting the multi-step parameters ........................................................ 8-5
8.3 Gun change control ................................................................................. 8-7
8.4 Double gun control .................................................................................. 8-8
8.5 Multi-gun simultaneous welding............................................................... 8-9
8.5.1 What is multi-gun simultaneous welding .............................................. 8-9
8.5.2 Restrictions .......................................................................................... 8-9
8.5.3 Setting the simultaneous manual operations to be enabled............... 8-10
8.5.4 Selecting the welder to be operated manually ....................................8-11
8.5.5 Manual operation ............................................................................... 8-12
8.5.6 External operations ............................................................................ 8-16
8.5.7 Recording SYNCSPOT (FN303): simultaneous spot welding function8-18
8.5.8 Executing SYNCSPOT (FN303): simultaneous spot welding function 8-23
8.5.9 Error detection of tip consumption amount difference ........................ 8-25
8.1Functions using external signals
8.1 Functions using external signals

The servo gun can be operated (just like an air gun) using signals from an external source. All these
functions are described together in this section.
The input signals must be assigned in order for these functions to be executed. (Since these signals were
not assigned at the factory, the functions will not work without assigning them first.) The names of the spot
welding input signals are given in this section but no details are given on the methods used to assign them.
For details on the operation methods, refer to the "Basic Operations Manual".
8.1.1 External wide open

Spot welding input signals: "External wide open"
■ Servo Gun
The servo gun is set to wide release (position of the wide open end default value) by means of an
external signal.
Settled side tip does not move at this time. Operation stops when the input signal is set to OFF
during release processing. For this reason, signals must be input for a sufficient period of time to
ensure that the servo gun is definitely opened all the way to the wide open position.
This function can be used only in the playback mode. This is ignored during operation.
The wide open operation is initiated when the rise at which the signal goes from OFF to ON is
detected.
Moving side
W ide open end default
tip value
Signal input
Settled side
tip
Fig. 8.1.1 External wide open

■ Air Gun
The execution conditions are the same as those for the servo gun. “Gun full open” signal is output.
8.1.2 External small open

Spot welding input signals: "External small open"
■ Servo Gun
The function is the same as "External wide open," except that the release position is the
"Pressurizing stroke position."
Moving side
Signal input W elding stroke
tip
Settled side
tip
Fig. 8.1.2 External small open

■ Air Gun
The execution conditions are the same as those for the servo gun. “Gun half open” signal is output.
8-1
8.1.3 External welding

Spot welding input signals: "External welding"
■ Servo Gun, Air Gun

This is used for manual welding by means of external signals.
Manual welding can be executed by operations from the teach pendant in the teach mode; if
external signals are used, it can be done in the playback mode. To ensure safety, manual welding
based on an external signal is valid only in the playback mode.
The processing is performed when the rise at which the signal goes from OFF to ON is detected.
Moving side
tip
Signal input
Settled side
tip
Pressurizing
Start position
Clearance position Open
Fig. 8.1.3 External welding
8.1.4 External manual pressurizing

Spot welding input signals: "External squeeze"
■ Servo Gun
Manual squeeze (pressurizing) can be executed by operations from the teach pendant in the teach
mode; if external signals are used, it can be done in the playback mode. To ensure safety, manual
pressurizing based on an external signal is valid only in the playback mode.
The processing is performed when the rise at which the signal goes from OFF to ON is detected.
■ Air Gun
The execution conditions are the same as those for the servo gun. “Gun squeeze” signal is output.
8.1.5 Re-welding
Spot welding input signals: "Re-welding"

This is used for re-welding by means of external signals.
It is enabled only in the playback mode.
The welding is executed under the welding conditions for the welding that was executed
immediately before when the rise at which the signal goes from OFF to ON is detected.
If it has been input during start, the welding command in the current step is executed again. If WI is
input, operation moves to the next step.
The welding command in the current step is executed again even when it is input during stop, but
operation will not move to the next step even if the WI signal is input. Operation moves to the next
step by restart.
8-2
8.1.6 Tip consumption amount reset

Spot welding input signals: "Reset consumption", "Reset consump.(m)", "Reset consump.(s)"
The tip consumption amounts can be cleared to zero using an external signal. (They cannot be
preset to the desired values.)
■ Exclusively with servo guns

With <External> set for start select:
● When the "Reset consumption" input signal is set to ON, the tip consumption amounts of the
moving side tip and settled side tip are both reset.
● When the " Reset consump.(m)" input signal is set to ON, the tip consumption amount of the
moving side tip only is reset.
● When the " Reset consump.(s)" input signal is set to ON, the tip consumption amount of the
settled side tip only is reset.
This function cannot be used when <Internal> has been set for start select. In the case of the gun
changing specifications, the tip consumption amounts are not reset when the guns are not
connected.
When <internal> has been set for start select, reset the tip consumption amounts using R339
(Preset consumption of tips).
8.1.7 External gun search

Spot welding input signals: "External gun search 1" "External gun search 2" "External gun search
3"
■ Exclusively with servo guns

(Not supported at present time.)
8.1.8 External tip dressing

Spot welding input signals: "External tip dressing"

(Not supported at present time.)
8.1.9 Gun contact detection

Spot welding input signal: "Gun contact detection"

When the signal that indicates that the gun is touching the work is input from an external source, the
buzzer on the teach pendant sounds intermittently while the signal is ON.
8-3
8.2Multi-step welding force control
8.2 Multi-step welding force control
8.2.1 Outline of multi-step welding force control

A constant welding force system which applies a constant welding force while the tips are in contact
with the welding material is normally used as the system for applying the tip welding force. However,
the operator may want to change the welding force depending on the material used. This function
enables the welding force to be controlled while the welding force is applied in accordance with the
welding force sequence which has been set for each welding condition.
Multi-step welding force control roughly divides up the pressure application time into four steps: the
initial pressure application time, squeeze time, welding pressure application time and holding
pressure time. For each of these times with the exception of the initial pressure application time, it
enables the welding force to be further varied in four steps.
Pressure applied
Release
Pressure application operation operation
Holding welding force 4


Welding force 4
Welding force 3
Welding force 2
Welding force 1
Welding forces match

Squeeze pressure 4
Squeeze pressure 3
Initial pressure
Squeeze pressure 2
Squeeze pressure 1
Welding completion
wait
When the welding force

change function is disabled
Squeeze
Squeeze
Squeeze
Squeeze
Welding
Welding
Welding
Welding
Holding
Holding
Holding
Holding
time 1
time 1
time 2
time 2
time 3
time 4
time 1
time 2
time 3
time 4
time 3
time 4
Initial pressure Squeeze pressure Welding pressure Holding pressure

application application application processing application processing
processing processing
Gun signal
Power-on signal
WI signal
Power-on start signal
from robot to welder Power-on start signal
from welder to robot
Power-on of
welder Welding 1 Cooling Welding 2
power-on power-on
Control by welder
Fig. 8.2.1 Multi-step welding force function
8-4
8.2.2 Setting the multi-step parameters

This section describes how to use the multi-step welding force function. This function can be used
with servo guns only.
1 Open the spot welding condition editing screen.
Set "Pressure multi" to "Enabled."
2 Use the [ENABLE] and [Down] key to scroll to the next page.
>>The parameters for multi-step control are displayed on two screen pages as
shown below.
＋
8-5
Parameter Description/Explanation
Initial pressure This specifies the initial welding force. The welding force
which was set on the previous page is set here.
Squeeze pressure These are used to set the squeeze welding force and time for
and time 1 to 4 up to four steps.
The squeeze welding force is the welding force which is used
before the pressure application signal or power-on signal is
output.
Application is not executed during any period in which "0" has
been set for either the welding force or time.
Weld pressure and These are used to specify the actual welding force and time
time 1 to 4 for up to four steps.
The actual welding force is the welding force which is used
after the pressure application signal or power-on signal is
output.
Hold pressure and These are used to specify the holding welding force and time
time 1 to 4 for up to four steps.
The holding welding force is the welding force which is used
after the welding completion (WI) signal is input.
If the welding completion (WI) signal is input during the processing of actual welding
force parameters 1 to 4, the actual welding force processing is aborted, and
processing transfers to the holding welding force.
3 Upon completion of the settings, press <Complete> f12 key.

>>The settings are now written in the spot welding constants file.
8-6
8.3 Gun change control
8.3 Gun change control

There is an application that uses a tool changer to change the spot welding guns, hands or other tools so that
a single robot can be employed for a multiple number of uses.
If the tool to be changed is a spot welding gun or hand and it is air-driven, it can be changed by I/O
sequences. On the other hand, if it is a servo gun or other servo-driven tool which is to be changed, it is not
possible to disconnect it in order to implement the change while still keeping the power supplied to their
motors. Therefore, changing servo guns and other such tools requires a function that makes it possible to
electrically connect and disconnect the motors used to drive these tools.
This function is called the mechanism change (optional).
Connecting and disconnecting the tools mechanically must be implemented using I/O sequences.
Drive unit Sub-mechanism No.
Axes 1 to 6 Mechanism 1 Robot
Axis 7 Mechanism 2 Mechanism 2-1 Gun
Axis 8 Mechanism 3 Positioner Mechanism 2-2 Gun
Mechanism 2-3 Positioner

Axis 9 No setting
Mechanism No. Mechanism

Sub-mechanism
Fig. 8.3.1 Configuration of mechanism change
For details on how this function is handled, refer to the optional instruction manual “Mechanism Change”.
8-7
8.4 Double gun control
8.4 Double gun control

“Double gun control” is controlling two gun arms by one motor. One servo gun has two gun arms. First gun
arm is controlled as sub-mechanism No. 1, and second gun arm is controlled as sub-mechanism No. 2.
According to its mechanical construction, connecting and disconnecting procedure is unnecessary. Other
setting and operating procedure is similar as those for normal gun change application.
Cautions for this application are written below.
1. As same as normal gun change application, parameters are necessary for each gun (sub-mechanism).
2. One motor/encoder is commonly used for two guns (sub-mechanism), so there is only one encoder
correction value. After the encoder correction procedure for sub-mechanism No.1 is completed, this value
must be copied to sub-mechanism No. 2.
3. Mechanical connecting and disconnecting procedure is unnecessary. Just designate the desired gun
(sub-mechanism) number at each step in the program. Please refer to the following function commands.
FN238 CHGXXGUN
FN302 CHGXXMEC
For details on how this function is handled, refer to the optional instruction manual “Mechanism Change”.
8-8
8.5 Multi-gun simultaneous welding

In a multi-gun system under which a multiple number of spot welding guns are controlled, welding jobs can
be undertaken by applying pressure to a multiple number of these guns simultaneously.
This section describes the operating procedure for simultaneously welding with multiple guns in this way.
8.5.1 What is multi-gun simultaneous welding

Depending on the shape of the work to be welded, the positions of the weld points and other such
factors, the cycle time can be reduced by welding a multiple number of weld points at one time.
STEP2 STEP4 STEP2

STEP1 STEP5 STEP1
STEP3
STEP3
(a) Single gun (b) Simultaneous welding by multi-gun

Fig. 8.5.1 Multi-gun simultaneous welding (servo gun)
If, for instance, two points are to be welded using a single gun as shown in above figure (a), the
operation requires that five steps be performed. This welding job is performed twice, in steps 2 and
4, requiring in each step an operation time for the pressure application, power-on and release
sequence. Furthermore, the robot moves 3 times, and an acceleration/deceleration operation is
performed each time. In contrast, with simultaneous welding using multiple guns such as the two
guns shown in figure (b), the number of steps is reduced to three, and the two points are welded
simultaneously at step 2. This means that, in terms of the operation time taken, the pressure
application, power-on and release sequence is performed only once. In addition, the robot moves
only twice.
By practicing simultaneous welding in this way, both the time taken to execute the welding and the
time taken for the robot to move can be reduced.
However, this function may not be used by some the multi-gun specifications due to work shapes
and other restrictions.
8.5.2 Restrictions
The servo gun is normally not equipped with equalize mechanism by mechanical structure. Instead,
the robot itself that holds the gun or the work carries out position control of settled side tip at welding
(equalize control). For this control, a clearance amount and bending amount per gun are necessary
as parameter values, and also it is necessary to detect the tip consumption amount of each gun.
When these values differ with each gun, robot actions differ in respective guns. In this function, this
action is carried out with one gun as a standard. The gun to become the standard is called master
gun, and guns other than the master gun are called slave guns.
In this manner, one gun is made as the standard of actions, other guns are not at most suitable
positions due to tip consumption amount or bending amount. This difference may cause work
deformation or pressure shortage at settle-tip, which please note.
Deformation of work due to

difference of tip consumption
amount of the settled side or
bending amount is unavoidable.
<Gun 1> <Gun 2> <Gun 1> <Gun 2>
(a) Recording position (b) Pressurizing position with worn tips
Fig. 8.5.2 Problems caused by multi-gun simultaneous welding
8-9
How to select the guns
1 : It is recommended that guns featuring a mechanical equalizing function be used as

POINT the slave guns. This makes it possible to eliminate the effects produced by
differences in tip consumption amounts.
2 : In order to ensure that the deflection amount is the same, use the guns of the same
model wherever possible.
Furthermore, in order to enable a multiple number of guns to reach the zero touch position at the
same time, use the same contact speed and contact position offset for the servo gun characteristics
of all the guns. (Normally the factory settings can be used as is for these parameters.)
When servo guns are used, all the guns to be used for the simultaneous welding perform the
pressure application and release operations at the same time. Even if one of the guns completes the
welding ahead of the others, the guns will not be released until the conditions enabling all the guns
to be released are established.
Pressurizing simultaneously Releasing simultaneously
Fig. 8.5.3 Pressure application and release operations
8.5.3 Setting the simultaneous manual operations to be enabled

Since, with a standard multi-gun system, the welding operations cannot be performed
simultaneously, the system is set in such a way that simultaneous welding operations will not be
performed in error by manual operations.
For this reason, in order to enable manual operations such as welding, pressure application and
stroke switching to be performed simultaneously for a multiple number of guns, the settings must
be changed. These settings can be changed only by an operator whose qualifications level is
EXPERT or above.
1 Press <Spot Conditions> key. Alternatively, select <Service Utilities> key, [20
Spot welding application] and [Spot teach/playback conditions].
>>The following welding condition setting menu used exclusively for spot welding
now appears.
8-10
2 On the menu displayed, set the [8 Manual Gripper Pressure] to "Enabled."

The settings are saved in the file.
8.5.4 Selecting the welder to be operated manually

If manual welding or other manual operations are to be performed from the teach pendant, the
welder which is to be operated must first be declared. This operation method is described below.
The number of the welder used when the welding function is automatically recorded is determined
by the welder number which is selected here.
1 In the teach or playback mode, press <Select Spot> f key. Alternatively, input
the R315 short-cut code.
>>A screen such as the one shown below now appears. Now input all the numbers
of the welders that will be the target of the operations performed from this point.
If, for instance, the operations are to apply to both welders 1 and 2, either 12 or 21
may be input. Input the welder numbers so that they are enumerated.
Here, only the numbers for the welders registered ahead of time can be input.
>> The numbers of the welders targeted for the current operation are displayed in
the application area on the status window. They are indicated by the bold
numbers on the top row.
In the example given below, welders 1 and 2 are targeted. The '^' above the number
1 indicates that welder 1 serves as the master.
The welder to be input first is the master.
>> From this point, the manual welding and spot welding commands are recorded
for the welders targeted for operation.
POINT Air guns and servo guns cannot be selected at the same time.
8-11
8.5.5 Manual operation
When proceeding with manual operation, keep away from the spot welding gun.
If a dry run is to be performed, be absolutely sure to turn off the power (weld OFF) before
proceeding so that the welding current will not flow even when a manual welding
operation is performed by mistake.
DANGER If a person should be sandwiched or receive an electric shock, death or serious injury may
result.
Switching the stroke

If a multiple number of welders have been selected by the welder select signals, the stroke is switched
simultaneously for the guns connected to those welders.
In case of air gun
2 Press the [ENABLE] and <Stroke Change> keys together.

＋ >>The half open signal is set to OFF, and the full open signal is set to ON.
Full open signall
Half open signal
Fig 8.5.4 Air gun stroke manual switching
3 Once more, press the [ENABLE] and <Stroke Change> keys together.
＋ >> Conversely, the half open signal is set to ON, and the full open signal is set to
OFF. In this way, the half open signal and full open signal are repeatedly set to
ON or OFF alternately.
2 First, press <Stroke Select> key, and select the desired setting from among
the five stroke settings.
>> The number at the top left of <Stroke Select> key is switched in the following
sequence: 0  1  2  3.
Under the initial setting, the lower the number, the wider the release amount.
Shown right is the correlation between the displayed number and the setting
menu used for the spot constants/servo gun conditions.
0: Wide open end default value
1: Stroke 1
2: Stroke 2
3: Stroke 3
4: Welding stroke
There is no need to select the same setting for the guns which will be operated
simultaneously. Move the guns to the respective target positions for the switching
operation.
8-12
3 While grasping enable switch, press the [ENABLE] and [Stroke Change]
keys together.
＋ >>The gun axes move to the respective stroke positions of the guns previously
set.
＋ Stroke
Change
f key
pressed
Stroke
Change
f key Stroke
Wide Change
release Stroke 1 pressed
f key
pressed
Stroke 2
Stroke 4
Stroke 3
Welding stroke
Settled side tip

Fig. 8.5.5 Servo gun stroke manual switching
Applying pressure (no welding)

2 Move the robot to the pressurizing position.
In case of air gun
3 Press the [ENABLE] and [CLAMP ARC] keys together.

＋ >> The welding pressure control signal and pressurizing signal are output. The
guns now apply the pressure.
The power-on signal is not output. No welding current flows.
Welding pressure control signal
Pressurizing signal
Fig 8.5.6 Air gun manual pressurizing operation
In actual fact, the welding force control signal which was set in the "Welding
conditions for manual welding" is output.
The welding force signal is output in accordance with the ON or OFF setting for the
pressurizing signal output which was set in the "weld sequences applying for
manual welding."
4 Press the [ENABLE] and [CLAMP ARC] keys together once more.
＋ >> The welding force control signal and pressurizing signal are now turned off.
 The gun is released.
8-13
3 While grasping enable switch, press the [ENABLE] and [CLAMP ARC] keys
together.
＋ >>The gun axes move to the "Pressure application stroke" position, which is a spot
welding constant/servo gun operating condition, for the gun serving as the
master. (The settled tip on the robot body does not move.)
＋
Welding
Moving side stroke
tip
Settled side
tip
Welding stroke position Pressurizing position
Fig. 8.5.7 Servo gun manual pressurizing operation
If the [CLAMP ARC] key or enable switch is released during the pressurizing
operation, the operation is suspended immediately.
• If the difference between the master gun position and slave gun position
POINT before the pressure is applied by the servo guns is greater than ±5%, all the
guns selected first move to the pressure application stroke position.
Welding
2 Move the robot to the position where manual welding is performed.
In case of air gun
3 Press the [ENABLE] and <Manual Weld> keys together.

>>Following exactly the same procedure as for playback:
＋ Welding conditions which have been set using [Welding conditions with manual
welding]
Spot welding is performed using the welding sequence which was set in
"Welding sequence for manual welding."
4 The gun will not be released unless the welding completion signal (WI) is
input from the welding controller. If the welding controller is being adjusted,
＋ the gun can be forcibly released by pressing the [ENABLE] and <Cancel WI>
keys together.
8-14
3 While grasping enable switch, press the [ENABLE] and <Manual Weld>
keys together
＋ >>Following exactly the same procedure as for playback
Welding conditions which have been set using [Welding conditions with
manual welding]
Spot welding is performed using the welding sequence which was set in
＋ "Welding sequence for manual welding."
All the welders involved in the simultaneous welding use the welding
conditions and sequences with the same numbers. However, the parameters
can be set for each welder so that it is possible to set the welding force and
other conditions individually.
Unlike when the pressure is applied manually, the robot itself moves.
(Equalizing operation)
When "Yes" is selected for the equalizing operation in the manual mode
Moving side tip
Stroke
(upon
Stroke (during completion)
pressurizing)
Settled clearance amount Settled clearance

amount
Settled
side tip
Start position Clearance position Pressurizing Release
Fig. 8.5.8 Manual servo gun welding
4 The guns are not released until the welding completion signals (WI) for all
the welders which performed the welding operations simultaneously are
＋ input. If a welder is being adjusted, its gun is forcibly released by
simultaneously pressing the [ENABLE] and <Cancel WI> keys.
8-15
8.5.6 External operations

Using external input signals, the major release, minor release, pressure application and welding
operations can be performed simultaneously by a multiple number of guns.
The following input signals must be allocated in order to execute these functions. (They were not
allocated at the factory and so will not function until they are allocated.)
Table 8.5.1 Input signals used for external simultaneous spot welding operations
Input signal name Description of function
External wide open This signal is to open the gun widely.
In case of servo gun, gun moves to wide open position. In case of air gun, gun is
in the status of half-open signal OFF and full-open signal ON.
This process is initiated when the signal rise at which the signal is set from OFF to
ON is detected.
External small open This signal is to move the gun to small open position.
In case of servo gun, gun moves to the pressurization stroke position. In case of
air gun, gun is in the status of half-open signal ON and full-open signal OFF.
ON is detected.
External squeeze This signal is to press gun without moving robot.
In case of servo gun, the gun mechanism applies the pressure. In case of air gun,
the pressurization signal is set to ON.
To initiate the release operation, proceed with full or half open.
ON is detected.
External weld This signal is to perform the welding operation which accompanies the equalizing
operation of the robot.
Welding condition This signal specifies the welding conditions No. in which external welding or
select external pressurizing is to be performed.
If the signal has not been allocated, the number designated by the spot welding
conditions is used.
Welding sequence This signal specifies the welding sequences No. in which external welding or
select external pressurizing is to be performed.
If the signal has not been allocated, the number designated by the spot welding
sequence is used.
Sync welding select This signal is to select the discrete welders which are to perform the sync welding.
If, for instance, pressure is to be applied with welders 1 and 2 simultaneously
using welder 1 as the master, the external pressure application signal of welder 1
will be input while simultaneous welding select signals 1 and 2 of welder 1 are
turned ON.
Six of these signals for each welder (making a total of 36 signals for all the
welders) can be allocated.
Unit select This signal is to specify in binary format the unit to be operated when a multi-unit
system is used.
Four signals can be allocated per welder (total: 24 signals).
These signals are input at the timings shown below. In order for external operations to be executed,
the motor power must have been turned ON in the playback mode.
8-16
External wide open

External small open
External squeeze
External weld At least 0.01 sec
Sync welding select
Unit select
Welding condition select

Welding sequence select
Operation start
Fig. 8.5.9 External operations
Functions to select the welding conditions and welding sequences using external
inputs are not supported at present time.
POINT For this reason, the "welding condition numbers and welding sequence numbers
used for manual welding," which are used for internal manual operations and
which are set as part of the spot welding conditions, are used for the welding
conditions and welding sequences with external operations.
8-17
8.5.7 Recording SYNCSPOT (FN303): simultaneous spot welding function

The simultaneous spot welding command is a function command. It can be recorded using the [FN]
key in the same way as the timer commands and input/output commands.

SYNCSPOT FN303 Simultaneous spot welding

Parameter No.1 Welder This is used to specify the number of the welder which
number will be performing the welding. The gun set in this
parameter serves as the simultaneous welding master
gun.
(0 to 6)
Parameter No.2 Condition# This is used to specify the number of the welding
condition which determines the welding force, welding
condition signal, etc. for the gun which was set in
parameter No.1.
(1 to 255)
Parameter No.3 Welding This is used to specify the number of the welding
sequence sequence which determines items such as the output
number timings of the pressure application signal, power-on
signal, stroke signal for the gun which was set in
parameter No.1.
(1 to 64)
Parameter No.4 Welder This is used to specify the number of the welder which
number will be performing the welding.
(0 to 6)
Parameter No.5 Condition# This is used to specify the number of the welding
condition which determines items such as the welding
force, welding condition signal for the gun which was
set in parameter No.4.
(1 to 255)
Parameter No.6 Welding This is used to specify the number of the welding
sequence sequence which determines items such as the output
number timings of the pressure application signal, power-on
signal, stroke signal for the gun which was set in
parameter No.4.
(1 to 64)
Parameters No.7 to Welder These are used to set the welder numbers, welding
No.18 number condition numbers and welding sequence numbers for
Condition# welders 3 and following which are to perform the
Welding simultaneous welding in the same way as with welder
sequence 1 and welder 2.
number
Parameter No.19 Welding point Use this parameter when controlling the welding
number points. The welding point numbers are output when
welding trouble has occurred to enable the hitting
points to be specified. Set this is "0" when it is not
going to be used.
(0 to 16000)
Since this function has a large number of parameters, a special parameter input method is provided.
8-18
Recording FN303 SYNCSPOT function

1 Press [FN] [3] [0] [3] [Enter].
>> The following screen now appears.
The numbers in the "No." column are the index numbers of the welders which are to
perform the simultaneous welding.
The number of lines indicated with the index numbers correspond to the number of
welders which have been registered. Up to six lines are displayed but only two lines
are displayed when only two welders have been registered.
Input the welder number, welding condition number and welding sequence number on
each index line. Also input the welding point number.
The welder which has been set as index number 1 serves as the master.
If the number of welders which are to perform the simultaneous welding is less than
the number of registered welders, extra input columns will be displayed.
Input "0" for the gun number in these areas.

The settings are recorded in the program.
>> A list of programs, such as the one below, appears.
Recording the move command
POINT In case of servo gun, position of move command just before SYNCSPOT command is the
position where zero contact is made with the work when the moving and settled side tips of
all the guns to be used for sync welding are not worn.
8-19
Recording FN303 SYNCSPOT function at the same time as move command

While the function can also be input using the [FN] key as mentioned above, the simultaneous spot welding
function can be recorded automatically at the same time as when the movement command is recorded in
order to improve the operating ease. Simply by moving the robot to the strike point position and pressing the
[O.WRITE / REC] key, two steps—the position (movement command) and spot welding (function
command)—can be recorded at the same time. The procedure involved is described below.
Whether the tips are new or worn, be absolutely sure to initiate a gun search and
complete the measurements of the tip consumption amounts before beginning the
teaching work.
POINT Bear in mind that if the teaching work is undertaken while a significant difference exists
between the tip consumption amounts of the tips used and the tip consumption amounts
stored in the robot's memory, the pressure will be applied at a different position from the
pressure application position that was taught, making it impossible to achieve the suitable
welding pressure and possibly deforming the work.
1 Move the robot close to the hitting point position.
2 Select the multiple number of guns to be used for simultaneous welding using
the welder select signals.
3 Set the number of the master gun used for manually operating a multiple
number of guns simultaneously in "Manual simultaneous welding master"
among the spot welding teach/playback conditions.
4 In order to place FN303 (sync spot welding command) in the automatic

recording status, press the [CLAMP ARC] key on the teach pendant once.
>>A red circle now appears in the application area (the part which is immediately
below the comment and which is circled in red in the figure below) of the status
window.
If, in this state, "Manual simultaneous welding" among the spot welding
teach/playback conditions has been set to valid, the FN303 simultaneous spot
welding function is recorded together with the movement command. At this time, all
the guns connected to the selected welder are recorded.
In this status, the spot welding command is not recorded yet.
5 Move the robot to the exact hitting point position.

In case of servo guns, first bring the settled side tip of the gun serving as the
master into contact with the work using the axis operation keys while gripping
enable switch (refer to figure (b) below).
Then bring the moving side tip into contact with the work as well by performing
the manual pressure application operation (pressing the [ENABLE] + [CLAMP]
keys together) (refer to figure (c) below).
＋ This is the hitting point position.
(a) Placed near the pressurizing position (b) The fixed side now touching (c) Now pressurizing
Fig. 8.5.10 Simultaneous pressure application
8-20
6 Check whether the gun is pressurizing properly.

When recording and/or modifying the welding points:
• Set the welding force to a level low enough not to cause the arm to bend.
• Then proceed with the pressurizing and recording or modifying by executing the
manual gun pressurizing operation.
When a high welding force is set and the "manual gun pressurizing" operation is
performed, the arm will bend, and the work will also bend in tandem. When a
recording and/or modifying operation is performed in this state, the correct position will
not be recorded.
When the teaching and/or modifying steps are played back in this way, pressurizing is
executed at the position where the work bends during playback as well.
This may cause the work to become deformed.
(a) Appropriate position (b) Excessive pressure by the fixed side (c) Insufficient pressure by the fixed side
Fig. 8.5.11 Correct pressurizing position
7 If OK, press [O.WRITE / REC] key.

>>The FN303 spot welding command is recorded at the same time as the movement
command of the position concerned. In the example shown in the figure below, the
movement command has been recorded in step 1 and the spot welding command
has been recorded in step 2.
>>The welding command and welding sequence number which are recorded at this
time are those set in the spot welding condition and sequence.
8 The gun is opened by executing the manual pressurizing operation (by pressing
＋ the [ENABLE] and [CLAMP ARC] keys together) once again. (Figure (b) below)
Operate the robot using the axis operation keys, and release the settled side tip
as well to move it away from the work. (Figure (c) below)
(a) Now pressurizing (b) Released at the fixed side (c) Work fully released
Fig. 8.5.12 Simultaneous release
9 Press the [CLAMP ARC] key again to prepare for the recording of the next step.
>> The red circle in the application area is cleared.
From now on, the spot welding command will not be recorded simultaneously even
when a move command is recorded.
When a hitting point is reached again, repeat the same operations starting with
step 2.
INFO. If only one welder has been selected by the welder select signal, the simultaneous spot
welding function will not be recorded and FN119, the regular spot welding function, will be
recorded instead.
8-21
Editing the function parameters

Use the screen editing function to change the welding condition number, welding sequence number or other
parameters after the function has been recorded.
1 Display the program monitor, and set it to the active status.

Now press the [Edit] key.
>>The program monitor is now renewed.
2 Align the cursor with SYNCSPOT function whose parameters are to be edited.
>>The following screen now appears.
3 Press the [Right] cursor key.

>>The display switches to a setting screen such as the one shown below. Move the
cursor and edit the parameters.

The settings are recorded in the program.
>>The display now returns to the screen editing screen.
8-22
8.5.8 Executing SYNCSPOT (FN303): simultaneous spot welding function

The function FN303 (simultaneous spot welding) can be executed by playing back the task program
or by using the check GO function. The welding operation is not executed by check BACK which
performs the pressure application OFF operation instead.
With servo guns used as an example, the simultaneous welding using welder 1 (gun 1) and welder 2
(gun 2) is described below.
1 Select the program in which the simultaneous spot welding function was
recorded.
External start signal 2 In accordance with the current operation mode, execute the program by
inputting the external start signal, pressing the start button or operating the
check GO key while holding down enable switch.
＋
3 Execute the movement command immediately before the simultaneous welding
function.
>>The guns head toward the positions shown below.
Clearance
amount at the
moving side
of gun 1 Position obtained with the
f ixed side of gun 2 as the
Clearance
reference
amount at
the moving
side of gun 2
Clearance
Clearance amount at Ignored
amount at the the fixed
fixed side of gun side of
1 gun 2
<Gun 1> <Gun 2>
Master
Fig. 8.5.13 Movement immediately before the simultaneous welding function
4 Execute the simultaneous welding function.
>>All the guns which are to perform the simultaneous welding apply pressure to the
work as shown below. The power-on signal is output as soon as the welding forces
are aligned.
Pressurizing Pressurizing
Gun 2 welding point

Gun 2 welding
point
<Gun 1> <Gun 2>

Master
Fig. 8.5.14 Executing the simultaneous welding function
5 Input the welding completion (WI) signal of welder 1.

>>The guns are not released.
8-23
6 Input the welding completion (WI) signal of welder 2.

>>Both guns are now released as shown below.
Clearance
amount at the
moving side of
gun 1
Clearance
amount at the
moving side of
gun 2
Clearance
amount at the
fixed side of
gun 1
<Gun 1> <Gun 2>
Master
Fig. 8.5.15 Ending the execution of the simultaneous welding function
7 Operation now moves on to the next step.
8-24
8.5.9 Error detection of tip consumption amount difference

If, when simultaneous welding is to be performed by the servo guns, the tip consumption amounts
of the guns differ significantly, this may deform the work, give rise to an inadequate welding force or
result in other kinds of trouble. It is possible to detect error when the difference in the tip
consumption amounts of the guns used for simultaneous welding has exceeded the allowable level
in such a case.
Described below is the method used to set the allowable level for detecting error.
The operator must have the qualifications level of EXPERT or above to set this parameter.
1 Press <Spot Constant> key in teach mode.

Alternatively, the same menu can be made to appear by selecting <Constant
Setting> followed by [13 Spot welding application].
2 Select [6 Servo gun usage condition] from among the menu items displayed,
and press the [Enter] key.
3 Display the "Gun # (common)" screen.
4 Input the allowable tip consumption amount difference in "Diff limit to weld
sync."
>>When tip consumption amount difference is greater than the value, error is detected
at the timing of performing sync welding command. If "0" has been set, error is
never detected.

8-25
NOTE
8-26
Chapter 9 Special Air Gun Functions
This Chapter describes special air gun functions targeting at those who using the
robot for spot welding applications.
9.1 Stroke Change by Function Command ...................................................... 9-1
9.1.1 Setting of stroke change by function command................................. 9-1
9.1.2 GUNOPEN; Full/half gun open function (FN218) .............................. 9-2
9.1.3 Spot welding sequence ..................................................................... 9-3
9.1.4 Example of behavior.......................................................................... 9-4
9.1Stroke Change by Function Command
9.1 Stroke Change by Function Command

Using the full/half gun open command (FN218) makes it possible to change air gun stroke in any step other than
a step in which the spot welding command (FN119) is recorded.
9.1.1 Setting of stroke change by function command

To use the full/half gun open command (FN218), declare the execution of air gun control using the
full/half gun open command (FN218).
Setting procedure
POINT If this setting is not made, the full/half gun open command (FN218) will not be displayed in
the list of “Function record statuses”.
To make this setting, set the operator class to EXPERT or higher in advance.
2 Press Spot Constant f key. (Pressing Constant f key and then choosing [13
Spot Welding Application] will display the same menu.)
 The Menu screen shown below will appear..
3 Choose the [1 Spot welder setting] menu.

9-1
4 Press the f-key Page to turn a page.

 The Setting screen shown below will appear.
5 Put the cursor on “Full/half gun open function”, and then press the [ENABLE]
＋ key and the [] or [] key at one time to set this parameter to “Enabled.”
6 After the completion of setting, press the f-key Complete.

 The set contents will be saved.
9.1.2 GUNOPEN; Full/half gun open function (FN218)

Using the FN218 command makes it possible to change air gun stroke.
If the parameter No. 2 of the FN218 is set to “Half gun open (0),” the “Half gun open” signal will
turn ON, and the “Full gun open” signal will turn OFF. If this parameter is set to “Full gun open (1),”
the “Full gun open” signal will turn ON, and the “Half gun open” signal will turn OFF.
The signal change will be made at the time when the FN218 is executed.

GUNOPEN FN218 Gun open
Parameter Data Function/Setting range

Used to make setting of the number of a welder to which air
Parameter 1 Welder No. gun having a stroke to be changed is connected.
Used to set the air gun to half open or full open mode.
Parameter 2 Half/Full
0: Half open/1: Full open
9-2
9.1.3 Spot welding sequence

To use the FN218 command, set the “Stroke (start)”, “Stroke (weld)”, and “Stroke (finish)”
parameters on the Welding condition/Sequence screen to “None” in advance, respectively.
Setting the “Stroke (start),” “Stroke (weld),” and “Stroke (finish)” parameters on the
Welding condition/Sequence screen to any item other than “None” may disable normal
IMPORTANT operation of the air gun.
Setting procedure
1 Press Spot Weld Cond f key. (Pressing Service Utilities f key and then
choosing [20 Spot Welding Application] and [2 Welding condition/Sequence]
will display the same screen.)
 The Setting screen shown below will appear.
2 If the [Weld condition] screen is displayed, press Weld Cond./Sequence f key

to display the [Weld Sequence] screen.
3 If multiple welders are used, press the [CLOSE] key to choose the tab of a
welder to which the applicable air gun is connected, and then make setting.
4 Put the cursor on the “Stroke (start)”, “Stroke (weld)”, and “Stroke (finish)”
＋ parameter respectively, and then press the [ENABLE] key and the [] or []
key at one time to set each parameter to “None”.
5 Put the cursor on “Sequence#,” enter a welding condition number, and then
press the [Enter] key.
Press the f-key Prev No or Next No to choose a welding sequence number
in “Sequence#,” and then make setting of all welding parameters to use
following Step 4.
6 After the completion of setting, press Complete f key on each page.
 The set contents will be saved.
9-3
9.1.4 Example of behavior
If the “Full/half gun open function” parameter on the [Spot welder setting] screen is set to
“Enabled,” “Half gun open signal” will turn ON and “Full gun open signal” turn OFF in all
IMPORTANT steps in which the full/half gun open command is not recorded.
Step N+2
GUNOPEN (1, 1)
Step N+1 (Move) Accuracy
FN218; Full gun open
Accuracy
Step N+3 (Move)
Step N (Move)
Step N+4 (Move)
Half open signal
Full open signal
Fig. 9.1.1 Example of playback operation
Step N+2
GUNOPEN (1, 1)
Step N+1 (Move)
FN218; Full gun open
Accuracy Step N+3 (Move)
Accuracy
Step N (Move)
Step N+4 (Move)
Half open signal
Full open signal
Fig. 9.1.2 Example of Check BACK operation
9-4
Chapter 10 Pressure direct weld function
This Chapter describes FN268 Spot welding function that can directly specify the
pressure (force) and the thickness of the panel to be welded. Required setting and
explanation of this function are described hereinafter.
10.1 Outline ................................................................................................... 10-1

10.1.1 FN268 function (Specified force weld)............................................ 10-1
10.1.2 Required settings ........................................................................... 10-1
10.1.3 The difference of the welding motion and the gun axis motion....... 10-1
10.2 Settings .................................................................................................. 10-2
10.2.1 Enabling the FN268 function .......................................................... 10-2
10.2.2 The settings for function record and the manual weld operation .... 10-3
10.2.3 Recording FN268 function.............................................................. 10-5
10.2.4 Manual recording of FN268 function .............................................. 10-6
10.2.5 Automatic recording of FN268 function .......................................... 10-6
10.3 Special functions for Specified force weld function................................. 10-7
10.3.1 <Cancel WI> operation is prohibited in motors OFF ...................... 10-7
10.3.2 Gun axis pressure limitation for manual axis operation .................. 10-7
10.4 Pressure limitation ................................................................................. 10-8
10.4.1 How to set the limitation values ...................................................... 10-8
10.4.2 The pressure limit in the welding condition screen....................... 10-10
10.4.3 The pressure limit in the [Spot Teach/Playback Condition] screen10-10
10.5 Troubleshooting ................................................................................... 10-11
10.1 Outline
10.1 Outline
10.1.1 FN268 function (Specified force weld)

This chapter describes the operation to use FN268 (specified force weld).
FN268 can specify the pressure and the panel thickness for the function parameters. When using this function,
it is possible to designate the pressure for each welding point one by one without changing the weld condition
number and the weld sequence number.
FN268 has the following 4 parameters.
- Weld condition output data

- Weld sequence No.
- Pressure
- Thickness
When recording this function, the preset value or the value that is the same with the previous one is displayed
as the default value. And then if [Enter] key is pressed without inputting value, the default value will be registered
as the actual function parameter. Which value (the preset value or the value that is the same with the previous
one) is adopted as the default value can be selected in the setting menu.
10.1.2 Required settings

To use FN268 function, please set "Specified force weld function" to "Enabled" in [Constant Setting] [13 Spot
Welding Application] [1 Spot welder setting] screen. By this setting, the spot welding related menu will change as
follows.
- Recorded function FN268 will be recorded.

- Spot Condition menu Default value for FN268, welding condition for manual weld operation etc.
becomes available.
- Welding condition menu The setting item of "Welding condition No.(automatic recording)" and
"Welding condition No.(at manual welding)" become disabled.
After enabling the FN268, it is necessary to make required settings for function recording and manual welding
execution. This setting operation can be done in "Spot Teach/Playback Condition" menu. In this menu, the
parameters that will be displayed as the default values and the weld condition to be used with a manual welding
operation are to be set.
The other settings (weld condition and weld sequence) are the same with the setting of a standard weld timer.
The details of “Spot welder setting” menu, "Spot Teach/Playback Condition" menu, and the FN268 function are
described in the next section.
10.1.3 The difference of the welding motion and the gun axis motion
If FN268 is enabled, there are some differences like the following when executing the function or manual
welding compared with the case where the FN268 is not used. The differences will be as follows;
- When executing the spot welding function FN268, the pressure and the thickness in the function parameters
will be used. The parameters in the weld condition data will not be used.
- In a manual weld operation, the pressure and the thickness in the weld condition setting are not used. The
operation will be executed by following the settings of "Manual cnd. (condition)" in [Spot Teach/Playback
Condition] menu.
- In motors OFF, it is not possible to cancel WI waiting condition with <Cancel WI> f key.
- If motor current that exceeds the manual pressure setting value flows in the motor when operating the gun
axis, the motion will be terminated forcibly.
10-1
10.2 Settings
10.2 Settings
10.2.1 Enabling the FN268 function

To use FN268 function, it is necessary to set "Specified force weld function" to "Enabled" in [Constant Setting]
[13 Spot Welding Application] [1 Spot welder setting] screen. Please follow the following operation.

Set the operator class to EXPERT or higher in advance.
2 Press Spot Constant f key. (Pressing Constant f key and then choosing [13
Spot Welding Application] will display the same menu.)
Title No.3 or higher menu line is displayed only in case of servo gun.
3 Choose the [1 Spot welder setting] menu.

4 Press Page up or Page down key to display the 2nd screen.

5 Select the "Specified force weld function" with up/down cursor keys and select
"Enabled" with [ENABLE] + left/right cursor keys.
＋
6 After the completion of setting, press Complete f key.
Contents are saved to the file.
Now the FN268 function gets available.
10-2
10.2 Settings
10.2.2 The settings for function record and the manual weld operation
1 Set the operator class to USER or higher in advance.
2 Press Spot Condition f key. (Pressing Service Utilities f key and then
choosing [20 Spot Welding Application] [1 Spot Teach/Playback Condition] will
display the same menu.)
(A) (B)
3 Select the default values for the function parameters that will be displayed
when recording FN268 spot welding function.
Align the cursor onto "Record cnd. select" using up/down cursor keys and
switch the setting with [ENABLE] + left/right cursor keys.
＋
"Previous val"; The values that are inputted at the previous record operation will be
used as default values.
"Setting val"; The values that are set in "Record cnd." Edit boxes are used as
default values.
4 If "Setting val." Is selected in the step 3, please input the parameters that will be
displayed when recording FN268 function.
If "Previous val." Is selected, go to the step 5.
Please input the data of row [A] by referring to Table 10.2.2 The details of "Spot
Teach/Playback Condition" setting items.
5 Set the weld condition for a manual weld operation.
Please input the data of row [B] by referring to Table 10.2.2 The details of "Spot
Teach/Playback Condition" setting items.
6 After finishing steps from 3 to for all weld timer, press <Complete> key.
Contents are saved to the file.
10-3
10.2 Settings
The setting item list of "Spot Teach/Playback Condition" is described hereinafter.
Table 10.2.1 Explanation for the "Record cnd."

Parameter Description
Record cnd. If "Record cnd. select" is set to "Setting val.", the values that are set here will be used
as default values for the parameters of FN268 function.
Prv. If "Record cnd. select" is set to "Previous val." side, the values displayed here will be
used as default values for the parameters of FN268 function. These values are
refreshed if values that are different from the default values are inputted when
recording FN268. These values cannot be edited in this screen.
Manual cnd. This is data that is used when manual welding is executed.
Table 10.2.2 The details of "Spot Teach/Playback Condition" setting items

Factory Air Servo
setting gun gun
Record cnd. select Previous This is a setting item to select data that will be used for
val. the default parameters when recording FN268 spot
welding function. If "Previous val." is selected, the
parameters of FN268 previously recorded will be used.
 
And if "Setting val." is selected, the values that are set in
the column of "Record cnd." will be used.
Input range: "Previous value" / "Setting value"

Condition data 0 Input the Weld condition output data in decimal value.
The data will be outputted as binary data. This item can
be set in "Record cnd." and "Manual cnd.".  
Input range: from 0 to 65535

Sequence number 1 Input the Weld sequence number to be used. This item
can be set in "Record cnd." and "Manual cnd."
 
Input range: from 1 to 64
Pressure 0.5 Input the servo gun pressure. This item can be set in
[kN] "Record cnd." and "Manual cnd.". In case of air gun, this
item is ignored.
 
Input range : from 0.5 to 10.0 [kN]
(from 50 to 1020 [kgf])
Total thickness 0.0 Input the total thickness of the welding point. This item
can be set in "Record cnd." and "Manual cnd.". In case
of air gun, this item is ignored.  
Input range : from 0.0 to 20.0 [mm]
Concerning the items that are not mentioned here, the setting contents of those are the same with a case
where the FN268 function is not used.
10-4
10.2 Settings
10.2.3 Recording FN268 function

The recording operation of this spot welding function is the same with that of FN119. But the parameters of
FN268 are different from those of FN119. The parameters of FN268 are shown as below.
Command No. Function name

Spot welding
SPOT2 FN268
Parameter Data Description and setting range

Weld condition data outputted to the weld
Weld condition
1 timer
output data
(from 0 to 65535)
Weld sequence number that controls the
Weld output timing of "Gun squeeze", "Weld
2
sequence No. command", "Gun full/half open" signals etc.
(from 1 to 64)
This is the servo gun pressure for the
welding motion. This setting value is
3 Pressure ignored in case of air gun.
(from 0.5 to 10.0 [kN])
Or (from 50 to 1020 [kgf])
This is the thickness of the panel to be
4 Thickness welded.
(0 to 20.00 [mm])
When inputting FN268 function, default values will be displayed. Related to this, the recording operation is
different from the normal spot welding function FN119. Refer to "10.2.4 Manual recording of FN268 function" and
"10.2.5 Automatic recording of FN268 function" for details.
About the gun number to be used

(Example)
Step1 100% LIN T1 < T1 = Servo gun >
Step2 SPOT2[1, 1, 2.94, 0.0]
Step3 100% LIN T2 < T2 = Air gun >
Step4 SPOT2[1, 1 ,2.94, 0.0]
When executing the spot welding function FN268 (SPOT2), the gun number is automatically selected due to
the tool number in the previous move command. The relationship between the gun number and the tool number
is decided via the following setting screen.
[Constant Setting] [13 Spot Welding Application] [2 Spot welding gun setting]
10-5
10.2 Settings
10.2.4 Manual recording of FN268 function

This FN268 can be recorded using FN key like FN119 function. Although in case of FN119, the default values
are not displayed when inputting the parameters, the default values will be displayed in case of FN268. If the
displayed value is valid, press [Enter] key to enter the parameter value. If you want a different value to be set,
input the number using numeric keys and then press [Enter] key to fix the parameter.
1 Press [FN], [2], [6], [8].
2 The default value of the 1st parameter will be displayed. If the value is OK, press
[Enter] key. If it is necessary to change the value, input the new value using
numeric keys and then press [Enter] key.
or
3 Repeat the same operation. If the displayed default value is OK, press [Enter].
And if you want different value, input the new value with numeric keys and then
press [Enter] key.
>>After finishing the all parameters, the function is recorded.
10.2.5 Automatic recording of FN268 function

If a new step (move command) is recorded with the gun status ON, a recording guide box for FN268 function
will show up after recording the move command. Please enter the required parameters in the same way with the
manual input of FN268.
1 Move the robot to a place where is close to the welding point.
2 Press [CLAMP / ARC] key 1 time to enable the automatic record function of the
spot welding function FN268
>> A red round mark is displayed in the status window's application area. If a new step
(move command) is recorded in this condition, the spot welding function FN268 is also
recorded automatically.
At this time, the spot welding function is not recorded yet.
3 Move the robot to the precise position for the spot welding operation.
＋ In case of servo gun, move the robot using axis operation keys with grasping
enable switch so that the fixed (settled) side tip touches the work-piece. And
then press [ENABLE] + [CLAMP / ARC] keys to make manual press operation to
make the moving side tip touch the surface of the work-piece.
4 If it is OK, press [O.WRITE / REC] key.
>> The move command for the position and the spot welding function FN268 are
recorded at the same time.
At this time, the record condition is decided depending on the setting of "Record cnd.
select" in the [1 Spot Teach/Playback Condition] screen. There are 2 patterns of
parameters to be used;
- Previous value : The values that were used in the previous FN268.
- Record condition : The values that are set in the [1 Spot Teach/Playback
Condition] screen in advance.
5 For the preparation for the next step recording, press [CLAMP / ARC] key 1 time.
>> The red mark will disappear.
By erasing the red mark, the spot welding function is not recorded even if a move
command is recorded. And if the next welding point comes, repeat the same
procedure from the step 2.
10-6
10.3 Special functions for Specified force weld function
10.3 Special functions for Specified force weld function
10.3.1 <Cancel WI> operation is prohibited in motors OFF

When "Specified force weld function" is set to "Enabled", WI (Weld Interlock) waiting condition can not been
canceled by pressing <Cancel WI> f key in motors OFF. When motors are turned OFF while waiting for WI signal
after executing of welding function or manual welding operation, the following INFORMATION will be displayed
when <Cancel WI> f key is pressed and the WI status is not canceled.
I2021 WI cancel operation is disabled. (Servo gun)
To cancel WI waiting condition, turn the motors ON before pressing <Cancel WI> f key.
This prohibition function works only in case where the "Specified force weld function" is set to "Enabled". If
"Specified force weld function" is set to "Disabled", canceling WI waiting condition with <Cancel WI> f key is
available even in motors OFF.
10.3.2 Gun axis pressure limitation for manual axis operation

If "Specified force weld function" is set to "Enabled", the gun pressure is controlled (limited) so that the
pressure does not exceed the pressure which is set in the "Pressure" in the "Manual cnd." column. If the actual
pressure exceeds the setting pressure while operating the gun axis with axis operation key, the following
ALARM will be displayed and the axis motion will stop.
A2055 Pressure already achieved to the designated value for manual operation.
At this time, motor power is still ON.

This function works only in case where the "Specified force weld function" is set to "Enabled". If "Specified
force weld function" is set to "Disabled", the press motion will be continued even if the pressure exceeds the
value that is set in the "Pressure" in the "Manual cnd." column.
10-7
10.4 Pressure limit
10.4 Pressure limitation

This function makes it possible to define the higher limit and the lower limit of the pressure. By this function,
the following input range is limited by the setting values.
- Pressure parameter in the FN268 function (including the Screen Editor)

- Pressure setting in the Weld condition setting
- Pressure setting of "Pressure" in "1 Spot Teach/Playback Condition" menu.
10.4.1 How to set the limitation values

The limitation values can be set in "Pressure limit" item in [Servo Gun general characters] menu.

Set the operator class to EXPERT or higher in advance.
2 Press <Spot Constant> key and then select [4 Servo Gun general characters].
The same menu can be opened <Constant Setting> [13 Spot Welding
Application] [4 Servo Gun general characters].
>>The following setting screen will be displayed.
3 Align the cursor with cursor keys and enter the gun number to which the
limitation setting is applied and then press [Enter] key.
(It is also possible to use [Prev Gun]/[Next Gun] keys to select the gun number)
or
(NOTE) A gun number that is larger than the number set in the [Spot welder setting]
menu cannot be set here.
10-8
10.4 Pressure limit
4 Set the lower limit of the pressure for the gun that is selected in the step 3
Set the cursor to "Pressure limit Low" and input the lower limit value of the
pressure by numeric keys and then press [Enter] key.
5 Set the higher limit of the pressure for the gun that is selected in the step 3
Set the cursor to "Pressure High" and input the higher limit value of the
pressure by numeric keys and then press [Enter] key.
6 After finishing steps from 3 to 5 for all welding gun, press <Complete> key.
>> The setting data will be saved to the internal memory.
Table 10.4.1 The details for the pressure limit function

Factory Air Servo
setting gun gun
The lower limit value for the pressure limit function.
When 0 is set, this function does not work.
Pressure limit Low 0  
Input range : 0.0 to 50.0 [kN]
0.0 to 5099.0 [kgf]
The higher limit value for the pressure limit function.
When 0 is set, this function does not work.
Pressure limit High 0  
Input range : 0.0 to 50.0 [kN]
0.0 to 5099.0 [kgf]
When the "High" is smaller than the "Low", the values are not registered.
And, when the limit values are "0", this pressure limit function does not work.
10-9
10.4 Pressure limit
10.4.2 The pressure limit in the welding condition screen

When the pressure limit is set as "Low = 0.3[kN]" and as "High= 3.5 [kN]", the pressure value in the "Welding
condition/Sequence" screen is limited as follows.
The input value is limited between 0.3 and 3.5 and if a value out of this range is inputted, it is not accepted.
10.4.3 The pressure limit in the [Spot Teach/Playback Condition] screen

When the pressure limit is set as "Low = 0.3[kN]" and as "High= 3.5 [kN]", the pressure value in the [1 Spot
Teach/Playback Condition] screen is limited as follows.
The input value is limited between 0.3 and 3.5 and if a value out of this range is inputted, it is not accepted.
10-10
10.5 Troubleshooting
The error codes related to the specified force weld function are described hereinafter.
I2021 WI cancel operation is disabled. (Servo gun)

[Contents] This error occurs when WI cancel is operated during a servo gun motor power OFF.
[Measure] Please operate WI cancel after a motor power on.
A2055 Pressure already achieved to the designated value for manual operation.
[Contents] Servo Gun Pressure already achieved to the designated value for manual operation.
[Measure] Pressure value is too low when servo gun axis does not move. Review pressure data. If this
error occurs again even if the pressure is modified, the servo gun axis is in a status in which the axis
cannot move unless a power that is larger than the setting value. Check the mechanical condition of
the servo gun axis.
10-11
NOTE
10-12

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■ Give this manual to the operator.

■ For help, call your distributor.

The following symbol is also used for particularly important checkpoints:

This is a particularly important checkpoint.

Chapter 1 Basic settings

1.2 Basic welder and gun settings ............................................................................................ 1-2

1.5 Servo gun tip consumption detection Expert settings....................................................... 1-15

Chapter 2 Spot welding condition

2.3 Useful welding condition editing functions .......................................................................... 2-4

Chapter 3 Spot weld sequence

3.3 Useful welding sequence editing functions ....................................................................... 3-10

Chapter 4 Servo gun tip consumption measurements

4.2 Gun Search Function .......................................................................................................... 4-2

4.4 Gun search reference write................................................................................................. 4-8

4.5 Executing gun search 2 first................................................................................................ 4-9

4.5.2 Designating the execution sequence by function command .......................................... 4-9

Chapter 5 Welding program teaching

5.3 Welding step teaching ......................................................................................................... 5-3

5.7 Setting of Clearance by Function Command ....................................................................5-12

Chapter 6 Useful functions

6.2 Short-cuts .................................................................................................................................. 6-2

6.4.3 Spot Welding Condition Setting....................................................................................... 6-14

Chapter 7 Tip dressing

7.2 Settings ............................................................................................................................... 7-2

Chapter 8 Special servo gun functions

8.4 Double gun control .............................................................................................................. 8-8

8.5 Multi-gun simultaneous welding .......................................................................................... 8-9

Chapter 9 Special Air Gun Functions

9.1.1 Setting of stroke change by function command ............................................................. 9-1

Chapter 10 Pressure direct weld function

1.1 Complete sequence of advanced setup work...........................................1-1

1.1 Complete sequence of advanced setup work

Spot welding setup start

Assignment of spot welding

Overall spot welding setup

Welder settings Mechanism machine constant settings

Servo gun welding force adjustment

Servo gun conditions settings

Servo gun tip consumption settings

Spot welding setup end

Fig. 1.1.1 Complete sequence of spot welding setup work

1.2 Basic welder and gun settings

Welder #1 Welder #2 Welder #3 Welder #4 Welder #5 Welder #6

Fig. 1.2.1 Spot welder (timer contactor) connections

Spot welding gun

Multi-gun specification Gun change specification

Fig. 1.2.2 Spot welding tool (gun) connections

1 Select the teach mode.

5 Upon completion of the settings, press <Complete> f key.

1.2.1 Spot welder settings

Guns 0 This is used to specify the number of spot welding tools.

1.2.2 Spot welding gun settings

Air Air-driven spot welding gun

1.3 Assignment of spot welding input/output signals

1.3.1 Spot welding input signal

Table 1.3.1 Spot welding input signal

1.3.2 Spot welding output signals

Table 1.3.2 Spot welding output signals

1.4 Expert settings for servo gun conditions

Servo gun conditions (common data)

Table 1.4.1 Servo gun conditions (common data)

Servo gun conditions (individual data)