YRC1000

OPERATOR’S MANUAL
FOR SPOT WELDING USING MOTOR GUN

Upon receipt of the product and prior to initial operation, read these instructions below
thoroughly, and retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”.
The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.

182903-1CD
0

MANUAL NO. RE-CSO-A054

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 DANGER
• This manual explains the various components of the YRC1000
system and general operations. Read this manual carefully and be
sure to understand its contents before handling the YRC1000.
• General items related to safety are listed in “Chapter 1.Safety” of
the YRC1000 INSTRUCTIONS. To ensure correct and safe
operation, carefully read the YRC1000 Instructions before reading
this manual.

CAUTION
• In some drawings in this manual, the protective covers or shields
are removed to show details. Make sure to install all the covers and
shields in place before operating this product.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized
modification voids the product warranty.

NOTICE
• 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 such modification is made, the manual number will
also be revised.
• 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.

ii 2 of 198
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.

Indicates an imminently hazardous

DANGER situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.

Indicates a potentially hazardous

WARNING situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.

Indicates a hazardous situation,

CAUTION which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.

NOTICE is the preferred signal word

NOTICE to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.

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

NOTE to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION”.

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 DANGER
• Before operating the manipulator, make sure the servo power is
turned OFF by performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence. (when in the play
mode or in the remote mode).
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN

• Observe the following precautions when performing a teaching

operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
Read and understand the Explanation of the Warning Labels before
operating the manipulator.

iv 4 of 198
 WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, etc., the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.

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

YRC1000 Controller YRC1000
YRC1000 Programming Pendant Programming Pendant
Cable between the manipulator and the controller Manipulator cable

v 5 of 198
 Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters or its
Pendant /Symbol Keys symbol printed on them are denoted with [ ].
ex. [ENTER]
Axis Keys [Axis Key] and [Numeric Key] are generic
/Numeric 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 The menu displayed in the programming
pendant is denoted with { }.
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 [SELECT] is
pressed, or that the item is directly selected by touching the screen.

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.

vi 6 of 198
 Contents

1 Spot Welding Application Using a Motor Gun................................................................................. 1-1

1.1 System Overview (Motor Gun) .......................................................................................... 1-1

1.2 Function Keys ................................................................................................................... 1-3

1.3 Setting of Motor Gun.......................................................................................................... 1-5

1.3.1 Posture of Motor Gun ........................................................................................... 1-6

1.3.2 Basic Configuration .............................................................................................. 1-6

1.3.3 Setting of Pulse to Stroke Conversion Data ......................................................... 1-6

1.3.4 Tentative Setting of Torque to Pressure Conversion Data ................................... 1-7

1.3.5 Register the Base Position for Wear Detection (Fixed Side)................................ 1-9

1.3.6 Execution of Motor Gun Auto Tuning Function................................................... 1-10

1.3.7 Confirmation of Motor Gun Auto Tuning Operation Status................................. 1-18

1.3.8 Clearance of MOTOR GUN AUTO TUNING Setting.......................................... 1-19

1.3.9 Setting of Torque to Pressure Conversion Data................................................. 1-21

1.3.10 Alarm ................................................................................................................ 1-22

1.4 System Setting (Motor Gun) ............................................................................................ 1-23

1.4.1 Gun Condition File.............................................................................................. 1-23

1.4.1.1 Entering Pulse to Stroke Conversion Data............................................ 1-28
1.4.1.2 Entering Torque to Pressure Conversion Data ..................................... 1-28

1.4.2 I/O Signals for a Motor Gun................................................................................ 1-29

1.4.2.1 Major I/O signal (Motor Gun)................................................................. 1-29
1.4.2.2 Welding I/F File ..................................................................................... 1-31
1.4.2.3 I/O Allocation ......................................................................................... 1-37
1.4.2.4 PSEUDO INPUT SIGNAL Window ....................................................... 1-40

1.4.3 Registering the Operation Tool........................................................................... 1-41

1.4.3.1 When Using a Single Arm Move Gun.................................................... 1-41
1.4.3.2 When Using a Double Arm Move Gun .................................................. 1-42

1.4.4 Setting the Software Limit Value ........................................................................ 1-43

1.4.5 Setting the Lost-tip Detection Value ................................................................... 1-44

1.4.6 Gun Detail Setting File........................................................................................ 1-45

1.4.7 Application Condition Setting.............................................................................. 1-49

1.5 Before Teaching .............................................................................................................. 1-55

1.5.1 Manual Spot ....................................................................................................... 1-55

1.5.2 Manual Dry Spot................................................................................................. 1-55

1.5.3 Manual Press ..................................................................................................... 1-55

1.5.4 Open/Close of Motor Gun................................................................................... 1-56

1.5.5 Mounting Tips ..................................................................................................... 1-56

1.5.6 Creation of Job ................................................................................................... 1-57

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 Contents

1.5.6.1 Job Creating Procedures for Pressure Instruction Registration ............ 1-57
1.5.6.2 Registering Steps .................................................................................. 1-59

1.6 Playback (Motor Gun) ...................................................................................................... 1-60

1.6.1 Check Run .......................................................................................................... 1-60

1.6.2 Execute Welding................................................................................................. 1-60

1.7 Welding Instruction (SVSPOT Instruction)....................................................................... 1-61

1.7.1 Registration of Welding Instruction (SVSPOT Instruction) ................................. 1-61

1.7.2 Setting of Gun Pressure ..................................................................................... 1-62

1.7.3 Welding Current and Welding Time Settings...................................................... 1-65

1.7.4 Gun Stroke Setting before Welding .................................................................... 1-65

1.7.4.1 Setting the Gun Stroke Position ............................................................ 1-65
1.7.4.2 Setting the Gun Stroke Motion Speed ................................................... 1-66
1.7.4.3 Motion Example..................................................................................... 1-66

1.8 Dry Spot (Motor Gun)....................................................................................................... 1-67

1.8.1 Registration of Dry Spot Instruction (SVGUNCL Instruction).............................. 1-67

1.8.2 Dry Spot Pressure Setting .................................................................................. 1-68

1.8.3 Workpiece Transfer Function Using a Motor Gun .............................................. 1-71

1.8.3.1 Operation Flow Chart ............................................................................ 1-71
1.8.3.2 Instruction for Grasping/Releasing Workpieces .................................... 1-72
1.8.3.3 Manual Operation for Grasping/Releasing Workpieces ........................ 1-74

1.9 Manual Pressure.............................................................................................................. 1-75

1.10 Clearance Move Instruction (SVSPOTMOV Instruction) ............................................... 1-78

1.10.1 Operation Flow ................................................................................................. 1-78

1.10.2 Setting the Teaching Type................................................................................ 1-79

1.10.3 Setting the Clearance Files............................................................................... 1-81

1.10.4 Operations for Teaching Welding Points .......................................................... 1-83

1.10.5 Clearance Move Instruction .............................................................................. 1-85

1.10.6 Clearance Move................................................................................................ 1-86

1.10.7 Press Teaching Function .................................................................................. 1-88

1.10.7.1 Operation Flow Chart .......................................................................... 1-88
1.10.7.2 Procedure for Registering the Position................................................ 1-89
1.10.7.3 Setting the Pressure Conditions .......................................................... 1-89
1.10.7.4 Setting the Gun Pushing Coefficient.................................................... 1-90

1.10.8 Work Search Function ...................................................................................... 1-92

1.10.8.1 Operating procedures.......................................................................... 1-92
1.10.8.2 Parameter............................................................................................ 1-93

1.11 Tip Dressing Instruction (SVDRESMOV Instruction) ..................................................... 1-94

1.11.1 Operation Flow ................................................................................................. 1-94

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 Contents

1.11.2 Teaching Type Setting ..................................................................................... 1-95

1.11.3 Tip Dress Condition .......................................................................................... 1-95

1.11.4 Dressing Position Teaching Operation ............................................................. 1-99

1.11.5 Tip Dress Instruction....................................................................................... 1-101

1.11.5.1 Tip Dress Instruction (SVDRESMOV) Flow ...................................... 1-102
1.11.5.2 Suspend and Restart of the Tip Dress Operation ............................. 1-103
1.11.5.3 Individual Control Instruction to a Dresser and a Gun....................... 1-103
1.11.5.4 Wear Detection with Tip Dressing Instruction ................................... 1-105

1.11.6 Dry Tip Dressing Operation ............................................................................ 1-107

1.11.7 Tip Dress Supervision .................................................................................... 1-108

1.12 Tip Wear Detection and Wear Compensation (Motor Gun)......................................... 1-112

1.12.1 Wear Detection and Wear Compensation Operation Flow Chart................... 1-112

1.12.2 Wear Detection............................................................................................... 1-113

1.12.2.1 Dry Spot Touch Motion...................................................................... 1-113
1.12.2.2 Movable Side Tip Detection .............................................................. 1-114
1.12.2.3 Example of Wear Detection .............................................................. 1-115

1.12.3 Spot Supervision Window Setting .................................................................. 1-116

1.12.4 Wear Compensation....................................................................................... 1-121

1.12.5 Tip Wear Compensation for Fixed Gun .......................................................... 1-122

1.12.5.1 Setting the User Coordinates ............................................................ 1-122
1.12.5.2 User Coordinate Number Setting ...................................................... 1-123
1.12.5.3 Example of Compensation ................................................................ 1-124

1.12.6 Teaching Positions with a Worn Tip ............................................................... 1-125

1.12.6.1 Teaching Example ............................................................................ 1-125
1.12.6.2 Parameters........................................................................................ 1-125

1.12.7 Wear Amount Loading.................................................................................... 1-126

1.12.8 Tip Mounting Position Error Detection............................................................ 1-127

1.12.8.1 Tip Mounting Position Error Detection Flow Chart ............................ 1-128
1.12.8.2 Tip Mounting Position Error Detection............................................... 1-130
1.12.8.3 Job Examples.................................................................................... 1-132
1.12.8.4 Importing the Tip Mounting Position Error......................................... 1-133
1.12.8.5 Monitoring the Failure of Mounting Tips ............................................ 1-136

1.13 Other Functions Using a Motor Gun ............................................................................ 1-137

1.13.1 Motor Gun Stroke ........................................................................................... 1-137

1.13.1.1 Registering the Full-open/Short-open Position.................................. 1-137
1.13.1.2 Registering the current position......................................................... 1-138
1.13.1.3 Registering by entering a numerical value ........................................ 1-138
1.13.1.4 Moving to Full-open/Short-open Position .......................................... 1-139
1.13.1.5 Moving to Full-open/Short-open Position While Other Window
is Displayed ........................................................................................ 1-139

1.13.2 Gun Change ................................................................................................... 1-140

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 Contents

1.13.2.1 Gun Change Instruction .................................................................... 1-140

1.13.2.2 Signal Status to Execute GUNCHG Instruction................................. 1-140
1.13.2.3 Gun Change Job .............................................................................. 1-142
1.13.2.4 Gun Changing Timing........................................................................ 1-144

1.13.3 Touch Teaching Function ............................................................................... 1-145

1.13.3.1 Setting the Workpiece Thickness ...................................................... 1-145
1.13.3.2 Registering and Confirming Positions by Touch Teaching................ 1-148

1.13.4 Signal Dry Spot............................................................................................... 1-149

1.13.4.1 Setting an Input Signal Number......................................................... 1-149

1.13.5 Gun Pressure Compensation Function........................................................... 1-151

1.13.5.1 Operation Flow Chart ........................................................................ 1-151
1.13.5.2 Overview ........................................................................................... 1-152
1.13.5.3 Setting the Pressure Compensation Value........................................ 1-155

1.13.6 Compensation of Gun Arm Bend for C-Gun and X-Gun

(SINGLE ARM MOVE) ..................................................................................... 1-157
1.13.6.1 Setting the Gun Arm Bend Compensation Coefficient ...................... 1-157
1.13.6.2 Compensation Example .................................................................... 1-158
1.13.6.3 Disabling Gun Arm Bend Compensation........................................... 1-159

1.13.7 Welding Conditions Group Output Function ................................................... 1-160

1.13.7.1 Operation Flow Chart ........................................................................ 1-160
1.13.7.2 Procedure for Assigning the Group Output Signal ............................ 1-160
1.13.7.3 Setting the Group Output Tag ........................................................... 1-162
1.13.7.4 Group Output..................................................................................... 1-163

1.13.8 Workpiece Thickness Detection Function....................................................... 1-164

1.13.8.1 Outline ............................................................................................... 1-164
1.13.8.2 Instruction .......................................................................................... 1-165
1.13.8.3 Operation Procedures ....................................................................... 1-166
1.13.8.4 Related Functions ............................................................................. 1-176
1.13.8.5 Notes ................................................................................................. 1-178

1.13.9 Automatic Tool Number Select Function for Guns ......................................... 1-179
1.13.9.1 Setting of Validating the Function...................................................... 1-179
1.13.9.2 Setting of Tool Number...................................................................... 1-179

1.14 Loading the DX100 Motor Gun Condition File ............................................................. 1-180

1.15 The Instruction List (Motor Gun) .................................................................................. 1-185

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 1 Spot Welding Application Using a Motor Gun
1.1 System Overview (Motor Gun)

1 Spot Welding Application Using a Motor Gun

1.1 System Overview (Motor Gun)

An I/O signal diagram of a typical system is shown below.

Fig. 1-1: Spot Welding System I/O Signal Diagram

WELDING
Controller CONDITION Power
(8 bits max.) Source

WELDING
COMMAND

WELDING
COMPLETE

WELDING
ERROR

WELDING
ERROR RESET

WELD ON/OFF

Welding motor gun

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1 Spot Welding Application Using a Motor Gun
1.1 System Overview (Motor Gun)

• Welding conditions (level signals)

• Sets the welding conditions for the welder.
• The output format can be set as binary or discrete.
• Can handle up to 255 conditions in binary.

8 bits
128 64 32 16 8 4 2 1
(8) (7) (6) (5) (4) (3) (2) (1)
The numbers in parentheses are for discrete.

• WELDING COMMAND (level/pulse)

Outputs the start instruction to the welder.
• WELDING ERROR RESET(level)
Resets the welding alarm status of the welder.

SUPPLE-
For details on signal contents, refer to chapter 1.4.2.2
MENT Welding I/F File.

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 1 Spot Welding Application Using a Motor Gun
1.2 Function Keys

1.2 Function Keys

Each function used for spot welding is allocated on the [NUMERIC KEY]s
of the programming pendant.

Displays the MANUAL PRESS window.

Displays the WORK HOME POSITION window.

[FWD] + [TASK ORIGIN]

With the WORK HOME POSITION window in the teach
mode, press these keys to move the manipulator to the
work home position.
Displays the SVSPOT instruction in the input buffer line in
order to register spot welding operation.

[INTERLOCK] + [SPOT]
With the MANUAL PRESS window, press these keys to
execute manual spot welding.
Displays the SVGUNCL instruction in the input buffer line in
order to register dry spot welding operation.

[INTERLOCK] + [GUN CLOSE]

With the MANUAL PRESS window, press these keys to
execute manual dry spot welding.
[INTERLOCK] + [WELD ON/OFF]
Turns the welding ON/OFF signal ON or OFF.

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1 Spot Welding Application Using a Motor Gun
1.2 Function Keys

The SHORT OPEN POSITION SETTING window appears

the first time this key is pressed.
The selection No. for the short open position is replaced by
pressing this key while the SHORT OPEN POSITION
SETTING window is appeared.

[INTERLOCK] + [SHORT OPEN]

The movable side tip moves to the selected short open
position.
The FULL OPEN POSITION SETTING window appears the
first time the key is pressed.
The selection No. for the full open position is replaced by
pressing this key while the FULL OPEN POSITION
SETTING window is appeared.

[INTERLOCK] + [FULL OPEN]

The movable side tip moves to the selected full open
position.
[INTERLOCK] + [WELD ALM RST]
A welder alarm reset signal is output to the welder while
these keys are held down.

[INTERLOCK] +[PRESSURE]
With the MANUAL PRESS window or the JOB window,
press these keys to execute pressurizing.

[INTERLOCK] +[RELEASE]
Executes releasing.

[INTERLOCK]+ [SEARCH]
Executes searching a work.

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 1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

1.3 Setting of Motor Gun

Set up the motor gun by following the procedures below. The dynamic
characteristics of the motor gun need to be automatically identified by the
Motor Gun Auto Turning function so that the pressurization is executed by
the optimum pressure torque instruction for the each motor gun.
Before execution of Motor Gun Auto Turning function, procedures
described in the chapters from chapter 1.3.1 "Posture of Motor Gun" to
chapter 1.3.5 "Register the Base Position for Wear Detection (Fixed
Side)" are necessary.
After execution of Motor Gun Auto Turning, register the base position for
the wear detection again because of the changes of the detection
accuracy.

Prepare for Motor-Gun Auto Tuning operation

Set the posture of the motor gun
for pressing downward
(Refer to Chap. 1.3.1)

Basic configration of Gun Condition file

(Refer to Chap. 1.3.2)

Setting of the conversion data from

pulse to stroke
(Refer to Chap. 1.3.3)

Tentative setting of
the conversion data from torque to pressure
(Refer to Chap. 1.3.4)

Register the base position for

wear detection (fixed side)
(Refer to Chap. 1.3.5)

Execution of Motor-Gun Auto Tuning

(Refer to Chap. 1.3.6)

Setting of the conversion data from torque to pressure

(Refer to Chap. 1.3.9)

Register the base position for

wear detection (fixed side)
(Refer to Chap.1.3.5)

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 1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

When executing the welding instruction, the weld complete

signal may be already turned ON at the beginning of the
welding instruction. At that time, "AL4621: WELD COM-
PLETE SIGNAL ERROR" may occur.
To prevent the alarm, set the item "WELD COMPLETE OFF
NOTE WAIT TIME" in chapter chapter 1.4.7 "Application Condi-
tion Setting". Setting the item allows the controller to wait a
set time until the weld complete signal is turned OFF.
Also, the alarm can be prevented by adjusting the output
pulse time of the weld complete signal by the welder.Please
contact to the welder manufacturer if they allows changing
the output pulse time.

1.3.1 Posture of Motor Gun

Set up the motor gun to the posture shown in the figure below.

downward
Direction to press

1.3.2 Basic Configuration

By referring to chapter 1.4.1 "Gun Condition File", set up the following
items in the Gun Condition file.
• GUN TYPE
• WELDER NO.
• TORQUE DIR
• MAX PRESSURE

1.3.3 Setting of Pulse to Stroke Conversion Data

Refer to chapter 1.4.1.1 Entering Pulse to Stroke Conversion Data for
this setting.

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 1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

1.3.4 Tentative Setting of Torque to Pressure Conversion Data

In order to use Motor Auto Tuning function, it is necessary to set the
torque to pressure conversion data of the Gun Condition file tentatively.
Normally, the tentative setting is already set. Therefore, confirm that
pressing can be done correctly by the maximum pressure and half of the
maximum pressure.
If the tentative setting is not set, set the gun motor torque at the maximum
pressure and half of the maximum pressure as shown in the following
procedures.

<Ex. when the maximum pressure is 6000(N)>

Find and set the torques(%) at 6000(N) and 3000(N)

1. Set a value to {THICKNESS FORCE GAUGE} and select “ENABLE” at

{PRESS MEASUREMENT MODE} on the “MANUAL PRESS” window.

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1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

2. Set the pressure value to the pressure file.

– As the unit of this pressure, specify torque(%).
– Specify 5(%) to the touch speed of the pressure file.
3. Register SVGUNCL instruction to a JOB.
– Specify the pressure file set at the step 2.
4. Execute the JOB and measure the pressure with the force gauge.
5. Execute the above procedures 2 through 4 with the different toque(%)
to find a toque(%) for the pressure to be maximum.
6. Execute the above procedures 2 through 4 with the different toque(%)
to find a torque(%) for the pressure to be half of the maximum one.
7. Set torques (%) for both maximum and half of the maximum pressure.
And then, change the SETTING from “NOT DONE” to “DONE”.

Pressurization will not be executed in case the Gun Condi-

tion file is incomplete.
NOTE
When applying the pressure for the first time, set a tentative
value to the Gun Condition file.

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 1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

1.3.5 Register the Base Position for Wear Detection (Fixed Side)
Register the base position for wear detection by following the procedures
below.

Mount a new tip

Clear the base position

for the wear detection.
(Refer to Chap 1.12.3)

Register a base position

by dry spotting touch motion.
(Refer to Chap. 1.12.2.1)

In case a gun is shipped with the manipulator, the base

position for the wear compensation (fixed side) setting is
done.
5% is set to touch speed and 1000N is set to the pressure
as its initial condition for the gun shipped with the manipula-
tor.
NOTE
In this consequence, when the wear detection is executed,
W

follow the conditions described above (touch speed: 5%,

pressure: 1000N).
When modifying those values, clear the base position for
the wear compensation data and register the new base
position again.

Execute the wear detection operation. If the wear detection

NOTE operation is not done, the stable pressure cannot be
acquired.

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 1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

1.3.6 Execution of Motor Gun Auto Tuning Function

By referring to the following procedures, execute Motor Gun Auto Tuning.
This function automatically repeats applying pressure to identify the
dynamic characteristics parameter of the motor gun.
This identification takes 5 to 10 minutes.

NOTE Before execution of the auto tuning operation, assure the

safety.

Before the execution of the auto tuning operation, confirm

NOTE that the center of both gun tips matches well at the contact
position because tips are pressed at maximum pressure by
the dry spotting motion during the auto tuning operation.

After the execution of Motor Gun Auto Turning function, do

NOTE not fail to re-measure the pressure and reset the torque to
pressure conversion data.

An alarm “4708: Motor Gun Auto Tuning incomplete”

occurs, in case SVSPOT instruction is executed while Motor
NOTE Gun Auto Tuning is in incomplete status.
Be sure to execute the Motor Gun Auto Tuning function.

1. Select {SPOT WELDING} on the {Main Menu}.

2. Select {MOTOR GUN AUTO TUNING}.
– The MOTOR GUN AUTO TUNING window appears.

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1 Spot Welding Application Using a Motor Gun
1.3 Setting of Motor Gun

3. Select the gun number using [PAGE] or {PAGE}.

4. Change the mode to the play mode, and then press [SERVO ON
READY] .
– The servo power is turned ON, then {EXECUTE} button appears.

– When pressing the start button on the programming pendant while

the MOTOR GUN AUTO TUNING window is appeared, the following
confirmation dialog appears. Select “NO” to execute the Motor Gun
Auto Tuning.

If pressing the [START] button after selecting the “YES” in

NOTE the confirmation dialog, the JOB will be played back.
Do not press the [START] button unintentionally.

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5. Press {EXECUTE} button.

– If the wear compensation has not been executed, the confirmation
dialog to prompt performing the wear compensation will appear.
Refer to chapter 1.3.5 "Register the Base Position for Wear
Detection (Fixed Side)", and execute the wear compensation.

– If the wear compensation has been executed, the confirmation

dialog to execute the Motor Gun Auto Tuning will appear.

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6. Select “YES” in the dialog box.

– The MOTOR GUN AUTO TUNING operation is executed.

– The status of MOTOR GUN AUTO TUNING operation can be

confirmed by the SPECIFIED OUTPUT signal (#50906).
• Select {IN/OUT} under the {Main Menu}.
• Select {SPECIFIED OUTPUT}.
• Press [PAGE], {PAGE}, or the select button to indicate-
SOUT#0719(#50906).
• This signal is turned ON during the MOTOR GUN AUTO TUNING
operation.

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During the MOTOR GUN AUTO TUNING operation, the fol-

lowing operations are not available:
• Moving to other windows
• Key operation
• Operations by the start button
• External start operation
• IO JOG operation
• Work home position return operation
• Operations by the moving type command of the data
NOTE transmitting function
<During the MOTOR GUN AUTO TUNING operation>
Seeing the dialog “Do you carry out motor gun auto” after
pressing the {EXECUTE} button on the MOTOR GUN
AUTO TUNING window is the start of this operation, and
the end of this operation is pressing the button to close the
dialog “Motor gun auto tuning was completed” or the dialog
“Result of tuning had abnormalities.”.
Also, it is defined as “during the MOTOR GUN AUTO TUN-
ING operation” while the dialog “Do you continue motor gun
auto tuning?” is displayed after Hold is executed while exe-
cution of this function.

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– The MOTOR GUN AUTO TUNING operation is stopped or

suspended in case one of the following operation is executed.
{Stop: Impossible to continue}
• Emergency stop
• Mode change
– When the operation is stopped, the MOTOR GUN AUTO TUNING
operation finishes incompletely.
{Suspend: Possible to continue}
• Hold operation
– When it is suspended (by Hold operation), a confirmation dialog box
appears to ask “CONTINUE” or” SUSPEND”.

– Select “CONTINUE” to continue the operation.

– Select “SUSPEND” and the MOTOR GUN AUTO TUNING operation
finishes incompletely.

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– After MOTOR GUN AUTO TUNING operation is successfully done,

a confirmation dialog box for registration appears as shown in the
figure below. Then, move to step 8.

– In case there is a possibility of false detection of touch due to high

friction torque of the gun, a dialog box appears as shown in the
figure below to notify an error in MOTOR GUN AUTO TUNING
operation. Then, move to step 7.

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7. Select “OK”.
– A message “The false detection of touch may occur by friction
torque of motor gun. Check the factor of high friction torque.”
appears.

– If no failure is found to the gun, set the touch pressure a higher

value than the value of friction torque value. Then, start the MOTOR
GUN AUTO TUNING operation from the step 4 again. For the
setting of touch pressure, refer to chapter 1.4.6 "Gun Detail
Setting File".
8. Select “REGIST”.
– {STATUS} on the window changes from {INCOMPLETE} to
{COMPLETE}. The date is registered to {ENFORCEMENT DAY}.

– If “CANCEL” is selected, the MOTOR GUN AUTO TUNING

operation does not complete.

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The result of the MOTOR GUN AUTO TUNING operation is

stored in the MOTOR GUN AUTO TUNING file.

NOTE And the MOTOR GUN AUTO TUNING file is stored in FILE/
GENERAL DATA.
Please do not load MOTOR GUN AUTO TUNING file to
other controllers.

1.3.7 Confirmation of Motor Gun Auto Tuning Operation Status

1. Select {SPOT WELDING} under the {Main Menu}.
2. Select {MOTOR GUN AUTO TUNING}.
– The MOTOR GUN AUTO TUNING window appears.
3. Select the gun number using [PAGE] or {PAGE}.
– The operation is completed if {COMPLETE} is indicated at
{STATUS}.
– The operation is not completed if {INCOMPLETE} is indicated at
{STATUS}.

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1.3.8 Clearance of MOTOR GUN AUTO TUNING Setting

When re-setting the gun condition file due to the change of the gun, etc,
clear the Motor Gun Auto Tuning setting by following the procedures
below.
1. Select {SPOT WELDING} under the {Main Menu}.
2. Select {MOTOR GUN AUTO TUNING}.
– The MOTOR GUN AUTO TUNING window appears.
3. Select the gun number using [PAGE] or {PAGE}.
4. Select {DATA} - {CLEAR DATA].

– A confirmation dialog box appears.

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5. Select “YES”.
– {STATUS} changes from {COMPLETE} to {INCONPLETE}.
– The data will not be deleted if “NO” is selected.

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1.3.9 Setting of Torque to Pressure Conversion Data

After the execution of Motor Gun Auto Turning function, by following the
procedure below, re-measure the pressure and reset the torque to
pressure conversion data.
1. Set a value to {THICKNESS FORCE GAUGE} and select “ENABLE” at
{PRESS MEASUREMENT MODE} on MANUAL PRESS window.

2. Set the pressure value to the pressure file.

– As the unit of this pressure, specify torque(%).
– Specify 5(%) to the touch speed of the pressure file.
3. Register SVGUNCL instruction to a JOB.
– Specify the pressure file set at the step 2.
4. Execute the JOB and measure the pressure with the force gauge.
5. Execute the above procedures 2 through 4 with the different torque(%)
to measure a torque(%) for the pressure.
6. Input the acquired data to “Torque to pressure conversion” in the gun
condition file. Up to 12 data can be registered.

On MANUAL PRESS window, set a value to {THICKNESS

FORCE GAUGE} and select “ENABLE” to {PRESS MEA-
SUREMENT MODE}.
NOTE The PRESS MEASUREMENT MODE becomes “UNABLE”
in case the mode is changed from the teach mode to the
play mode. Set “ENABLE” again when the mode is
changed.

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1.3.10 Alarm
Alarm Message Cause Remedy
No.
4708 Motor Gun Auto Tuning Motor Gun Auto Tuning operation Motor Gun Auto Tuning function by
is not executed is not executed but SVSPOT following the procedures below.
instruction is executed 1. Select {SPOT WELDING} -
{MOTOR GUN AUTO
TUNING}.
2. Change the mode to the play
mode, turn the servo power
ON, and then press
{EXECUTE} button.
3. Select “REGIST” after Motor
Gun Auto Tuning operation is
completed.
4. After Motor Gun Auto Tuning
function, do not fail to re-
measure the gun pressure and
reset the torque to pressure
conversion data.

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1.4 System Setting (Motor Gun)

The items to be determined at the system setting, such as the gun and the
welder, are specified in the system setting files.

1.4.1 Gun Condition File

The gun characteristics are set in the gun condition file.

 Gun Condition Window

1
2
3
4
5

7
6

8
9
10

11
12
13
14
15
16

17

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1. GUN NO.
Shows the No. of the gun to be used.
When using two guns or more, select the No. by pressing [PAGE].
2. SETTING
Shows whether the gun condition file has been set or not. For the file
where the values have not been entered, “NOT DONE” appears, while
for the file where the values have already been entered, “DONE”
appears.
3. GUN TYPE
Shows the gun type. Select from “C-GUN,” “X-GUN (SINGLE ARM
MOVE)” and “X-GUN (DOUBLE ARM MOVE).”
4. WELDER NO.
Shows the No. of the connected welder.
5. TORQUE DIR
Specifies the pressure direction of the gun axis motor. When the direc-
tion to increment the motor encoder value and the pressure direction of
the gun are the same, select “+”. When they are different, select “-”.
6. PULSE, STROKE
Shows the relationship between the encoder pulse value of the gun axis
motor and the gun stroke. The pulse value for the specified gun stroke
can be calculated by interpolation of these values. Refer to
chapter 1.4.1.1 Entering Pulse to Stroke Conversion Data for more
details.
7. TORQUE, PRESSURE
Shows the relationship between the gun axis motor torque and the tip
pressure. The torque value for the specified pressure can be calculated
by interpolation of these values. Refer to chapter 1.4.1.2 Entering
Torque to Pressure Conversion Data for more details.
8. MAX PRESSURE
Enter a maximum pressure that the gun can apply.
If the value specified by the pressure file exceeds it, an alarm occurs
when executed.
In the teach mode, the torque is restricted by the maximum pressure.
In case an appropriate value is specified to the maximum pressure, an
alarm “4328 SERVO TRACKING ERROR” or “1303 ARITHMETIC
ERROR (SERVO)” may occure in the teach mode.
9. PRESSURE COMPENSATION
Set the difference of the pressure between the upwards and the down-
wards.
Refer to chapter 1.13.5 "Gun Pressure Compensation Function"for
the details.
10. GUN ARM BEND COEF.
Set the gun arm bend compensation volume per 1000N.
Refer to chapter 1.13.6 "Compensation of Gun Arm Bend for C-Gun
and X-Gun (SINGLE ARM MOVE)" for the details.
11. GUN PUSHING COEF
Set the gun axis pushing volume per 1000N.
Refer to chapter 1.10.7.4 Setting the Gun Pushing Coefficient for the
details.

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12. GUN INSTALLATION STATUS

Set the gun installation status.
Select “ROBOT-HANDLE” or “FIXED”.
13. TOOL NO.
Displayed after validating the “AUTO TOOL. NO. SELECT FOR GUN”
on the APPLICATION CONDITION SETTING window when “12.GUN
INSTALLATION STATUS” is “ROBOT-HANDLE”.
Refer to chapter 1.13.9 "Automatic Tool Number Select Function for
Guns".
14. USER COORDINATE NO.
Displayed when “12.GUN INSTALLATION STATUS” is ”FIXED”.
Set the user coordinate No. for the gun to use. Refer to
chapter 1.4.7 "Application Condition Setting".
15. MOVEMENT RATIO AFTER CLOSE (LOW) (displayed only
when “X-GUN (DOUBLE ARM MOVE)” is selected)
Shows the lower tip movement ratio when the gun closes more by the
tip wear. Enter 60% when the ratio of upper tip movement: the lower
tip movement = 4:6.
16. MOVEMENT RATIO IN SENSING (UP) (displayed only
when “X-GUN (DOUBLE ARM MOVE)” is selected)
Shows the ratio when the upper side tip passes the sensor, for
detecting the upper side tip wear using a sensor. Enter 70% when the
ratio of the upper side tip movement: the lower side tip movement =
7:3.
17. COMPLETE
Press this button to complete “2. SETTING”.

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 Operation

1. Select {SPOT WELDING} from the main menu.

2. Select {GUN CONDITION}.

– GUN CONDITION window appears.

3. Select a gun No. by pressing [PAGE].

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4. Select the item to be set.

– For “GUN TYPE,” pressing [SELECT] displays “C-GUN,” “X-GUN
(SINGLE ARM MOVE)” and “X-GUN (DOUBLE ARM MOVE)”
alternately.

5. Enter the numerical value, and press [ENTER].

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1.4.1.1 Entering Pulse to Stroke Conversion Data

To specify the gun stroke in mm, enter data about the relationship
between the gun axis motor encoder pulse value and the gun stroke
(mm).
Follow the procedures explained below.
Up to 12 points of data can be entered.
1. Set the applicable gun stroke by a jog operation with the programming
pendant.
– Read the pulse value of the gun axis motor encoder on the
programming pendant.
2. Repeat the steps 1 for 12 points in total.
– When the relationship between two values are known from the
machine drawing, calculate the data for the 12 points.
3. Enter the obtained data of 12 items in “PULSE” and “STROKE” in the
gun condition file.

1.4.1.2 Entering Torque to Pressure Conversion Data

To specify the pressure in N, enter data about the relationship between
the gun axis motor torque (%) and the pressure (N).
Refer to chapter 1.3.9 "Setting of Torque to Pressure Conversion Data"
for setting procedures.

When the gun condition file has not been set, the pressure
cannot be applied.
NOTE
When applying the pressure for the first time, set any value
in the gun condition file.

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1.4.2 I/O Signals for a Motor Gun

1.4.2.1 Major I/O signal (Motor Gun)

Table 1-1: Input Signals to YRC1000

Signal Contents To Standard Setting Display
Setting
WELD COMPLETE Shows that the welder completed Welder IN13 Welder I/F
the welding normally. Used as a Refer to
confirmation signal for welding instruction chapter 1.4.2.2
(SVSPOT, SVSPOTMOV) and manual spot
welding.
After this signal is input, the welding
sequence is completed, and the operation
moves to the next step.
DRY TIP DRESS Use to perform the TIP DRESS instruction Interlock Unused I/O Allocation
(WITHOUT PRESSING) (SVDRESMOV) without pressing or board, etc. Refer to
DRY TIP DRESS dressing. chapter 1.4.2.3
(WITHOUT DRESSING)
TMR COOL WTR ERR Monitors an abnormal state of the cooling Cooling water IN9 Pseudo Input
water for the welder. When this signal is flow switch Signal
input, an alarm occurs to stop the Refer to
manipulator. The servo power supply stays chapter 1.4.2.4
ON.
GUN COOL WTR ERR Monitors an abnormal state of the cooling Cooling water IN10 Pseudo Input
water for the gun. When this signal is input, flow switch Signal
an alarm occurs to stop the manipulator. Refer to
The servo power supply stays ON when the chapter 1.4.2.4
alarm occurs.
TRANS THERMO ERR This alarm signal from the gun transformer Gun IN11 Pseudo Input
is input directly into the DX100. This signal transformer Signal
is normally ON (normally closed) and when Refer to
it is OFF, an alarm occurs. The servo chapter 1.4.2.4
power supply stays ON when the alarm
occurs.
WELD ON/OFF Inputs the WELD ON/OFF selector switch Interlock #20022 Pseudo Input
(from PLC) status from a PLC such as the interlock board, etc. Signal
board. The WELD ON/OFF signal is output Refer to
to the welder according to this signal and chapter 1.4.2.4
the manipulator status. When this signal is
input (ON), the state of the WELD ON/OFF
signal to the welder becomes OFF, and
welding is not done.

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Table 1-2: Output Signals from YRC1000

Signal Contents To Standard Setting Window
Setting
WELDING Sets the welding conditions for the welder. Welder 4 bits Welder I/F
CONDITION • The output format can be set as binary or from Refer to
(LEVEL signals) discrete (bit number.) OUT11 chapter 1.4.2.2
1 (1)
2 (2) • Can handle up to 255 conditions. The most
4 (3) significant bit is the parity bit when specified.
8 (4)
16 (5)
32 (6) OUT19
64 (7) OUT20
128 (8) OUT21
OUT21
WELDING Unused
CONDITION
PARITY
WELDING Outputs the start command to the welder. This Welder Unused Welder I/F
COMMAND command is NOT necessary for the welder which uses Refer to
the WELDING CONDITION signal as a start signal. chapter 1.4.2.2
WELDING Resets the error status in the welder. Welder OUT18 Welder I/F
ERROR Outputs by “INTERLOCK” + “WELD ALM RST”. Refer to
RESET chapter 1.4.2.2
WELD ON/OFF Outputs the status of the input signals from the interlock Welder OUT17 Welder I/F
board by considering the robot status. Refer to
chapter 1.4.2.2

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1.4.2.2 Welding I/F File

The welder characteristics are set in the welding I/F file.

2
3

4
5
6
7
8
9
10
11
12
13

1. WELDER NO.
Shows the number of the welder to be used.
When using two welders or more, select the welder No. by pressing
[PAGE].
2. WELD COMPLETE
Indicates the signal that welding is completed normally.
This signal is used to confirm the completion of the welding when exe-
cuting the welding instruction (SVSPOT, SVSPOTMOV) or the manual
spot.
After this signal is input, the welding sequence is completed, and the
operation moves to the next step.
3. WELD COMPLETE WAIT TIME
Set the wait time from the start of the welding instruction (SVSPOT,
SVSPOTMOV) or the manual spot to the inputting the WELD COM-
PLETE signal.
4. WELDING ERROR RESET
Resets the error status in the welder. Outputs by [INTERLOCK] +
[WELD ALM RST].
5. WELDING CONDITION
Outputs the welding condition signal to the welder.
The set welding condition No. (set at WTM tag) is outputted through the
signal set in this item when executing the welding instruction (SVSPOT,
SVSPOTMOV) or the manual spot.
6. WELD COND OUTPUT FORMAT
Set the output format of the welding condition.
Select “BINARY” or “DISCRETE”.
7. WELD COND OUTPUT TYPE
Set the output type of the welding condition signal.
Select “LEVEL”, “PULSE” or “START SIGNAL”.
Refer to Welder Start Timing .

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8. WELD COND OUTPUT TIME

When the WELD COND OUTPUT TYPE is “PULSE” or “START SIG-
NAL”, the welding condition signals are turned ON for the time specified
at this item.
Refer to Welder Start Timing .
9. WELD COND MAX NUM
Set the maximum number of the welding condition.
If the greater value than this setting is set as the WELDING CONDI-
TION (WTM tag) the value will not be outputted through the welding
condition signals.
10. WELDING CONDITION PARITY
The parity signal for the WELDING CONDITION.
When executing the welding instruction (SVSPOT, SVSPOTMOV) or
the manual spot, the value of WELDING CONDITION PARITY and
WELDIG CONDITION are outputted at the same time.
Settings of the odd/even number parity is performed using the parame-
ter. (For the details, refer to “ YRC1000 GENERAL OPERATOR’S
MANUAL (RE-CSO-A051) 8.10.3.4 AxP006: PARITY SPECIFICATION
FOR WELDING CONDITIONS”.)
11. WELDING COMMAND
The welding command signal to the welder.
This signal is output when executing the welding instruction (SVSPOT,
SVSPOTMOV) or the manual spot.
Setting is unnecessary when WELD CONDITION functions as wellder
start instruction.
12. WELD GROUP OUTPUT
The weld group output signal for the welder.
The set welding group output No. (set at WGO tag) is outputted through
the setting signal in this item when executing the welding instruction
(SVSPOT, SVSPOTMOV) or the manual spot.
Refer to chapter 1.13.7 "Welding Conditions Group Output Function".
13. STICK DETECT DELAY TIME
Set the sticking detect delay time.
An alarm occurs if the gun does not open for more than the setting time
because the gun has stuck when execute the welding instruction
(SVSPOT, SVSPOTMOV) or the manual spot.

Be sure that the allocated user signals are not used in the
NOTE any JOBs. If the same signals are used in the JOBs, mal-
functions will result.

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 Welder Start Timing

• When the weld cond output type is set to “LEVEL”:

1st pressurization 2nd pressurization

Open
Speed command
Torque command
Speed commnad

& Torque command

Close t

Weld
Complete

When WST=0
Welding
Condition

Welding
Command

t
When WST=1

Welding
Condition

Welding
Command

When WST=2

Welding
Condition

Welding
Command

SUPPLE-
As for WST(welder start timing), refer tochapter 1.7 Welding
MENT Instruction (SVSPOT Instruction).

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• When the weld cond output type is set to “PULSE”:

1st pressurization 2nd pressurization

Open
Speed command
Torque command
Speed commnad

& Torque command

Close t

Weld
Complete

t
Weld Cond
Output Time
When WST=0
Welding
Condition

t
Welding
Command

t
When WST=1 Weld Cond
Output Time

Welding
Condition

Welding
Command

Weld Cond
When WST=2 Output Time

Welding
Condition

Welding
Command

SUPPLE-
As for WST(welder start timing), refer to chapter 1.7 Welding
MENT Instruction (SVSPOT Instruction).

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• When the weld cond output type is set to “START SIGNAL”:

1st pressurization
2nd pressurization
Open
Speed command
Speed commnad Torque command

& Torque command

Close t

Weld
Complete

t
Weld Cond
When WST=0 Output Time

Welding
Condition

t
Welding
Command

t
When WST=1

Welding
Condition

Welding
Command

When WST=2

Welding
Condition

Welding
Command

SUPPLE-
As for WST(welder start timing), refer to chapter 1.7 Welding
MENT Instruction (SVSPOT Instruction).

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 Operation

1. Select {SPOT WELDING} from the main menu.

2. Select {WELDER IF}.

– The WELDER IF window appears.

3. Select a welder No. by pressing [PAGE].

4. Select the item to be set.
5. Enter a numerical value, and press [ENTER].

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1.4.2.3 I/O Allocation

 I/O Allocation Window

1
2
3
4
5

1. DRY TIP DRESS (WITHOUT PRESSING)

Use this signal to execute the tip dresser instruction (SVDRESMOV)
without pressure of the gun.
Refer to chapter 1.11.6 "Dry Tip Dressing Operation".
2. DRY TIP DRESS (WITHOUT DRESSING)
Use this signal to execute the tip dresser instruction (SVDRESMOV
instruction) without dressing.
Refer to chapter 1.11.6 "Dry Tip Dressing Operation".
3. GUN CHUCK (WELDER1)
Displayed when the gun change function is valid.
Also, shows the item(s) according to the number of the welders.
Use this signal to confirm the connection of the gun. In general, allocate
the chuck confirmation signal of ATC.
Refer to chapter 1.13.2 "Gun Change".
4. GUN UNCHUCK (WELDER1)
Displayed when the gun change function is valid.
Also, shows the item(s) according to the number of the welders.
Use this signal to confirm the disconnection of the gun. In general, allo-
cate the unchuck confirmation signal of ATC.
Refer to chapter 1.13.2 "Gun Change".
5. GUN ID NO. (WELDER1)
Displayed when the gun change function is valid.
Also, shows the item(s) according to the number of the welders.
This signals are binary signals to confirm the gun number.
Refer to chapter 1.13.2 "Gun Change".
6. GUN UNCHUCK REQUEST (WELDER1)
Displayed when the gun change function is valid.
Also, shows the item(s) according to the number of the welders.
Use this signal to disconnect the gun. In general, allocate the unchuck
signal of ATC. (Chuck=OFF, Unchuck=ON)
Refer to chapter 1.13.2 "Gun Change".

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 Operation
1. Select {SPOT WELDING} from the main menu.
2. Select {I/O ALLOCATION}.

– The I/O ALLOCATION window appears.

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3. Select the signal No. to be set.

– The number can now be entered.

4. Enter the numerical value and press [ENTER].

Be sure that the allocated user signals are not used in the
NOTE any JOBs. If the same signals are used in the JOBs, mal-
functions will result.

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1.4.2.4 PSEUDO INPUT SIGNAL Window

The following signals can be validated in the PSEUDO INPUT SIGNAL
window.
• TMR COOL WTR ERR (timer cooling water error)
• GUN COOL WTR ERR (gun cooling water error)
• TRANSTHERMO ERR (transformer thermostat error)
• WELD ON/OFF (welding ON/OFF)
1. Select {IN/OUT} from the main menu.
2. Select {PSEUDO INPUT SIG}.

– The PSEUDO INPUT SIGNAL window appears.

3. Move the cursor to the signal whose validity/invalidity is to be set, and

press [INTERLOCK] + [SELECT].
– Each time [INTERLOCK] + [SELECT] are pressed, “ (invalid)” and
“ (valid)” alternately appear.

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1.4.3 Registering the Operation Tool

The registration method of operation tool differs depending on whether it
is a single arm move gun or a double arm move gun.
Considering the following cases, refer to “YRC1000 INSTRUCTIONS
(RE-CTO-A221) 8.3 Tool Data Setting” for the tool coordinate value and
tool data setting.

1.4.3.1 When Using a Single Arm Move Gun

Register the tool coordinate value so that TCP is the tip position of the
fixed side tip.
Set the tool posture data so that the direction from the fixed side tip to the
movable side tip is positive (+) side of Z-axis.

Movable side tip

Tool Z-axis direction

TC P

Fixed side tip

Be sure to set the direction of tool Z-axis facing the movable

NOTE side tip.
If the Z-axis is not set in the correct direction, the tip wear
cannot be properly compensated for.

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1.4.3.2 When Using a Double Arm Move Gun

Register the tool coordinate value so that TCP is the contact position of
the both fixed side tip and movable side tip.
Set the tool posture data so that the direction from the lower side tip to the
upper side tip is positive (+) side of Z-axis.

Upper side tip

Tool Z-axis direction

TCP

Lower side tip

Be sure to set the tool Z-axis in the direction from the lower
NOTE side tip to the upper side tip. If the Z-axis is not set in the
correct direction, the wear tip cannot be properly compen-
sated for.

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1.4.4 Setting the Software Limit Value

For the motor guns, the position where the new tip contacts each other is
set as the zero-point (pulse = 0), and the pulse software limit is set at
further pressing position from the zero-point.
It is because the gun needs to be closed more than the zero-point when
the tips become worn.
<Setting Example>

The contact position of Since the softlimit is set as When the softlimit is set
the new tip is set as the zero-point, the tips do not at further pressing position
the zero-point. reach the contact position from the zero-point, the tips
when the tips become worn. reach the contact position.

Parameters
S1CxG800: Pulse software limit (+ side)
S1CxG810: Pulse software limit (- side)
<Example>
When S1CxG800=50000 and S1CxG810=0:
The motor gun moves in the range from 0 to 50,000 pulses.
To move the tip to the contact position when the tips become worn,
set -3,000 for S1CxG810 so that the motor gun moves in the range
from -3,000 to 50,000 pulses.
When setting the value for S1CxG810, consider the pulse amount
equivalent to the total of maximum wear amounts of both tips and the gun
arm bend when maximum gun pressure is applied.

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1.4.5 Setting the Lost-tip Detection Value

The gun-axis pulse can be monitored to output the signal when the tips of
motor gun are detached.

<Setting Example>
Shank position
of the new tip

Shank
Shank motion range
0 when the tip becomes worn
-3000
Tip
Shank motion range
-10000 when the tips are detached

The signal is output when the tips are detached, and the shank moves out
of its normal motion range.
Parameters
S2C003=17 (S1 (gun-axis) uses Interference 1.)
S2C067=0 (Monitors pulses.)
S3C064=-3000, S3C072=-10000
(The signal is output in the range of -3000 to -10000.)

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1.4.6 Gun Detail Setting File

Set the special gun related setting in the GUN DETAIL SETTING window.

 Gun Detail Setting Window

1
2

3
4
5
6
7
8

9
10
11
12

13
14
15

1. GUN No.
Shows the gun No. to use.
When using two guns or more, select the gun No. by pressing [PAGE].
2. STROKE MOTION SPEED
Set the speed to move to the welding start stroke value (specified value
at BWS tag) when executing the welding instruction (SVSPOT).
Refer to chapter 1.7.4 "Gun Stroke Setting before Welding".
3. TOUCH SPEED
Performs the closing motion of the gun by the specified speed in this
item when using the gun pressure tag (WP tag) of the press instructions
(SVSPOT, SVGUNCL, SVSPOTMOV).
Inputting the DRY SPOT SIGNAL (CONTINUE) performs the closing
motion of the gun by the specified speed in this item as well.
4. FINAL TOUCH SPEED START POSITION
Set the position to decelerate to the speed set in “4. FINAL TOUCH
SPEED”. The followings are the actual position to reduce the speed by
the each pressure instruction.
(1) SVSPOT or SVGUNCL without TWC-B/TWC-BE tag.
Reduces the speed from the position where it is away by the set-
ting value towards the gun open direction from the last touch posi-
tion detected by the dry spot touch motion of the wear detection.
(Refer to chapter 1.12.2.1 Dry Spot Touch Motion.)
When the dry spot touch motion of the wear detection has not
been executed,
– In case of SVSVPOT or SVGUNCL without TWC-A/TWC-AE
tag, the speed is not reduced, and the gun closes by the touch
speed set in the pressure file from the beginning until it detects
the contact to the work.

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–In case of SVGUNCL with TWC-A/TWC-AE tag, the gun closes

by the set speed in the “5. FINAL TOUCH SPEED” from the
beginning until it detects the contact to the work.
(2) SVGUNCL with TWC-B/TWC-BE tag.
Reduces the speed from the position where it is away by the set-
ting value towards the gun open direction from the last movable tip
position detected by the movable tip detecting motion of the wear
detection. (Refer to chapter 1.12.2.2 Movable Side Tip Detec-
tion.)
When the movable tip detecting motion of the wear detection has
not been executed, the gun closes by the set touch speed in “5.
FINAL TOUCH SPEED” from the beginning of the SVGUNCL until
it detects the contact to the work.
(3) SVSPOTMOV
The fixed tip and the movable tip move to the teaching position of
the SVSPOTMOV (the position where the fixed tip and movable tip
touch the work) by the specified speed in the SVSPOTMOV
instruction. After that, the gus executes the touch motion by the
speed set in the “5.FINAL TOUCH SPEED”.
5. FINAL TOUCH SPEED
When operating the pressure instruction (SVSPOT, SVGUNCL,
SVSPOTMOV), the gun starts the closing motion by the touch speed set
in the pressure file. However, before contacting the work, the speed is
reduced to the set speed in this item according to “4. FINAL TOUCH
SPEED START POSITION”.

If the touch speed set in the pressure file is smaller than this setting, the
gun closes by the touch speed in the pressure file until it touches the
work.
When setting “0”, the final touch speed becomes 5%.
6. TOUCH PRESSURE
Set the detection pressure for the touch detection (when the gun detects
the contact to the work).
After the touch detection, the gun executes the pressure by the set
pressure in the pressure file.
Also, when “0” is set in the touch pressure, the touch pressure becomes
600N.
7. ALLOWABLE TOUCH RANGE (MOVABLE SIDE)
8. ALLOWABLE TOUCH RANGE (FIXED SIDE)
Set the allowable range of the touch detection position for the both mov-
able side (gun open side) and the fixed side (gun close side).

Enables to detect an error, such as the tips installing error, by monitor-

ing the allowable touch range of the touch detection position in the each
operation of the pressure instruction (SVSPOT, SVGUNCL, SVSPOT-
MOV).

If the difference between the touch reference position and the touch
detection position when executing the pressure instruction is not within
the range, an alarm “TOUCH DETECTION RANGE OVER” occurs.
When setting “0”, the monitoring for the allowance touch range
becomes invalid.
The touch reference position is described below according to the each
pressure instruction to be used.

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(1) SVSPOT or SVGUNCL without TWC-B/TWC-BE tag.

The touch reference position is the last touch position detected by
the dry spot touch motion of the wear detection (Refer to
chapter 1.12.2.1 Dry Spot Touch Motion).

When the dry spot touch motion of the wear detection has not
been executed, the monitoring for the allowance touch range
becomes invalid.
(2) SVGUNCL with TWC-B/TWC-BE tag.
The touch reference position is the last movable tip position
detected by the movable tip detecting motion of the wear detection
(Refer to chapter 1.12.2.2 Movable Side Tip Detection.).

When the movable tip detecting motion of the wear detection has
not been executed, the monitoring for the allowance touch range
becomes invalid.
(3) SVSPOTMOV
The touch reference position is the gun teaching position of
SVSPOTMOV.
9. PRESSURE FILE NO.
Specify the pressure file No. for the “DRY SPOT SIGNAL(FILE)”.
Refer to chapter 1.13.4 "Signal Dry Spot" for more details.
10. DRY SPOT SIGNAL (FILE)
Operates the dry spot by the universal input set in this item according to
the pressure file specified in the “9. PRESSURE FILE NO.”.
Refer to chapter 1.13.4 "Signal Dry Spot" for more details.
11. DRY SPOT PRESSURE (CONTINUE)
Set the pressure for the “DRY SPOT PRESSURE (CONTINUE)”.
Refer to chapter 1.13.4 "Signal Dry Spot" for more details.
12. DRY SPOT SIGNAL (CONTINUE)
Operates the dry spot by the universal input set in this item according to
the pressure specified in the “11. DRY SPOT PRESSURE (CON-
TINUE)”.
Refer to chapter 1.13.4 "Signal Dry Spot" for more details.
13. THICKNESS
Input the thickness of the work to operate the welding.
Refer to chapter 1.13.3 "Touch Teaching Function" for more details.
14. GUN STROKE
Shows the distance between tips when operating the TOUCH TEACH-
ING function.
The value changes when pressing the [SHIFT]+[ENTER] at the same
time in a JOB window.
Refer to chapter 1.13.3 "Touch Teaching Function" for more details.
15. TCP ADJUSTMENT
Shows the adjustment distance of the fixed tip when operating the
TOUCH TEACHING function. Refer to chapter 1.13.3 "Touch Teach-
ing Function" for more details.

If the value of the TOUCH PRESSURE is too small, the gun

mis-detects the touch and may bounce. In this case, set the
NOTE value, which is greater than the current setting value of the
touch pressure. The touch pressure should be set from
600N to 1000N.

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 Operation
1. Select {SPOT WELDING} from the main menu.
2. Select {GUN DETAIL SETTING}.

– The GUN DETAIL SETTING window appears.

3. Select the gun No. by pressing the [PAGE] button.

4. Select the item to set.
5. Input the value, and press [ENTER].

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1.4.7 Application Condition Setting

Regarding the miscellaneous items for the spot (motor gun) application,
set them in the APPLICATION CONDITION SETTING window.

 Application Condition Setting

1
2

3
4
5
6

7
8
9
10
11

12
13

14
15

16
17
18
19
20
21
22
23
24
25

26
27
28

29
30
31

1. CLEARANCE TEACHING METHOD

Set the teaching method of the clearance teaching function.
Select from the three teaching methods below.

UPPER TIP : Teaching with the upper tip contacting the workpiece.
LOWER TIP: Teaching with the lower tip contacting the workpiece.
GUN CLOSE: Teaching with both tips contacting the workpiece.
Refer to chapter 1.10.2 "Setting the Teaching Type" for more details.
2. MAX NUMBER OF WELDER CONNECT
Set the number of the welders.

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3. WEAR DETECT METHOD

Set the method of wear detection.
Select from the two methods below.
RIN: Operates the wear detection by using a sensor.
TOUCH: Operates the wear detection by performing the board touch.
4. WEAR VALUE CALCULATE METHOD
Set the calculate method of the wear value when operating the wear
detection by using the TWC-C.
Select from the two conditions below.
TOTAL VALUE :Multiplying the current detected total value of the wear
(fixed side wear value + movable side wear value)
by the value of the “WEAR RATIO (FIXED SIDE)”
in the SPOT SUPERVISION window makes the
fixed side wear value, and the rest of the wear value
becomes the movable side wear value.
ADD :Multiplying the wear difference between the current and
the last detected total value of the wear by the value of
the “WEAR RATIO (FIXED SIDE)” in the SPOT
SUPERVISION window, and adding the product
above and the last fixed side wear makes the fixed
side wear value. Also, the addition of the rest of the
wear difference and the last movable side wear value
becomes the movable side wear value.
5. ORDER OF WEAR DETECT INSTRUCTION
Set the order of the wear detect instruction.
Select from the two conditions below.
TWC-A → TWC-B : Calculates the wear value only when TWC-A is
executed first (dry spotting touch motion), and
then TWC-B (movable side tip detection motion)
is executed next.
NO LIMIT: There is no order to execute the instructions.
6. WEAR COMPENSATE TEACH METHOD
Set the confirmation method when teaching the positions under the con-
dition that the tip is worn out.
Select from the three conditions below.
MESSAGE: Displays the message ”Compensated position”
after teaching the positions.
CONFIRM+MSG:The confirmation dialog “Compensate?” appears
when teaching operation.
If pressing “YES”, the positions will be registered.
After the registration, the message “Compensated
position” appears.
NOT CONFIRM: The confirmation dialog and the message do not
appear on the screen when teaching the positions.

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7. THICKNESS DETECTION FUNCTION

Set “VALID” or “INVALID” of the THICKNESS DETECTION FUNCTION.
Refer to chapter 1.13.7.4 Group Output for more details.
8. THICKNESS ERROR NOTICE
Set the action when the thickness error occurs.
ALARM: Raise an alarm when the thickness error occurs.
SIGNAL: Outputs the universal signal for 100msec pulse instead of
raising an alarm.
9. THICKNESS ERROR NOTICE GOUT#
When setting the “SIGNAL” at the “8. THICKNESS ERROR NOTICE”,
this item is displayed. Set the universal signal to output when the thick-
ness error occurs. If “0” is set, the signal is not outputted.
10. THICKNESS CHECK MODE SELECT GIN#
Set the universal signal No. to switch to the THICKNESS MEASURE
MODE. Setting the value except “0” validates this item. If validated,
unable to switch to the THICKNES MEASURE MODE by using the pro-
gramming pendant.
11. THICKNESS ALARM IGNORE GIN#
Set the universal signal No. to ignore the THICKNESS DETECTION
function.
Setting the value except “0” validates this item.
12. WELD GROUP NUMBER
Set the maximum value of the group number when performing the group
output to the welder.
Refer to chapter 1.13.7 "Welding Conditions Group Output Function".
13. WELD GROUP ORIGINAL NO.
Set the signal outputting method when performing the group output to
the welder.
Select from the two methods below.
0 Origin: The set value in the group output number (WGO tag) minus
1 is outputted as the signal.
1 Origin: The set value in the group output number (WGO tag) is
outputted as the signal.
Refer to chapter 1.13.7 "Welding Conditions Group Output Function"
more details.
14. WELD COMPLETE DETECT METHOD
Set the detection method of the weld complete signal, which is inputted
from the welder.
Select form the two conditions below.
BIT UP: Rising the signal is regarded as the completion of the
welding.
STATUS: It is regarded as the completion of the welding, when
the status of the signal is ON. If the weld complete
signal is already turned ON at the beginning of the
welding instruction, the welding instruction will be
terminated immediately.

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15. WELD COMPLETE OFF WAIT TIME

When “14. WELD COMPLETE DETECT METHOD” is “STATUS”, set-
ting becomes valid.
The controller waits for the setting time until the weld complete signal is
turned OFF if it is already turned ON at beginning of the welding instruc-
tion. If the weld complete signal is not turned OFF after passing the set-
ting time, an alarm occurs.
16. WEAR WARNING VALUE (UPPER)

17. WEAR WARNING VALUE (LOWER)

Outputs the pulse (pulse time length for 500msec) of the wear detection
error signal (specified output #51535) when the wear value is more than
the setting value.
Becomes invalid when “0” is set.
18. WEAR MINUS THRESHOLD (UPPER)

19. WEAR MINUS THERSHOLD (LOWER)

Outputs the pulse (pulse time length for 500msec) of the wear detection
error signal (specified output #51534) when the wear value is less than
the setting value.
Becomes invalid when “0” is set.
20. WEAR DIFFERENT THRESHOLD (UPPER)

21. WEAR DIFFERENT THRESHOLD (LOWER)

Outputs the pulse (pulse time length for 500msec) of the wear detection
error signal (specified output #51534) when the difference between the
wear value from the last time and the current value is more than the set-
ting value.
22. WEAR POS. THRSHLD AFTER CHG (UP)

23. WEAR POS. THRSHLD AFTER CHG (LOW)

24. WEAR NEG. THRSHLD AFTER CHG (UP)

25. WEAR NEG. THRSHLD AFTER CHG (LOW)

If performing the wear detection while the tip change signal (specified
input #41135) is turned ON, the wear value is compared with the set
threshold value. Outputs the pulse (pulse time length for 500msec) of
the wear detection error signal (specified output #51534) when the wear
value is out of the threshold range.
26. ERROR DISP TYPE
Set the indication type to show an alarm when the alarm occurs by the
NADEX welder side.
Select from the two types below.
DISP ALARM: Displays the alarm.
DISP MESSAGE: Displays the message.
27. ALARM SIGNAL SELECT BIT (WELD1)
The items are shown according to the set numbers in the “2.MAX NUM-
BER OF WELDER CONNECT”.
Specify the signal by a bit (up to 16-bit) which is used as alarm signals
among the signals from the NADEX welder when NADEX welder gener-
ates an alarm.

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28. ERROR CODE BIT (WELD1)

The items are shown according to the set numbers in the “2.MAX NUM-
BER OF WELDER CONNECT”.
Specify the signal by a bit (up to 16-bit) which is used as error code
among the signals from the NADEX welder when NADEX welder gener-
ates an error.
29. AUTO TOOL NO. SELECT FOR GUN
Set “VALID” or “INVALID” of the” AUTO TOOL NO. SELECT FOR GUN”
function.
When” AUTO TOOL NO. SELECT FOR GUN” is “VALID”, and the sta-
tus is selected as “ROBOT-HANDLING” in the “GUN INSTALLATION
STATUS” of the GUN CONDITION window, the tool, which is set at the
“TOOL NO.” in the GUN CONDITION window, is automatically selected
when selecting the JOB.
Refer to chapter 1.13.9 "Automatic Tool Number Select Function for
Guns".
30. MOTION WHEN MANUAL HANDLING
Set whether to permit or prohibit moving the manipulator by the pro-
gramming pendant during the manual handling (Refer to
chapter 1.8.3 "Workpiece Transfer Function Using a Motor Gun").
Select from the three conditions below.
PERMIT: Permits to move the all manipulators.
PROHIBIT: Prohibits the FWD, BWD and TEST operations.
CONFIRM: Displays the confirmation dialog when starting the JOG,
FWD, BWD and TEST operations. If selecting the “YES”
in the dialog, JOG,FWD, BWD and TEST operations can
be performed.
31. WEAR COMP. METHOD FOR TWIN GUN
Set the wear compensation method of the twin guns.
Select from the four methods below.
NO COMP: The wear compensation is not executed.
USE 1ST GUN: Executes the wear compensation by the wear value of
the gun specified at the first GUN tag in the SVSPOT
instruction.
USE 2ND GUN: Executes the wear compensation by the wear value of
the gun specified at the second GUN tag in the
SVSPOT instruction.
AUG. VALUE: Executes the wear compensation by the average value
of the both guns.

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 Operation
1. Select {SPOT WELDING} from the main menu.
2. Select {APPLI COND.}.

– The APPLICATION CONDITION SETTING window appears.

3. Select the item to set.

4. Input the value, and press [ENTER].

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1.5 Before Teaching

1.5 Before Teaching

Before using the motor gun, confirm the following operation instructions.

1.5.1 Manual Spot

For manual spot, perform the following operations.
1. Press [0/MANUAL SPOT] of the [Numeric Key].
2. Press [INTERLOCK] + [./SPOT].
– Spot welding is started and finished after the specified time.
Manual spot is executed while these keys are held down when the
MANUAL PRESS window is displayed.
Manual spot operates under the conditions that are set in the MANUAL
PRESS window.

SUPPLE-
Refer to chapter 1.9 Manual Pressure for the condition set-
MENT tings.

1.5.2 Manual Dry Spot

For manual dry spot, perform the following operations.
1. Press [0/MANUAL SPOT] of the [Numeric Key].
2. Press [INTERLOCK] + [2/GUN CLOSE].
– Dry spot is started and finished after the specified time.
Manual dry spot operates under the conditions that are set in the
MANUAL PRESS window.

SUPPLE-
Refer to chapter 1.9 Manual Pressure for the condition set-
MENT tings.

1.5.3 Manual Press

For manual press, perform the following operations.
1. Press [0/MANUAL SPOT] of the [Numeric Key].
2. Press [INTERLOCK] + [8/PRESSURE].
– Pressurizing is started and is kept till the next releasing operation is
started.
3. Press [INTERLOCK] + [9/RELEASE].
– Pressurizing is released and the gun is opened.
Manual press operates under the conditions that are set in the MANUAL
PRESS window.

SUPPLE-
Refer to chapter 1.9 Manual Pressure for the condition set-
MENT tings.

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1.5.4 Open/Close of Motor Gun

Open and close the motor gun in the following operations.
1. Press [EX. AXIS].
– The LED on [EX. AXIS] lights up.
2. Choose the control group of the gun-axis
– Each time [EX.AXIS] is pressed, the objective external axis
alternates.
3. Press [FAST] or [SLOW] key to select the axis manual speed.
– Refer to “YRC1000 GENERAL OPERATOR’S MANUAL (RE-CSO-
A051) 2.2.0.5 Select Manual Speed” for the details.
4. Press [S+] or [S-].
– The motor gun performs an “open motion” or a “close motion.”

• The opening and closing directions of the motor gun differ

depending on the gun type.
NOTE • When setting the manual speed, be sure to select “slow
speed” to check the opening and closing directions of the
gun.

1.5.5 Mounting Tips

Mount a tip in a dry spot motion.
For dry spot, refer to chapter 1.5.2 "Manual Dry Spot".

NOTE For teaching, be sure to use a new tip with no wears.

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1.5.6 Creation of Job

This section explains how to prepare a job for a robot axis and a gun axis.

1.5.6.1 Job Creating Procedures for Pressure Instruction Registration

1. Select {JOB} under {Main Menu}.
2. Select {CREATE NEW JOB}.

3. Enter a job name.

4. Set a control group.
– Set a control group which includes a gun-axis.
– The gun-axis is registered as a station.
– When it is a gun mounted on a robot, be sure to register “Robot +
Station (gun-axis)” control group.
– The pressure compensation function and gun arm bend
compensation function do not work properly when the job is only for
a control group of gun-axis.
– Refer to chapter 1.13.5 "Gun Pressure Compensation Function"
for the details of gun pressure compensation.
– Refer to chapter 1.13.6 "Compensation of Gun Arm Bend for C-
Gun and X-Gun (SINGLE ARM MOVE)" for the details of arm bend
compensation.

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(Example Case) Robot: R1, Gun-Axis: S1

Select “R1+S1” for a control group

5. Press [ENTER]
– Refer to “YRC1000 GENERAL OPERATOR’S MANUAL (RE-CSO-
A051) 3.1.3 Registering a Job” for the details.

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1.5.6.2 Registering Steps

 When using SVSPOT instruction

Register steps in the following procedures.

Tip on the movable side

4 6
5 9 1

4 8
Workpiece 7
3 2
Tip on the fixed side

1. Register the positions from 1 to 4 as steps 1 to 4.

2. Close the gun till it reaches to the position 5, and then register it as
step 5 in the job.
3. Open the gun till it reaches to the position 6, and then register it as
step 6 in the job.
4. Register the positions from 7 to9 as steps 7 to 9.

• Position 5 should not touch the workpiece. Give 5 to 10

mm space between the workpiece and the tip.
• By registering SVSPOT (Welding Execution) instruction
NOTE after step 5, the tool end touches the workpiece in the
touch motion.
• For the double arm move gun, teach positions 4 and 5 in
the same step, and also positions 6and 7 in the same
step.

 When using SVSPOTMOV instruction

Execution of teaching operation using SVSPOTMOV instruction requires
less procedures than using SVSPOT instruction. For the details, refer to
chapter 1.10 Clearance Move Instruction (SVSPOTMOV Instruction).

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1.6 Playback (Motor Gun)

1.6 Playback (Motor Gun)

This section explains about the check run and the actual welding.

1.6.1 Check Run

Confirm the taught path in a the check run. Dry run is possible during the
check run operation because welding instructions such as SVSPOT are
not carried out in the check run operation.
1. Set the mode switch to [PLAY] on the programming pendant.
2. Select {UTILITY} in the menu area.
3. Select {SETUP SPECIAL RUN}.
4. Select “CHECK-RUN” and set “VALID” to it.

1.6.2 Execute Welding

After having confirmed the taught path, start the welding operation.
SVSPOT instruction becomes available after turning OFF the check run
operation.

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1.7 Welding Instruction (SVSPOT Instruction)

1.7 Welding Instruction (SVSPOT Instruction)

1.7.1 Registration of Welding Instruction (SVSPOT Instruction)

Press [/SPOT] on the programming pendant to register SVSPOT
instruction.

SVSPOT GUN#(1) PRESS#(1) WTM=1 WST=1

1 2 3 4
1. Gun No.
Specifies a gun No. to be used for welding.
2. Gun pressure file No.
Specifies a file No. to which a pressure is set.
Or, the pressure can be directly specified by WP tag instead of using
PRESS tag.
In case specification by both Press and WP tags are omitted, the pres-
sure file is used as its pressure condition. At this time, the file number
becomes the number set to the welding condition number (WTM tag).
3. Welding condition No.
Specifies a welding condition No. set to the welder.
4. Welder startup timing
Specifies a timing to start the welder.
The timing is chosen from the following conditions.
• WST=0: The welder starts at the same time as the execution of
SVSPOT instruction.
As the welder starts its operation before pressurization, a squeeze
time at the welder is required.
• WST=1: The welder starts at the same time as the pressure reaches
the 1st pressure.
• WST=2 : The welder starts at the same time as the pressure reaches
the 2nd pressure.

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1.7 Welding Instruction (SVSPOT Instruction)

 Welder startup timing

Open

Gun motion

Close t

Pressure

Weld sigal
In case of touch motion
(WST=0)
t

Weld sigal
In case of the 1st pressure
(WST=1)
t

Weld signal
In case of the 2nd pressure
(WST=1) t

1.7.2 Setting of Gun Pressure

The pressure for welding can be specified by the pressure file selected by
SVSPOT instruction.

 Gun Pressure window

1
2
3

4
6

1. CONDITION NO.
Shows the pressure file number. Press [PAGE] to select a file number.
2. SETTING.
Shows the setting status of the pressure file.
“NOT DONE” is indicated if a value is not input.
“DONE” is indicted if a value is input.
3. TOUCH SPEED
Shows the gun closing speed with a link speed (%).
4. 1ST TO 4TH PRESS
Shows the pressure at each step.

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5. 1ST TO 4TH END CONDITION

Shows the corresponding pressurization condition at each level.
Select either “PRESS” or “END WAIT”.
PRESS TIME: Apply pressure for a time specified at “6” item on
this window.
END WAIT : Stop applying pressure when a weld complete signal
is input from the welder.
In case “END WAIT” is specified to either {1ST PRESS}, {2ND PRESS}
or {3RD PRESS}, the pressure condition of the press next to the speci-
fied press is no longer indicated.
6. 1ST TO 4TH PRESS TIME
Shows the pressure time for each pressure. In case “END WAIT” is
selected at item “5”, this item dose not appear.

To item “4”, set a value so that the following equality to be

true.

NOTE 1000 <= 1ST to 4TH PRESS

If the gun pressure is not set by following the above men-
tioned instructions, the actual pressure over the specified
pressure cannot be guaranteed.

 Operation procedures
1. Press {SPOT WELDING} on the {Main Menu}.
2. Select {GUN PRESSURE}.

– The GUN PRESSURE window appears.

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3. Select a file number by pressing [PAGE].

4. Select an item to be specified.
5. Input a numeric value and press [ENTER].
– For {END CONDITION}, “PRESS TIME” and “END WAIT” alternate
each time [SELECT] is pressed.
6. Move the cursor to {SETTING} and press [SELECT].
– “DONE” appears to this item.

Table 1-3: <Example>

PRESS (N) END CONDITION
1ST PRESS 2000 PRESS TIME 0.20 sec
2ND PRESS 1500 PRESS TIME 0.10 sec
3RD PRESS 2200 PRESS TIME 0.20 sec
4TH PRESS 1800 END WAIT -

0.2 0.1 0.2

Pressure
2000 2200

1000 1500 1800

t

Weld Complete

Gun pressure can be edited during the playback operation.

NOTE The edited content is reflected after the gun pressure set-
ting is done.

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• If the touch speed is too fast, the gun axis may bounce.
Reduce the speed to be slower than the present value.
• Modified settings are deleted in case following operations
are executed while editing the gun pressure.
NOTE 1, Change the page
2, Change the mode from play to teach
3, Switch to other file editing menu
4, Turn OFF the power supply
• The touch speed is limited to the maximum teaching
speed in the teach mode.

1.7.3 Welding Current and Welding Time Settings

The welding current and the welding time are set to the welder.
Refer to the Operator’s manual of the welder.

The welding condition No. set to the welder should be the

NOTE same as the welding condition No. specified in the SVSPOT
instruction.

1.7.4 Gun Stroke Setting before Welding

At the execution of SVSPOT instruction, the gun can move to a specified
position before the touch motion starts.

Without gun stroke setting With gun stroke setting

Touch motion Stroke motion Touch motion

1.7.4.1 Setting the Gun Stroke Position

SVSPOT GUN#(1) PRESS#(1) WTM=1 WST=1 BWS=10.0
1
1. Gun stroke position before welding
At the execution of SVSPOT instruction, the gun moves to a specified
opening position. Then, the touch motion starts and the gun moves to
the pressurizing position.
When this item is omitted, the touch motion starts immediately at the
SVSPOT instruction.

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1.7.4.2 Setting the Gun Stroke Motion Speed

1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {GUN DETAIL SETTING}.
– The GUN DETAIL SETTING window appears.
3. Select a gun No. by pressing [PAGE].
4. Select {STROKE MOTION VELOCITY}.
– STROKE MOTION VELOCITY
The gun stroke motion speed under the SVSPOT instruction is
specified.

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

1.7.4.3 Motion Example

The figure below shows an example of a motion with the following
conditions.
Gun stroke position before welding:10.0 mm
Gun stroke motion speed: 100.0%
Touch press motion speed: 20%.

10mm

Stroke motion Touch motion

Motion speed: 100% Motion speed: 20%

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 1 Spot Welding Application Using a Motor Gun
1.8 Dry Spot (Motor Gun)

1.8 Dry Spot (Motor Gun)

For dressing a tip and mounting a tip, a gun motion to apply pressure
without welding (dry spot) is required.
Dry spot can be also registered in a job to be executed.

1.8.1 Registration of Dry Spot Instruction (SVGUNCL Instruction)

Register SVGUNCL instruction by pressing [2/GUN CLOSE] among the
[Numeric Key] on the programming pendant.

SVGUNCL GUN#(1) PRESSCL#(1)

1 2
1. Gun No.
Specifies a gun No. to execute dry spot.
It is used in common with SVSPOT instruction.
2. Pressure file No.
As a pressure condition, choose one out of the following four tags.
• PRESSCL tag (dry spot pressure file)
The dry spot pressure file is regarded as its pressure condition.
Set a file number to the tag.
• WP tag (direct pressure setting)
A pressure is directly specified to a tag.
• PRESSTWC tag (pressure condition for the wear detection)
A pressure condition for the wear detection.
Apply pressure by the values set to {TOUCH SPEED} and {DETEC-
TION PRESSURE} in the spot supervision file.
For the details, refer to chapter 1.12 Tip Wear Detection and Wear
Compensation (Motor Gun).
• DRS tag (tip dress condition)
The tip dress condition file is regarded as its pressure condition.
Setting at {PRESSURE CONDITION} in the tip dress condition file is
employed and other settings are not.
Set a file number to the tag.
For the details, refer to chapter 1.11 Tip Dressing Instruction
(SVDRESMOV Instruction).

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1.8 Dry Spot (Motor Gun)

1.8.2 Dry Spot Pressure Setting

The pressure for dry spot is specified by the pressure file selected by the
SVGUNCL instruction.

 PRESSURE window

1
2
3
4

5
6

10
9
8

1. FILE NO.
Shows the dry spot pressure file No.
Select a number by pressing [PAGE].
2. TIP DRESSER ROTATION REQUEST
Shows the universal output signal number in synchronization with the
dry spot pressure.
3. PRE CUT TIME
Shows the time from when the tip dresser rotation request is output till
the moment the gun starts applying pressure.
4. END CUT TIME
Shows the time after the pressurization is finished and before the tip
dresser rotation request is turned OFF.
5. TOUCH SPEED
Shows the gun closing speed with a link speed (%).
6. PRESS UNIT
Shows the units for dry spot pressure. Select “N” or “% (TORQUE).”
7. 1ST to 4TH PRESS
Shows the dry spot pressure at each step.
8.1ST to 4TH PRESS TIME
Shows the pressure time of each dry spot pressure.
9. 1ST to 4TH PRESS OUT
Shows the ON/OFF status of the universal output signal which is output
in synchronization with each dry spot pressure.
When a synchronizing signal is output to a tip dresser, etc., select “ON.”
10. 1ST to 4TH PRESS SIGNAL
Shows the No. of the universal output signal which is output in synchro-
nization with each dry spot pressure.

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As for a value to “7”, set a value so that the following equal-

ity to be true.

NOTE 1000 <= 1ST to 4TH PRESS

If the gun pressure is not set following the above mentioned
instructions, the actual pressure over the specified pressure
cannot be guaranteed.

 Operating procedure
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {PRESSURE}.

– Pressure window appears.

3. Select a file No. by pressing [PAGE].

4. Select an item to be set.
5. Enter a numerical value, and press [ENTER].
– To {PRESS UNIT}, press [SELECT] to display “N” and
“% (TORQUE)” alternately.
– To {OUT} item, press [SELECT] to display “ON” and “OFF”
alternately.

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Table 1-4: <Example>

PRESS (N) END CONDITION OUT
1ST PRESS 2000 0.50 ON
2ND PRESS 2200 0.50 ON
3RD PRESS 0.0 0.00 OFF
4TH PRESS 0.0 0.00 OFF
Tip dresser
rotating signal

PRE CUT TIME = 1.0 (sec) and END CUT TIME = 1.0 (sec)

0.5 0.5

Dry spot pressure

2000 2200

1000

Synchronizing signal
(DOUT1)

Synchronizing signal
(DOUT2)

Tip dresser
rotation request
(DOUT3)

t
1.0 1.0

NOTE If the touch speed is too fast, the gun axis may bounce.
Reduce the speed to be slower than the present setting.

NOTE The touch speed is limited to the maximum teaching speed

in the teach mode.

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1.8 Dry Spot (Motor Gun)

1.8.3 Workpiece Transfer Function Using a Motor Gun

1.8.3.1 Operation Flow Chart

With the dry spot instruction, workpieces can be transferred.
When this instruction is performed, the force control for grasping a
workpiece and the tip wear compensation are available so that the
workpiece can be stably handled using a motor gun.
The following shows the operation flow chart for the workpiece transfer
function.

Start

Set the conditions for Set pressure for

grasping/releasing grasping workpices
workpieces

Teach a position

Register instructions for

grasping/releasing
workpieces

End

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1.8 Dry Spot (Motor Gun)

1.8.3.2 Instruction for Grasping/Releasing Workpieces

<Example>
SVGUNCL GUN#(1) PRESSCL#(1) ON
1 2 3 4
1. Instruction for grasping/releasing workpieces
2. GUN#(1)
Specifies the gun No. to grasp the workpiece.
3. PRESSCL#(1)
Specifies a dry spot condition file (pressure for grasping workpiece set-
ting) No.
Or, the pressure can be directly specified by using WP tag instead of
using PRESS tag.
4. ON
Specifies whether the workpiece is grasped (ON) or released (OFF).

1. Select {JOB} on the {Main Menu}.

2. Select {JOB CONTENT}.
– JOB CONTENT window appears.

3. Press [INFORM LIST].

4. Select {DEVICE}.
– Select {SVGUNCL} for the instruction of grasping.

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1.8 Dry Spot (Motor Gun)

5. Move the cursor to {SVGUNCL} and press [SELECT] twice.

– DETAIL EDIT window appears.
(For transferring workpieces, adding the transfer tag is required on
this window.).

– When “UNUSED” is selected for {WEAR DETECT}, the following

dialog box appears.

6. Edit the tag item of the instruction.

– Select {CONSTANT} from the dialog box.
• ON: Grasps the workpiece
• OFF: Releases the workplace

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1.8 Dry Spot (Motor Gun)

7. Press [INSERT] and then press [ENTER].

(1) The window returns to JOB CONTENT window after pressing
[ENTER].
(2) The instruction can be inserted by pressing [ENTR] while LED
indicator is lit by pressing [INSERT].

1.8.3.3 Manual Operation for Grasping/Releasing Workpieces

This section describes how to grasp/release workpieces by manual
operation from the programming pendant.
With this operation, the workpiece can be easily grasped/released when
teaching the position for transferring workpieces.
This operation can be performed only in the teach mode.
1. Contact the fixed side tip to the workpiece to let the manipulator grasp
the workpiece.
– Pressure is applied when pressing [INTERLOCK] + [8].
To set the pressure conditions, use {TOUCH SPEED}, {PRESSU
UNIT} or {PRESSURE} on MANUAL PRESS window.
2. Release the Workpiece
– Press [INTERLOCK] + [9] to release the gun axis.

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1.9 Manual Pressure

1.9 Manual Pressure

 Manual pressure window

1
2
3
4

5
6
7

8
9
10
11

12
13
14
15
16

1. GUN NO.
Specifies the gun number to execute pressurization.
2. PRESS MEASUREMENT MODE
Select “ENABLE” when measuring the pressure with a force gauge.
For the gun closing speed, just before the upper and lower tips to con-
tact, the gun decreases its speed till the speed to the final touch speed
specified on GUN DETAIL SETTING window. When “ENABLE” is set to
{PRESS MEASUREMENT MODE}, the gun’s position where it starts
decreasing the speed is offset for the distance equal to the thickness of
the force gauge, and start decreasing the speed before the upper and
lower tips contact the gauge. With this setting, measurement of the
pressure with the same condition as the normal pressurization becomes
possible.

This mode is disabled when the mode is changed to play even if

“ENABLE” is selected.
3. THICKNESS FORCE GAUGE
Specify the thickness of the force gauge to this item after “PRESS MEA-
SUREMENT MODE” is enabled.
4. ROBOT FOR PRESSURE/BEND COMPENSATION
Select a robot for the pressure and bend compensation operations.

NOTE The bend compensation is not executed by MANUAL DRY

SPOT ([INTERLOCK] + [2]).

5. TOUCH SPEED
Specifies a touch speed when applying pressure manually.
6. PRESS UNIT
Shows the units for manual pressure. Select “N” or “% (TORQUE).”
7. PRESSURE
Specifies the pressure for manual pressure.

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1.9 Manual Pressure

8. MANUAL DRY SPOT MODE

Pressurizing method for the dry spot is specified by selecting either
“FILE” or “CST PRESS”. With this procedure, “TOUCH SPEED” and
“PRESSURE” are specified as follows.
• When “FILE” is selected
TOUCH SPEED: It is defined by the dry spot pressure file
condition specified by “PRESSURE FILE NO.”
PRESSURE : It is defined by the dry spot pressure file
condition specified by “PRESSURE FILE NO.”.
• When “CST PRESS” is selected
TOUCH SPEED: It is defined by the value input to
“CONST PRESS TOUCH SPEED”.
PRESSURE : It is defined by the pressure input to
“CONST PRESSURE”.
9. PRESSURE FILE NO.
This item appears when “FILE” is selected to “MANUAL DRY SPOT
MODE”. Specifies the dry spot pressure file number for the manual dry
spot operations.
10. CONST PRESS TOUCH SPEED
This item appears when “CST PRESS” is selected to “MANUAL DRY
SPOT MODE”. Specifies the touch speed for the constant pressurizing
operations.
11. CONST PRESSURE
This item appears when “CST PRESS” is selected to “MANUAL DRY
SPOT MODE”. Specifies the pressure for the constant pressurizing
operations.
12. MANUAL SPOT MODE
“FILE” is always specified while executing the pressurizing operations
at the manual spot.
13. GUN PRESSURE FILE NO.
Specifies the gun pressure file number in welding operation.
14. WELDING CONDITION(WTM)
Specifies the welding condition number to be output to the welder.
15. WELDER STARTUP TIMING(WST)
Shows the timing to start-up the welder. Select one condition out of the
following three conditions.
•Touch motion : Start-up the welder at the same timing with
the execution of SVSPOT instruction.
A squeeze time at the welder is required
because the welder starts its operation before
pressurization starts.
•1ST PRESSURE : Start-up the welder at the same timing with
the execution of the1ST PRESSURE.
•2ND PRESSURE : Start-up the welder at the same timing with
the execution of the 2ND PRESSURE.

16. WELD GROUP OUTPUT(WGO)

Specifies a welding group No. output to the welder.
For the details, refer to chapter 1.13.7 "Welding Conditions Group
Output Function"

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1.9 Manual Pressure

 Operating procedures
1. Press [0/MANUAL SPOT] of the [Numeric Key].
– MANUAL PRESS window appears.

2. Select an item to set.

3. Input a value, and press [ENTER].
– To {WELDER STARTUP TIMING(WST)}, press [SELECT] to
alternate “TOUCH MOTION”, “1ST PRESSSURE” and “2ND
PRESSSURE”.
– To {MANUAL SPOT MODE}, press [SELECT] to alternate “FILE”
and “CST PRESS”.

 Manual Press Operation

Refer to chapter 1.5.1 "Manual Spot" , chapter 1.5.2 "Manual Dry
Spot" and chapter 1.5.3 "Manual Press" for the manual press operation.

The manual press ([INTERLOCK] +[8]) and the manual dry

spot ([INTERLOCK] +[2]) are available even if the MANUAL
PRESSURE window is not opened.
However, in this case, the available gun is not the one
selected on the manual pressure window but the gun
NOTE included in the job currently selected. For this reason,
these operations are not available when a gun is not
included in the currently selected job.
Also, the robot for pressure/bend compensation is the one
included in the currently selected job. For this reason, pres-
sure/bend compensation is not available when a robot is not
included in the currently selected job.

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

After teaching this instruction at the welding points, execution of all the
following operations become enabled by this instruction only.
1. Moving to a position short before the welding operation point.
(moving to a clearance position)
2. Moving to a welding position
3. Welding operation
4. Moving to a position just behind the welding operation point.
(moving to a clearance position)
The clearance position mentioned above means the position where the
gun is opened over the welding position by the clearance distance
specified by the clearance file.

1.10.1 Operation Flow

The following shows the teaching operation flow chart for the clearance
move instruction.

Start

Specify following teaching types

-Teaching type 1: Lower-tip teaching
Specify a teaching type -Teaching type 2: Upper-tip teaching
-Teaching type 3: Gun-close teaching

Set the following clearance data

Specify a clearance file -Upper tip clearance distance
-Lower-tip clearance distance
-Board thickness
(for the teaching type 1 and 2)

Teach a welding point Specify following teaching data

-Teaching point (teaching)
-Moving speed
-Clearance file No.
-Pressure/welding conditions

End

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10.2 Setting the Teaching Type

The following three types of settings are available; the lower-tip teaching,
the upper-tip teaching, and the gun-close teaching.
Follow the procedures to select one out of the three types before teaching
the welding point.

(1) Lower-tip teaching (2) Upper-tip teaching (3) Gun-close teaching

(inputting of board thickness (inputting of board thickness (inputting of board thickness
is necessary) is necessary) is unnecessary)

Upper tip
(Movable side)

Lower tip
(Fixed side)

1. Select {SPOT WELDING} on the {Main Menu}.

2. Select {APPLI COND.}.

– APPLICATION CONDITION SETTING window appears

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

3. Select {CLEARENCE TEACHING METHOD}.

– Move the cursor to {CLEARENCE TEACHING METHOD} and press
[SELECT]. A selection dialog box for the teaching methods
appears.

– Three teaching methods are available.

• UPPER TIP : Teaching with the upper tip contacting the workpiece
• LOWER TIP : Teaching with the lower tip contacting the workpiece
• GUN CLOSE : Teaching with both tips contacting the workpiece
4. Select a desired teaching method.
– Press [SELECT] to change the method.

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10.3 Setting the Clearance Files

In this section, setting procedures of various data to the clearance file are
explained.
• When selecting “UPPER TIP” or “LOWER TIP” as the clearance
teaching method, setting of {TICKNESS} in the clearance file before
teaching the welding point is required.
• No need to set {TICKNESS} in the clearance file before teaching the
welding point when selecting “GUN CLOSE” for the clearance teach-
ing method.
• Up to 32 clearance files can be used.
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {CLEARANCE SETTING}.

– CLEARANCE SETTING window appears.

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

– Amount of clearance and operation conditions can be set.

– There are three moving patterns.
• MOVE&CLOSE
• SQUARE
• MOVE&OPEN

– {DISTANCE TO UPPER TIP(IN)} and {DISTANCE TO LOWER

TIP(IN)} are the amount of clearance for closing motion.
{DISTANCE TO UPPER TIP(OUT)} and {DISTANCE TO LOWER
TIP(OUT)} are the amount of clearance for opening motion.
– This file is specified by the SVSTPOTMOV instruction’s clearance
tag.
(Up to 32 files can be specified.)
3. Select desired items.
– {DISTANCE TO UPPER TIP}, {DISTANCE TO LOWER TIP}, and
{THICKNESS} can be set in the 1/10mm length.
4. Input a value and press [ENTER].
– Move the cursor and press [SELECT] to enter the value.

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

– After entering each value, press [ENTER] to set the value.

1.10.4 Operations for Teaching Welding Points

The following describes the outline of the procedure for teaching the
welding point.
1. Select {JOB} on the {Main Menu}.
2. Select {JOB}.

– JOB CONTENT window appears.

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

When registering pressure instructions (SVSOPT,

SUPPLE- SVGUNCL, SVSPOTMOV and SVDRESMOV),create a job
MENT
which includes a gun axis control group.

3. Press [SHIFT] + [MOTION TYPE] to display SVSPOTMOV.

– To execute the clearance teaching, display SVSPOTMOV by

changing motion type ( [SHIFT] + [MOTION TYPE]) and register it.
– This can be done only when the manipulator is in operating status
(while the [ROBOT] LED indicator is lit.).
4. Edit the tag item of the instruction.
5. Press [INSERT], then press [ENTER].
– Following window appears when the clearance move instruction has
been registered.

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10.5 Clearance Move Instruction

The following describes the clearance move instruction.

<Example>
SVSPOTMOV V=1000.0 PLIN=1 PLOUT=1 CLF#(1) GUN#(1)
PRESS#(1) WTM=1 WST=1 WGO=1
SVSPOTMOV : Clearance move instruction
V=1000.0 : Linear motion speed for clearance
(1000.0mm/s for this example)
PLIN=1 : Positioning level at the clearance position before welding
PLOUT=1 : Positioning level at the clearance position after welding
CLF#(1) : Clearance file number (file 1 for this example)
GUN#(1) : Motor gun number (Motor gun 1 is used for this example.)
PRESS#(1) : Pressure condition file number
(Pressure condition file 1 is used for this example.)
WTM=1 : Welding condition number (Welding condition 1 is used
for this example.)
WST=1 : Welder start-up timing
WGO=1 : Welding condition group output (Refer to chapter 1.13
Other Functions Using a Motor Gun )

The tag using method of GUN, PRESS, WTM, and WST,

etc. are same as that of SVSPOT instruction.
NOTE
For the details of these tags, refer tochapter 1.7.1 "Regis-
tration of Welding Instruction (SVSPOT Instruction)".

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10.6 Clearance Move

The following describes the clearance move.

 When the positioning level (PLIN) is used

Table 1-5: Job Example: Work 1

0000 NOP
0001 MOVJ VJ=100.0 →1
0002 SVSPOTMOV V=1000.0 PLIN=0 CLF#(1) GUN#(1) →2
PRESS#(1) WTM=1 WST=1
0003 SVSPOTMOV V=1000.0 PLIN=0 CLF#(1) GUN#(1) →3
PRESS#(1) WTM=1 WST=1
0004 SVSPOTMOV V=1000.0 PLIN=0 CLF#(1) GUN#(1) →4
PRESS#(1) WTM=1 WST=1
0005 SVSPOTMOV V=1000.0 PLIN=0 CLF#(1) GUN#(1) →5
PRESS#(1) WTM=1 WST=1
0006 SVSPOTMOV V=1000.0 PLIN=0 CLF#(1) GUN#(1) →6
PRESS#(1) WTM=1 WST=1
0007 MOVL V=1000.0 →7
0008 END

Clearance file setting: 1

PLIN = 0
DISTANCE TO UPPER TIP (IN, OUT) : 20.0mm
DISTANCE TO LOWER TIP (IN, OUT) : 10.0mm
THICKNESS : 2.0mm

1 7

Clearance for
upper tip:
20.0mm

2 3 4 5 6
Weld Weld Weld Weld Weld

Clearance for
lower tip:
10.0mm

1 7

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

 When the positioning level (PLOUT) is used

Table 1-6: Job Example: Work 1

0000 NOP
0001 MOVJ VJ=100.0 →1
0002 SVSPOTMOV V=1000.0 PLOUT=0 CLF#(1) GUN#(1) →2
PRESS#(1) WTM=1 WST=1
0003 SVSPOTMOV V=1000.0 PLOUT=0 CLF#(1) GUN#(1) →3
PRESS#(1) WTM=1 WST=1
0004 SVSPOTMOV V=1000.0 PLOUT=0 CLF#(1) GUN#(1) →4
PRESS#(1) WTM=1 WST=1
0005 SVSPOTMOV V=1000.0 PLOUT=0 CLF#(1) GUN#(1) →5
PRESS#(1) WTM=1 WST=1
0006 SVSPOTMOV V=1000.0 PLOUT=0 CLF#(1) GUN#(1) →6
PRESS#(1) WTM=1 WST=1
0007 MOVL V=1000.0 →7
0008 END

Clearance file setting: 1

PLOUT = 0
DISTANCE TO UPPER TIP (IN, OUT) : 20.0mm
DISTANCE TO LOWER TIP (IN, OUT) : 10.0mm
THICKNESS : 2.0mm

1 7

Clearance for
upper tip:
20.0mm

2 3 4 5 6
Weld Weld Weld Weld Weld

Clearance for
lower tip:
10.0mm

1 7

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10.7 Press Teaching Function

1.10.7.1 Operation Flow Chart

Teaching of the clearance move instruction can be executed while the gun
is applying pressure.
The following shows the operation flow chart for this function.

Start

Select “GUN CLOSE” as a Refer to chapter 1.10.2

teaching type
“Clearance Teaching Function”.

Move the manipulator

to the welding point

Apply pressure

Register the welding point

Release applying pressure

End

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1.10 Clearance Move Instruction (SVSPOTMOV Instruction)

1.10.7.2 Procedure for Registering the Position

The following describes the procedures for registering the position.
Note that this function is a part of the clearance teaching function, and is
available only when the clearance teaching type is the gun-close teaching.

1. Move the fixed side tip until it contacts the workpiece, and then apply
pressure.
– To apply pressure, press [INTERLOCK] + [8].
– The condition under MANUAL PRESS ([INTERLOCK] + [8]) on
MANUAL PRESS window is used as the pressure condition.
2. Confirm the pressure status and register the position.
– SVSPOTMOV instruction appears in the input buffer line of the job
input display while it is pressurized.
In case it doesn’t appear, press [8] to switch the indication.
– The taught position is registered after the wear compensation
amount of the gun axis is added. Yaskawa recommends that the
pressure is applied in the level which the gun axis does not bend
when teaching.
3. Stop applying the pressure.
– Press [INTERLOCK] + [9] to release the gun axis.

1.10.7.3 Setting the Pressure Conditions

The following describes settings for the pressure conditions.
The pressure condition is specified with {TOUCH SPEED}, {PRESS UNIT}
and {PURESSURE}.
The following window can be displayed by pressing [0].

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1.10.7.4 Setting the Gun Pushing Coefficient

By setting a value to the gun pushing coefficient, the position of the gun is
registered after subtracting the pressure pushing value from the gun
position when executing press teaching.
By setting the gun pushing coefficient correctly, the contact point of the tip
and the workpiece can be registered as a teaching point regardless of the
pressure during press teaching operation.

Releasing Teaching Registering

position position position

Press Gun pushing Gun pushing

teaching coefficient unset coefficient set

Movable
side

 Setting of gun pushing coefficient

1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {GUN CONDITION}.
– GUN CONDITION window appears.

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3. Set a value to {GUN PUSHING COEF}.

– Set the value (0 to 10.0 [mm/1000N]) to the gun pushing coefficient
to compensate the registering position when press teaching is
performed.
– Press [SELECT] to input the numerical value.

4. Press [ENTER].

 Calculation of Gun Pushing Coefficient

To {GUN PUSHING COEF}, set pushing amount [mm] per 1000N.
Fig. 1-2: Relation Between Pressure and Gun Axis Position [mm]
Gun axis position (mm)

Pressure direction

Pressure (N)

Following the relation mentioned above, calculate the change of gun axis
position per 1000N pressure and set it to {GUN PUSHING COEF}.
{GUN PUSHING COEF} is set with [mm] unit.

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1.10.8 Work Search Function

The workpiece position over the tool Z-axis direction can be automatically
detected.

1.10.8.1 Operating procedures

1. Manually move the motor gun to the welding point.
2. Start the searching operation.
– Press [INTERLOCK] + [5] to down the movable side tip. When the
movable side tip touches the workipiece, the fixed side tip is moved
up with the movable side tip keeping touch to the workpiece until the
workpiece is detected.
– While the workpiece is being detected, a message "In process of
search” appears and it is deleted after the detection is completed.
3. Release pressing [INTERLOCK] + [5] after the message is deleted.

Move to the welding point Serch the workpiece while

[INTERLOCK] + [5] is pressed

After the detection, confirm the positions of the motor gun and the
workpiece, register SVSPOTMOV instruction by referring to
chapter 1.10.7 "Press Teaching Function".
In case pressing [INTERLOCK] + [5] is released or Hold is pressed during
the workpiece detection, the detecting operation is discontinued.

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1.10.8.2 Parameter
SICxG175: Threshold of the workpiece detection by the movable side tip
Specifies the threshold of workpiece detection by the movable side tip
0: 10 [N]
Others: SICxG175 [N]
<example> When the following value is set, the detecting threshold is 20
[N].
SICxG175=20

• When the workpiece rigidity is low, detection may take

time and this delay can cause a damage to the workpiece.
For this reason, do not use this function when the work-
piece rigidity is low.
• Should an error occurred, increase the value of
NOTE S1CxG175 one by one from its default value to find a
value with which the error does not occur. In case an error
is detected when the value is 0, increase the value of
S1CxG175 one by one from 11 to find a value with which
the error does not occur.
• This function is not available to the double arm moving
gun.

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1.11 Tip Dressing Instruction (SVDRESMOV Instruction)

1.11 Tip Dressing Instruction (SVDRESMOV Instruction)

As well as the clearance move instruction (SVSPOTMOV Instruction), all
the following operations become available only by this instruction after
teaching this instruction at a dressing position.
1. Moving to a position short before the dressing position
(moving to the clearance position)
2. Moving to a dressing position
3. Dressing operation
4. Moving to a position just behind the dressing position
(moving to the clearance position)
The clearance position mentioned above means the position where the
gun is opened over the dressing position by the clearance distance
specified by the tip dress condition file.

1.11.1 Operation Flow

The following shows the operation flow chart for the tip dressing
instruction teaching.

Start

Set the following teaching type

-Teaching type 1: Lower-tip teaching
Select a teaching type -Teaching type 2: Upper-tip teaching
-Teaching type 3: Gun-close teaching

Set the following conditions:

-Pressure condition
Set a clearance file
-Clearance condition
-Dresser condition

Set the following teaching data

Teach a dressing point -Teaching position (teaching)
-Moving speed
-Tip dress condition file No.

End

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1.11 Tip Dressing Instruction (SVDRESMOV Instruction)

1.11.2 Teaching Type Setting

The teaching type setting procedures are same as that of the clearance
move instruction (SVSPOTMOV). Refer to chapter 1.10.2 "Setting the
Teaching Type" .

1.11.3 Tip Dress Condition

The pressure, clearance and dressing conditions when the tip dress
instruction (SVDRESMOV) is executed are set on the tip dress condition
window.

 Tip dress condition window

1
2
3
4
5 6

7
8
9
10
11
12
13
14
15
16
17
18
19

1. FILE NO.
Shows the tip dress condition file No.
Press [PAGE] to choose the number.
2. DRESSER
Select “IO” when using a dresser which is controlled by IO.
When using a servo dresser, select the servo dresser’s control group.
3. PRESS CONDITION
This pressure condition is used when executing a tip dressing instruc-
tion (SVDRESMOV), or a dry spot instruction (SVGUNCL) which uses a
tip dress condition file (DRS tag).
4. TOUCH SPEED
Shows the gun closing speed with a link speed (%).
5. 1ST TO 2ND PRESS
Set the pressure at each step

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6. END CONDITION
“PRESS TIME” and “DRESS LENGTH” can be selected as the condition
for ending the operation.

– When “PRESS TIME” is selected

Pressing time is designated.
When “0” is set, no pressing is executed and the manipulator
completes its operation.
In case “PRESS TIME” is selected to {FIRST PRESS}, set values
other than 0.00 to “PRESS TIME”.
– When DRESS LENGTH” is selected
Length for dressing is designated.
An alarm with a message “Tip Dress Time Over” occurs in case the
manipulator does not dress the designated length within ten
seconds. The time to alarm can be modified with the following
parameter.
AxP108: Tip Dress Time Over Detecting Time
(Unit: 0.1 sec, Initial value:0)
Set “50” for 5.0 seconds
Set “0” for 10 seconds
7. CLEARANCE CONDITION
Set the clearance conditions for the execution of the tip dress instruction
(SVDRESMOV).
In the tip dress instruction (SVDRESMOV), the clearance file is not used
but the clearance operation is done in this condition.
The pattern of the SVDRESMOV is always SQUARE, whereas one out
of three clearance operation patterns (MOVE&CLOSE, SQUARE AND
MOVE&OPEN) can be selected in the SVSPOTMOV.
8. DISTANCE TO UPPER TIP
9. DISTANCE TO LOWER TIP
Set the distance between the dresser and the point of the tip.
In the tip dress instruction (SVDRESMOV), the manipulator and the gun
will move so that tips are distanced from the dresser by the distance set
in this item before and after the dressing operation.
10. THICKNESS
When “upper-tip” or “lower-tip” is selected for the teaching type, this
item need to be set.
11. ROTATION WAIT TIME
Set this item as a waiting time from starting the tip dressing instruction
(SVDRESMOV) to the gun closing.
12. IO CONDITION
Set IO for the tip dress instruction (SVDRESMOV).
13. ROTATION REQUEST
This item appears when “IO” is specified to {DRESSOR}.
Set a signal which is output same time with the execution of the tip
dress instruction (SVDRESMOV).
14. DRESS EXECUTING
This item appears when a servo dresser control group is specified to
{DRESSOR}.
Set a signal which is output same time with the execution of the tip
dress instruction (SVDRESMOV).
15. SERVO DRESSER CONDITION
This item appears when a servo dresser control group is specified to

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{DRESSOR}.
16. ROTATION DIRECTION
Set a rotating direction of the servo dresser.
17. ROTATION SPEED (1ST PRESS)
18. ROTATION SPEED (2ND PRESS)
Set a rotating speed of the servo dresser.
When the tip dress instruction (SVDRESMOV) is started, the dresser
rotates at a rotation speed (1st press), and the speed shifts to a rotation
speed (2nd press) when the gun pressure is changed to the 2nd press
and this speed is kept till the tip dress instruction (SVDRESMOV) is
completed.
19. SPEED FLUCTUATION LIMIT
Set the speed fluctuation tolerance value for the tip dress instruction
(SVDRESMOV). Alarm may occur in case the actual speed is
decreased (or increased) from the speed specified at {ROTATION
SPEED (1ST PRESS)} or {ROTATION SPEED (2ND PRESS)}.

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 Operating procedures
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {TIP DRESS CONDITION}.

– TIP DRESS CONDITION window appears.

3. Select a file No. by pressing [PAGE].

4. Select a desired item.
5. Input a numeric value and press [ENTER].

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1.11.4 Dressing Position Teaching Operation

1. Select {JOB} on the {Main Menu}.
2. Select {JOB}.

– JOB CONTENT window appears.

When registering a pressure instruction (SVSPOT,

NOTE SVGUNCL, SVSPOTMOV or SVDRESMOV), create a job
in which a gun axis control group is included.

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3. Press [SHIFT] + [MOTION TYPE] to indicate SVSPOTMOV.

4. Press [MOTION TYPE] to indicate SVDRESMOV .

– Changing the motion type with [MOTION TYPE] is available only

while the manipulator is in operation status ([ROBOT] LED light is in
lit status).
– SVSPOTMOV and SVDRESMOV alternate each time [MOTION
TYPE] is pressed.
5. Edit the instruction tag item.
6. Press [INSERT], and then press [ENTER].
– Following items appear on the window when the tip dress instruction
is registered.

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1.11 Tip Dressing Instruction (SVDRESMOV Instruction)

1.11.5 Tip Dress Instruction

Following shows the tip dress instruction.
SVDRESMOV
V=500.0 VCL=100.0 VOP=100.0 PLIN=0 PLOUT=0 GUN#(1) DRS#(1)
1 2 3 4 5 6 7
1. Speed
Set the speed.
2. Gun pressure speed
Set the closing speed for the manipulator and the gun before dressing
operation.
In case this tag is omitted, the speed specified at 1.Speed is employed.
3. Gun open speed
Set the opening speed for the manipulator and the gun after dressing
operation.
In case this tag is omitted, the speed specified at 1.Speed is employed
4. Positioning IN level
Set the positioning level at the clearance position before dressing.
5. Positioning OUT level
Set the positioning level at the clearance position after dressing.
6. Gun number
Set a gun number for executing the tip dress operation.
7. Tip dress condition
Set a condition file number for executing the tip dress operation.

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1.11.5.1 Tip Dress Instruction (SVDRESMOV) Flow

Move to the clearance position Closing Apply Opening Dresser

Dresser rotation start operation pressure operation rotation finish

Rotation wait time

Rotation request
I/O dresser

Dresser
rotation speed

Dresser
executing signal
Servo dresser

Rotation speed (2nd press)

Rotation speed (1st press)

Dresser
rotation speed

2nd press

1st press

Gun pressuring status

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1.11 Tip Dressing Instruction (SVDRESMOV Instruction)

1.11.5.2 Suspend and Restart of the Tip Dress Operation

– In case the execution of the tip dress instruction (SVERESMOV) is
suspended with Hold operation after the gun close motion is started,
the robot and the gun will stop after they move to the clearance
position.
– In case the execution of the tip dress instruction (SVERESMOV) is
suspended with Hold operation or by an emergency stop and then
restarted, tip dressing instruction (SVERESMOV) is executed from
the beginning.
– Even if the execution of the tip dress instruction (SVERESMOV) is
suspended by an emergency stop, outputting of “rotation request”
(for the IO dresser) or “dress executing signal” (for the servo
dresser) is kept ON.
– In case the execution of the tip dress instruction (SVERESMOV) is
suspended with Hold operation or by an emergency stop, the
rotation of the servo dresser will stop.

1.11.5.3 Individual Control Instruction to a Dresser and a Gun

In the tip dress instruction (SVERESMOV), coordinated motion of the
manipulator, gun and dresser is available. However, instructions below
enable independent operations of the gun and the dresser.

 DRESSON Instruction
Use this instruction when dresser rotation is required.

DRESSON DRS#(1)
1
1. Tip dress condition
Specifies the tip dress condition file number

About DRESSON instruction

– This instruction turns ON the outputting of “rotation request” (for the
IO dresser) or “dress executing signal” (for the servo dresser) set to
the specified tip dress condition.
– For the servo dresser, this instruction rotates the servo dresser.
– This instruction waits for the time set to {ROTATION WAIT TIME} in
the specified tip dress condition.
In case a job is suspended with Hold operation or by an emergency stop
after the execution of DRESSON instruction.
– Outputting of “rotation request” (for the IO dresser) or “dress
executing signal” (for the servo dresser) are kept turned ON.
– For the servo dresser, the servo dresser rotation is stopped.
(And it resumes the rotation after the job is re-executed.)
In the DRESSON instruction, pressurizing of the gun is not executed.

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 DRESSOF Instruction
Use this instruction when stopping the rotation of the dresser.

DRESSOF DRS#(1)
1
1. Tip dress condition
Specifies the tip dress condition file number

About DRESSOF instruction

– This instruction turns OFF the outputting of “rotation request” (for the
IO dresser) or “dress executing signal” (for the servo dresser) set to
the specified tip dress condition.
– For the servo dresser, this instruction stops rotating the servo
dresser.

 SVGUNCL Instruction
The tip dress condition file can be specified to SVGUNCL instruction.

SVGUNCL GUN#(1) DRS#(1)

1 2

1.Gun number
Set the gun number to execute the tip dress operation.
2. Tip dress condition
Specify the tip dress condition file number

When specifying the tip dress condition file to SVGUNCL instruction

– Pressure is applied under the pressure condition in the specified tip
dress condition.
– When the servo dresser is rotated by DRESSON instruction, the
rotation speed is shifted to the rotation speed (2nd press) at the
same time when the 2nd pressure is reached.
– The wear compensation at the previous move instruction and arm
bend compensation at pressurization are executed.

Even if the tip dress condition file is specified in SVGUNCL instruction,

“rotation request” (for the IO dresser) or “dress executing signal” (for the
servo dresser) will not be turned ON. Also, the servo dresser doesn’t
rotate.

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1.11.5.4 Wear Detection with Tip Dressing Instruction

By adding tags for wear detection (TWC-A, TWC-C) to Tip Dressing
Instruction (SVDRESMOV Instruction), amount of wear is detected.

<Example>
SVDRESMOV GUN#(1) DRS#(1) TWC-A
SVDRESMOV GUN#(1) DRS#(1) TWC-C
For the details of TWC-A, TWC-C and wear detecting operation, refer to
chapter 1.12 Tip Wear Detection and Wear Compensation (Motor Gun).
When detecting wears with Tip Dressing Instruction (SVDRESMOV
Instruction), set a value to {DRESSER THICKNESS} on SPOT
SUPERVISION window.
Please note that this instruction is not available for registering the base
position for wear detection.

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 DRESSER THICKNESS setting

1. On APPLICATION CONDITION SETTING window, select “GUN
CLOSE” at {CLEARANCE TEACHING METHOD}.
2. Contact the fixed side tip to the servo dresser, and then press
[INTERLOCK] + [8] to apply pressure.
3. Select {SPOT WELDING} on the {Main Menu}.
4. Select {SPOT SUPERVISION}
– SPOT SUPERVISION window appears.

5. Select a gun number by pressing [PAGE].

6. Select {DATA} and {DRESSER THICKNESS REGISTER}.
– Thickness of the dresser is registered.
7. Press [INTERLOCK] + [9] to release pressurization.

In case a certain thickness is to be fixed, directly input the value to

{DRESSER THICKNESS}. At this time, it is not necessarily apply
pressure by pressing [INTERLOCK] + [8].

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1.11.6 Dry Tip Dressing Operation

{DRY TIP DRESS (WITHOUT PRESSING)} and {DRY TIP DRESS
(WITHOUT DRESSING)} signals enable dry tip dressing operation.
For the settings of this signal, refer to chapter 1.4.2.3 I/O Allocation.

 Dry tip dressing operation (without pressing) signal

When executing SVDRESMOV instruction after turning ON this signal:
– the gun close motion is not executed.
– the gun pressurization is not executed.
– in case of the servo dresser, although the gun pressurization is not
executed, the dresser’s rotating speed changes to the 2nd rotation
speed after the manipulator and the gun move to the clearance
position and the time set to {1st time} elapsed.
Also, when this signal is turned ON, SVGUNCL instruction to which the tip
dress condition file is specified (SVGUNCL instruction to which DRS# tag
is used) is no longer executed.

 Dry tip dressing operation (without dressing) signal

When executing SVDRESMOV instruction after turning ON this signal:
– Outputting of “rotation request” (for the IO dresser) or “dress
executing signal” (for the servo dresser) at the tip dress condition file
specified by SVDRESMOV is not turned ON.
– The servo dresser is not rotated even if it is a servo dresser.
– It does not wait for the time specified at {ROTATION WAIT TIME} on
the tip dress condition file specified by SVDRESMOV.
Also, DRESSON instruction is no longer executed when this signal is
turned ON.

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1.11.7 Tip Dress Supervision

On this window, dress length, dress time, servo dresser starting torque
and dressing torque can be monitored.
Furthermore, by setting the allowable values and universal output signal
numbers, designated signal can be turned ON in case one of the above
mentioned values exceeded the value in {TOLERANCE}.
Updating of the current value and comparing of the current value with the
value in {TOLERANCE} are performed when executing the SVGUNCL
Instruction (SVGUNCL DRS#( ) …) or SVDRESMOV Instruction to which
TIP DRESS COND FILE is designated.
However, updating of the current value and comparing of the current value
with the value in {TOLERANCE} would not be performed in case above
mentioned instructions are suspended due to emergency stop, Hold
operation or occurrence of an alarm.
Also, in case a selected dresser designated by Tip Dress Condition File is
I/O dresser, set “0” to both {STARTING TORQUE} and {DRESSING
TORQUE} and comparing of the current value with the value in
{TOLERANCE} is not performed.

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 TIP DRESS COND. Window

1
2

1. DRESS LENGTH
(CURRENT, TOLERANCE, SETTING(OUT#))
Current length for dressing operation is indicated.
Tolerance range for this operation: 0.00 to 9.99 mm
– Condition to ON the signal
Current value < Tolerance range
– Condition to OFF the signal
Current value >= Tolerance range
2. DRESS TIME (CURRENT, TOLERANCE, SETTING(OUT#))
Current dressing time is indicated.
Tolerance range for this operation: 0.00 to 9.99 sec
– Condition to ON the signal
Current value > Tolerance range
– Condition to OFF the signal
Current value =< Tolerance range
3. STARTING TORQUE (CURRENT, TOLERANCE, SETTING
(OUT#))
An absolute data for servo dresser average torque, which is measured
between 100 msec and 300 msec after the rotation is started, is indi-
cated.
Tolerance range for this operation: 0 to 300%
In case pressure is applied no later than 300 msec after the rotation is
started, “0” is indicated to {CURRENT} of {STARTING TORQUE}. Also,
at this time, the universal signal will not be controlled.
– Condition to ON the signal
Current value < Tolerance range (minimum value) or Current value>
Tolerance range (maximum value)
– Condition to OFF the signal
Tolerance range (minimum value) =< Current value =< Tolerance
range (maximum value)

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4.DRESSING TORQUE(CURRENT, TOLERANCE, SETTING

(OUT#))
Servo dresser average torque absolute data measured between the
pressure reach time and pressure complete time is indicated.
Tolerance range for this operation: 0 to 300%
– Condition to ON the signal
Current value < Tolerance range (minimum value) or Current value>
Tolerance range (maximum value)
– Condition to OFF the signal
Tolerance range (minimum value) =< Current value =< Tolerance
range (maximum value)
5. CLEAR TORALENCE OUTPUT
OFF all the universal output signals designated to DRESS LENGTH,
DRESS TIME, STARTING TORQUE and DRESSING TORQUE when a
specified CLEAR TORALENCE OUTPUT is changed from OFF to ON.

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 Operating procedures
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {TIP DRESS SUPERVISION}.

– TIP DRESS SUPERVISION window appears.

3. Select a COND No. by pressing [PAGE].

4. Select a desired item.
5. Input a numeric value and press [ENTER].

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1.12 Tip Wear Detection and Wear Compensation (Motor Gun)

1.12 Tip Wear Detection and Wear Compensation (Motor Gun)

1.12.1 Wear Detection and Wear Compensation Operation Flow Chart

Mount a new tip

Teach the manipulator operation position

Clear the base positions.

(Refer to chapter 1.12.3)

Register the base position (fixed side) by

dry spot touch motion.
(Refer to chapter 1.12.2.1.)

Register the base position (movable side) by

dry spot movable side tip detecting motion
(Refer to chapter 1.12.2.2.)

Perform welding

Tip dressing

Read the position by dry spot touch motion.

(Refer to 1.12.2.1.)

Read the position by movable side tip detecting motion.

(Refer to 1.12.2.2.)

Calculate the wear amount for movable and fixed side tips.

When the wear amount is

less than the allowable value.

Outputting a tip replacement request signal

(only when specified).

Tip replacement

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1.12 Tip Wear Detection and Wear Compensation (Motor Gun)

1.12.2 Wear Detection

This section explains the method to detect the tip wear amount by dry spot
touch motion and movable side tip detection.

After registering the wear base position, do not change the

pressure condition settings used for the wear detection dry
NOTE spot motion.
In case the setting is changed, the wear detection may not
be executed appropriately.

As a pressure condition for the wear detection dry spot

motion, the dry spot pressure file (PRESSCL tag) can be
used other than the wear detection pressure condition
(PRESSTWC tag) described in chapter 1.12.2.1 Dry Spot
Touch Motion and chapter 1.12.2.2 Movable Side Tip
Detection.
When the wear detection pressure condition (PRESSTWC
tag) is used, the dry spot is executed under the condition of
the {TOUCH SPEED} and {DETECT PRESSURE} on the
SUPPLE-
MENT spot supervision window.
When the dry spot pressure file (PRESSCL tag) is used, the
dry spot is executed under the dry spot pressure file condi-
tion.
Setting in the dry spot pressure file can be changed during
the operation because the file may be used in other pur-
poses other than wear detecting. For this reason, it is recom-
mended to use the wear detection pressure condition
(RESSTWC tag).

1.12.2.1 Dry Spot Touch Motion

The gun axis position is acquired when the movable side (upper) tip
touches the fixed side (lower) tip.
Dry spot touch motion is carried out by a SVGUNCL (dry spot) instruction.
“Base position (fixed)” will be registered when this operation is executed
while “base position (fixed)” is not registered on the spot supervision
window.
When executing the dry spot touch motion again after this registration is
done, the position difference between the detected position and the base
position is calculated as the whole wear amount (total amount of fixed side
wear amount and movable side ware amount).
<Example>
SVGUNCL GUN#(1) PRESSTWC TWC-A
1 2 3
1. Gun No.
2. Wear detection pressure condition
3. Wear detection operation type

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1.12.2.2 Movable Side Tip Detection

The gun axis position is acquired when the movable side (upper) tip
passes the sensor.
The movable side tip detection operation is carried out by a SVGUNCL
(dry spot) instruction.
“Base position (movable)” will be registered when this operation is
executed while “base position (movable)” is not registered on SPOT
SUPERVISION window.
When executing the movable side tip detection motion again after this
registration is done, the position difference between the detected position
and the base position is calculated as the wear amount at the movable
side.
If this operation is done after the procedures described in
chapter 1.12.2.1 Dry Spot Touch Motion, the wear amount of the fixed
side and the movable side are calculated independently and the results
are indicated on the spot supervision window.
<Example>
SVGUNCL GUN#(1) PRESSTWC TWC-B
1 2 3
1. Gun No.
2. Wear detection pressure condition
3. Wear detection operation type

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1.12.2.3 Example of Wear Detection

Dry spot touch motion Movable side tip detecting motion

Movable side tip

Sensor Sensor
1 3 (light emitting side) 4 6 (light receiving side)

2 5

Fixed side tip

<Job Example>
1. MOVJ
2. SVGUNCL GUN#(1) PRESSCTWC TWC-A
(Dry spot touch motion)
3. MOVJ
4. MOVJ
5. SVGUNCL GUN#(1) PRESSTWC TWC-B
(Movable side tip detecting motion)
6. MOVJ

For the double arm move gun, teach a job so that the upper
side tip passes the sensor detecting zone when using the
sensor detection.
NOTE Also, set the polarity of the signal that is output from the
sensor, by the setting item “WEAR DETECT SENSOR
POLARITY” in chapter 1.12.3 "Spot Supervision Window
Setting".

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1.12.3 Spot Supervision Window Setting

Shows the tip wear amount, etc.
Also, the wear amount detection relevant settings can be performed.

 Spot supervision window

2
3

4
5
6
7
8
9
10
11

12
13
14
15
16
17
18

1. GUN NO.
Shows the gun No.
Select the No. by pressing [PAGE].
2. WELD COUNT
(CURRENT, TOLERANCE, SETTING(OUT#))
The numbers that the welding instruction (SVSPOT, SVSPOTMOV) is
performed is indicated to {CURRENT} as the present value.
Also, the universal output signal specified at {SETTING (OUT#)} is
turned ON when a value in {CURRENT} has exceeded a value in {TOL-
ERANCE}.
3. RESET COUNT
The value at {WELD COUNT (CURRENT)} can be cleared when the
signal specified to {RESET COUNT} is turned ON.
4. WEAR (M) (CURRENT, TOLERANCE, SETTING(OUT#))
Present wear amount at the movable side tip is indicated.
The value is updated when the wear detection is finished.
Also, the universal output signal specified at {SETTING (OUT#)} is
turned ON when the value in {CURRENT} has exceeded the value in
{TOLERANCE}.

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5. WEAR (F)
Present wear amount at the fixed side tip is indicated.
The value is updated when the wear detection is finished.
Also, the universal output signal specified at {SETTING (OUT#)} is
turned ON when the value in {CURRENT} has exceeded the value in
{TOLERANCE}.
6. RESET WEAR (M)
The value at {RESET WEAR (M)} can be cleared when the signal spec-
ified to {RESET WEAR (M)} is turned ON.
7. RESET WEAR (F)
The value at {RESET WEAR (F)} can be cleared when the signal speci-
fied to {RESET WEAR (F)} is turned ON.
8. TIP MOUNTING ERROR (M)
Movable side tip mounting error is indicated.
The value is updated when the tip mounting error detection is finished.
For the details, refer to chapter 1.12.8 "Tip Mounting Position Error
Detection".
9. TIP MOUNTING ERROR (F)
Fixed side tip mounting error is indicated.
The value is updated when the tip mounting error detection is finished.
For the details, refer to chapter 1.12.8 .
10. BASE POS (M)
In case {BASE POS (M)} has not been register, the detected position is
registered as the base position by the execution of the movable side tip
detection motion.
11. BASE BOS (F)
In case {BASE POS (F)} has not been register, the detected position is
registered as the base position by the execution of the dry spot touch
motion.
12. DETECTED THICKNESS (CURRENT, SETTING(M))
Detected thickness of the workpiece is indicated to this item when the
workpiece thickness detecting function is used.
If a value more than 0 is set to {SETTING (M)}, the detected thickness is
written to the specified register.
For the details, refer to chapter 1.13.8 "Workpiece Thickness Detec-
tion Function".
13. TOUCH SPEED
Set the gun closing speed with a link speed (%) when executing a wear
detecting dry spot motion (executing SVGUNCL using PRESSTWC
tag).
14. DETECT PRESSURE
Set the detecting pressure for the touch detection when executing the
wear detecting dry spot motion (executing SVGUNCL using
PRESSTWC tag).
15. WEAR RATIO (FIXED SIDE)
To the wear amount detected by the wear detection operation (TWC-C),
specify the wear ratio to the fixed side tip.
16. WEAR COMPENSATION OFFSET (FIXED SIDE)
If the fixed side tip is required to be always shifted for a certain amount,
set the certain shifting amount to this item.
17. WEAR DETECT SENSOR DIN NO.
Set a direct-in No. to which a sensor signal used for the movable side tip
detecting motion (wear detecting operation (TWC=B)) is input.

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18. WEAR DETECT SENSOR POLARITY

Set the polarity of the sensor signal used for the movable side tip detect-
ing motion (wear detecting motion (TWC=B)).
Select {ON -> OFF}: Normal status is ON and it turns OFF when the tip
passes the sensor.
Select {OFF -> ON}: Normal status is OFF and it turns ON when the tip
passes the sensor.

 Operating procedures
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {SPOT SUPERVISION}.

– SPOT SUPERVISION window appears.

3. Select a gun No. by pressing [PAGE].

4. Select a desired item.
5. Input a numeric value and press [ENTER].

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 Manual clearing procedures of weld count and wear amount

1. Select {DATA} in the menu area.
2. Select {CLEAR W.COUNT/WEAR}.

3. Select “YES”.

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 Clearing the wear detection base position

After modifying the wear detection motion, etc. clear this value.
1. Select {DATA} in the menu area.
2. Select {CLEAR BASE POS}.

3. Select “YES”.

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1.12.4 Wear Compensation

The manipulator motion and the gun stroke are adjusted according to the
amount of tip wear.
Wear compensation is performed to the following positions.
– To the teaching position short before SVSPOT instruction
– To the teaching position short before SVGUNCL instruction to which
WP tag or DRS tag is used.
– SVSPOTMOV teaching position
– SVDRESMOV teaching position
The figure below shows an example of the compensation under the
following conditions.
Single arm gun, Movable side wear amount: 3 mm, Fixed side wear
amount: 5 mm

Movable side tip

3 mm
Workpiece

5 mm

Fixed side tip

Compensate the fixed side tip Compensate the gun strok for
5mm in the Z-axis+ direction 8 (=5+3) mm.
on the user coordinates.

<Job Example>
MOVJ
MOVJ ← In this position, wear compensation is done.
SVSPOT GUN#(1) PRESS#(1) WTM=1 WST=1
MOVJ
MOVJ

The fixed side tip is always shifted in the Z-axis + direction

NOTE on the tool coordinates. Therefore, be sure to register the
tool position and direction correctly. (Refer to
chapter 1.4.3 "Registering the Operation Tool".)

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1.12.5 Tip Wear Compensation for Fixed Gun

The tip wear for the fixed gun (the gun that is not mounted on the manipulator)
can be detected and compensated in the following manner.

The wear amount of the tip for the fixed gun cannot be
detected by the fixed sensor.
NOTE
Build a system so that the sensor can move into the fixed
gun’s motion range to detect the tip wear.

1.12.5.1 Setting the User Coordinates

Set the user coordinate with its home position located on the fixed tip end.
The + direction of the Z-axis must be directed towards the movable tip.

User coordinates

Z
X

The YRC1000 has the External Reference Point Control

Function (the function to execute teaching or playback
operation with the manipulator TCP set to a point in space).
NOTE If the direction of coordinates used for the External Refer-
ence Point Control Function is the same as that of the
above coordinates, resetting the user coordinates is not
required.

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1.12.5.2 User Coordinate Number Setting

1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {GUN CONDITION}.
3. Move the cursor to {GUN INSTALLATION STATUS} and press
[SELECT].
– Select “FIXED”.
– {USER COORDINATE NO.} is indiated.

4. To {USER COORDINATE NO.}, specify a user coordinate No.

specified to the gun.

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1.12.5.3 Example of Compensation

The manipulator motion and the gun stroke are adjusted according to the
amount of tip wear.
Wear compensation is performed to the following positions.
– To the teaching position short before SVSPOT instruction
– To the teaching position short before SVGUNCL instruction to which
WP tag or DRS tag is used.
– SVSPOTMOV teaching position
– SVDRESMOV teaching position
<Job Example>
MOVJ
MOVJ ← In this position, wear compensation is done.
SVSPOT GUN#(1) PRESS#(1) WTM=1 WST=1
MOVJ
MOVJ

<Example of compensation>
Single arm move, Movable side wear amount: 3 mm, Fixed side wear
amount: 5mm

Movable side tip

3 mm
Workpiece

5 mm

Fixed side tip

Compensate the fixed side tip Compensate the gun strok for
5mm in the Z-axis+ direction 8 (=5+3) mm.
on the user coordinates.

The workpieces is compensated in the Z-axis + direction on

the specified user coordinates. Therefore, be sure to regis-
NOTE ter the position and direction of the user coordinates cor-
rectly. (Refer to chapter 1.12.5.1 Setting the User
Coordinates.)

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1.12.6 Teaching Positions with a Worn Tip

When teaching positions with a worn tip, the teaching position is
registered, adjusted by tip wear amount.

1.12.6.1 Teaching Example

Workpiece

Tip with 5 mm wear

New tip
t
Perform teaching with Even after the tip is replaced,
electr
a 5 mm-worn tipith the operation is performed with the
5-m same relative positions of the workpieces
and the top of the tip as it is performed
with the worn tip.

• Adjustment of the teaching point on the basis of the wear

amount is performed to the following positions.
– To the move instruction teaching point short before
the SVSPOT instruction.
– To the move instruction teaching point short before
NOTE the SVGUNCL instruction to which WP or DRS tag is
used.
– To the SVSPOTMOV teaching point.
– To the SVDRESMOV teaching point.
• The wear amount is ignored when registering positions in
other move instructions.

1.12.6.2 Parameters
AxP010: Invalid wear range for teaching point adjustment (units: μm)
Set the invalid range of the wear amount out of which compensation
becomes enabled. Compensation is not carried out when the wear
amount is within the invalid range.
<Example>
In case of AxP010 = 1000:
Wear amount ≥ 1mm : The taught position is registered
adjusted by the wear amount.
Wear amount < 1mm : The taught position is registered
disregarding the wear amount.

AxP014: Displaying method when the teaching is performed

0 : A message “Compensated position.” appears when the position
is registered.
1 : The dialog box appears before the position is registered with a
message “Compensate? YES/NO.”.

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1.12.7 Wear Amount Loading

Detected wear amount can be loaded in a job.
The wear amount is stored in the system D variable ($D). Use GETS
instruction and load the wear amount.

<Example>
GETS D000 $D030
The wear amount of Gun 1 (movable side) is stored in D000.
(Unit: μm)
$D30 Gun 1 movable side (upper) wear amount
$D31 Gun 1 fixed side (lower) wear amount
$D32 Gun 2 movable side (upper) wear amount
$D33 Gun 2 fixed side (lower) wear amount
$D34 Gun 3 movable side (upper) wear amount
$D35 Gun 3 fixed side (lower) wear amount
$D36 Gun 4 movable side (upper) wear amount
$D37 Gun 4 fixed side (lower) wear amount
$D38 Gun 5 movable side (upper) wear amount
$D39 Gun 5 fixed side (lower) wear amount
$D40 Gun 6 movable side (upper) wear amount
$D41 Gun 6 fixed side (lower) wear amount
$D42 Gun 7 movable side (upper) wear amount
$D43 Gun 7 fixed side (lower) wear amount
$D44 Gun 8 movable side (upper) wear amount
$D45 Gun 8 fixed side (lower) wear amount
$D46 Gun 9 movable side (upper) wear amount
$D47 Gun 9 fixed side (lower) wear amount
$D48 Gun 10 movable side (upper) wear amount
$D49 Gun 10 fixed side (lower) wear amount
$D50 Gun 11 movable side (upper) wear amount
$D51 Gun 11 fixed side (lower) wear amount
$D52 Gun 12 movable side (upper) wear amount
$D53 Gun 12 fixed side (lower) wear amount

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1.12.8 Tip Mounting Position Error Detection

The cause of the pressure position error when pressure is applied can be
sorted to two causes; tip wear and tip mounting position error.
By handling the causes separately, the real wear amount of tip itself can
be handled to decide the tip ideal replacing timing.

SPOT SUPERVISION window

Amount of wear

Manage separately

SPOTSUPERVISION
SPOT SUPERVISIONwindow
window
Tip Mounting Position Error

Tip mounting Tip wear

position error

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1.12.8.1 Tip Mounting Position Error Detection Flow Chart

 When the wear amount is imported to a tip mounting position error

after a wear amount detection job is executed.

Mount a new tip

Teach a manipulator motion positions

Clear the base positions

(Refer to 1.12.3)

Execute wear detection job

Register the base position (fixed side)

with dry spot touch motion
(Execute TWC-A) (Refer to 1.12.2.1)

Register the base position (movable side)

with movable side tip detecting motion
(Execute TWC-B) (Refer to 1.12.2.2)

Execute welding

Tip dressing

Execute wear detection job

(Execute TWC-A, TWC-B)

Calculate wear amount

If the wear amount is

Tip replacement request signal output
less than tolerance amount (only when it is specified)

Tip replacement

Execute wear detection job

(Execute TWC-A, TWC-B)

Immport tip mounting position error

on the SPOT SUPERVISION window

-Calculate tip mounting position error

-Clear the wear amount

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 When the tip mounting position error is detected with a job for tip
mounting position error detection.

Mount a new tip

Teach a manipulator motion position

Clear the base positions

(Refer to 1.12.3)

Execute wear detection job or

tip mounting position error detection job

Register the base position (fixed side)

with dry spot touch motion
(Execute TWC-A or TWC-AE)
(Refer to 1.12.2.1)

Register the base position (movable side)

with movable side tip detecting motion
(Execute TWC-B or TWC-BE)
(Refer to 1.12.2.2)

Execute welding

Tip dressing

Execute wear detection job

(Execute TWC-A, TWC-B)

Calculate wear amount

If the wear amount is

less than tolerance amount Tip replacement request signal output
(only when it is specified)

Tip replacement

Execute tip mounting position

error detection job
(Execute TWC-AE, TWC-BE)

-Calculate tip mounting position error

-Clear the wear amount

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1.12.8.2 Tip Mounting Position Error Detection

The method to execute the tip mounting position error detection operation
by dry spot touch motion and by movable side tip detection motion are
described here.
The following two methods are for detecting the tip mounting position
error.

This operation must be performed after new tips are

mounted.
NOTE If this operation is executed with the worn tip, signals on
wear (signal to request tip replacement, etc.) will not be out-
put properly since the wear itself is regarded as the tip
mounting position error.

 When the wear amount is imported to a tip mounting position error

after a wear amount detection job is executed.
Apply this method when wear detection and tip mounting position error
detection are to be executed in the common job.
• Dry spot touch motion (TWC-A)
The gun axis position is acquired when the movable side tip touches
the fixed side tip.
Execute SVGUNCL instruction (dry spot) for the dry spot touch
motion.
<Example>
SVGUNCL GUN#(1) PRESSTWC TWC-A
• Movable side tip detecting motion (TWC-B)
The gun axis position is acquired when the movable side tip position
is detected.
Execute SVGUNCL instruction (dry spot) for the movable side tip
detecting motion.

<Example>
SVGUNCL GUN#(1) PRESSTWC TWC-B
After wear is detected by the above mentioned instruction, import the wear
amount to the tip mounting position error on the SPOT SUPERVISION
window.

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 When the tip mounting position error is detected with a job for tip
mounting position error detection.
By adding tags for tip mounting position error detection (TWC-AE, TWC-
BE) to the dry spot instruction (SVGUNCL), tip mounting position errors
can be detected.
• Dry spot touch motion (TWC-AE)
The gun axis position is acquired when the movable side tip touches
the fixed side tip.
Execute SVGUNCL instruction (dry spot) for the dry spot touch
motion.

<Example>
SVGUNCL GUN#(1) PRESSTWC TWC-AE
• Movable side tip detecting motion (TWC-BE)
The gun axis position is acquired when the movable side tip position
is detected.
Execute SVGUNCL instruction (dry spot) for the movable side tip
detecting motion.

<Example>
SVGUNCL GUN#(1) PRESSTWC TWC-BE

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1.12.8.3 Job Examples

Dry spot touch motion Movable side tip detecting motion

Movable side tip

1 3 4 6
Plate

2 5
Fixed side tip

<Job Example>

 When the wear amount is imported to a tip mounting position error

after a wear amount detection job is executed.
1. MOVJ
2. SVGUNCL GUN#(1) PRESSTWC TWC-A
(Dry spot touch motion)
3. MOVJ
4. MOVJ
5. SVGUNCL GUN#(1) PRESSTWC TWC-B
(Movable side tip detecting motion)
On the SPOT SUPERVISION window, import the present wear amount
to the tip mounting position error.
6. MOVJ
Welding operation

 When the tip mounting position error is detected with a job for tip
mounting position error detection.

1’. MOVJ
2’. SVGUNCL GUN#(1) PRESSTWC TWC-AE
(Dry spot touch motion)
3’. MOVJ
4’. MOVJ
5’. SVGUNCL GUN#(1) PRESSTWC TWC-BE
(Movable side tip detecting motion)
6’. MOVJ

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Teach the following two positions to be the same position.

• in the job for tip mounting position error detection: the
position short before the dry spot touch motion
– “ 1’ ” in the above explanation
NOTE • in the wear detection job: the position short before the
dry spot touch motion
– “ 1 ” in the above explanation
Also, teach positions short before the movable side tip
detecting motion (“ 4 ” and “ 4’ ” in the above explanation) to
be the same position.

1.12.8.4 Importing the Tip Mounting Position Error

 Operation Procedures
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {SPOT SUPERVISION}.

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– SPOT SUPERVISION window appears.

3. Select a gun No. by pressing [PAGE].

4. Select {DATA} -{IMPORT T.M.ERROR}.

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5. Select “YES”.

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1.12.8.5 Monitoring the Failure of Mounting Tips

The failure of mounting tips can be monitored by the following parameters.
A1P56 : Universal output for the failure of mounting tips
A1P57 : Limit of tip mounting position error
(movable side) [μm]
A1P58 : Limit of tip mounting position error
(fixed side) [μm]

<Example>
AIP56=5, AIP57=1000 and AIP58=2000
The universal output signal 5 is output when either of the following
condition meets.
The limit of tip mounting position error (movable side) >= 1mm
The limit of tip mounting position error (fixed side) >= 2mm

The signal is not output when the value of the universal out-
NOTE put parameter (A1P56) or the value of both A1P57 and
A1P58 are 0.

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1.13 Other Functions Using a Motor Gun

1.13 Other Functions Using a Motor Gun

1.13.1 Motor Gun Stroke

The motor gun stroke is classified into two; full open and short open.

1.13.1.1 Registering the Full-open/Short-open Position

Eight stroke positions can be registered for full open and short open
respectively.

 Full Open Position Setting

1
2

1. GUN NO.
Shows the gun for position setting.
Select a gun No. by pressing [PAGE].
2. SEL
The mark “” is displayed at the currently selected position.
3. POSITION
Shows the gun stroke.

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1.13.1.2 Registering the current position

1. Press [3/FULL OPEN] or [-/SHORT OPEN] of the numeric keys.
– FULL OPEN POS SET window (or SHORT OPEN POS SET
window) appears.

2. Select a gun No. by pressing [PAGE].

3. Select a position to register a gun stroke and press [MODIFY] +
[ENTER].

1.13.1.3 Registering by entering a numerical value

1. Press [3/FULL OPEN] or [-/SHORT OPEN] of the numeric keys.
– FULL OPEN POS SET window (or SHORT OPEN POS SET
window) appears.

2. Select a position to register a gun stroke.

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

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1.13.1.4 Moving to Full-open/Short-open Position

1. Press [3/FULL OPEN] or [-/SHORT OPEN] of the numeric keys.
– FULL OPEN POS SET window (or SHORT OPEN POS SET
window) appears.

2. Select a gun No. by pressing [PAGE].

3. Change the position by pressing repeatedly [3/FULL OPEN] or
[-/SHORT OPEN].

4. Press [INTERLOCK] + [3/FULL OPEN] or [INTERLOCK] + [-/SHORT

OPEN].
– While FULL OPEN POS SET window (or SHORT OPEN POS SET
window) appears, pressing [FWD] moves the gun to the stroke set in
the {POSITION} which the cursor stay at.

1.13.1.5 Moving to Full-open/Short-open Position While Other Window is Displayed

By pressing [INTERLOCK] + [3/FULL OPEN] or [INTERLOCK] + [-/
SHORTOPEN] while the control group of the gun axis is selected by the
operation of pressing [SHIFT] + [EX. AXIS], the gun axis of the selected
group moves to FULL OPEN or SHORT OPEN position.

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1.13.2 Gun Change

1.13.2.1 Gun Change Instruction

Gun change is executed by the GUNCHG (gun change) instruction.

<Example>
GUNCHG GUN#(1) PICK
A B
1.Gun No.
2. Designation of connecting or disconnecting a gun
When “PICK (gun connected)” is selected, the power supply of the gun
motor is turned ON.
When “PLACE (gun disconnected)” is selected, the power supply of the
gun motor is turned OFF.

1.13.2.2 Signal Status to Execute GUNCHG Instruction

The signals must be in the status shown in the following table when
executing GUNCHG instruction.
Signal Name Input/ Explanation Signal
Output Status
Gun ID No. Input A binary signal to identify the gun Agree
(3 bits) number. with Gun
No. 1)
Gun Chuck Input The signal to confirm that the gun is ON
connected.
Normally, a chucking confirmation signal
of ATC is allocated.
Gun Unchuck Input The signal to confirm that the gun is OFF
disconnected.
Normally, an unchucking confirmation
signal of ATC is allocated.
Gun Unchuck Output The signal to connect the gun. OFF
Request Normally, a chucking signal of ATC is
allocated. (CHUCK = OFF, UNCHUCK =
ON)
1 The signal must agree with the gun number as shown in the following example.

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<When the Gun ID No. signal start with IN10, and the Gun ID No. signal
end with IN12:>
Gun No. IN10 IN11 IN12
GUN# (1) ON OFF OFF
GUN# (2) OFF ON OFF
GUN# (3) ON ON OFF
GUN# (4) OFF OFF ON
GUN# (5) ON OFF ON
GUN# (6) OFF ON ON

The signals listed in the table above are confirmed when the YRC1000
control power supply is turned ON.
If the signal status indicates that the gun is connected when YRC1000
controller is turned ON, the servo power supply for the gun motor turns
ON when the servo is turned ON.
If the signal status indicates that the gun is not connected when YRC1000
controller is turned ON, the servo power supply for the robot motor turns
ON when the servo is turned ON, but the servo power supply for the gun
motor is not turned ON.

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1.13.2.3 Gun Change Job

The following example explains the gun change job.

<Example of I/O Allocation>

Input Signal Output Signal
Gun Chuck IN1 Gun connect/disconnect SOL OUT1
Gun Unchuck IN2 Gun 1 cover open/close SOL OUT2
Coupling confirmation IN3
Gun 1 presence LS IN4
Gun 1 cover open limit IN5
Gun 1 cover close limit IN6
Gun ID No. signal (start) IN21
Gun ID No. signal (end) IN23

<Example of Mounting a Gun>

Job name: GUN 1 PICK
Control group: R1
NOP
MOVJ VJ=30 Moves to the standby position.
WAIT IN#(3)=OFF Confirms ATC uncoupling.
WAIT IN#(2)=ON Confirms ATC unchucking
WAIT IN#(4)=ON Confirms Gun 1 presence.
DOUT OT#(2)=ON Opens Gun 1 cover.
WAIT IN#(5)=ON Confirms Gun 1 cover opened.
:
MOVL V=500 Moves to the position which is just above the
Gun 1’s placing table.
MOVL V=100 PL=0 Moves to the ATC coupling position.
WAIT IN#(3)=ON Confirms ATC coupling.
DOUT OT#(1)=OFF ATC chucking
WAIT IN#(1)=ON Confirms ATC chucking.
GUNCHG GUN#(1) PICK Turns ON the gun motor power.
TIMER T=0.2 Waits for 0.2 seconds.
MOVL V=1000 Lifts the Gun 1.
:
WAIT IN#(4)=OFF Confirms Gun 1 absence.
DOUT OT#(2)=OFF Closes Gun 1 cover.
WAIT IN#(6)=ON Confirms Gun 1 cover closed.
:
MOVJ VJ=30 Moves to the standby position.
END

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<Example of Removing a Gun>

Job name: GUN 1 PLACE
Control group: R1
NOP
MOVJ VJ=30 Moves to the standby position.
WAIT IN#(3)=ON Confirms ATC coupling.
WAIT IN#(4)=OFF Confirms Gun 1 absence.
DOUT OT#(2)=ON Opens Gun 1 cover.
WAIT IN#(5)=ON Confirms Gun 1 cover opened.
:
MOVL V=500 Moves to the position which is just above
the Gun 1’s placing table.
MOVL V=100 PL=0 Moves to Gun 1 placing position.
WAIT IN#(4)=ON Confirms Gun 1 presence.
GUNCHG GUN#(1) PLACE Turns OFF gun motor power.
TIMER T=0.2 Waits for 0.2 seconds.
DOUT OT#(1)=ON ATC unchucking
WAIT IN#(2)=ON Confirms ATC unchucking
MOVL V=1000 Disconnects the gun.
:
WAIT IN#(4)=ON Confirms Gun 1 presence.
DOUT OT#(2)=OFF Closes Gun 1 cover.
WAIT IN#(6)=ON Confirms Gun 1 cover closed.
:
MOVJ VJ=30 Moves to the standby position.
END

NOTE Be sure to confirm the unchucking status when moving an

automatic tool changer to the chuck position.

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1.13.2.4 Gun Changing Timing

The timing to change a gun is illustrated below.

PLACE
Gun Status
PICK
ON
Coupling Confirmation
OFF
Gun ID No. Signal ON
OFF
CHUCK
Connect/Disconnect SOL
UNCHUCK
ON
Gun Chuck
OFF
ON
Gun Unchuck
OFF
Gun-Axis Servo ON

OFF

GUNCHG PICK GUNCHG PLACE

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1.13.3 Touch Teaching Function

Even if the fixed tip position cannot be visually confirmed when teaching, it
is possible to register the position where the fixed tip touches the
workpiece by moving the movable tip to touch the workpiece.

Workpiece
thickness: d mm

Distance beween
tips: s mm
Correction in the Tool
Z+ direction for (s-d) mm

1.13.3.1 Setting the Workpiece Thickness

 GUN DETAIL SETTING Window (Workpiece Thickness Setting)

1
2
3

1. THICKNESS
Enter the thickness of workpiece to be welded.
2. GUN STROKE
Shows the distance between tips at the touch teaching. Pressing
[SHIFT] + [ENTER] on the JOB window changes the value.
3. TCP ADJUSTMENT
Shows the corrected distance of fixed tip at the touch teaching.

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 Operation
1. Select {SPOT WELDING} in the {Main Menu}.
2. Select {GUN DETAIL SETTING}.

– GUN DETAIL SETTING window appears.

3. Select a gun No. by pressing [PAGE].

4. Select “THICKNESS.”

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

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1.13.3.2 Registering and Confirming Positions by Touch Teaching

1. Select {JOB} on the {Main Menu}.
2. Select {JOB}.

3. Move the manipulator to the welding position.

4. Move the movable tip to touch the workpiece.
5. Press [SHIFT] + [ENTER].

Workpiece
thickness: d mm

Distance between
tips: s mm Correction in the
ToolZ+ direction for (s-d) mm

Teaching position Corrected position

(Press [SHIFT] + [ENTER] to register) (Move the manipulator by pressing [FWD])

– Press [SHIFT] + [ENTER] on the JOB window to make a correction

in the tool coordinates Z+ axis direction.
– Press [FWD] to move the manipulator to confirm the corrected
position that is actually registered.
– After having taught the position by pressing [SHIFT] + [ENTER], the
manipulator correction amount can be confirmed on GUN DETAIL
SETTING window.

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1.13.4 Signal Dry Spot

Gun-pressure can be applied by inputting an external signal.

Gun-pressure can be applied by an external signal for dry

NOTE spot only.
Welding cannot be carried out by an external signal.

1.13.4.1 Setting an Input Signal Number

1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {GUN DETAIL SETTING}.

– GUN DETAIL SETTING window appears.

3. Select a signal number to be set.

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 DRY SPOT SIGNAL(FILE)

• After the signal is input, pressurizing is started.
• Pressure is applied according to the settings in the dry spot pressure
file specified by {PRESSURE FILE NO.}
• The gun stops applying pressure after a specified time period.
• In case DRY SPOT (FILE) motion is stopped by the emergency stop,
the gun will stay at the position where it is stopped.

 DRY SPOT SIGNAL(CONTINUE)

• The signal input and pressurizing is started as well as the above, but
pressurizing is continued during the signal input.
• Pressure is applied according to the setting specified by {DRY SPOT
PRESSURE(CONTINUE)}.
• When the signal is turned OFF, the gun stops applying pressure.
• In case DRY SPOT (COTINUE) motion is stopped by the emergency
stop during the gun closing or opening, the gun will stay at the posi-
tion where it is stopped. But when the gun is stopped by the emer-
gency stop during pressurization, by turning ON the servo and then
turning OFF the signal, the gun can return to the position where DRY
SPOT (CONTINUE) motion is started.

• When the signal number “0” is selected, the Signal Dry

Spot is disabled.
• The dry spot signal (file) motion is executed when specify-
ing the same signal to both DRY SPOT SIGNAL(FILE)
NOTE and DRY SPOT SIGNAL(CONTINUE) and inputting the
signal.
• In case the same signal is specified to several guns and it
is input, only the gun with the smallest gun number among
the same-number specified guns executes pressurization.

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1.13.5 Gun Pressure Compensation Function

1.13.5.1 Operation Flow Chart

With the gun pressure compensation function, the gun pressure can be
kept stable even when the motor gun posture changes.
The following shows the operation flow chart for the gun pressure
compensation.

Start

Set the pressure-to-torque

conversion value
Register the data for applying pressure (for applying pressure downwards).
downwards in the GUN CONDITION file.

Set the pressure compensation value.

(Set the pressure difference between
Set the PRESSURE COMPENSATION
pressurizing downwards and upwards.)
value in the GUN CONDITION file.

Teach the welding point.

End

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1.13.5.2 Overview
The following describes outline of the gun pressure compensation
function.

The pattern 1 is shown in the fig. 1-3; applying pressure downwards, and
the pattern 2 is shown in the fig. 1-4; applying pressure upwards.
In case of the pattern1, since the pairs of pressure and torque data (twelve
pairs at maximum) is set with the gun pressurizing downwards (see
fig. 1-6Pressure-to-torque Conversion (For Pattern 1)) in the GUN
CONDITION file, the torque of the motor gun for the specified pressure is
calculated just by interpolation of these pairs of data.
Fig. 1-3: Pattern 1 (Applying Pressure Downwards)

Z-axis + direction
on the tool coordinates

Fig. 1-4: Pattern 2 (Applying Pressure Upwards)

Z-axis + direction
on the tool coordinates

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Fig. 1-5: GUN CONDITION File (Downward Pressure)

Fig. 1-6: Pressure-to-torque Conversion (For Pattern 1)

Toque
Measured values
(%)

Calculated by interpolation

Pressure (kgf)

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For the pattern 2 shown in fig. 1-4Pattern 2 (Applying Pressure Upwards),

the weight of the motor gun itself may cause deviation of pressure.

Using the gun pressure compensation function, by setting one pressure

compensation value (see fig. 1-7), the motor torque of the motor gun is
calculated using the pressure-to-torque conversion value of pattern 1 and
the inclination of the Z-axis + on the tool coordinates at welding so that the
pressure can be kept stable even when the motor gun posture changes.
(See fig. 1-8.)

Fig. 1-7: Pressure Compensation (For Pattern 2)

Pressure Pattern 2
compensation value

Measured values
Toque

(%)

Pattern 1

Pressure (kgf)

Fig. 1-8: Motor Gun Posture

Z-axis + direction
on the tool coordinates

Upper tip
Inclination of Z-axis +
on the tool coordinates
Inclination of Z-axis +
on the tool coordinates

Lower tip Z-axis + direction

on the tool coordinates

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1.13.5.3 Setting the Pressure Compensation Value

The following describes settings for pressure compensation value of
pattern 2.
For details on the data registration of pattern 1; applying pressure
downwards (settings for pressure-to-torque conversion value), refer to
chapter 1.3.9 "Setting of Torque to Pressure Conversion Data".
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {GUN CONDITION}.

– GUN CONDITION window appears.

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3. Select {PRESSURE COMPENSATION}.

– By Specifying the pressure for compensation (0 to 9999N) at
PRESSURE COMPENSATION, the pressure is compensated when
the motor gun changes its posture.
– Press [SELECT] to input the value for compensation.

4. Press [ENTER] after inputting the value.

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1.13.6 Compensation of Gun Arm Bend for C-Gun and X-Gun (SINGLE ARM MOVE)
The gun arm bend at pressurizing can be compensated by the corrective
manipulator motion.

Compensation motion in the

tool Z+ direction for (K × F ÷ 1000) mm

Specify each compensation value (X, Y, Z directions of the tool

coordinate) for the gun arm bend with the pressure of 1000N.
When K is defined as the gun arm bend compensation coefficient (mm/
1000N) and F is the gun pressure (N), the robot position is corrected in
each coordinate direction of the tool for (K × F ÷ 1000) mm in
synchronization with gun pressure.

1.13.6.1 Setting the Gun Arm Bend Compensation Coefficient

1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {GUN CONDITION}.
– GUN CONDITION window appears.

3. Select a gun No. by pressing [PAGE].

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4. Select “GUN ARM BEND DOEF.”

– GUN ARM BEND DOEF.
Set the compensation amount for gun arm bend per 1000N
pressure.

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

NOTE If “0” is entered, the gun arm bend compensation function

will not be effective.

1.13.6.2 Compensation Example

The gun arm bend compensation operation is done by the

robot when following instructions are executed.
• SVSPOT instruction
• SVGUNCL instruction to which DRS tag is added.
• SVSPOTMOV instruction
NOTE • SVDRESMOV instruction
In case the robot is not included in the job control group, the
gun arm bend compensation will not be executed.
<Example>
R1+S1 : Gun arm bend compensation is executed
S1R1+ : Gun arm bend compensation is unexecuted

When 2.0 (mm/1000N) is specified for the gun arm bend compensation
coefficient:
Gun Pressure (N) Gun Arm Bend Compensation
Amount (mm)
0 0.0
1000 2.0
2000 4.0
3000 6.0

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1.13.6.3 Disabling Gun Arm Bend Compensation

The gun arm bend compensation can be disabled at each SVSPOT/
SVSPOTMOV instruction.
Set the gun arm bend compensation disabling tag (BCOFF tag) to
SVSPOT/SVSPOTMOV instruction to disable it.

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1.13.7 Welding Conditions Group Output Function

1.13.7.1 Operation Flow Chart

With the welding conditions group output function, a group signal is output
to the welder during welding.
The following shows the operation flow chart for the welding conditions
group output function.

Start

Assign the universal signal

for the group output

Set the group output tag

End

1.13.7.2 Procedure for Assigning the Group Output Signal

The following describes how to assign the signal number for group output
when executing the SVSPOT/SVSPOTMOV instruction.
1. Select {SPOT WELDING} on the {Main Menu}.
2. Select {WELDER IF}.

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3. Select the desired item.

– Set {GROUP OUTPUT}.
Enter the LSB output number to the start and MSB output number to
the end.

4. Input the numerical value and press [ENTER].

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1.13.7.3 Setting the Group Output Tag

The following describes the settings for the group output.
When the job contents are displayed, by pressing [SHIFT] + [MOTION
TYPE], the instruction in the input line can be switched from the normal
motion interpolation (MOVJ, MOVL, MOVC, MOVS) to the clearance
move interpolation.
1. Select {JOB} on the {Main Menu}.
2. Select {JOB}.

– JOB CONTENT window is displayed.

3. Press [SHIFT] + [MOTION TYPE] to display “SVSPOTMOV” or
“SVSPOT”.

– The group output can be set to either the following two instructions.
• SVSPOTMOV
• SVSPOT
4. Press [SELECT].
– The cursor moves to “SVSPOTMOV” or “SVSPOT”
5. Press [SELECT] again.
– The DETAIL EDIT window appears.

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6. Select {WELD GRP OUT}.

– Press [SELECT] to display the selection dialog box. (The initial
value is “UNUSED.”)
(1) Select {WGO=}.

(2) Set the output value.

7. Press [ENTER].
8. Press [ENTER] again.

1.13.7.4 Group Output

The origin of the group output can be set with "0".
“0 origin” or “1 origin” can be selected from {WELD GROUP ORIGNAL
NO.} on APPLICATION CONDITION SETTING window.
When “0 origin” is selected: the value set to WAGO is output as a signal.
When “1 origin” is selected: the value 1 is subtracted from the value set
to WAGO is output as a signal.

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1.13.8 Workpiece Thickness Detection Function

1.13.8.1 Outline
The workpiece thickness detection function monitors the thickness of
workpiece to be welded at the every SVSPOT instruction and
SVSPOTMOV instruction. This function does not, however, monitor the
workpiece thickness when executing the SVGUNCL instruction.
An alarm can be generated if the workpiece is missing.

Movable side electrode

Workpiece Partial workpiece

Fixed side electrode

[Normal operation] [Error]

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1.13.8.2 Instruction

 SVSPOT (Spot Welding Instruction)

To use the workpiece thickness detection function, set the tag for the
function to SVSPOT/SVSPOTMOV instruction.

SVSPOT GUN# ( ) PRESS# ( ) WTM= WST=

1 2 3 4

BWS= TH= THA=

5 6 7

THM=
8

1. TH=
Workpiece thickness (unit: mm, -999.9 to 999.9)
Set the workpiece thickness to be welded.
The detected thickness can be automatically specified if the thickness
measuring mode is used.
2. THA=
Allowable ratio of workpiece thickness (unit: %, 0 to 100)
Set the allowable value to THA by the ratio over the thickness value
which is set to “TH”.
3. THM=
Allowable workpiece thickness (unit: mm, 0.0 to 10.0)
Set the allowable value to THM by the unit mm.

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1.13.8.3 Operation Procedures

 Setting of Workpiece Thickness Monitoring

• Set the mode switch of programming pendant to the teach

mode.

SUPPLE-
• Set the security mode to the edit mode or management
MENT mode to edit job data.
• In the operation mode, only error contents reference is
allowed.

1. Select {JOB}, then {JOB} on the {Main Menu}.

– JOB CONTENT window appears.

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2. Set SVSPOT/SVSPOTMOV instruction.

– Move the cursor to the “SVSPOT/SVSPOTMOV” and press
[SELECT].

– Press [SELECT] again to display DETAIL EDIT window.

– Move the cursor to “THICKNESS” and press [SELECT]. Then,

select “TH=” .

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3. Set the workpiece thickness (TH).

– Move the cursor to “THICKNESS”, and press [SELECT].

– Enter a value and press [ENTER].

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4. Set the allowable workpiece thickness (THA, THM).

– Set THA= 0 to 100 [%]
(THA: Specifies the allowable range for the detected
workpiece thickness by using a percentage.)
or THM= 0.0 to 10.0 [mm]
(THM: Specifies the allowable range for the detected
workpiece thickness by using an absolute value).
Move the cursor to “THICK RATIO”, and press [SELECT].

– Enter a value, and press [ENTER].

(Value: Specify by a numeric value or I variable.)

– Press [ENTER] again.

* Returns to the JOB CONTENT window.

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 Setting of Workpiece Thickness Measurement

• Set the mode switch of programming pendant to the Play

mode.
SUPPLE-
MENT • When it is in the thickness measure mode, whether the
detected thickness is within the allowable range or not is
not monitored.

1. Set the mode switch of programming pendant to the Play mode.

2. Select {JOB}, then {JOB} on the {Main Menu}.

– JOB CONTENT window appears.

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3. Select {THICKNESS MEASURE} under {UTILITY}.

– “Thickness measure mode” appears in the message display area.

The {THICKNESS MEASURE} is displayed with an asterisk mark

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• Universal signal can be used to switch to the measure

mode.
• When using the universal signal to switch to the thickness
measure mode, perform the following settings to “THICK-
NESS CHECK MODE SELECT GIN#” on APPLICATION
CONDITION SETTING window.

THICKNESS CHECK MODE SELECT GIN#

0 : Switches to the thickness measure mode by
using the programming pendant.
1 to 2048: Switches to the thickness measure mode while
NOTE the specified universal signal is input.
• Note that when “THICKNESS CHECK MODE SELECT
GIN#” on APPLICATION CONDITION SETTING window
is set with other than 0, it is impossible to switch to the
thickness measure mode by using the programming pen-
dant.
• While above universal signal is input, to switch again to
the thickness measure mode after the measure mode is
canceled by one of the operations described in How to
Cancel Thickness Measure Mode , turn off then on the
universal signal.

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4. Execute the job.

– The “TH” tag value of SVSPOT instruction will be rewritten with the
detected workpiece thickness, the value when the pressure reaches
the touch pressure, at each weld point.
The following formula is used to calculate the “TH” value.

Value of measured workpiece thickness

= Gun axis position at the touch detection (mm)
+ DMF (Fixed side wear amount + Movable side wear amount, mm)
− SMF (Fixed side tip mounting error + Movable side tip mounting
error, mm)

• The value close to the actual workpiece thickness can be

obtained by considering the gun bend or pushing length.
The following parameter can decide whether to consider
the gun bend or pushing length.

A1P59:Consider the gun bend or pushing length when

detecting workpiece thickness
0 : Not consider the gun bend and pushing length.
1 : Consider the gun bend length.
The value of measured workpiece thickness is
compensated by the gun bend length calculated
with the following formula.
NOTE “GUN ARM BEND COEF.” of the gun condition file
x Touch pressure
2 : Consider the gun pushing length.
The value of measured workpiece thickness is
compensated by the gun pushing length calculated
with the following formula.
“GUN PUSHING COEF” of the gun condition file
x Touch pressure
• Do not change the above parameter between when mea-
suring and when monitoring. Detection cannot be per-
formed properly.
• A1P59 is set with 2 (The gun pushing amount is consid-
ered) as the default.

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 Execution of Workpiece Thickness Monitoring

• Set the mode switch of programming pendant to the play

mode.
SUPPLE-
MENT
• Cancel the thickness measure mode.
* Refer to How to Cancel Thickness Measure Mode .

If playback of a job is performed with the thickness measure mode

canceled, the workpiece thickness detected at each weld point is
compared with the value of “TH”, “THA”, and “THM” tag.
If the comparison result is not acceptable, the alarm “Thickness Error”
occurs.

The formula for comparison is as follow.

For THM tag:

[Acceptable Result]
TH - THM ≤ The detected thickness ≤ TH + THM
[Not-Acceptable Result]
TH - THM >The detected thickness
Or
The detected thickness > TH + THM

For THA tag:

[Acceptable Result]
TH - (TH  THA / 100) ≤ The detected thickness
TH + (TH  THA / 100)
[Not-Acceptable Result]
TH - (TH  THA / 100) > The detected thickness
Or
The detected thickness > TH + (TH  THA / 100)

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By modifying the following items on APPLICATION

CONDITION SETTING window, the universal output is
output by pulse (pulse width: 100 msec) instead of
generating alarms when the result of comparing is NG.
• Thickness error notice
Select “Alarm” or “Signal”.
• Thickness error notice gout#
This item is indicated when “Signal” is selected to
{Thickness error notice}.
Set a pulse output signal which is output when the result
is NG.
SUPPLE- The job execution is not suspended even if the result is NG
MENT
when “Signal” is selected to {Thickness error notice}.
At this time, whether to execute SVSPOT/SVSPOTMOV
instructions or to skip the execution and execute the next
instruction can be set with the following parameters
• AIP60: Specifying the operation of SVSPOT/
SVSPOTMOV instructions which was detected
to be NG.
0 : Execute SVSPOT/SVSPOTMOV instructions
which was detected to be NG.
1 : Skip SVSPOT/SVSPOTMOV instructions
which was detected to be NG and execute the
next instruction.

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1.13.8.4 Related Functions

 Signal Output during Thickness Measure Mode

During the thickness measure mode, the universal output set in the
parameter S4C165 is turned ON. For example, if the parameter S4C168
is 20 (S4C168=20), OUT20 is turned ON.”.
This parameter can be used to stop welding during the thickness measure
mode.

 Disabling Thickness Monitoring

While the universal input signal specified to “THICKNESS ALARM
IGNORE GIN#” on APPLICATION CONDITION SETTING window is
input, the workpiece thickness monitoring function is disabled, and the
same operation is performed as when the TH tag is unused.
THICKNESS ALARM IGNORE GIN#
0 : Not used
1 to 2048 : When the specified universal signal is input, the
workpiece thickness monitoring function is disabled.

 Display and Output of Detected Thickness

• The detected thickness is displayed in mm on the SPOT

SUPERVISION window.
• The latest detected thickness is always displayed on the
window.
SUPPLE-
MENT • Even if the power to the controller is turned OFF, the
detected thickness value will remain.
• If the value is set to the setting “M” of “DETECTED THICK-
NESS” on the SPOT SUPERVISION window, the detected
thickness value is output to the register of the set number.

1. Select {SPOT WELDING} under {Main Menu}, then select {SPOT

SUPERVISION}.

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– SPOT SUPERVISION window appears.

2. Set the value to the setting “M” of “THICKNESS DETECTED”.

Set the register number when outputting the detected thickness value
to register.

 How to Cancel Thickness Measure Mode

1. Cancel the thickness measure mode, and switched to the monitoring
mode.
– Performing one of the following operations cancels the thickness
measure mode and switches to the monitoring mode:

1) Execution of END instruction in Playback

2) Switching to Teach Mode
3) Canceling “THICKNESS MEASURE” from the menu

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1.13.8.5 Notes
1. It is recommended that the "TH" tag of SVSPOT/SVSPOTMOV
instruction be set just before thickness measurement after teaching
operation.
If the “TH” tag is specified before that, the alarm “Thickness Error” may
occur during test operation, which results in less operating efficiency.
2. The value of detected workpiece thickness is affected by the delay of
detection timing and gun arm bend at the touch motion. Therefore, an
absolute accuracy cannot be guaranteed.
The faster the touch speed becomes and the more the touch pressure
increases, the bigger the error will be. If the pressure specified in the
thickness measure mode is equal to that in the monitoring mode, the
absolute accuracy will be approximately 1 mm or less.
3. The detected workpiece thickness is calculated by converting the
pulse data at touch detection to the stroke according to the pulse-to-
stroke conversion table registered in the Gun Condition file.
Therefore, the detected workpiece thickness is affected by the
accuracy of the pulse-to-stroke conversion data.

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1.13.9 Automatic Tool Number Select Function for Guns

When using a JOB including a gun, a tool corresponding to the gun can be
automatically selected by this function.
If more than one gun are used in cases such as the gun change, set the
tool file corresponding to each gun according to chapter 1.4.3
"Registering the Operation Tool"

Z
X
Z
X Y

Y
Gun 2

Gun 1

Tool file 1 Tool file 2

When teaching a gun, the appropriate tool needs to be selected according

to the gun for teaching. This tool selection can be automatically performed
by this function .
The automatic tool selection is performed when a JOB is selected and an
executed JOB is changed by a CALL or JUMP instruction. However, if a
JOB does not include a robot or gun, the tool remains unchanged.
Also, even if a tool is selected by this function, it can be manually changed
to other ones. (Refer to “YRC1000 GENERAL OPERATOR’S MANUAL
(RE-CSO-A051) 2.3.4.1 Selecting Tool”.)
The correspondence of a gun and a tool number needs to be performed in
the gun condition file.

1.13.9.1 Setting of Validating the Function

When using the automatic tool number select function for guns, validate
“AUTO TOOL NO. SELECT FOR GUN” on the application condition
setting window. (Refer to chapter 1.4.7 "Application Condition Setting"
for the operating procedure.)
When setting “GUN INSTALLATION STATUS” in the gun condition file for
“FIXED”, the automatic tool selection is not performed to the gun even if
this function is validated.

1.13.9.2 Setting of Tool Number

Set “TOOL NO.” in the gun condition file.
(Refer to chapter 1.4.1 "Gun Condition File" for the operating
procedure.)

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 1 Spot Welding Application Using a Motor Gun
1.14 Loading the DX100 Motor Gun Condition File

1.14 Loading the DX100 Motor Gun Condition File

Some files in the DX100 motor gun condition files cannot be loaded to the
YRC1000 due to different formats. Thus, load the DX100 condition files in
the table below to the YRC1000 by using the {LOAD DX100 SPOT FILES}
in the sub-menu of the {EX. MEMORY} in the main menu.

The DX100 condition file The YRC1000 condition file to which

to be loaded the setting in the loaded files are
reflected
Motor Gun Pressure Data Motor Gun Pressure Data
SPRESS.CND SGPRS.CND
Pressure Data Pressure Data
SPRESSCL.CND SGPRSCL.CND
Spot Gun Cond Data
SGSPEC.DAT
Spot Gun Cond Data Gun Detail Setting
SGUN.DAT SGDTL.DAT
Spot Management Data
SGSPTMNG.DAT
Spot I/O Allocation data Spot I/O Allocation Data
SPOTIO.DAT SGIO.DAT
Spot Welder Cond Data Spot Welder IF Data
SWELDER.DAT SGWELDIF.DAT
Clearance Setting Clearance Setting
CLEARNCE.DAT SGCLARNC.DAT

 Operation
1. Select {LOAD DX100 SPOT FILES} in the {EX.MEMORY}.

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1 Spot Welding Application Using a Motor Gun
1.14 Loading the DX100 Motor Gun Condition File

– The Load DX100 Spot Files window appears.

2. Select {FOLDER SELECT} tab.

3. Select the connecting device in the DEVICE SELECT combo box.

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1 Spot Welding Application Using a Motor Gun
1.14 Loading the DX100 Motor Gun Condition File

4. Select the folder containing the files to be loaded in the FOLDER

SELECT list.

5. Select {FILE SELECT} tab.

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1 Spot Welding Application Using a Motor Gun
1.14 Loading the DX100 Motor Gun Condition File

6. Select the item(s) to load in the YRC1000 file list.

7. Press {LOAD} in the bottom right in the window.

– The confirmation dialog appears.

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1 Spot Welding Application Using a Motor Gun
1.14 Loading the DX100 Motor Gun Condition File

8. Press {LOAD} in the dialog box.

– The selected condition files are loaded.

9. Press {CLOSE} in the dialog box.

– The dialog box is closed.

10. Press {CLOSE} in the bottom right in the window.

– The Load DX100 Spot Files window is closed.

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 1 Spot Welding Application Using a Motor Gun
1.15 The Instruction List (Motor Gun)

1.15 The Instruction List (Motor Gun)

The following table shows the instruction list regarding the motor gun.
• <> indicates numerical or alphabetical data.
• If multiple items are shown in one section, select one of the items.

SVSPOT Function Executes the gun pressure and welding.

Additional GUN# (<gun 1 condition file number>) 1 to 12
Item PRESS# (<gun 1 pressure file number>) 1 to 255
WP= <gun 1 pressure value> 1 to 9999N
WTM=<gun 1 welding condition> 1 to 255
WST=<gun 1 welder startup timing> 0 to 2
BWS=<gun 1 start stroke position> 0.0 to1000.0mm
WGO=<gun 1 group output> 0 to 255
TH=<gun 1 thickness> -999.9 to 999.9mm
THA=<gun 1 thickness allowable range> 0 to 100%
THM=<gun 1 thickness allowable range> 0 to 10.0mm
GUN# (<gun 2 condition file number>) 1 to 12
PRESS# (<gun 2 pressure file number>) 1 to 255
WP= <gun 1 pressure value> 1 to 9999N
WTM=<gun 2 welding condition> 1 to 255
WST=<gun 2 welder startup timing> 0 to 2
BWS=<gun 2 start stroke position> 0.0 to1000.0mm
WGO=<gun 2 group output> 0 to 255
TH=<gun 2 thickness> -999.9 to 999.9mm
THA=<gun 2 thickness allowable range> 0 to 100%
THM=<gun 2 thickness allowable range> 0 to 10.0mm
GUN# (<gun 3 condition file number>) 1 to 12
PRESS# (<gun 3 pressure file number>) 1 to 255
WP= <gun 3 pressure value> 1 to 9999N
WTM=<gun 3 welding condition> 1 to 255
WST=<gun 3 welder startup timing> 0 to 2
BWS=<gun 3 start stroke position> 0.0 to1000.0mm
WGO=<gun 3 group output> 0 to 255
TH=<gun 3 thickness> -999.9 to 999.9mm
THA=<gun 3 thickness allowable range> 0 to 100%
THM=<gun 3 thickness allowable range> 0 to 10.0mm
BCOFF (<bend compensation invalid>)
Example MOVL V=1000
SVSPOT GUN#(1) PRESS#(1) WTM=1 WST=1MOVL V=1000

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 1 Spot Welding Application Using a Motor Gun
1.15 The Instruction List (Motor Gun)

SVGUNCL Function Executes the gun pressure.

Additional GUN# (<gun 1 condition file number>) 1 to 12
Item
PRESSCL# (<dry pressure file number>) 1 to 32
WP=<gun pressure value>, 1 to 9999N
PRESSSTWC (<wear detection condition>),
DRS# (< tip dress condition file number>) 1 to 16
TWC-A (<wear detection motion>)
TWC-B (<wear detection motion>)
TWC-C (<wear detection motion>)
TWC-AE (<tip mounting error detection motion>)
TWC-BE (<tip mounting error detection motion>)
T=<pressure time>
ON/OFF (<ON/OFF>)
Example MOVL V=1000
SVGUNCL GUN#(1) PRESSCL#(1)
MOVL V=1000
SVSPOTMOV Function Executes the motion to the clearance position, the gun pressure and
welding.
Additional V=<play speed> 0.1 to the max
Item speed mm/sec
VCL=<gun pressure speed> 0.1 to the max
speed mm/sec
VOP=<gun open speed> 0.1 to the max
speed mm/sec
PLIN= <position IN level > 0 to 8
PLOUT= <position OUT level> 0 to 8
CLF# (<clearance file number>) 1 to 32
GUN# (<gun condition file number>) 1 to 12
PRESS# (<gun pressure file number>) 1 to 255
WP= (gun pressure value) 1 to 9999N
WTM= (welding condition) 1 to 255
WST= (welder startup timing) 0 to 2
WGO= (group output) 0 to 255
TH= (thickness) -999.9 to 999.9mm
THA= (thickness allowable range) 0 to 100%
THM= (thickness allowable range) 0 to 10.0mm
BCOFF (<bend compensation invalid>)
Example SVSPOTMOV V=1600.0 CLF#(1) GUN#(1) PRESS#(1) WTM=1
WST=1

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 1 Spot Welding Application Using a Motor Gun
1.15 The Instruction List (Motor Gun)

SVDRESMOV Function Executes the motion to the clearance position, the gun pressure and the
dress.
Additional V=<play speed> 0.1 to the max
Item speed mm/sec
VCL=<gun pressure speed> 0.1 to the max
speed mm/sec
VOP=<gun open speed> 0.1 to the max
speed mm/sec
PLIN= <position IN level > 0 to 8
PLOUT= <position OUT level> 0 to 8
GUN# (<gun condition file number>) 1 to 12
DRS# (<tip dress condition file number>) 1 to 16
Example SVDRESMOV V=1600.0 GUN#(1) DRS#(1)
DRESSON Function Rotates the dresser.
Additional DRS# (<tip dress condition file number>) 1 to 16
Item
Example DRESSONDRS#(1)
DRESSOF Function Stops rotating the dresser.
Additional DRS# (<tip dress condition file number>) 1 to 16
Item
Example DRESSOF DRS#(1)
GUNCHG Function Connects or disconnects the gun.
Additional GUN# (<gun condition file number>) 1 to 12
Item
PICK (<connect the gun>)
PLACE (<disconnect the gun>)
Example GUNCHG GUN#(1) PICK

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YRC1000
OPERATOR’S MANUAL
FOR SPOT WELDING USING MOTOR GUN

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbH Robotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542

YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199

PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741

Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO. RE-CSO-A054

C Printed in Japan November 2017 17-11

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