DX100 OPTIONS

INSTRUCTIONS
FOR MULTI-LAYER WELDING FUNCTION

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

MOTOMAN INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 Operator’s instructions above corresponds to specific usage.
Be sure to use the appropriate instruction.

Part Number: 156446-1CD

Revision: 0

MANUAL NO.

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DX100

MANDATORY
• This manual explains the Multi-layer Welding Function of the DX100
system. Read this instruction carefully and be sure to understand its
contents before handling the DX100 and available functions.
• Listed in Chapter 1 are general safety related items:: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.

CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Replace all covers and shields before
operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If modification occur, the revision number changes
on the manual.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.

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Notes for Safe Operation

Read this manual carefully using the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.

Indicates a potentially hazardous

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.

Always be sure to follow explicitly the

MANDATORY items listed under this heading.

Must never be performed.

PROHIBITED

Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items

To ensure safe and efficient operation at all times, be sure to

NOTE follow all instructions, even if not designated as "CAUTION"
and "WARNING".

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DX100

WARNING
• Before operating the manipulator, turn OFF the servo power by
pressing the emergency stop button on the front door of the DX100
or the programming pendant.
The SERVO ON LED is OFF when the servo power is OFF.
Injury or damage to machinery may result if the emergency stop circuit
does not stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button

• Clear the cell of all items that could interfere with the operation of
the manipulator with the Emergency Sop button engaged.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem. The emergency stop buttons are
located on the right of the front door of the DX100 and the programming
pendant.

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CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. Repair any problems that are found
immediately and make sure other necessary processing can be
performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the DX100
cabinet after use.
Damage to the programming pendant can occur if left .in the
manipulator’s work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller

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Descriptions of the programming pendant, buttons, and displays are

shown as follows:

Equipment Manual Designation

Programming Character [ ] indicate keys with characters printed on them.
Pendant Keys ex. [ENTER]
Symbol The keys which have a symbol printed on them
Keys are not denoted with [ ] but depicted with a small
picture. GO BACK

ex. page key PAGE

The cursor key is an exception, and a picture is
not shown.
Axis Keys “Axis Keys” and “Number Keys” are generic
Number Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays { } indicate menu displayed in the programming
pendant.
ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • "
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.

Registered Trademark
In this manual the trademark (™) and register trademark (®) symbols
have been omitted.

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1 Outline ............................................................................................................................................ 1-1

1.1 Multi-layer Welding Function ............................................................................................. 1-1

1.2 Features ............................................................................................................................ 1-1

1.3 Customer Support Information........................................................................................... 1-2

2 Basic Operations............................................................................................................................. 2-1

2.1 Robot Posture Control by Euler Angles ............................................................................. 2-1

2.1.1 Outline .................................................................................................................. 2-1

2.1.2 Operation.............................................................................................................. 2-2

2.1.2.1 Cartesian coordinate system................................................................... 2-2
2.1.2.2 Tool coordinate system ........................................................................... 2-3

2.2 Point Variables................................................................................................................... 2-3

2.2.1 Outline .................................................................................................................. 2-3

2.2.2 Registering Point Variables .................................................................................. 2-4

2.2.2.1 Changing the number of the point variable ............................................. 2-5
2.2.2.2 Registering a move instruction together with a point variable ................. 2-8

2.2.3 Deleting a Point Variable .................................................................................... 2-10

2.2.3.1 Deleting the move instruction ................................................................ 2-10
2.2.3.2 Deleting the point variable designation ................................................. 2-11

2.2.4 Editing the Point Variable (Taught Position Data) .............................................. 2-13

2.3 Memory and Playback Function ...................................................................................... 2-14

2.3.1 Outline ................................................................................................................ 2-14

2.3.2 Instructions for Memory and Playback Function................................................. 2-14

2.3.3 Application Example ........................................................................................... 2-15

2.4 Multi-layer Welding Tool Shift Function ........................................................................... 2-17

2.4.1 Outline ................................................................................................................ 2-17

2.4.2 Tool Shift Coordinate System............................................................................. 2-17

2.4.3 Registering ......................................................................................................... 2-18

2.5 Search and Shift Function ............................................................................................... 2-19

2.5.1 Outline ................................................................................................................ 2-19

2.5.2 Items to be Set for SRSFT Instruction................................................................ 2-20

2.5.3 Registering ......................................................................................................... 2-21

2.5.4 Application Example of SRSFT Instruction......................................................... 2-23

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2.6 Search Function for Sticking ............................................................................................ 2-24

2.6.1 Outline ................................................................................................................2-24

2.6.2 Items to be Set for SRSTCK Instruction ............................................................. 2-24

2.6.3 Registering.......................................................................................................... 2-26

2.7 Shift Function ................................................................................................................... 2-28

2.7.1 Outline ................................................................................................................2-28

2.7.2 Continuity of Shift Function................................................................................. 2-29

2.7.3 Shift Amount Display .......................................................................................... 2-30

2.8 Beveling Width Measuring Function ................................................................................ 2-31

2.8.1 Outline ................................................................................................................2-31

2.8.2 Items to be Set for SRGAP instruction ............................................................... 2-31

2.8.3 Registering.......................................................................................................... 2-32

2.9 Overriding Welding Condition Function ........................................................................... 2-34

2.9.1 Outline ................................................................................................................ 2-34

2.9.2 Operation ............................................................................................................ 2-34

2.9.3 Welding Condition Adjustment Display............................................................... 2-35

2.9.4 Parameters for the Units to Adjust Conditions.................................................... 2-38

2.10 Confirm the Welding Operation in Teach Mode............................................................. 2-39

2.10.1 Outline .............................................................................................................. 2-39

2.10.2 Operation .......................................................................................................... 2-39

2.10.3 Display .............................................................................................................. 2-39

2.11 How to Restart After an Emergency Stop in the Middle of Weaving.............................. 2-40

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1 Outline
DX100 1.1 Multi-layer Welding Function

1 Outline

1.1 Multi-layer Welding Function

The DX100 is used to weld a workpiece with multiple layers which,
otherwise, cannot be satisfactorily welded with a single layer. The first
layer is welded while the COMARC instruction executes the arc sensing
for correcting the path. At the same time, the path is stored and jobs for
the 2nd and following layers are created automatically based on the
stored path by the memory and playback function.
Since the workpieces subjected to the multi-layer welding are generally
thick and have problems such as “variations in welding accuracy”,
“distortion during welding”, and “positioning errors due to setting error”,
simply reproducing the taught path is not enough to attain high-quality
welding. For the solution of these problems, the search function and the
arc sensing function are used.

1.2 Features
The main features of multi-layer welding function are listed below.

Items Contents Features

Point variables The taught position data on the 1st By using the point variables where
layer are registered in point the taught position data on the first
variables. These point variables layer are registered, the time
can be used for weldings on the required for the teaching for the
2nd and following layers. second and the following layers
can be reduced.

Memory and playback function Stores the corrected path of the Reproducing the corrected path on
first layer by the arc sensor and the first layer for the second and
reproduces the stored path on the the following layers realizes the
second and the following layers. high-quality welding.
For reproducing the corrected path
for the second and the following
layers, either the same direction as
the welding on first layer or the
reversed direction can be selected.

Search and shift function Four shift patterns are available. At One instruction executes search
the execution of the instruction, the and shift functions, which simplifies
amount of the deviation from the the operation.
taught position is automatically Specifying the shift type such as
calculated and the following steps shift in parallel or shift in rotation
are shifted accordingly. makes the correction of the
workpiece positioning error easy.

Overriding Welding Condition During playback operation, the Overriding the welding conditions
Function welding conditions can be adjusted such as arc sensing, weaving
and changed. amplitude, realizes easy
adjustment of the welding
conditions.

Shift function After the search and shift Since it is not necessary to change
operations, the taught position can the target position on the master
be modified during the shift workpiece, the modification of the
operation in teach mode. taught position is easy.

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DX100 1.3 Customer Support Information

1.3 Customer Support Information

If you need assistance with any aspect of your DX100 system, please
contact Yaskawa Motoman Customer Support at the following 24-hour
telephone number:

(937) 847-3200

For routine technical inquiries, you can also contact Yaskawa Motoman
Customer Support at the following e-mail address:

techsupport@motoman.com

When using e-mail to contact Yaskawa Motoman Customer Support,

please provide a detailed description of your issue, along with complete
contact information. Please allow approximately 24 to 36 hours for a
response to your inquiry.

Please use e-mail for routine inquiries only. If you have an

NOTE urgent or emergency need for service, replacement parts,
or information, you must contact Yaskawa Motoman
Customer Support at the telephone number shown above.

Please have the following information ready before you call:

• System DX100
• Robots MH5L
• Positioner MH95
• Primary Application Welding
• Controller DXM100
• Software Version Access this information on the
Programming Pendant’s LCD display
screen by selecting {MAIN MENU} -
{SYSTEM INFO} - {VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller data
plate

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DX100 2.1 Robot Posture Control by Euler Angles

2 Basic Operations

2.1 Robot Posture Control by Euler Angles

2.1.1 Outline
Different from the robot control of the ordinary coordinate systems, Euler
angles control the robots optimum posture for welding. See fig. 2-1 for the
robot posture using Euler angles.
The Euler angles in the base coordinate system are as follows:
A) The angle between the X-axis and the Z-axis of the tool
coordinate system projected on the X-Y plane of the base
coordinate system (-180° < A ≤ 180°)
B) The angle between the Z-axis of the tool coordinate system
and the X-Y plane of the base coordinate system
(-90° < B ≤ 90°)
C) The angle to move X and W-axis of the tool coordinate
system on X’ and Y’-axis where X’, Y’ and Z’ are the axes in
such coordinate system as Z-axis of the base coordinate
system is moved on Z-axis of the tool coordinate system by
rotating the base coordinate system around Z-axis and then
around Y-axis (-180° < C ≤ 180°)
Fig. 2-1: Euler Angles
+Zg (base coordinate system)

+ZT (tool coordinate system)

+ZT (tool coordinate system)

+YT (tool coordinate system)

+YT (tool coordinate system)
+Z (base coordinate system )

+X (base coordinate system) B

A +Y (base coordinate system)

C
+Y (base coordinate system)

+XT (tool coordinate system)

+XT (tool coordinate system)
+X (base coordinate system)

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DX100 2.1 Robot Posture Control by Euler Angles

2.1.2 Operation

2.1.2.1 Cartesian coordinate system

When selecting the Cartesian coordinate system , pressing X, Y, or Z key
moves the tool in parallel to the X, Y, or Z axis in the base coordinate
system. Accordingly, pressing axis key changes the tool posture without
changing the position of the tool center point as shown in Fig. 2-2.
Fig. 2-2: Jog Motion in Posture Control

+Z

-A +A
A rotation

-B

B rotation

+B

+C

C rotation

-C

A) Rotates around the Z-axis in the base coordinate system

B) Rotates the tool in horizontal and vertical motion to the X-Y
plane
c) Rotates centering around the tool axis

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DX100 2.2 Point Variables

2.1.2.2 Tool coordinate system

When selecting the tool coordinate system through the programming
pendant, the robot moves as shown in fig. 2-3.
Changing the posture is the same .as the Cartesian coordinate system.
Fig. 2-3: Jog Motion in Tool Coordinate System

+Z
+Y

-B

+B
+X

2.2 Point Variables

2.2.1 Outline
The point variables store and manage the taught position data in the job.
The point variables can be used to move the robot to the same position
multiple times in one job.
Registering the taught position data to the point variables can reduce the
time required for teaching within the job.

Difference between the point variables and the position variables (P***)
• The position variables can be read or written from/to all jobs while
the point variables use only the job where these point variables are
registered. Therefore, point variables may use identical numbers for
other jobs.
• The taught position data and the shift amount can be stored in the
position variable. In the point variables, only the taught position data
can be stored.
• 128 position variables are available as a standard (can be expanded
to 5,000). A point variable is created when a move instruction is
registered in the job, and the point variable number can be set
arbitrarily in the range of 0 to 9999.
• By using the instructions SET and SETE, a position variable can be
used for a registerd position; however, these instructions cannot be
used to register a position to a point variable.
• The position variables cannot be deleted (can be left without
position data). The point variables are deleted when the job where
these point variables are registered is deleted.

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DX100 2.2 Point Variables

2.2.2 Registering Point Variables

Replacing the taught position data of the move instruction with the point
variable.
1. Move the cursor to the instruction area, and press [SELECT] twice on
the desired move instruction
– The detail edit display of the move instruction appears.

2. Select “UNUSED” of “POINT VARIABLE,” and select “T”

3. Press [SELECT], and enter a point variable number
4. Press [ENTER]
– The entered point variable number (T0000) appears in the input
buffer line.

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DX100 2.2 Point Variables

5. Press [ENTER]
– The entered contents are registered in the job. If another point
variable with the same number has been already used in the same
job, the already used point variable, even if no taught position data is
specified in the point variable, is registered. Newly created and
numbered point variable has no taught position data regardless of
SERVO ON/OFF status.

• When a point variable with no taught position data

specified is registered, “” is indicated for the TOOL
number in the job content display.
NOTE
• The job in which the point variable with no taught position
data specified is registered can not be loaded/saved by
FC2 (same as for the position variables).

2.2.2.1 Changing the number of the point variable

There are two operation methods to change the number of the point
variable.

 Operation method 1 for changing number of point variables

1. Move the cursor to the instruction area, and press [SELECT] on the
desired move instruction
2. Move the cursor to the point variable whose number to be changed,
and press [SELECT]
– A new number for the point variable can be typed.

3. Press [SELECT], and enter a point variable number

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DX100 2.2 Point Variables

4. Press [ENTER]
– The entered point variable number (T0011) appears in the input
buffer line.

5. Press [ENTER]
– The entered contents are registered in the job. If another point
variable with the same number has been already used in the same
job, the already used point variable, even if no taught position data is
specified in the point variable, is registered. Newly created and
numbered point variable has no taught position data regardless of
SERVO ON/OFF status.

• When a point variable with no taught position data

specified is registered, “” is indicated for the TOOL
number in the JOB CONTENT display.
NOTE
• The job in which the point variable with no taught position
data specified is registered can not be loaded/saved by
FC2 (same as for the position variables).

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DX100 2.2 Point Variables

 Operation method 2 for changing number of point variables

1. Move the cursor to the instruction area, and press [SELECT] twice on
the desired move instruction
– The detail edit display of the move instruction appears.

2. Enter a point variable number

3. Press [ENTER]
– The entered point variable number (T0011) appears in the input
buffer line.

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DX100 2.2 Point Variables

4. Press [ENTER]
– The entered contents are registered in the job. If another point
variable with the same number has been already used in the same
job, the already used point variable, even if no taught position data is
specified in the point variable, is registered. Newly created and
numbered point variable has no taught position data regardless of
SERVO ON/OFF status.

• When a point variable with no taught position data

specified is registered, “” is indicated for the TOOL
number in the job content display.
NOTE
• The job in which the point variable with no taught position
data specified is registered can not be loaded/saved by
FC2 (same as for the position variables).

2.2.2.2 Registering a move instruction together with a point variable

1. Press [MOTION TYPE] to select the desired move instruction
– Each time [MOTION TYPE] is pressed, the move instruction is
switched in the following order: “MOVJ”→ “MOVL”→ “MOVC”→
“MOVS”→ “MOVJ.

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DX100 2.2 Point Variables

2. Press [SELECT]
– The detail edit display of the selected move instruction appears.

3. Select “UNUSED” of “POINT VARIABLE,” and select “T”

4. Enter a point variable number

5. Press [ENTER]
– The entered point variable number appears in the input buffer line.

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DX100 2.2 Point Variables

6. Press [ENTER]
– The entered contents are registered in the job. If another point
variable with the same number has been already used in the same
job, the already used point variable, even if no taught position data is
specified in the point variable, is registered. Newly created and
numbered point variable has no taught position data regardless of
SERVO ON/OFF status.

• When a point variable with no taught position data

specified is registered, “” is indicated for the TOOL
number in the job content display.
NOTE
• The job in which the point variable with no taught position
data specified is registered can not be loaded/saved by
FC2 (same as for the position variables).

2.2.3 Deleting a Point Variable

2.2.3.1 Deleting the move instruction

1. Move the cursor to the line number of the move instruction to be
deleted

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DX100 2.2 Point Variables

2. Press [DELETE] and [ENTER]

2.2.3.2 Deleting the point variable designation

• When the deleted point variable is not used for other move
instructions in the same job, it becomes in unused status,
but retains the taught position data. However, the point
NOTE variables in unused status will be deleted when another
job is selected.
• A move instruction with the point variable that has no
taught position data specified can be also deleted.

1. Move the cursor to the instruction area, and press [SELECT] twice on
the desired move instruction
– The detail edit display of the move instruction appears.

2. Select the point variable (T0010 in the explanation) to be deleted, and

select “UNUSED” of “POS LEVEL,” “NWAIT,” and “UNTIL”

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DX100 2.2 Point Variables

3. Press [ENTER]
– The modified contents appears in the input buffer line.

4. Press [ENTER]
– The entered modification is registered in the job. The taught position
data of the deleted point variable is reregistered.

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DX100 2.2 Point Variables

2.2.4 Editing the Point Variable (Taught Position Data)

The taught position data can be edited by entering a numerical value.
Refer to DX100 OPTIONS INSTRUCTIONS FOR TEACHING POINT
ADJUSTMENT FUNCTION WITH PROGRAMMING PENDANT
(manual No.: HW0485569).
1. In JOB CONTENT display, select {POSITION ADJUSTMENT} from
the pull-down menu of {UTILITY}
– The position adjustment display appears.

2. Select an item to be changed in the position adjustment display

– Selecting the point variable displays the list of point variables. Select
a point variable whose position data is to be corrected.

3. Enter a numerical value, and press [ENTER]

– Enter a value by using the number keys.
4. Select “COMPLETE”

For the details of changing the taught position data, refer to

SUPPLE YASNAC XRC Options Instructions for Teaching Point
-MENT
Adjustment Function with Programming Pendant .

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2 Basic Operations
DX100 2.3 Memory and Playback Function

2.3 Memory and Playback Function

2.3.1 Outline
The memory and playback function is used to correct the robot motion
path for the correction amount measured by COMARC sensor and saved
every sampling time set in the parameter. At the welding of the first layer,
the result (correction amount) of the sensing by COMARC function is
saved, and the saved correction amount is used at the welding of the
second and following layers for correcting the robot motion path.
For the welding of the second and following layers, the corrected path can
be reproduced in the reverse direction of the welding of the first layer.

• COMARC function
The COMARC function is necessary to use the memory
NOTE and playback function.
An expansion storage is needed to use the memory and
playback function.

2.3.2 Instructions for Memory and Playback Function

The instructions used for the memory and playback function are listed
below.

Sensor Instructions

MEMON Function Starts the memory and playback function.

Instruction Data 1 REC Saves the path correction

item amount measured by
COMARC.

PLY Executes the correction

for the saved correction
amounts in the forward
direction.

BACKPLY Executes the correction

for the saved correction
amounts in the reversed
direction.

Data 2 MPF# (File number) 1 to 50

MEMOF Function Cancels the memory and playback function.

Instruction None
items

Arithmetic Instructions

CLEAR Function Deletes a memory replay file.

Instruction MPF Deletes all the memory

items and playback files.

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DX100 2.3 Memory and Playback Function

2.3.3 Application Example

Create a welding job with two layers and three paths.
Execute the sensing by using the COMARC function while welding the
first layer, and weld the first path of the second layer in the reverse
direction of the welding on the first layer, then weld the second path of the
second layer in the same direction of the welding on the first layer.

Job

NOP

MOVJ VJ=100 Stand-by point

MOVJ VJ=60 Moves the robot to the approach position.

MOVL T0000 V=200 Welding start position T0000

ARCON AC=330 AV=30 V=40

COMARCON AMP=1.0 FREQ=3.5•• Starts the arc sensor.

MEMON REC MPF#(1) Starts the saving operation for the memory and
playback function.

MOVL T0001

MOVL T0002

MOVL T0003

MOVL T0004

MEMOF Stops the memory and playback function.

COMARCOF Stops the arc sensor.

ARCOF AC=200 AV=25 T=0.1 End of welding on 1st layer

GETS PX000 $PX040 Gets the correction amount measured by COMARC

function.

SFTON P000 BF Shifts for the correction amount.

'2Layer 1Path (Welding on 1st path of 2nd layer)

MOVL T0005 Moves the robot to the approach position for 2nd
layer.

SFTON P001 TF Shifts the welding start position for 1st path of 2nd
layer.

MOVL T0004 V=200

ARCON AC=250 AV=28 V=40

MEMON BACKPLY MPF#(1) Starts the reproduction of the welding on the 1st layer
in the reversed direction.

MOVL T0003

MOVL T0002

MOVL T0001

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DX100 2.3 Memory and Playback Function

Job

MOVL T0000

MEMOF

ARCOF AC=180 AV=20 T=0.1

SFTOF Cancels the shift function.

'2Layer 2path (Welding on 2nd path of 2nd layer)

MOVL V=200 Move the robot to the approach position for 2nd layer.

SFTON P002 TF Shifts the welding start position for 2nd path of 2nd
layer.

MOVL T0000 V=200

ARCON AC=200 AV=25 T=0.1

MEMON PLY MPF#(1) Starts the reproduction of the welding on the 1st layer
in the forward direction.

MOVL T0001

MOVL T0002

MOVL T0003

MOVL T0004

MEMOF Cancels the memory replay function.

ARCOF AC=180 AV=20 T=0.1

MOVL T0005

MOVJ VJ=100

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DX100 2.4 Multi-layer Welding Tool Shift Function

T0000

T0001

T0002

T0003

T0005
T0004

2nd path of 2nd layer

1st path of 2nd layer

1st path of 1st layer

2.4 Multi-layer Welding Tool Shift Function

2.4.1 Outline
For multi-layer welding, teaching the welding path on the 1st layer and
shifting the taught positions to weld on the second and following layers
can largely reduce the time required for teaching.

2.4.2 Tool Shift Coordinate System

The coordinates for the multi-layer welding tool shift function are
determined by the positional relation between the robot coordinate and
the tool coordinate.
Multi-layer welding tool shift coordinate X: Z-axis of the tool coordinate
projected on X-Y plane of the robot coordinate system
Multi-layer welding tool shift coordinate Y: Direction to Z-axis of the tool
coordinate
Multi-layer welding tool shift coordinate Z: Direction to Z-axis of the robot
coordinate

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DX100 2.4 Multi-layer Welding Tool Shift Function

Multi-layer welding tool shift coordinate B: The posture angle from X-axis
of the multi-layer welding tool shift coordinate in the direction to Z-axis
+Z
+Y

-B

+B
+X

• Posture angle setting

SUPPLE With the multi-layer tool shift function, the multi-layer tool
-MENT
shift coordinates A and C can not be set.

2.4.3 Registering
Specify the tag TF in SFTON (shift ON) instruction, and the taught
positions for the move instructions after the SFTON instruction will be
shifted for the shift amount set in the position variable (P***) in the
multi-layer tool shift coordinate system.

Instruction: SFTON
Format: SFTON P000 TF

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DX100 2.5 Search and Shift Function

2.5 Search and Shift Function

2.5.1 Outline
The search and shift function (SRSFT) detects the workpiece position
error by using the search sensor and correct the taught position.
SRSFT instruction starts searching the tool end from the point the tool
ends is not in contact with the workpiece and stops searching when the
tool end contacts the workpiece. There are four motion patterns. Each
motion pattern is shown below.

Searching

Only travelling

Pattern 1 Pattern 2

Pattern 3 Pattern 4

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2.5.2 Items to be Set for SRSFT Instruction

Set the following items for SRSFT instruction.

Item Contents

PATTERN Search motion pattern

1 to 4 (The numbers correspond to the patterns shown
below)

SHIFT 0 (no shift), 1 (shift in parallel), 2 (shift in rotation)

VELOCITY Search speed in units of cm/min

DIR_START (P1) Position P1 in the figure below

DIR_END (P2) Position P2 in the figure below

OFFSET 1 (L1) The distance L1 in the figure below (in units of mm)

OFFSET 2 (L2) The distance L2 in the figure below (in units of mm)

RETRACT AMOUNT The distance B in the figure below (in units of mm)

MAX. SEARCH An alarm occurs if the search is not ended within the
DISTANCE set travel distance.

END_POINT (P3) The search end position at teaching (position P3 in the

figure below)

Pattern 1 Pattern 2

P1 P1

P3
P2 L1 P3 P2 L1
B
B L2 B

Pattern 3 Pattern 4
P1 P2
P1 P2

L1
B L1 P3 B
P3
L2
B L2
B

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2.5.3 Registering
1. Move the cursor to the address area
2. Press [INFORM LIST]
3. Select “MACRO”

– The macro instruction list appears.

4. Select “SRSFT”
– The argument setting display for SRSFT instruction appears.

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5. Move the manipulator to the travel start point (P1), and press
[MODIFY] with the cursor on “UNREGIST” of P1, then press [ENTER]
to register the position of P1.

6. Move the manipulator to the travel end point (P2), and press [MODIFY]
with the cursor on “UNREGIST” of P2, then press [ENTER] to register
the position of P2.

7. Press [ENTER] twice to return to the job content display.

8. With the job content display, press [INTERLOCK] + [TEST START] to
execute the SRSFT instruction.
– The manipulator starts searching and stops.
9. Register the manipulator stop position for END_POINT (P3) in the
argument setting display.

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2.5.4 Application Example of SRSFT Instruction

Job

SFTOF3D Cancels the 3-dimension shift.

MOVJ VJ=60

SRSFT PTN=3 SFT=1 V=360•• Searches for 1st point (Shift in parallel).

MOVJ VJ=60

SRSFT PTN=3 SFT=2 V=360•• Searches for 2nd point (Shift in rotation). 

MOVJ VJ=60

SRSFT PTN=1 SFT=1 V=360•• Searches for 3rd point (Shift in parallel). 

MOVJ VJ=60

MOVL V=200 Moves to the welding start point.

Workpiece actual position

Shift in
rotation
Shift in parallel
Shifts the start
point in parallel

Workpiece taught position

Shift in parallel

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DX100 2.6 Search Function for Sticking

2.6 Search Function for Sticking

2.6.1 Outline
The search function for sticking (SRSTCK) detects the edge face of the
workpiece. There are 6 searching patterns.

2.6.2 Items to be Set for SRSTCK Instruction

Set the following items for SRSTCK instruction.

Item Contents

PATTERN Search pattern (See the patterns below)

SHIFT Shift type

0 (no shift), 1 (shift in parallel),
2 (shift in rotation)

VELOCITY Search speed in units of cm/min

DIR_START (P1) Position P1 in the figure below

DIR_END (P3) Position P2 in the figure below

OFFSET 1 (L1) The distance L1 in the figure below

(in units of mm)

OFFSET 2 (L2) The distance L2 in the figure below

(in units of mm)

RETRACT AMOUNT (B) The retract distance after the search

INITIAL MAX. SEARCH The distance M1 in the figure below

DISTANCE (M1) (in units of mm)

STICK FEED (S) The feed pitch S in the figure below

(in units of mm)

MAX SEARCH DISTANCE The maximum distance for searching

(in units of mm)

EDGE DETECTING If nothing is detected within this distance, the

DISTANCE (M2) end of this distance is considered as the
edge (in units of mm).

EDGE SEARCH SPEED Final searching speed in units of cm/min

EDGE SEARCH OFFSET (M3) The distance M3 in the figure below

(in units of mm)

END_POINT (P3) Search end position

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DX100 2.6 Search Function for Sticking

Pattern 1
Pattern 11

Pattern 2 Pattern 12

Pattern 3 Pattern 13

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DX100 2.6 Search Function for Sticking

2.6.3 Registering
1. Move the cursor to the address area
2. Press [INFORM LIST]

Pattern 1 Pattern 11

P1 P2 P1 P2

L1
B
B

M2 S

M3 P3
M1
P3

L2

Pattern 2
Pattern 12

P1 P2 P1 P2
S

L1
B
P3 B

M2
L2 M3 S
M1
P3

Pattern 3
Pattern 13

P1 P2 P1 P2
S

L1

B B

M2
P3
L2
M1 P3

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DX100 2.6 Search Function for Sticking

– The macro instruction list appears.

3. Select “MACRO”

4. Select “SRSTCK”
– The argument setting display for SRSTCK instruction appears.

5. Move the manipulator to the travel start point (P1), and press
[MODIFY] with the cursor on “UNREGIST” of P1, then press [ENTER]
to register the position of P1.

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DX100 2.7 Shift Function

6. Move the manipulator to the travel end point (P2), and press [MODIFY]
with the cursor on “UNREGIST” of P2, then press [ENTER] to register
the position of P2.

7. Press [ENTER] twice to return to the job content display.

8. With the job content display, press [INTERLOCK] + [TEST START] to
execute the SRSTCK instruction.
– The manipulator starts searching and stops.
9. Register the manipulator stop position for END_POINT (P3) in the
argument setting display.

2.7 Shift Function

2.7.1 Outline
The shift function shifts the positions in the section between SFTON
instruction and SFTOF instruction.
In SFTON instruction, specify a coordinate system for the shift amount.
The coordinate systems that can be specified are BF, RF, TF, UF, BP
(travelling axis), and EX (station axis). When two SFTON instructions with
different coordinate systems specified are executed consecutively, the
positions are shifted for the specified two shift amounts.
Example:
:
SFTON P000 BF (100.000 mm to X direction is specified in P000)
SFTON P001 RF (100.000 mm to Y direction is specified in P001)
MOVL V=100 (Shifts the position for 100.000 mm to X direction in
the base coordinate system, and for 100.000 mm to Y direction in the
robot coordinate system.):

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DX100 2.7 Shift Function

When two SFTON instructions with the same coordinate system specified
are executed, the last STFON instruction is valid.
Example:
:
SFTON P000 BF (100.000 mm to X direction is specified in P000.)
SFTON P001 BF (100.000 mm to Y direction is specified in P001.)
MOVL V=100 (Shifts the positions for 100.000 mm to Y direction in
the base coordinate system.)
:
In SFTOF instruction, the coordinate system for canceling shift function
can be specified. When the coordinate system is not specified, all the
coordinate systems for shift function are cancelled.

2.7.2 Continuity of Shift Function

The shift function can be cancelled by executing SFTOF instruction or
selecting another job.
While editing the job such as changing or deleting the taught position data
in SFTON status, the taught position data without the shift amount are
registered. Accordingly, the taught position data can be corrected during
the welding of the 2nd and following layers.
During the shift operation, “SFT” and the coordinate system that is
specified in SFTON instruction are indicated on the job content display.

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DX100 2.7 Shift Function

2.7.3 Shift Amount Display

1. Select {ROBOT} from the top menu
2. Select {SHIFT} from the sub menu
– The shift amount display appears.

3. Select a shift type

– Selecting a shift type, “PARALLEL” or “3D,” and a coordinate,
“BASE,” “ROBOT,” “TOOL,” and “USER,” displays the shift amounts
in the corresponding coordinate system.

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DX100 2.8 Beveling Width Measuring Function

2.8 Beveling Width Measuring Function

2.8.1 Outline
The beveling width measuring function measures the beveling width by
using the search function. The measured width is stored in the specified
variable number by using SRGAP instruction. According to the measured
beveling width, the welding conditions will be changed.
The tool stop position after the search is the center of the beveling.

Searching

Only travelling

2.8.2 Items to be Set for SRGAP instruction

Item Contents

SHIFT Shift type:

0: No shift, 1: Shift in parallel, 2: Shift in rotation

VELOCITY Search speed in units of cm/min

VARIABLE_No. Variable number to store the measured beveling width

DIR_START (P1) Travel start point P1

DIR_START (P2) Travel end point P2

END_POINT (P3) Search end point P3

OFFSET 1 (L1) Offset amount of the start position (in units of mm)

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2.8.3 Registering
1. Move the cursor to the address area
2. Press [INFORM LIST]
3. Select “MACRO”

– The macro instruction list appears.

4. Select “SRGAP”
– The argument setting display for SRGAP instruction appears.

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5. Move the manipulator to the travel start point (P1), and press
[MODIFY] with the cursor on “UNREGIST” of P1, then press [ENTER]
to register the position of P1.

6. Move the manipulator to the travel end point (P2), and press [MODIFY]
with the cursor on “UNREGIST” of P2, then press [ENTER] to register
the position of P2.

7. Press [ENTER] twice to return to the job content display.

8. With the job content display, press [INTERLOCK] + [TEST START] to
execute the SRGAP instruction.
– The manipulator starts searching and stops.
9. Register the manipulator stop position for END_POINT (P3) in the
argument setting display.

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DX100 2.9 Overriding Welding Condition Function

2.9 Overriding Welding Condition Function

2.9.1 Outline
• During welding, each welding condition such as welding current,
welding voltage, speed, weaving single amplitude, and sensing con-
dition can be adjusted individually by using the specific keys shown
below on the programming pendant.
• The adjusted welding conditions can be automatically set for the tag
and condition file attached to the instruction to set the welding condi-
tion such as ARCON and ARCSET. However, when variables are
used for the welding condition or the condition file, this function is
invalid.
• For overriding the welding conditions, the following keys are used.

TUNING

TUNING

• The units for adjusting the welding conditions by pressing the above
keys can be set by the parameters listed in 2.10.5.

2.9.2 Operation
1. Select “WELD CND ADJ” from “UTILITY” in the job playback display
– The welding condition adjustment display appears.

2. Move the cursor to the condition to be adjusted

3. Adjust the condition by using the specific keys
– The welding is executed under the adjusted welding condition.
4. Press [ENTER]
– The adjusted welding condition is overwritten in the condition file of
the job.

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DX100 2.9 Overriding Welding Condition Function

5. Press [CANCEL]
– The job content display appears.

• Only the welding condition data that have been set are
displayed.
For example, when the weaving operation is not set, “***”
is displayed for “WEAV AMPLITUDE.”
NOTE And, when COMARC function is not used, “U/D
CONDITION” and “L/R CONDITION” are not displayed.
• When the instruction such as ARCOF are executed, the
adjustment is disabled and “***” is displayed for each
welding condition.

2.9.3 Welding Condition Adjustment Display

1
2
3
4
5
6

CURRENT
Move the cursor to the data and press the TUNING key to adjust the
welding current value.
The welding current is specified by the following instructions:
• The instruction item (AC=) to ARCON instruction
• The current value set in the welding start condition file (ASF# (*)
specified by ARCON instruction
(When an enhanced type file is used, the data will not be
overwritten.)
• The instruction item (AC=) to ARCSET instruction
• The instruction item (AC=) to ARCCUR instruction
• The set value by AWELD instruction
When ARCOF instruction is executed, the welding current adjustment is
disabled.
When COMARC function is used,  “U/D CONDITION” will be changed
in proportion to the welding current adjustment.
On the contrary, adjusting U/D CONDITION will not change the welding
current value.

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DX100 2.9 Overriding Welding Condition Function

VOLTAGE
Move the cursor to the data and press the TUNING key to adjust the
welding voltage value.
The welding voltage is specified by the following instructions:
• The instruction items (AV=, and AVP=) to ARCON instruction
• The voltage value set in the welding start condition file (ASF# (*))
specified by ARCON instruction
(when an enhanced type file is used, the data will not be overwrit-
ten.)
• The instruction items (AV=, and AVP=) to ARCSET instruction
• The instruction items (AV=, and AVP=) to ARCVOL instruction
• The set value by VWELD instruction
When ARCOF instruction is executed, the welding voltage adjustment is
disabled.

VELOCITY
Move the cursor to the data and press the TUNING key to adjust the
robot motion speed.
The speed is specified by the following instructions:
• The instruction item (V=) to ARCON instruction
• The speed set in the welding start condition file (ASF# (*)) specified
by ARCON instruction
• The instruction item (V=) to ARCSET instruction
• The instruction item (V=) to MOVL (SMOVL), MOVC (SMOVC), or
MOVS (SMOVS) instruction
When ARCOF instruction is executed, the robot motion speed adjust-
ment is disabled.

WEAV AMPLITUDE
Move the cursor to the data and press the specific keys to adjust the
weaving single altitude.
The weaving single altitude is specified by the following instructions:
• The weaving amplitude set in the weaving condition file (WEV# (*))
specified by WVON instruction
• The weaving amplitude set in the weaving condition file (WEV# (*))
specified by COMARCON (SCOMARCON) instruction
• The instruction item (AMP=) to COMARCON (SCOMARCON)
instruction
• The instruction item (AMP=) to COMARCSET (SCOMARCST)
instruction
When COMARCOF (SCOMARCOF) or WVOF instruction is executed,
the weaving amplitude adjustment is disabled.

U/D CONDITION
Move the cursor to the data and press the specific keys to adjust the
sensing condition (upward/downward).
The upward/downward sensing condition is specified by the following
instructions:
• The instruction item (U/D=) to COMARCON (SCOMARCON)
instruction

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DX100 2.9 Overriding Welding Condition Function

• The instruction item (U/D=) to COMARCSET(SCOMARCST)

instruction
When COMARCOF (SCOMARCOF) is executed, the upward/downward
sensing adjustment is disabled.

L/R CONDITION
Move the cursor to the data and press the specific keys to adjust the
sensing condition (left/right).
The left/right side sensing condition is specified by the following
instructions:
• The instruction item (L/R=) to COMARCON (SCOMARCON)
instruction
• The instruction item (L/R=) to COMARCSET (SCOMARCST)
instruction
When COMARCOF (SCOMARCOF) is executed, the left/right side
sensing adjustment is disabled.

DATA EDITING
Indicates whether the edition of a instruction or condition file is
completed or not.
When the conditions set in the instruction or condition file agree with
those set in the welding condition adjustment display, “DONE” is
displayed. When not agree, “UNDONE” is displayed.
During adjustment of the welding conditions by pressing the specific
key, “UNDONE” is displayed, and when [ENTER] is pressed and the
adjusted conditions are registered, “DONE” is displayed.

The welding current and voltage set in the enhanced type

welding condition file can be adjusted by the overriding
NOTE welding condition function, but the data in the welding
condition file will not be overwritten: the data in the welding
condition file will not be replaced by the adjusted data.

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DX100 2.9 Overriding Welding Condition Function

2.9.4 Parameters for the Units to Adjust Conditions

When using the specific keys to adjust a condition, the units for each
condition can be set by the following parameters.
Set the multiplication of the minimum unit of each condition.

Parameter Meanings Initial

Value

S3C1200 The units for adjusting the welding current value (When the specific key is 1
pressed once)
Min. units for the current value: 1 A, Min. units for the command value: 0.01
V

S3C1201 The units for adjusting the welding current value (When the specific key is 1
pressed consecutively)
Min. units for the current value: 1 A, Min. units for the command value: 0.01
V

S3C1202 The units for adjusting the welding voltage value (When the specific key is 1
pressed once)
Min. units for the voltage value: 0.1 V or 1 %, Min. units for command value:
0.01 V

S3C1203 The units for adjusting the welding voltage value (When the specific key is 1
pressed consecutively)
Min. units for the voltage value: 0.1 V or 1 %, Min. units for the command
value: 0.01 V

S3C1204 The units for adjusting the speed (When the specific key is pressed once) 1
Min. units: 1 cm/min

S3C1205 The units for adjusting the speed (When the specific key is pressed 1
consecutively)
Min. units: 1 cm/min

S3C1206 The units for adjusting the weaving single amplitude (When the specific key 1
is pressed once)
Min. units: 0.1 mm

S3C1207 The units for adjusting the weaving single amplitude (When the specific key 1
is pressed consecutively)
Min. units: 0.1 mm

S1E51 The units for adjusting the sensing U/D condition (When the specific key is 1
pressed once)
Min. units: 1 A

S1E52 The units for adjusting the sensing U/D condition (When the specific key is 1
pressed consecutively)
Min. units: 1A

S1E53 The units for adjusting the sensing L/R condition (When the specific key is 1
pressed once)
Min. units: 0.1 A

S1E54 The units for adjusting the sensing L/R condition (When the specific key is 1
pressed consecutively)
Min. units: 0.1 A

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DX100 2.10 Confirm the Welding Operation in Teach Mode

2.10 Confirm the Welding Operation in Teach Mode

2.10.1 Outline
ARCON/ARCOF instructions can be executed by TEST RUN in the teach
mode. By this operation, it is possible to confirm the welding conditions.

2.10.2 Operation
1. Press [WORK] to turn ON the LED
– Press [WORK] and the LED is lit. Press [WORK] again and the LED
is unlit.
2. Execute the test run (execute the welding)
3. Press [WORK] to turn OFF the LED

NOTE If the check run is enabled, turning ON the WORK LED

does not execute the welding.

2.10.3 Display
During the execution of the welding, “ARC” is indicated on the job content
display.
Fig. 2-4: “ARC” Indication During Welding

CAUTION
Executing the test run while “ARC” is indicated on the display executes
the welding.

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DX100 2.11 How to Restart After an Emergency Stop in the Middle of Weaving

2.11 How to Restart After an Emergency Stop in the Middle of

Weaving
If the emergency stop in the middle of weaving, the robot stopped
weaving operation in any position, and simply re-start, the robot runs
through the next step to the position of any origin.
A track when the robot restarted from the stopped position

A track when the robot restarted from the stopped position

Welding line

By the emergency stop, Target step

it stops at any position

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DX100 2.11 How to Restart After an Emergency Stop in the Middle of Weaving
NOTES

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DX100 OPTIONS
INSTRUCTIONS
FOR MULTI-LAYER WELDING FUNCTION

Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO.

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