FANUC Robot Series R-30iA CONTROLLER Servo Gun Function OPERATOR'S MANUAL PDF

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R-30*A CONTROLLER
Servo Gun Function

OPERATOR’S MANUAL
B-82634EN/01
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
SAFETY
B-82634EN/01 1.SAFETY PRECAUTIONS
1 SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety
precautions when operating a robot and its peripheral devices installed
in a work cell.
- s-3 -
1.SAFETY PRECAUTIONS B-82634EN/01
1.1 OPERATOR SAFETY
Operator safety is the primary safety consideration. Because it is

very dangerous to enter the operating space of the robot during
automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful

consideration must be made to ensure operator safety.
(1) Have the robot system operators attend the training courses held
by FANUC.
FANUC provides various training courses. Contact our sales office for
details.
(2) Even when the robot is stationary, it is possible that the robot is
still ready to move state and is waiting for a signal. In this state,
the robot is regarded as still in motion. To ensure operator
safety, provide the system with an alarm to indicate visually or
aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no operator can enter the
work area without passing through the gate. Equip the gate
with an interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an
emergency. For connection, see Fig.1.1.
(4) Provide the peripheral devices with appropriate grounding (Class

1, Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the
robot motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the
operator in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone

from turning it on when it is locked with a padlock.
-s- 4 -
(9) When adjusting each peripheral device independently, be sure to

turn off the power of the robot.
Limit switch which operates when the gate

is opened.
Panel board Note) Terminals FENCE1 and FENCE2

are on the PC board in the
operator's panel.
Fig.1.1 (a) Safety Fence and Safety gate (For R-J3iB CONTROLLER)
- s-5 -
Safety
防護柵 fence
Limit switch which operates when the gate is

扉が開いたときに作動するリミットスイッチ
opened.
Panel
パネルボードboard Note) Terminals EAS1,
（注）　EAS1,EAS11, 11 and EAS2, 21 are on the
EAS2,EAS21は操作パネル上のプリン
PC board on the operator’s panel.
ト板の端子台上に出されています。
EAS1 詳細はR-J3iC制御部保守説明書をご参照下さい。
Refer to the R-30iA CONTROLLER
MAINTENANCE MANUAL.
EAS11
EAS2
EAS21
Fig.1.1(b) Safety Fence and Safety (For R-30iA CONTROLLER)
-s- 6 -
1.1.1 Operator Safety

The operator is a person who operates the robot system. In this sense,
a worker who operates the teach pendant is also an operator.
However, this section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the power
of the robot controller or press the EMERGENCY STOP button,
and then proceed with necessary work
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker
other than the operator from entering the work area unexpectedly
and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's
reach.
The robot controller is designed to be connected to an external
EMERGENCY STOP button. With this connection, the controller stops the
robot operation when the external EMERGENCY STOP button is pressed.
See the diagram below for connection.
External EMERGENCY
STOP button Panel board
Note) Connect between EMGIN1 and EMGIN 2.

Terminals EMGIN1 and EMGIN2 are on the
Panel board.
Fig.1.1.1(a) Connection Diagram for External Emergency Stop Switch

(For R-J3iB CONTROLLER)
External EMERGENCY
STOP button
外部非常停止スイッチ
Panel board
パネルボード
EES1
EES11
EES2
EES21
Note) Connect between EES1 and EES11 and between EES2 and
EES21. Terminals EES1,
（注）　EES1-EES11間、 EES11, EES2 and EES21 are on
EES2-EES21間に接続します。
　　　　EES1,EES11、EES2,EES21はパネルボード上にあり
the Panel board. Refer to R-30iA CONTROLLER
　　　　ます。
MAINTENANCE MANUAL.
　　　　詳細はR-J3iC制御部保守説明書をご参照下さい。
Fig.1.1.1(b) Connection Diagram for External Emergency Stop Switch

(For R-30iA CONTROLLER)
- s-7 -
1.1.2 Safety of the Teach Pendant Operator

While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the
safety of the teach pendant operator.
(1) Unless it is specifically necessary to enter the robot work area,

carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be
sure to check the location and condition of the safety devices
(such as the EMERGENCY STOP button and the deadman's
switch on the teach pendant).
The teach pendant supplied by FANUC is provided with a teach pendant

enable switch and a deadman's switch in addition to the EMERGENCY
STOP button. The functions of each switch are as follows.
EMERGENCY STOP button : Pressing this button stops the robot in an
emergency, irrespective to the condition
of the teach pendant enable switch.
Deadman's switch : The function depends on the state of the
teach pendant enable switch.
When the enable switch is on - Releasing the finger from the dead
man's switch stops the robot in an
emergency.
When the enable switch is off-The deadman's switch is ineffective
NOTE
The deadman's switch is provided so that the
robot operation can be stopped simply by releasing
finger from the teach pendant in case of
emergency.
-s- 8 -
(4) The teach pendant operator should pay careful attention so that
no other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable
switch and the deadman's switch also have the
following function.By pressing the deadman's switch
while the enable switch is on, the emergency stop
factor (normally the safety gate) connected to the
controller is invalidated. In this case, it is possible
for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP
button. In other words, the system understands
that the combined operations of pressing the teach
pendant enable switch and pressing the deadman's
switch indicates the start of teaching.
The teach pendant operator should be well aware
that the safety gate is not functional under this
condition and bear full responsibility to ensure that
no one enters the fence during teaching.
- s-9 -
(5) When entering the robot work area, the teach pendant operator
should enable the teach pendant whenever he or she enters the
robot work area. In particular, while the teach pendant enable
switch is off, make certain that no start command is sent to the
robot from any operator's panel other than the teach pendant.
The teach pendant, operator panel, and peripheral device interface

send each robot start signal. However the validity of each signal
changes as follows depending on the ON/OFF switch on the Teach
pendant and the three modes switch on the Operator’s panel and
Remote condition on the software.
Operator ‘s panel Teach pendant Software remote Teach Operator’s Peripheral

Three modes switch ON/OFF switch condition pendant panel devices
T1/T2 On Independent Allowed to start Not allowed Not allowed
AUTO (Except RIA)
AUTO Off Remote OFF Not allowed Allowed to start Not allowed
AUTO Off Remote ON Not allowed Not allowed Allowed to start
NOTE) When starting the system using the teach pendant in the RIA specification, the three modes
switch should be T1/T2.
(6) To start the system using the operator's box, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
(7) When a program is completed, be sure to carry out a test run
according to the procedure below.
(a) Run the program for at least one operation cycle in the
single step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check
that the system operates automatically without trouble.
(e) After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
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1.1.3 Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the
following.
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power
switch, if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its
peripheral devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance
when the power is turned on, the worker should indicate that the
machine is being serviced and make certain that no one starts the
robot unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay
careful attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator's panel and observe the work being
performed. If any danger arises, the worker should be ready to
press the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also
turn off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
- s-11 -
1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.2.1 Precautions in Programming

(1) Use a limit switch or other sensor to detect a dangerous condition
and, if necessary, design the program to stop the robot when the
sensor signal is received.
(2) Design the program to stop the robot when an abnormal
condition occurs in any other robots or peripheral devices, even
though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in
programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2 Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate
the robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not come into contact with its
peripheral devices or tools.
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1.3 SAFETY OF THE ROBOT MECHANISM
1.3.1 Precautions in Operation

(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any
eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.

(1) When the work areas of robots overlap, make certain that the
motions of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion
program for the robot and program the motion so that it starts
from the origin and terminates at the origin. Make it possible for
the operator to easily distinguish at a glance that the robot motion
has terminated.
1.3.3 Precautions for Mechanisms

(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
- s-13 -
1.4 SAFETY OF THE END EFFECTOR

(1) To control the pneumatic, hydraulic and electric actuators,
carefully consider the necessary time delay after issuing each
control command up to actual motion and ensure safe control.
(3) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
1.5 SAFETY IN MAINTENANCE
(1) Never enter the robot work area while the robot is operating.
Turn off the power before entering the robot work area for
inspection and maintenance.
(2) If it is necessary to enter the robot work area with the power
turned on, first press the EMERGENCY STOP button on the
operator's box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system. When replacing the
parts in the pneumatic system, be sure to reduce the pressure in
the piping to zero by turning the pressure control on the air
regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn
off the circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(6) Before restarting the robot, be sure to check that no one is in the
robot work area and that the robot and its peripheral devices are
all in the normal operating state.
-s- 14 -
1.6 WARNING LABEL
(1) Greasing and degreasing label
Fig. 1.6 (a) Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated on
this label.
1) When greasing, be sure to keep the grease outlet open.

2) Use a manual pump to grease.
3) Be sure to use a specified grease.
- s-15 -
(2) Step-on prohibitive label
Fig. 1.6 (b) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely
affect the robot or controller and you may get hurt if you lose your
footing as well.
(3) High-temperature warning label
Fig. 1.6 (c) High-temperature warning label

Description
Be cautious about a section where this label is affixed, as the section
generates
heat. If you have to inevitably touch such a section when it is hot,
use a
protective provision such as heat-resistant gloves.
-s- 16 -
B-82634EN/01 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY.......................................................................................................s-1
1 OVERVIEW ............................................................................................. 1
1.1 FEATURES OF FANUC SERVO GUN .......................................................... 2
1.2 BASIC SPECIFICATION ............................................................................... 2
1.3 NAMES OF MAJOR SERVO GUN COMPONENTS ..................................... 3
1.4 CONTROL METHOD (MULTI-GROUP) ........................................................ 4
2 INITIAL SETTING.................................................................................... 5
2.1 SERVO GUN AXIS INITIALIZATION............................................................. 6
2.2 SETTING THE COORDINATE SYSTEM .................................................... 14
2.3 SETTING THE GUN CLOSE DIRECTION .................................................. 16
2.4 SETTING THE MAX PRESSURE................................................................ 17
2.5 SERVO GUN SETUP AND AUTOTUNING UTILITY................................... 18
2.6 PRESSURE CALIBRATION ........................................................................ 26
3 SERVO GUN MAIN SETUP SCREEN .................................................. 29
3.1 SERVO GUN SETUP SCREEN .................................................................. 30
3.2 SERVO GUN GENERAL SETUP SCREEN ................................................ 31
4 MANUAL OPERATIONS....................................................................... 33
4.1 MANUAL PRESSURIZATION (Shift+GUN)................................................. 34
4.2 MANUAL BACKUP (Shift+BU) .................................................................... 38
4.3 MANUAL WELDING .................................................................................... 40
4.4 GUN JOG OPERATION .............................................................................. 41
5 PROGRAMMING................................................................................... 42
5.1 SPOT WELDING INSTRUCTIONS ............................................................. 43
5.1.1 SPOT Instruction Format .......................................................................................44
5.1.2 Welding Sequence..................................................................................................48
5.1.3 Teaching Position ...................................................................................................49
5.1.4 Hold ......................................................................................................................50
5.1.5 E-Stop.....................................................................................................................50
5.1.6 Single-Step .............................................................................................................50
5.2 OTHER INSTRUCTIONS ............................................................................ 52
5.2.1 Press Motion Instruction ........................................................................................52
5.2.2 Pressure Instruction ................................................................................................52
5.2.3 Gun Zero Master Instruction ..................................................................................54
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TABLE OF CONTENTS B-82634EN/01
6 TIP WEAR DOWN COMPENSATION................................................... 55

6.1 OVERVIEW ................................................................................................. 56
6.2 STANDARD TIP WEAR PROGRAM LIST................................................... 57
6.3 PREPARATIONS FOR TIP WEAR DOWN COMPENSATION.................... 58
6.4 TWO-STEP MEASUREMENT METHOD .................................................... 59
6.5 ONE-STEP MEASUREMENT METHOD ..................................................... 63
6.6 OPERATIONAL SETTING AND ALARM PROCESSING ............................ 65
6.6.1 Tip Wear Detect Setup screen ................................................................................65
6.6.2 Tip Wear Standard screen ......................................................................................68
6.7 DATA RECOVERY ...................................................................................... 69
6.7.1 Recovery Mastering Data .......................................................................................69
6.7.2 Recovery from Lost of Tip .....................................................................................69
6.8 ACTIVE STROKE LIMIT PROTECTION ..................................................... 71
6.9 USING TIP WEAR MEASUREMENT PROGRAMS from R-J3iB................. 72
7 GUN SAG COMPENSATION................................................................ 75
8 EXT. TIP STICK SIGNAL DETECTION ............................................... 76
9 SERVO GUN MONITORING ................................................................. 80
10 SOFT PANEL ........................................................................................ 82
11 PRESSURE RELATED I/O SIGNALS .................................................. 83
11.1 PRESSURE ENABLE SIGNAL.................................................................... 84
11.2 NEXT STEP ENABLE.................................................................................. 85
11.3 PRESSURIZATION NOTIFICATION SIGNAL ............................................. 86
12 PRESSURE PROFILE CONTROL FUNCTION .................................... 88
12.1 OVERVIEW ................................................................................................. 89
12.2 PROFILE DATA........................................................................................... 90
12.2.1 Operation ................................................................................................................90
12.2.2 Meaning of each items ...........................................................................................91
12.2.3 Limitations..............................................................................................................92
13 GUN CHANGE FUNCTION................................................................... 93

13.1 OUTLINE ..................................................................................................... 94
13.1.1 Feature of function .................................................................................................94
13.1.2 Basic specification..................................................................................................94
13.1.3 Restrictions.............................................................................................................94
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B-82634EN/01 TABLE OF CONTENTS
13.1.4 System Configuration.............................................................................................95

13.1.5 Outline of installation.............................................................................................96
13.2 INITIAL SETUP............................................................................................ 97
13.3 GUN CHANGE SETUP ............................................................................... 98
13.4 SETTING THE REFERENCE POSITION .................................................. 105
13.4.1 Battery-less type guns ..........................................................................................105
13.4.2 Battery-mounted type guns ..................................................................................106
13.5 GUN CHANGE INSTRUCTION ................................................................. 107
13.5.1 GUN DETACH instruction ..................................................................................107
13.5.2 GUN ATTACH instruction ..................................................................................107
13.5.3 Sample program ...................................................................................................108
13.5.4 Foward execution .................................................................................................108
13.5.5 Backward execution .............................................................................................109
13.6 GUN CHANGE SEQUENCE ..................................................................... 110
13.7 GUN CHANGE STATUS ........................................................................... 111
13.8 SERVO GUN SETUP ................................................................................ 112
13.9 TEACHING ................................................................................................ 113
13.9.1 Notice for teaching ...............................................................................................113
13.9.2 Sample program ...................................................................................................114
13.9.3 Guidelines for gun change with multi-tasking .....................................................115
14 OVERTORQUE PROTECTION FEATURE ......................................... 116

14.1 Overview.................................................................................................... 117
14.2 OVERTORQUE PROTECTION SETUP .................................................... 118
15 PART THICKNESS CHECK FUNCTION ............................................ 125
15.1 THICKNESS CHECK CALIBRATION ........................................................ 126
15.2 THICKNESS CHECK GENERAL SETUP.................................................. 128
16 GUN OPEN FUNCTION at WELD FAULT.......................................... 131
16.1 Conditions of Gun Open ............................................................................ 132
16.2 GUN OPENING MOTION.......................................................................... 133
17 ALARM CODE LIST............................................................................ 134
APPENDIX
A GUN CHANGE REFERENCE POSITION SETUP METHOD
(BATTERY-LESS TYPE)..................................................................... 155
A.1 REFERENCE POSITION SETUP OF EACH POSITION TYPE ................ 156
A.1.1 REFERENCE POSITION SETUP FOR CALIBRATION TYPES 3 AND 4 .....156
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TABLE OF CONTENTS B-82634EN/01
A.1.2 Reference Position Setup for Calibration Types 5 and 6 .....................................158

A.2 QUICK MASTERING REFERENCE POSITION ........................................ 160
B TROUBLESHOOTING (GUN CHANGE) ............................................ 161
B.1 The attach instruction is executed when the gun is not attached............... 162
B.2 THE ROBOT STOPPED DURING CALIBRATION.................................... 163
B.3 CALIBRATION MOTION FAILED .............................................................. 164
B.4 A DIFFERENT GUN FROM THAT SPECIFIED BY THE ATTACH
INSTRUCTION IS ATTACHED.................................................................. 165
B.5 THE ATTACHED GUN HAS BEEN DETACHED BY MISTAKE (WITHOUT
USING THE DETACH INSTRUCTION). .................................................... 166
B.6 THE GUN AXIS OF A DETACHED GUN HAS MOVED. ........................... 166
B.7 THE BATTERY VOLTAGE HAS FALLEN. ................................................ 166
B.8 THE BATTERY RAN LOW WHILE THE GUN WAS DETACHED. ............ 167
C GUN ZERO MASTERING ................................................................... 168
C.1 GUN MASTER UTILITY ............................................................................ 169
C.2 Reset Alarm ............................................................................................... 170
C.3 Magnet Phase Detection (MPDT) .............................................................. 171
C.4 MASTERING ............................................................................................. 172
D SETTING GUN STROKE LIMITS........................................................ 174
E AUTOTUNE MACRO PROGRAM....................................................... 176
F PRESS ON NEW TIPS ........................................................................ 179
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B-82634EN/01 1.OVERVIEW
1 OVERVIEW
-1-
1.OVERVIEW B-82634EN/01
1.1 FEATURES OF FANUC SERVO GUN
• Many dedicated servo gun functions (such as manual operation,

soft-touch operation, and tip wear compensation).
• Automatic creation of tool paths optimized for spot welding.
• The same operations and instructions are usable for both air and
servo guns. The interface for air or servo guns has the same feel.
1.2 BASIC SPECIFICATION
Item Explanation
Pressure setting range 0.0-9999.9[N, kgf, lbf] (*1)
Stroke limit range 0.0-9999.9[mm] (*1)
Gun axis speed setting range 0-2000[mm/sec] (or) 0-100[%] ratio of gun axis speed to its maximum
Number of controlled axes Number of axes that can be controlled simultaneously: 6 robot axes + 3
extended axes + 1 gun axis
*1 Practical values are determined according to the specification of the servo gun mechanics. User can change
pressure unit.
-2-
B-82634EN/01 1.OVERVIEW
1.3 NAMES OF MAJOR SERVO GUN COMPONENTS

Motor for Servo Gun
Control movable tip.
Movable Tip
Servo gun axis
controlled by the above motor.
Fixed Tip
This tip controlled by 6axes of Robot
Fixed Arm
In this manual,
‘Arm’ usually indicates this Arm.
-3-
1.OVERVIEW B-82634EN/01
1.4 CONTROL METHOD (MULTI-GROUP)

This system controls a stationary tip (on six robot axes) and a movable
tip (on a servo gun axis) in a multi-motion group environment. Unlike
extended axis control, multi-motion group control allows control of
the six robot axes and the servo gun axis in separate motion groups.
This enables separate control of the robot and the gun.
Control method for servo gun system

Multi-Motion Group Control
Motion Group 1 Motion Group 2
6 Axes for Robot Axis for Servo gun

(1st axis of Group 2)
Extended axis Control
Motion Group 1
6 Axes for Robo Axis for Servo gun

(7th axis of Group 1)
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B-82634EN/01 2.INITIAL SETTING
2 INITIAL SETTING
The following initialization is necessary to control the servo gun.
Usually, the initialization needs to be performed only once when the
system is started.
2.1 Servo gun axis initialization

Initialize the settings related to the servo gun motor (such as motor
size, gear ratio, and maximum speed).
2.2 Tool coordinate system setting
Define a tool coordinate system at the end of the stationary tip.
2.3 Closing direction of the gun setting
Define a tool coordinate system at the end of the movable tip.
2.4 Max Pressure setting
Specify the Max tip pressure for the servo gun based on gun
mechanical limit (gun manufacturer must provide this
information)
2.5 Gun Setup Utility
Confirm the motion sign of the gun
Master gun axis
Setting stroke limits & tip displacement
Tune the servo parameters using Autotuning
2.6 Pressure calibration
Calibrate the pressure applied to the tips using a certified and
calibrated pressure gage (load cell).
-5-
2.INITIAL SETTING B-82634EN/01
2.1 SERVO GUN AXIS INITIALIZATION
Outline
This section describes how to start up the servo gun system with a
new controller that is properly configured with servo gun
software option and hardware.
If extended axis control or multi-group control is being used or

added to an existing system, a startup procedure matched to the
axis configuration must be evaluated.
Startup Procedure
The servo gun axis configuration begins by going to Controlled Start.
The servo gun axis is defined here and is usually done only (1) time per
gun. The remainder of the servo gun setup is done after proceeding to
Cold Start.
Servo Gun Axis Initialization

1. Go To Controlled Start
2. Add the Axis for the Servo Gun
3. Define the Axis and Equipment as a Servo Gun
4. Proceed to Cold Start
[1] Controlled Start

1 Turn the power ON while you press the PREV and NEXT keys on
the teach pendant. The following screen is displayed.
---------- CONFIGURATION MENU ----------
1. Hot start
2. Cold start
3. Controlled start
4. Maintenance
Select >
2 Type "3" and press ENTER to select 3. Controlled start. This starts
the controlled start process. After a while the Controlled Start menu
is displayed.
Tool Setup CONTROLLED START MENUS

1/1
FANUC Spot Tool +
1 F Number F00000
2 Load Spottool Macro DISABLE
:
-6-
NOTE
User can repower on by Teach pendant in R-30iA controller.
Please operate the following.
Fctn key -> 0:Next ->8:CYCLE POWER
[2] Setting the Gun Axis
To display the Gun Axis Setup screen, carry out the following
procedure at the Controlled Start menu.
1 Press the MENU key, and select Maintenance to display the

Robot Setup screen. This screen should display the
equipment name of the No.1 operation group (robot) and the
Servo Gun operation group
ROBOT MAINTENANCE CONTROLLED START MENUS

1/6
Setup Robot System variables
Group Robot Library/Option Ext Axes

1 R-2000iA/210F 0
2 Servo Gun Axes 0
[ TYPE ]ORD NO AUTO MANUAL
2 Move the cursor to Servo Gun, and press F4 MANUAL.

3 Type the hardware number for the starting axis. (Type "7" if
the robot is a 6-axis robot, and the servo gun axes are
assigned to the 7th axis onwards.) Press ENTER.
SELECT HARDWARE
Enter hardware number for starting axis
Default value = 7
If you make a mistake when entering the hardware number

for the starting axis, select 4. EXIT in the menu displayed
below to temporarily exit setup, and then carry out the Servo
Gun setting at the Robot Setup screen again.
From here on, if you make any further mistakes, continue

setting up the gun axis and complete the setup. The menu
below is displayed again. Correct the value at 1
Display/Modify Nobot Axes.
-7-
4 Add an axis for servo gun by the following steps.

*** Group 2 Total Servo Gun Axes = 0 ***
1. Display/Modify Servo Gun Axes = 0

2. Add Servo Gun Axis
3. Delete Servo Gun Axis
4. Exit
Select 2
Type in 2 and Press ENTER, then the following screen is

displayed.
***** SETUP TYPE *****

If select 1, gear ratio is pre-set to
default value, which may be wrong.
Select 2,to set gear ratio correctly.
1: Partial (Minimal setup questions)

2: Complete (All setup questions)
Setup Type __
4.1 Setup Type – Type in 1 or 2 and press ENTER

There are (2) modes available.
Please choice “Partial” or “Complete”
The following table is list of setting items in each mode.
Table 2.2 Setting items in each mode

Item Standard Custom
Motor size ○ ○
Amplifier number ○ ○
Brake number ○ ○
Tip displacement ratio [mm/rev] ×( 5.00 ) ○
Gun close direction ×(＋) ○
Gun open stroke limit [mm] ×( 999 ) ○
Gun close stroke limit [mm] ×( 999 ) ○
Motion sign ×(TRUE ) ○
Servo timeout △ △
Servo timeout value △ △
○: Set here.
×:Not set here. Default value in () is applied. You can
change in another setting screen.
△:Need setting if you set brake number to a value other than
0.
In the following case, user should choose “Partial”

User can set the items omitted during Partial setup mode,
with Gun setup utility
-8-
In the following case, user should choose “Complete(setup

mode)”
-As soon as cold start, gun axis will be jogged without
autotuning
-User knows clearly gun specification.
4.2 Motor Selection - Select the Motor from the list by typing in
the number associated with the motor being used (or the
special Motor ID number) and press ENTER
***** MOTOR SELECTION *****
1: ACa4/5000i 20A 6: ACAM6/3000

80A
2: ACa4/5000i 40A
3: ACa8/4000i 40A
4: ACa8/4000i 80A
5: ACa12/4000i 80A 0: Other
Select __
If you are using a motor that is not included in the list select,
“0: Other” to see a more detailed list of FANUC motors or
enter the Motor ID number. Consult with FANUC to obtain
the Motor ID number for a supported servo gun motor.
When selecting “0: Other”, the motor name, rpm limit and
amplifier size will be required to complete the motor
selection as shown below. If you select a motor from the
above list or enter the Motor ID number, proceed to the next
step 4.3, “Select Amplifier Number”
(a)Select motor type.

MOTOR SIZE (Alpha i, Alpha is)
34. ACa1 40. ACa30
35. ACa2 41. ACa40
38. ACa12 46. ACa4
39. ACa22 47. ACa8
Select __
-9-
(b) Select motor rpm type.

MOTOR TYPE
1. /2000 6. /2000i 12. /5000is

2. /3000 7. /1500i 13. /4000is
3. /5000i 10. /1500 14. /3000is
4. /4000i 11. /4000
5. /3000i
Select __
(c) Select current limit for the motor’s amplifier.
CURENT LIMIT FOR AMPLIFIRER
2. 4A 7. 80A
5. 40A 10. 20A 12: 160A
Select __
4.3 Amplifier Number

-Select the Amplifier Number by typing the number
associated with the amplifier used to drive this motor, then
press ENTER. The amplifier number will depend on the
hardware configuration being used. The robot amplifier is #1
and the 1st auxiliary axis amplifier is #2 and so on.
***** AMP NUMBER *****
Enter Amplifier Number (1-40) __
If you select “Partial mode ”, continue to set the following

items. If you select “Standard mode ”,please skip to
procedure 4.9 form 4.4
4.4 Tip Displacement Ratio

-Type in how far the gun tip advances per motor revolution
and Press ENTER.
***** TIP DISPLACEMENT RATIO *****
The number of mm’s traveled for one

rotation of the motor
Enter Tip Displacement Ratio __
-10-
4.5 Motor Direction

-Type in
TRUE: to assign positive polarity to the gun close
direction
FALSE: to assign negative polarity to the gun close
direction
Consult with FANUC for the proper setting of this item, or
enter “1:TRUE” if unknown and use the Gun Setup Utility at
Cold Start to determine the proper setting for this item
automatically.
***** MOTOR DIRECTION *****
Servo Gun 1 Motion Sign = TRUE

Enter (1:TRUE, 2:FALSE):
(Enter 1 if unknown) __
4.6 Gun Close Direction

- Type in the axis jog key that should close the gun.
***** GUN CLOSE DIRECTION *****
Select Gun Close Direction.

(1: Positive, 2:Negitive) __
• If Positive is chosen, tip openings are displayed as negative

values (+ jog key will close gun)
• If Negative is chosen, tip openings are displayed as negative
values (- jog key will close gun)
4.7 Gun Open Stroke Limit

-Type in the maximum tip opening for the gun in units of mm,
then press ENTER (always enter a positive value!)
***** GUN OPEN STROKE LIMIT *****
Stroke in mm from tip closed position

(positive value) __
4.8 Gun Close Stroke Limit – Type in the maximum tip travel
available in the closing direction after the tips touch, then
press ENTER (always enter a positive value!)
***** GUN CLOSE STROKE LIMIT *****
Stroke in mm from tip closed position

(positive value) __
-11-
4.9 Motor Direction

-Type in
TRUE: to assign positive polarity to the gun close
direction
FALSE: to assign negative polarity to the gun close
direction
Consult with FANUC for the proper setting of this item, or
enter
***** MOTOR DIRECTION *****
Servo Gun 1 Motion Sign = TRUE

Enter (1:TRUE, 2:FALSE):
“1:TRUE” if unknown and use the Gun Setup Utility at Cold

Start to determine the proper setting for this item
automatically.
4.10 Brake Number

- Type in the Brake circuit number that is used to release the
brake on the motor and press ENTER.
If no brake is used, type in 0.
If a brake is used, the Servo Off setup must be completed.
***** BRAKE SETTING *****
Enter Brake Number (0-8) __
4.11 Servo Timeout

-Type in the whether to use a servo timeout, then press
ENTER.
***** SERVO TIMEOUT *****
Servo Off is Disable

Enter (1: Enable, 2: Disable) ?
Select ? _
With “1: Enable” servo timeout is enabled and a timeout
value is required in the next step. Otherwise, the “Setting the
Gun Axis” procedure is complete.
NOTE
In the case servo timeout is enabled, an axis
is automatically braked if the axis has not
been used for a specified time. At the
moment a motion command is given, the
brake of the axis is released, start of
movement is delayed 500ms to wait until the
brake is released.
-12-
4.13 Timeout Value

- Type in the Timeout Value in seconds, then press ENTER.
***** TIMEOUT VALUE *****
Enter Servo Off Time (0.0~30.0) __

Axes are braked after waiting this time without robot motion.
5. Setup for the gun axis is finished.

The following screen automatically displays.
** Group 2 Total Servo Gun Axes = 1
1. Display/Modify Servo Gun Axis 1->6

2. Add Servo Gun Axis
3. Delete Servo Gun Axis
4. Exit
Select ? _
Select 1, to display and/or modify any axis that is already defined
Select 2, to add another Servo Gun axis
Select 3, to delete the last Servo Gun axis
Select 4, to exit when done configuring all axes.
[3] Define the Axis and Equipment as a Servo Gun

1. Press the MENUS key, then select “0 –next -- ”,
“4 SETUP SERVO GUN”.
2. Specify Equipment Type.
SETUP SERVO GUN CONTROLLED START

Press F4[CHOICE], and select a SERVO GUN.
MENUS
2/4
1 Equip number: 1 Specify the motion group for controlling the
2 Equip Type: [SERVO GUN] servo gun axis corresponding to the Equip
3 Motion Group(Gun): 2 Number selected.
4 Motion Group(Robot): 1
Specify an operation group for controlling the
[ TYPE ] EQUIP GUN_CFG [CHOICE] robot axis.
3. If this is a Gun Change system, the gun change function is enabled

from this screen. Decide whether to ENABLE the gun change
function now.
[4] Cold Start

1 Press the FCTN key in the Controlled Start menu, and select Cold
Start then Press ENTER when ready to proceed to Cold Start
-13-
2.2 SETTING THE COORDINATE SYSTEM
• Carried gun
Executing the SPOT instruction automatically generates the route of the
fixed side tip based upon the tool coordinate system that is set here.
Define the tool coordinate system as follows. For details on how to set
the tool coordinate system, see the "SPOT TOOL+ Operations
Manual."
1. Take the end of the fixed side tip as the origin of the tool
coordinate system. (Figure below: a)
2. Make sure that the close (longitudinal) direction of the fixed side
tip is parallel with one of the X/Y/Z axes of the tool coordinate
system. (Figure below: b)
b: Make sure that one of the X/Y/Z tool coordinate axes is

parallel with the longitudinal direction of the fixed side tip
(Example: +Z)
a: Align the origin of the tool coordinate system with the end of
the fixed side tip.
• Pedestal gun
Executing the SPOT instruction automatically generates the route of the
part based upon the tool coordinate system that is set here. Define the
tool coordinate system as follows. For details on how to set the user
coordinate system, see the "SPOT TOOL+ Operations Manual."
1. Make sure that the close (longitudinal) direction of the fixed side
tip is parallel with one of the X/Y/Z axes of the user coordinate
system. (Figure below: b)
b: Make sure that one of the X/Y/Z user coordinate
axes is parallel with the longitudinal direction of the
fixed side tip. (Example: -Z)
• Setting to Robot Close Direction to match the Coordinate System of the Gun
The robot close direction is used to generate the proper trajectory for
spot locations and for compensation (tip wear down compensation and
gun sag compensation).
1. Press the MENU key to display the Screen menu.

2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun, then General Setup screen.
-14-
SETUP Spot Weld G2 JOINT 10 %

GENERAL / EQ:1 Gun:1 4/11
:
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z ]
:
[ TYPE ] EQUIP GUN
5. Set the Close Direction (ROBOT) according to the following

table.
Close Direction (Robot) Carried gun

Specify the No. of the defined tool coordinate system. Also set the direction in which the
robot tip approaches the part.
Example) Set as follows if the direction is +Z in tool

coordinate system No.1:
UT:1 [+Z]
Pedestal gun
Specify the No. of the defined user coordinate system. Also set the direction in which the
robot must move to carry the part to the fixed tip.
Example) Set as follows if the direction is -Z in user frame

system No.1:
UF:1 [-Z]
-15-
2.3 SETTING THE GUN CLOSE DIRECTION
NOTE
If this step was already completed with the Gun
Setup Utility, this section can be skipped.
The gun close direction is used to generate the proper trajectory for spot
locations and for compensation (tip wear down compensation and gun
sag compensation).
Gun tip
In case of gun closing by “+” key, set to PLUS.
In case of gun closing by “-” key, set to MINUS.
Robot tip:
Specify the No. of the defined tool coordinate system and
directional component in that coordinate system is the longitudinal
direction (close direction) of the fixed side tip.
1. Press the MENU key to display the Screen menu.

2. Select 6 SETUP.
4. Select Servo Gun, then General Operation screen.

:
:
[ TYPE ] EQUIP GUN
5. Set the Close Direction (GUN) first according to the following

procedure.
PROCEDURE
1 Set the Close Direction (GUN) to match the jog key that you want
to close the gun with.
PLUS to use the +X key to jog gun closed
MINUS to use the –X key to jog the gun closed
2 If you will be using the Gun Setup Utility to confirm the close
direction, skip ahead to step 2.5.
NOTE
1 In Gun setup utility, user can set motion sign for
current gun close direction. Please operate
according to Gun setup utility
2 Please confirm max gun pressure before Gun setup
utility
-16-
2.4 SETTING THE MAX PRESSURE
The max pressure of the servo gun should be defined prior to autotuning
the gun.
1 Go to the servo gun general setup screen
3 Set the Max Pressure to match the pressure limit of the gun.
(gun manufacturer must provide this information).
NOTE
Pay attention to the working units for Max Pressure.
The units of pressure (force) are set by the value of
the system variable $SGSYSCFG.$PRS_UNITS:
0 = Kilograms force(kgf)
1 = Pounds force(lbf)
2 = Newtons (nwt)

:
5 Max Pressure (kgf): 500.0
:
[ TYPE ] EQUIP GUN
-17-
2.5 SERVO GUN SETUP AND AUTOTUNING UTILITY
The FANUC servo gun software provides Gun setup utility to tune the
servo parameters for the gun without the aid of special tuning
equipment, or user intervention.
There are (2) basic ways to autotune the servo gun.
The Gun Setup utility ensures that the servo gun is set up correctly
before you autotune the gun. If you try to autotune a gun that is set
up incorrectly it can cause damage to the gun. This utility will take you
through some basic setup steps before the actual tuning exercises are
initiated. This includes:
MOTION SIGN SETTING
MASTERING
TIP DISPLACEMENT RATIO SETTING
AXIS LIMIT (Stroke Limit) SETTING
NOTE
If the BZAL or Pulse Not Establised faults exist, they
need to be reset before jogging and mastering of
the gun axis can be executed. Refer to the Gun
Master Utility in the Appendix of the Servo Gun
Manual for details on resetting these faults.
WARNING
Jogging the gun fully open into the gun’s hardstops
can cause damage to the gun.
NOTE
If setting Mastering (Appendix C), Motion sign, tip
displacement(gear ratio),gun closing direction,strok
limit (Appendix D) is completed, gun tuning is
executed by autotune program like R-J3iB.Please
refer Appendix E about more deatil.
-18-
Gun Setup Utility Execution Procedure
1. Press MENUS.
2. Select UTILITIES.
3. Press F1, [TYPE] and select Gun Setup. You will see a screen
similar to the following.
UTILS Gun Setup G2 JOINT 10 %

EQ:1 Gun:1 1/2
1.Set gun motion sign: INCOMP

2.Set Gun specs, master gun INCOMP
Tip Displacement: 5.00(mm/rev)
Open stroke limit: -999.00(mm)
Close stroke limit: 999.00(mm)
3.Auto Tune: INCOMP
4.Thickness Check calibration: INCOMP
Press enter to perform this step.

[ TYPE ]EQUIP SKIP RESTART
NOTE
The F3 key, SKIP, can be used to set the status of
Steps 1-2 to complete (COMP) without actually
performing the tasks. This can be done if the user is
certain that these items have been set correctly
during the controlled start axis setup and that
mastering has already been executed. In this case,
Skip ahead to Step 17 of this procedure after these
items are set to COMP.
4. Press F4, RESTART to set steps 1-2 to incomplete if they are not
already.
5. Move the cursor to item 1 and press ENTER. You will see a screen
Set Motion Sign G2 JOINT 10 %

EQ:1 Gun:1 1/1
1.HOLD the SHIFT key and SLOWLY Jog
the Servo Gun movable tip using the
+X key (+Y if 2nd gun of dual gun).
2.Did the gun OPEN or CLOSE? *****
USE F4 or F5 to make selection.
3.Press F3 COMP when finished.
[ TYPE ] COMP OPEN CLOSE
-19-
NOTE
This screen will allow you to set the gun motion
sign. The gun should always close when you press
the jog key [+ or -] that matches the Close Direction
(Gun) set on the servo gun general setup screeen.
This step will set the internal motion sign variable to
make this happen.
6. Follow the steps listed on this screen in order.

7. When you are finished, press F3, COMP. Item 1 status is now
complete. You will see a screen similar to the following.
EQ:1 Gun:1 1/1
1.Set gun motion sign: COMP
2.Set Gun specs, master gun INCOMP
3.Auto Tune: INCOMP

8. Move the cursor to item 2, and press ENTER. You will see the
following 2 prompts.
Do you know your gun’s Tip

Displacement?
[YES] [NO]
Do you know your gun's

stroke limits ?
[YES] [NO]
NOTE
Please specify tip displacement and stroke limit
according to gun manufacturer’s specification.
If gun specification is unknown, set the value
according to actual gun.
-20-
Answering prompt message decides next setting operation.
Tip displacement Stroke limit Setting operation

YES YES １
NO YES ２
YES NO ３
NO NO ４
If you would like to change setting operation, return by Prev key, then
answer prompt message again
Setting operation -1
Set Gun specs G2 JOINT 10 %
EQ:1 Gun:1 1/1
Set Tip Displacement,master,set limits
1.Move Servo Gun(s) to closed position.
Press F4 CLOSED when done.
2. Enter Tip Displacement here
*****(mm/rev)
3.Enter open limit here: *****(mm)
4.Enter close limit here:****(mm)
5.Press F3 when done.
[ TYPE ] COMP CLOSE
(a) Jog the gun slowly until the tips are touching each other and
press F4, CLOSED. When you press F4, CLOSED, the gun
will be mastered.
(b) Specify tip displacement into item 2, press ENTER key.
(c) Specify open limit into item 3, press ENTER key. And
Specify close limit into item 4, press ENTER key.
(d) Press F3[COMP]to complete this step.
EQ:1 Gun:1 1/1
2.SLOWLY jog to desired max opening.
Press F5 OPEN when done.
3.Measure the distance between tips and
enter here: ****(mm)
4.Enter open limit here: ****(mm)
5.Enter close limit here:****(mm)
[ TYPE ] COMP CLOSE OPEN
will be mastered, and one reference position for the tip
displacement calculations will be recorded.
-21-
(b) Jog the gun SLOWLY until it is at the desired max stroke
distance and press F5, OPEN. When you press F5, OPEN,
the second reference position for the tip displacement
calculation is recorded.
(c) Measure the distance in millimeters between the tips. Type
that value on line 3, press ENTER。
(d) Specify open limit into item 3, press ENTER key. And
Specify close limit into item 4, press ENTER key.
(e) All setting is completed, then press F3[COMP].
EQ:1 Gun:1 1/1
3.Enter the Tip Displacement Here
*****(mm/rev)
[ TYPE ] COMP CLOSED OPEN
will be mastered.
distance and press F5, OPEN.
(c) Type the tip displacement in mm/rev on line 3, press ENTER,
then press F3, COMP.

EQ:1 Gun:1 1/1
3.Measure the distance between tips and
enter here.*****(mm)
[ TYPE ] COMP CLOSED OPEN
will be mastered, and one reference position for the tip
displacement calculations will be record.
-22-
distance and press F5, OPEN. When you press F5, OPEN,
the second reference position for the tip displacement
calculation is recorded.
(c) Measure the distance in millimeters between the tips. Type
that value on line 3, press ENTER.
(d) Press F3, COMP
9. Completion of setting gun specification, you will see a series of
prompt boxes similar to the following.
Propmt Box 1
The servo gun setup utility always displays the new and old max
tip speed so that the user can see how much it should be changed.
Adjusting the max tip speed now, based on the tip displacement
ratio (called gear ratio in system variable) allows the user to setup
the gun for the correct max speed.
If the new velocity is different it is recommended to accept the

update and respond YES, otherwise respond NO.
Max tip speed can be updated, based on
new gear ratio. Velocity changes
FROM: 666.7 TO: 896.0mm/sec
Do you wish to update the max tip speed ?

[YES] [NO]
NOTE
If the tip speed changes, the user cannot proceed
to the Autotune step until power is cycled to update
the max tip speed.
Prompt Box 2
This box displays what the Open Stroke limit will be set to based
on the data provided during step 2. Unless this value exceeds the
gun specification for max tip opening, respond YES to this
prompt.
Open Stroke Limit will be set to magniture
148.00mm
Do you accept this value?
[YES] [NO]
Prompt Box 3
This box informs the user that the close stroke limit will be set to
20.0mm if the YES is selected. Yes is the default value.
If the gun manufacturer specified a value that is differs from this,
then repond NO and set the Close Stroke Limit directly. If the
close stroke limit has already been set in advance to the correct
value, then respond NO.
Otherwise, respond YES.
-23-
Select YES to set the close stroke limit

magnitude to 20.00mm (default value).
Select NO, if you do not wish to modify the

close stroke limit
[YES] [NO]
Please refer Appendix D (the section on setting the Stroke limit )

directly later in this chapter if needed.
10. After you have completed items 1 and 2, you will see a screen
similar to the following. and the F3, EXEC button will appear at the
bottom
Tuning with the Gun Setup Utility (Step 3 of Gun Setup Utility)
EQ:1 Gun:1 1/2

2.Set Gun specs, master gun COMP
3.Auto Tune: INCOMP

CAUTION
The Servo gun axis moves at max speed, during autotuning.Autotuning can be
performed with the teach pendant enabled or disabled.
Please make sure that no personnel are in the vicinity of the gun, when you execute
autotuning.
NOTE
The following conditions must be met for the tuning process to start from the Gun
Setup Utility:
-Not in STEP mode
-No faults exist
-No holds exist
-Servo gun is not in machine lock
-The control reliable keyswitch is in AUTO or T2.
-Gun is in STROKE mode
-24-
NOTE
After Autotuning is started, the servo gun will perform the following by opening and
closing the gun:
-Acceleration settings
-Inertia measurements
-Friction measurements
-Spring constant measurements
-Force control gain settings
NOTE
When robot is in T2 mode, TP is ENABLE,user have to keep pressing SHIFT key
and deadman switch.
When robot is in AUTO mode, TP is DISABLE, user does not have to keep pressing
SHIFT key and deadman switch.
1. Press SHIFT-- F3 to start the auto tuning process.

2. If Autotuning completed successfully a screen similar to the
following should appear
EQ:1 Gun:1 1/2

2.Set Gun specs, master gun COMP
3.Auto Tune: COMP

3. If acceleration times were changed during autotuning, then

SVGN-050 “Autuning: Re-power required” is posted.
Repowering the controller makes the new acceleration effective,
and clears the SVGN-50 message.
If autotuning did NOT complete successfully (indicated by status

FAILED instead of COMP), then try the following:
• Make sure axis limits are set properly.
• Check motor selection.
• Re-perform autotuning until it completes successfully.
NOTE
Please refer to the Part Thickness Check section of the Servo Gun manual for details
on performing Thickness Check Calibration
-25-
2.6 PRESSURE CALIBRATION
This section describes the process for setting up pressure calibration

(data). This data is used to obtain the torque and speed settings that are
used during execution of the SPOT or PRESS_MOTN instruction.
NOTE
-Calibration should be carried out with a certified and calibrated force/pressure gage.
-It is important to validate the calibration data by periodically checking the tip
pressure. If the calibration data no longer produces the desired results, then
calibration should be performed again. Consult with the servo gun manufacturer for
recommendations on calibration settings and frequency.
-Max torque value entered into calibration table must be less than or equal to the
max torque defined on servogun setup screen.
-Speed value entered into calibration table is the target speed at contact for object.
-Typically, speed can be increased as torque(force) is increased. The rigidity of the
gun mechanism should be considered too, in order to keep the impact force
acceptable. More rigid guns may require lower contact speeds. Typical values for
contact speed are between 25mm/sec – 125mm/sec.
-Pressure calibration can be checked with override less than 100%. However, 100%
override should be used during actual calibration measurements.
-The calibration points do not have to be entered in ascending (force) order.
PROCEDURE
1. Go to the Servo Gun General Setup screen.
2. Select Pressure Cal.
(Move the cursor to <*DETAIL*> and press the ENTER key.)
SETUP Servogun G2 JOINT 10 %
:
11 Pressure Cal: COMP <*DETAIL*>
12 Tip Wear Standard: COMP <*DETAIL*>
[ TYPE ] EQUIP GUN
3. The Start Message screen is displayed. Select F4 YES.
G2 JOINT 10 %
To perform pressuring motion,

press SHIFT + F3:PRESSURE key.
After pressuring motion,

set the measured pressure value.
Do you start calibration?

YES NO
-26-
4. The Pressure Calibration screen is displayed. Set the following

items.
Pressuring Time (sec): Dwell time for pressuring measurement

Thickness of Gage (mm): Thickness of gage (*1)
PRESSURE CALIB / EQ:1 Gun:1 1/10
1 Calibration Status: INCOMP Gun Open Value (mm): Gun axis open value after pressuring
2 Pressuring Time(sec): 1.5 ends (*2)
3 Thickness of Gauge(mm): 12.7 The maximum stroke in the open
4 Gun Open Value(mm): 115.0 direction is set as the standard value.
Torque(%) Speed(mm/sec) Pressure(Kgf)
5 5.0 % 100 45.0 Kgf
6 10.0 % 100 110.0 Kgf
:
Open value (*2)

Load cell
Thickness of gage
(*1)
5. Bring the fixed side tip into contact with the base of the force
PRESSURE CALIB / EQ:1 Gun:1 1/10
gauge.
1 Calibration Status: INCOMP 6. Specify torque and speed, then press the Shift key and
2 Pressuring Time(sec): 1.5 F3 PRESSURE. The movable tip executes the following
3 Thickness of Gauge(mm): 12.7 sequence:
4 Gun Open Value(mm): 115.0
Torque(%) Speed(mm/sec) Pressure(Kgf) - Move from current position to contact the pressure gauge at
6 10.0 % 100 100.0 Kgf the specified speed and torque.
7 0.0 % 100 0.0 Kgf - Continue to apply pressure, for the specified pressuring time
:
(dwell)
- Move to specified gun Open value
PRESSURE 7. Look at the pressure waveform and check the overshoot.
If the overshoot is acceptable, then read the value on the
force gage and enter this value. If the overshoot value is not
NOTE acceptable, then reduce speed, and measure force again.
Move the cursor to the
Torque line before executing
100 Kgf
the pressuring operation. If
the cursor is on a line that
does not designate the
torque, the pressuring
operation is not carried out.
8. Specify the torque(%) and repeat steps 6, 7, for the desired number
of calibration points. Up to 10 (minimum two) torque and gun close
speed values can be set.
If the your process requires a force of 100-500Kgf , then include
measurements at or near 100 kgf and 500kgf (min and max force).
-27-
9. After measuring the pressure several times, move the cursor to

Calibration Status, and press F4 COMP to accept the new
calibration data.
10. Calibration points are checked, and if criteria are not met, an alarm
is posted, and cal status is set to incomplete.
Pressure Pressure Pressure
Torque Torque Torque
OK NG(Alarm) NG(Alarm)
11. If calibration points are ok, then calibration complete screen is

displayed. Press either F2 END or the PREV key to exit pressure
calibration screen.
Calibration Status: COMP
Point Torque Speed Force

1 10.0% 100% 100.0 Kgf
2 25.0% 100% 250.0 Kgf
3 40.0% 100% 400.0 Kgf
4 50.0% 100% 500.0 Kgf
-28-
B-82634EN/01 3.SERVO GUN MAIN SETUP SCREEN
3 SERVO GUN MAIN SETUP SCREEN

This section explains the setup items on the servo gun setup screen.
These items should be set correctly prior to welding operation with the
servo gun.
Many of the items in this setup screen are functions that are explained in
other sections of this document.
-29-
3.SERVO GUN MAIN SETUP SCREEN B-82634EN/01
3.1 SERVO GUN SETUP SCREEN
Specify details of settings related to servo gun-based spot welding by

SETUP\Servogun G1 JOINT 100% referring to the descriptions of the corresponding items (listed on the
SERVO GUN SETUP 1/3 subsequent pages):
1 Equip number: 1
2 General Setup: <*DETAIL*>
1 Press the MENUS key to bring up the screen menu.
3 Manual Operation Setup: <*DETAIL*> 2 Select “6 SETUP”.
3 Press F1“[TYPE]” to display the pull-up menu.
[ TYPE ] EQUIP
4 Select “Servo Gun” to display the SERVO GUN SETUP screen.
Table 3.1 Descriptions of items for spot weld sequence setup

Equip number Equipment number shows the currently selected equipment number.
General setup The features of the servo gun are set in General setup screen.
Put the cursor on the <*DETAIL*>, then press enter key to display the General setup screen.
Manual Operation The setup related to the manual operation are set in the Manual Operation setup screen.
setup Put the cursor on the <*DETAIL*>, then press ENTER to display the Manual Operation setup
screen.
Refer to the Manual Operation section for more detail
-30-
B-82634EN/01 3.SERVO GUN MAIN SETUP SCREEN
3.2 SERVO GUN GENERAL SETUP SCREEN
Specify the general setting details related to the servo gun by referring
to the descriptions of the corresponding items (listed on the subsequent
pages):
1. Press the MENUS key to bring up the screen menu.
2. Select “6 SETUP”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Servo Gun” to display the SERVO GUN SETUP screen.
5. Select “8 General Setup” by placing the cursor on <*DETAIL*>
and pressing the ENTER key). The General Setup screen appears.
SETUP\Servogun G1 JOINT 100%

SETUP Spot Weld G1 JOINT 10 % GENERAL / EQ:1 Gun:1 1/13
1 Tip Wear Comp: DISABLE
SERVO GUN SETUP 8/9
2 Gun Sag Compensation: DISABLE
1 Equip number: 1
2 General Setup: <*DETAIL*> 4 Close Direction(Robot): UT: 1 [+Z ]
3 Manual Operation Setup: <*DETAIL*> 5 Max Motor Torque(%): 100.0
6 Max Pressure(kgf): 500.0
[ TYPE ] EQUIP Max Gun Torque(%): 10.5
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*>
10 Tip Wear Standrd: INCOMP <*DETAIL*>
11 Thickness check: <*DETAIL*>
12 Gun Stroke limit: <*DETAIL*>
13 OverTorque protection: <*DETAIL*>
[ TYPE ] EQUIP GUN ENABLE DISABLE
Table 3.2 Descriptions of items for servo gun setup

Tip Wear Comp Tip Wear Down Comp specifies whether to perform tip wear compensation.
Default value: DISABLE DISABLE = current tip wear measurement values are NOT applied as compensation to spot
locations (and PRESS_MOTN locations).
ENABLE = current tip wear measurement values are applied as compensation to spot
locations (and PRESS_MOTN locations).
To use the tip wear compensation function, it is necessary to acquire a reference position and
calculate a compensation value using TP programs. See Tip wear Compensation section for
details.
Gun Sag Compensation Gun Sag Compensation specifies whether to perform the spot gun deflection compensation
Default value: DISABLE based on the Gun Sag amount for the pressure schedule selected
DISABLE = gun deflection compensation is not performed.
ENABLE = the gun deflection compensation is performed.
Refer to Gun Sag Compensation section for details.
Close Direction (Gun) Close Direction specifies the direction in which the movable tip is to be closed.
Default value: PLUS Refer to Initial Settings section for detail
Close Direction (Robot) Close Direction specifies the tool coordinate system frame number and which component of
Default value: UT:1 +Z the tool coordinate system indicates the direction in which the stationary tip closes.
Refer to Initial Settings section for detail
Max Motor Torque (%) Max Motor Torque specifies a limit to the maximum torque of the servo gun motor in usual
Default value: 100.0 operation. The torque specified here is applied to the servo gun axis when pressurization is
-31-
3.SERVO GUN MAIN SETUP SCREEN B-82634EN/01
not taking place. Usually, the limit should not be adjusted by the user.
The valid data range is between 1.0 and 140.
Max Pressure (Kgf) Max Pressure specifies a limit to the pressure to be applied during pressurization. Any
Default value: 500.0 kg pressure higher than the value specified here will not be generated. A similar limit is also
placed during pressure input. This value should be specified by the gun manufacturer.
Refer to Initial Settings section for detail on how to set this item and change the units.
The valid data range is between 1.0 and 9999.9.
Tip stick detect distance Specifies the tip opening after the weld complete signal to check the tip stick detection signal,
[mm] if used. Set the tip stick detection signal in the weld I/O screen.
Default: 5 Refer to tip stick detection section for more details
Tip Wear Detection Items in this screen are used to specify how tip wear measurements are executed and how to
process tip wear related alarms.
Refer to Tip Wear Compensation section for details.
Put the cursor on the <*DETAIL*>, then press ENTER to bring up this screen.
Pressure Cal Open the pressure calibration screen. Pressure Cal specifies the motor torque to be
generated, then measuring the pressure applied by the specified torque can yield a relational
expression between the motor torque and pressure. When pressure adjustment is
completed, the display changes from INCOMP to COMP. If the display remains at INCOMP,
it is impossible to perform a spot welding sequence, manual welding, manual pressurization,
and pressurization operation.
Refer to Initial Settings section for more detail.
Tip Wear Standard This screen displays information about the status of tip wear compensation including data
recorded during tip wear setup/initialization. When the reference positions are set, the display
changes from INCOMP to COMP. See Tip wear Compensation section for details.
Thickness Check This screen displays information about the setup of Part Thickness check.
Refer to Part Thickness Check Function section for more details.
Gun Stroke Limit This screen displays the stroke limits for the gun axis. These limits are referenced from the
master position, and more specifically, from the “reference zero position” when tip wear
compensation is initialized. The stroke limits can be changed from this screen.
Refer to Initial Settings section for more detail
Overtorque Protection This screen displays the Overtorque Protection status and settings. It is recommended to
keep this function enabled to protect the gun axis from damage caused by the user jogging
the tips to a high pressure.
Refer to Overtorque Protection section for more details.
-32-
B-82634EN/01 4.MANUAL OPERATIONS
4 MANUAL OPERATIONS
The following manual operations can be done using the teach pendant.
4.1 Manual Pressurization (Shift+GUN)

Pressurization can be performed manually by operating keys on
the teach pendant
4.2 Manual Backup stroke (Shift+BU)
The servo gun opening can be changed to pre-set values with
operating keys on the teach pendant.
4.3 Manual Welding
Welding can be performed manually by operating keys on the
Manual welding screen.
4.4 Jog operation (group 2 manual operation)
Jogging is possible on the servo gun movable axis in the same
manner as for robot jogging.
-33-
4.MANUAL OPERATIONS B-82634EN/01
4.1 MANUAL PRESSURIZATION (Shift+GUN)
The gun can be closed to pre-set pressures by using the GUN key on the
teach pendant
User has to set the following prior to operation

1. Specify the Pressuring time and the start and end distance. See
Detail [1].
2. Specify (or confirm) the details of the Pressure Schedule. See
Detail [2]
Procedure
SETUP \ Servogun\
MANUAL / EQ:1 Gun:1 1/5
Manual Pressure
1 Pressuring Time(sec): 1.0
2 Start distance type: INITIAL DIST
3 End distance type: INITIAL DIST
Manual Backup
4 Backup Speed(%): 100
5 Backup stroke: <*DETAIL*>
[ TYPE ] EQUIP GUN
SERVOGUN \ DATA
PRESSURE / EQ:1 Gun:1 1/99
No. P(lbf) Thick(mm) Manual Comment
1 150.0 10.0 TRUE [gage check]
2 0.0 0.0 FALSE [ ]
3 0.0 0.0 FALSE [ ]
4 0.0 0.0 FALSE [ ]
5 0.0 0.0 FALSE [ ]
6 0.0 0.0 FALSE [ ]
7 0.0 0.0 FALSE [ ]
8 0.0 0.0 FALSE [ ]
9 0.0 0.0 FALSE [ ]
10 0.0 0.0 FALSE [ ]
[ TYPE ] EQUIP GUN DETAIL COPY >
Pressing the GUN1 key on the teach pendant displays a window

including the Pressure Schedule numbers that are available for
manual pressurization. While the window is displayed, pressing
the GUN1 key switches through all pressure schedules available
for manual pressurization
When a key other than the GUN1 key is pressed, or if all keys are
unused for a while, the window disappears automatically.
-34-
Gun number
GUN 1 Pressure
schedule
GN1- 1
FRNT PANEL Comment
180.0Kgf
GN1 No. 1 GN1 No. 2 GN1 No. 3 Pressure
FRNT PANEL REAR PANEL SIDE PANEL
180.0Kgf 195.0Kgf 185.0Kgf
SHIFT
GUN 1 Pressing the GUN 1 key while holding down the SHIFT key
triggers pressurization.
The gun will move to the specified start distance then close to the
specified pressure
Once pressurization has started, you do not have to keep pressing

the GUN 1 key.
If you want to discontinue the movement, release the SHIFT key.
When the specified Pressuring time elapses, the gun will open to
the specified End distance
The stationary tip (on the robot) will not move during
pressurization. In addition, neither the gun sag compensation nor
the tip wear down compensation on the stationary side is
performed.
NOTE
If macro programs are assigned to UK1, SU1, UK3,
and SU3 by macro setting, pressing these keys
makes the corresponding MACRO programs override
manual operation; pressing the GUN1 key will not
trigger manual pressurization. (UK[1]/UK[3] mean
GUN1 key/ GUN2 key, SU[1]/SU[3] mean
SHIFT+GUN1 key/ SHIFT+GUN2 key respectively.)
-35-
Detail [1]
Specifying the Pressuring time and whether to open the gun
1. Display the SERVO GUN SETUP screen.

MENUS key → “6 SETUP” → F1“[Type]”
→ “Servo Gun”
2. Select “ Manual Operation Setup” (by placing the cursor on <*
DETAIL *>, then pressing the ENTER key). The Manual
operating screen appears.
T2 G1 JOINT 10%
SETUP\Servogun
SERVO GUN SETUP 3/3
1 Equip number: 1
2 General Setup: <*DETAIL*>
3 Manual Operation Setup: <*DETAIL*>
[ TYPE ] EQUIP

Manual Pressure
1 Pressuring Time(sec):0.0
Manual Backup
3. Specify the following items:
Pressuring Pressurization is continued for the specified Pressuring time.

Time:
Start INITIAL DIST – the gun will close to pressure, directly from
Distance its current (initial) position
Type BACKUP STROKE – the gun will first move to the selected
manual backup, then it will close to pressure
End Distance INITIAL DIST – the gun will open to the position that it started
Type to close from
BACKUP STROKE – the gun will open to the selected
Manual Backup
PART THICKNESS – the gun will open to the programmed
part thickness
-36-
Detail [2]
Specifying Pressure Schedule details
1. Display the Pressure Schedule screen.

DATA key → F1”[TYPE]” → “Pressure”
2. Pressing F4“DETAIL” displays the servo gun Pressure Schedule
detail screen.
SERVOGUN \ DATA
No. P(lbf) Thick(mm) Manual Comment
1 350.0 2.5 TRUE [gage check]
2 0.0 0.0 FALSE [ ]
TRUE status can be
3 0.0 0.0 FALSE [ ]
selected by GUN
4 0.0 0.0 FALSE [ ]
key。
5 0.0 0.0 FALSE [ ]
6 0.0 0.0 FALSE [ ]
7 0.0 0.0 FALSE [ ]
8 0.0 0.0 FALSE [ ]
9 0.0 0.0 FALSE [ ]
10 0.0 0.0 FALSE [ ]
Prev F4 DETAIL
List screen
Detail screen
T2 G1 JOINT 10%
SERVO\GUN\DATA
PRESSURE / EQ:1 Gun:1 No:1 4/4
1 Comment: [rear_flrpn]
2 Weld Pressure(kgf): 350.0
3 Part Thickness(mm): 2.5
4 Gun Sag Comp Value(mm): 0.7
[ TYPE ] EQUIP GUN LIST
NOTE
Depending on your software (options and settings),
the DETAIL screen may differ slightly from the
example below.
-37-
4.2 MANUAL BACKUP (Shift+BU)
The open position of the servo gun can be changed to pre-set values by
operating the BU key on the teach pendant.
1 Display the SERVO GUN SETUP screen by pressing the

following keys:
MENUS key → “6 SETUP” → F1“[Type]” → “Servo Gun”
2 Select “ Manual Operation Setup” (by placing the cursor on <*

DETAIL *>, then pressing the ENTER key).
The Manual operating screen appears.

Manual Pressure
1 Pressuring Time(sec):0.0
Manual Backup
3 Set the Backup Speed to a value other than 100% if needed. 100%
is the default choice and is recommended.
SERVO GUN DATA G1 JOINT 10 %

BACKUP / EQ:1 Gun:1 1/15
No. Comment Stroke(mm) Manual
1 [OPEN SMALL] 10.000 TRUE
2 [ ] 20.000 FALSE
3 [ ] 30.000 FALSE
4 [OPEN MID] 40.000 TRUE
: :
15 [OPEN LARGE ] 150.000 TRUE
:
30 [GUN CLOSED] 0.000 TRUE
[ TYPE ] EQUIP GUN RECORD CLEAR
This screen can be displayed by the following precedure.
DATA key →F1[TYPE] →6 Manual Bkup
In the Backup data table specify the opening amount and select
“TRUE” from “Manual” to make the backup position available for
manual operations.
-38-
Procedure
Pressing the BU (Backup) key displays a window including the
corresponding stroke number. While the window is displayed,
pressing the BU key switches the stroke number.
When a key other than the BU key is pressed, or if all keys are kept
unused for a while, the window disappears automatically.
Gun number
Stroke schedule
number
BU1 No. 1
BU 1 OPEN SMALL Comment
50.00mm
Stroke amount
BU1 No. 1 BU1 No. 2 BU1 No. 3

OPEN SMALL OPEN MIDDL OPEN LARGE
50.00mm 80.00mm 120.00mm
SHIFT Pressing the BU 1 key while holding down the SHIFT key triggers
gun axis operation.
BU 1
Once gun axis operation has been started, you need not keep
pressing the BU (Backup) key.
If you want to discontinue the operation, release the SHIFT key.
This procedure triggers gun axis operation only. The stationary
arm (on the robot) will not operate during gun axis operation.
No tip wear compensation is performed.
If any MACRO program is assigned to UK[2], SU[2], UK[4] or
SU[4], these key operation will not execute manual stroke but
execute the MACRO program.
-39-
4.3 MANUAL WELDING
Welding can be performed manually by using the Manual welding

screen.
NOTE
Welding requests weld schedule. Please refer
SPOTTOOL+ Manual for setting weld schedule. Also,
sim-weld can check welding motion for user. Please
refer to 10.SOFT PANEL about sim-weld
Procedure
Display the Manual weld screen.
1. Select the MENUS key to bring up the screen menu.
2. Select “ MANUAL FCTNS”.
4. Select “Spot welding”. The MANUAL FCTN Spot screen
appears.
The currently active welding schedule is

AUTO G1 JOINT 10% displayed here.
MANUAL\FCTNS
2/4 If welding has not been performed, no current
Manual Weld (Last Weld) values are displayed (*****).
1 Start distance sched: ( 0) 1
2 Pressure schedule: ( 0) 1
3 Weld schedule: ( 0) 0
4 End distance sched: ( 0) 1
Weld duration(ms): 0
The start distance, end distance and

[ TYPE ] EXEC pressure schedules are specified here.
Specify the schedules to use for the manual weld

- Hold down the SHIFT key, then press F3“EXEC” causes
pressurization, welding, and opening to be performed
- This causes the gun to close under the specified conditions
and welding will begin once the gun is pressurized. Once
welding has started, you need not keep pressing F3“EXEC”.
If you want to discontinue the movement, release the SHIFT key.
In this welding sequence, the gun tip moves, but the robot tip does not.
-40-
4.4 GUN JOG OPERATION
Jogging is possible on the servo gun movable axis in the same manner
as for the robot axis. Usually, the stroke of the servo gun can be
changed using the Backup function (BU key). However, jogging can be
used on the servo gun movable axis, for example, for zero-position
mastering.
Operating procedure
1. Confirm the motion group number.
G2 JOINT 10 %
This value is the current motion group
number. If the servo gun is in motion
group 2, the group number must be G2.
To switch the group number, press the FCTN key, and select
“CHANGE GROUP”.
The value G# switches each time CHANGE GROUP is selected.
FCTN
3 CHANGE GROUP
2. Decrease the override value in advance.
+％ Increases the override value.
-％ Decreases the override value.
3. The keys shown below are used to move the movable tip.
SHIFT
+X
-X +X SHIFT ＋ (J1) :Move the tip in the
(J1) (J1) positive direction.
-X
SHIFT ＋ :Move the tip in the
(J1)
negative direction.
-41-
5.PROGRAMMING B-82634EN/01
5 PROGRAMMING
This section describes programming operation related to spot weld of
servo gun.
-42-
B-82634EN/01 5.PROGRAMMING
5.1 SPOT WELDING INSTRUCTIONS
Instructions used in a program to specify servo gun operation are

generically called spot welding instructions. Processes (such as closing,
pressing, welding, and opening) specified using a spot welding
instruction are called a spot welding sequence.
Spot welding instructions perform tip wear compensation and arm
deflection compensation as well as the following welding sequences.
Start Distance :
The specified Start Distance (SD) openings are passed through on the
way to the taught spot location
Pressurization;
Pressurization (clamping, squeezing) is performed according to the
specified pressure schedule number (P).
Welding:
The specified weld schedule number (S) is sent to the weld controller
when the pressure reaches the specified value.
End Distance :
The gun is opened in response to the welding completion signal. The
gun opens through the specified End Distance (ED).
-43-
5.1.1 SPOT Instruction Format
This instruction specifies Start distance (SD), pressure schedule (P), weld
schedule (S), and End Distance (ED) directly.
SPOT [SD=m, P=n, S=i, ED=m]
m : Distance schedule numbers (1-$sgsyscfg.$dst_elm (default=99))

n : Pressure schedule number (1 to $sgsyscfg..$sch_elm(default=99))
i : Welding schedule number (0 to 255)
Set each schedule for SPOT instruction in DATA screen.

1. Press DATA key, display DATA screen
2. Press F1[TYPE]
DATA: Registers
SPOT [SD=m, P=n, S=i, ED=m]
1/200
R[ 1: ]=0
R[ 2: ]=0
__________________ ]=0
| 1 Registers | ]=0
| 2 Position Reg | ]=0
| 3 KAREL Vars | ]=0
| 4 KAREL Ponsn | ]=0
| 5 Pressure | ]=0
| 6 Manual Bkup | ]=0
| 7 Distance | ]=0
| +-----------------
| TYPE |
This number is indicated to weld controller as weld schedule.
-44-
Distance Schedule Setting

To program a spot instruction, it is necessary to specify the Distance
schedules used for both Start Distance (SD) and End Distance (ED).
SERVO GUN DATA _ Start Distance specifies the clearance trajectory for both tips of the
DISTANCE / EQ:1 Gun:1 1/99
No. Gun(mm) Robot(mm) Comment servo gun when closing to the spot weld and End Distance specifies the
1 5.0 5.0 [small\\\\\] clearance when opening after the spot weld.
2 10.0 5.0 [ ]
3 20.0 5.0 [ ]
4 10.0 10.0 [standard ] 1. Press the DATA key to display the DATA screen.
5 20.0 10.0 [ ] 2. Press F1“[TYPE]” to display the pull-up menu.
6 20.0 20.0 [ ]
7 24.0 24.0 [large ] Select “Distance”.
8 24.0 24.0 [ ] 3. The servo gun Distance table appears.
9 24.0 24.0 [ ] 4. Edit the tip clearance distances here. Press F4 – Detail to see the
10 24.0 24.0 [ ]
detail screen.
[ TYPE ] EQUIP GUN DETAIL COPY
SERVO GUN DATA _

DISTANCE DETAIL / EQ:1 Gun:1 No:4 5/5 5 Edit the attributes to define how the selected distance
schedule will perform when used
1 Distance gun(mm): 10.0 End distance (ED) attributes – defines the attributes
2 Distance robot(mm): 10.0
used when the schedule is used as an End distance
End distance (ED) attributes SPOT [SD=m, P=n, S=i, ED=m]
3 Termination Type: CNT 80
4 Acc instruction: ACC 100
Start distance (SD) attributes – defines the attributes
used only when the schedule is used in a stand alone
Start distance (SD) attributes instruction or a manual operation
5 <*DETAIL*>
[ TYPE ] EQUIP GUN END
SERVO GUN DATA _

DISTANCE DETAIL / EQ:1 Gun:1 No:1 1/3
Manual/StandAlone(start dst attrib)

1 Termination Type: CNT100
2 Acc instruction: ACC100
3 Speed(%): 100
[ TYPE ] EQUIP GUN [CHOICE]
-45-
Pressure Schedule Setting

To program a spot instruction, it is necessary to specify the pressure
schedule number that determines the weld pressure and part thickness.
1: L P[1] 2000mm/sec CNT100

SERVO GUN\DATA _
: SPOT [SD=m, P=n, S=i, BU=m]
No. P(Kgf) Thick(mm) Manual Comment 1. Press the DATA key to display the DATA screen.
1 350.0 2.6 FALSE [spot 1-10 ]
2 200.0 1.4 FALSE [spot 11-15]
3 0.0 0.0 FALSE [ ] Select “Pressure”.
4 0.0 0.0 FALSE [ ] 3. The servo gun Pressure Schedule list setting screen appears.
5 0.0 0.0 FALSE [ ]
6 150.0 8.0 FALSE [tip dress ]
7 0.0 0.0 FALSE [ ] F4 DETAIL Displays the detail setting of the Pressure schedule
8 200.0 12.5 TRUE [gage check] for editting.
9 0.0 0.0 FALSE [ ]
10 0.0 0.0 FALSE [ ] F5 COPY Pressing this key with the cursor on the schedule of
a copy source displays a prompt for the schedule
[ TYPE ] EQUIP GUN DETAIL COPY > number for a copy destination.
SERVO\GUN\DATA _ 4 Pressing F4“DETAIL”. The servo gun Pressure Schedule detail

PRESSURE / EQ:1 Gun:1 No:1 1/5 screen appears. Pressing F4“LIST” brings you back to the
1 Comment: [spot 1-10]
Pressure Schedule list screen.
Descriptions of items to be set up

Comment A comment can be added to each Pressure Schedule.
Weld Pressure (Kgf) Weld Pressure specifies the pressure to be applied when a spot welding instruction is
Minimum: 0.0 executed.
Maximum: 9999.9
Part Thickness (mm) Part Thickness specifies the thickness of the workpiece to be welded.
Minimum: 0.0
Maximum: 1000.0
Gun Sag Comp Value (mm) Gun Sag Comp Value specifies a compensation amount if “Gun Sag Comp Value” has been
Minimum: -1000.0 set to ENABLE on the General Setup screen.
Maximum: 1000.0
Adjusted (%) This item is displayed by $SGSYSCFG.$SHO_PRS_SPD_=TRUE.
Default: 100% The following screen is displayed. This item can adjust contact speed at pressure. The
speed rate can be changed based on speed which is calibrated in pressure calibration.
Contact speed can be increased/decreased up to maximum / minimum joint speed
SERVO\GUN\DATA _
PRESSURE / EQ:1 Gun:1 No:1 1/5
1 Comment: [spot 1-10]
Contact speed :
Calibrated (mm/sec) : 100.0
5. Adjusted: ( 100mm/sec) 100.0%
-46-
Servo Gun SPOT Trajectory
The following positions are created from the taught position and the
specified Start and End Distance schedule.
Taught Playback
Position Sequence
Start These positions are End

Distance Automatically generated Distance
Synchronized Pressing
Contact pos pos
GUN
side
Panel
ROBOT
side
Time
(Start/End Distance Setting)

Gun [mm] Specify the approach position of the movable 1 Start and End Distance
Min.: 0.0 side tip as a distance from the part
Max.: 1000.0 Gun
.
Gun(mm)
Thick(mm)
Robot [mm] Specify the approach position of the fixed side Robot(mm)
Min.: 0.0 tip as a distance from the part.
Robot
Max.: 1000.0
Closing and Opening Trajectory according to SPOT termination type
When executing a motion option SPOT, both tips of the

servo gun arrive at the metal surface for the specified
Sample Program
spot location at the same time.
1: L P[1] 1000mm/sec CNT 100 The trajectory of the tips will vary according to the
2: L P[2] 1000mm/sec CNT50
specified Start/End Distance and termination type
SPOT[SD=1,P=1,S=1,ED=1]
Specified term type
FINE/CNT0 : tips will pause momentarily at the
specified start/end distances
P[2]
CNT1-100 : tips will round the corner through the
Start start/end distance with less deceleration. CNT100
Distance specifies the minimum deceleration to and from the
spot.
Increasing CNT
P[1]
-47-
5.1.2 Welding Sequence

This section describes a welding spot instruction-based welding
sequence.
1: L P[1] 2000mm/sec CNT100

: SPOT[SD=1,P=3,S=5,ED=2]
･ A welding sequence is executed when the specified pressure is

reached.
･ The welding sequence outputs welding schedule signals between
the R-J3 controller and welding machine timer, and waits for the
Weld completion signal.
･ The welding sequence is specified using the same screens
(SETTING menu and “Spot welding”) as for the air gun.
Identify this as force control start tolerance

Pressure
Specified pressure
Output signals
*1 Weld start delay

Welding condition (i, j)
Welding strobe
Welding command *2
Input signal
Welding completion
Pressurization Welding sequence Opening
*1) When the tip is moving to the pressurization position, if the

specified pressure (including its tolerance) is reached, all signals
from the additional signal to the welding permission signal are
output sequentially.
If the specified pressure is not reached, the warning message
“SVGN-020Pressure shortage ” appears, resulting in program
execution being discontinued.
Weld start delay can be set in SETUP/Spot Equip screen.
*2) When the Weld completion signal is input, it turns off all output
signals, and triggers an opening sequence. When the opening
sequence ends, the next instruction is executed
-48-
5.1.3 Teaching Position

When a spot welding instruction is taught, the stationary (robot)
tip should be touching the panel.
(2) The movable tip can be in any position. However, it is
Movable tip
recommended to have at leave at least a small open
distance, since the movable tip returns to this open distance
in single step mode.
Panel
Stationary tip
(1) Jog the stationary tip until it touches the panel.
(3) While holding down the SHIFT key, press F2”SPOT”.
To teach a position, it is best to use a new tip.

If tip wear compensation is enabled, the last measured wear
amount is automatically considered during teaching and touchup.
Use the Cartesian representation of position data. If spot welding
instruction is attached to the Joint angles representation of position
data, an alarm is issued when the instruction is executed. (Usually,
the Cartesian representation of position data is taught.)
Position[1] Position[1]
X W J1 J4
Y P J2 J5
Z R J3 J6
5.1.4 Hold
When an alarm or pause occur during execution of the SPOT
instruction (during the spot sequence), both the robot axis and the
gun axis decelerate and come to a stop.
When execution of the program is paused during pressure control,
program execution is stopped. The following system variable can
be used to set the specification to be used when the hold input
signal is input during pressurization:
$SGSYSCFG. $REL_PRESS
= 0: Maintains the pressure.
= 1: Releases the pressure.
When program execution is paused, the weld signal and weld

condition signal turn OFF.
A restart resumes program execution from the spot sequence.
When program execution is paused between start of pressuring
and end of welding, a restart executes pressuring again (initial
pressure), and welding is carried out after the specified pressure is
reached.
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5.1.5 E-Stop
When an emergency stop or power down occurs during pressure
control, the pressure is not maintained.
When an emergency stop or power down occurs, the weld signal
and weld condition signal turn OFF.
A restart resumes program execution from the spot sequence.
When an emergency stop or power down occurs between start of
pressuring and end of welding, a restart executes pressuring again
(initial pressure), and welding is carried out after the specified
pressure is reached. (In the case of a power interruption, power fail
recovery must be enabled.
5.1.6 Single-Step
When an operation instruction with the SPOT option is executed in the
single-step mode, the machine first passes through the approach
position and stops at the taught position.
Then, it restarts the spot welding sequence from the approach position
and completes the sequence (including pressurization) by the 2nd single
step execution.
Current L P [1] 2000mm/sec CNT100 SPOT [P=1,S=1,BU=0]
position
Step forward Step forward

(1st) (2nd)
Stops at the taught position. Executes pressurization

and opens the gun.
NOTE
The taught position is reproduced only in step
execution mode. In the continuous execution
mode, taught position is not passed through.
Changing the taught position reproduction mode

The following system variable can be used to specify whether to pass
through the taught position when the spot welding instruction is
executed in the single-step mode:
$SGSYSCFG.$STEP_TCHPT=TRUE(Enabled)/FALSE(Disabled)
TRUE: Stops at the taught position. (default setting)
FALSE: Does not stop at the taught position.
-50-
Stop positions during execution of step forward (details)
Start Opening
Taught Start
Distance position
position Distance
Gun tip
Pressuri-
zation
Taught
position
position show
Gun
mode
Stroke
($SGSYSCFG.
$STEP_TCHPT
Robot tip
Pass→ Stop <1> Pass→ Pass→ Stop <2>

Enabled CNT0 CNT 0 (pressurizati
Enabled
on)
(TRUE)
Pass→ Stop <1> --- --- Stop <2>
Disabled
CNT0
Stop <1> --- --- Pass→ Stop <2>
Enabled (pressurizati
Disabled on)
(FALSE)
Stop <1> --- --- --- Stop <2>
Disabled
Pass→: Position at which the machine does not stop and passes through
Stop : Position is which playback stops until FWD is pressed again
--- : Position at which the machine neither stops nor passes through
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5.2 OTHER INSTRUCTIONS
This section describes other (non-spot) instructions for the servo gun
function.
5.2.1 Press Motion Instruction

The Press Motion instruction is intended to perform pressurization of
the servo gun without performing welding. This instruction is
commonly used for tip dressing/grinding operations.
The Press Motion instruction does not open the gun or perform welding
after pressurization is completed.
Like spot welding instructions, the Press motion instruction carries out
tip wear compensation and arm deflection compensation when it is used
as a motion option.
Instruction format
Stand Alone format:
1: PRESS_MOTN [SD=m, P=n]
Motion Option format:
1: L P[1] 2000mm/sec FINE Press_motn [SD=1, P=1]
Pressurization is performed according to the Start distance and

pressure schedule numbers specified.
The pressurization instruction can be used as both motion option
and standalone instructions.
- Motion option instruction
The additional-operation instruction controls both movable
and stationary tips during a pressurization sequence. It also
performs tip wear compensation and gun deflection
compensation.
The pressurization instruction performs only pressurization it does
not open the gun. So, it is necessary to teach Pressuring time and
gun opening separately. (See the sample program.)
Sample Program
1:L P[1] 100mm/sec FINE Line 1: Closes to pressure at taught
: Press_motn [SD=1, P=2] position
2: WAIT 2.00sec Line 2: Pressuring time
3:L P[2] 100mm/sec FINE Line 3: Gun Opening
5.2.2 Pressure Instruction

The pressure instruction is intended to limit the maximum torque of the
servo gun to the specified pressure when ordinary motion statements
rather than spot welding and pressurization instructions are used to
control gun motion. It can be used when load becomes too heavy if the
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maximum torque is applied to the servo gun axis, for example, to press
the servo gun against the workpiece for a purpose other than spot
welding. It cannot be used to control the pressure used in a spot
welding or pressurization instruction.
Instruction format
Pressure specification instruction
Pressure[tl]kgf
Pressure condition number (1 to 9999) gun 1
NOTE
Maximum Pressure is limited by "Max
Pressure(Kgf)" in General Setup in SETUP SPOT
Weld screen at executing the instruction.
Pressure standard instruction

Pressure standard gun 1
The pressure standard instruction restores the max. motor torque%

specified on the servogun setup screen.
It also modifies the excessive-error threshold value in order to
prevent excessive error at pressurization.
The pressure standard instruction cancels changes made by the
pressure specification instruction to the torque limit value and
excessive-error threshold value, and resumes their previous values.
If the current pressure has been modified using the pressure
specification instruction, resume its previous value, using the
pressure standard instruction. Otherwise, the operation continues
with a low torque, resulting in a decreased cycle time.
NOTE
If the pressure specification instruction is used to lower the pressure applied to
grasp the workpiece, keep the newly specified pressure until the workpiece is
conveyed and released. If the previous pressure is resumed when the workpiece
is held on the gun, the torque limit is lifted, causing the maximum torque to be
generated, which is likely to run an excessive load on the workpiece and gun.
Sample program
1: Pressure[100]Kgf Line 1: Pressure change
2: L P[1] 100mm/sec CNT50 Line 2: grasp workpiece
3: L P[2] 100mm/sec CNT50 Line 3: Move to a point
4: L P[3] 100mm/sec FINE Line 4: Release workpiece
5: Pressure standard gun1 Line 5: Resume to the previous value
If a spot welding instruction (or pressurization instruction) is used

along with a pressure instruction used to limit the gun axis motor
torque, the pressure specified in the spot welding instruction (or
pressurization instruction) overrides the pressure specified in the
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spot welding instruction. If the pressure instruction specifies 100

kgf, for example, when a spot welding instruction is executed with
a Pressure Condition of 200 kgf, a pressure of 200 kgf is generated
5.2.3 Gun Zero Master Instruction

This subsection explains other instructions. Currently, the gun zero
mastering instruction is available.
The gun zero mastering instruction performs zero-point mastering for

the gun axis at the current position.
Instruction format
Gun Zero Master［#］
#: Gun number (1 to 6)
Sample program
1:L P[1] 100mm/sec FINE Line 1: 0 kgf must be specified for
: Press_motn [SD=1, P=98] pressure condition P=[98].
2: WAIT 0.5 sec Line 2: waits to let the position settle
3. Gun Zero Master [1] Line 3: sets the mastering for gun 1.
4: L P[2] 100mm.sec FINE Line 4: opens the gun
NOTE
The above sample program cannot perform zero-point
mastering for a gun of which the mastering position is
completely shifted or that for which mastering is not
complete.
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B-82634EN/01 6.TIP WEAR DOWN COMPENSATION
6 TIP WEAR DOWN COMPENSATION
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6.TIP WEAR DOWN COMPENSATION B-82634EN/01
6.1 OVERVIEW
Tip Wear Compensation is used to compensate for changes at the servo

gun tips. These changes include wear resulting: from welding, dressing,
etc. and growth resulting from tip change, electrode change, etc. Tip
Wear Compensation adjusts the final position of both weld tips when
executing the SPOT or PRESS_MOTN instruction.
It is necessary to measure the amount of tip wear down in order to use
this function. The tip wear compensation function works by using
Teach Pendant programs and macros that are included with the Servo
Gun software option.
TIP WEAR MEASURING METHODS
Two standard methods of tip wear measurement are available that do not
require external sensors. They are called TWO STEP and ONE-STEP.
Only one method can be used for each gun/equipment.
TWO-STEP (i.e. fixture-based, fixture-touch) Æ First, the gun is
closed and re-mastering is done. Next, the gun is brought to a rigid
plate/fixture in the cell -often mounted on the tip dresser- and the
moving tip closes to the fixture (fixture-touch) while the gun opening is
measured. The unique wear amount on each tip is determined
accurately using this method.
1st Step (Re-Master/Calibrate) 2nd Step (fixture-touch)
Position #1 Position #2
The two-step method is the most accurate, since the unique wear of each
tip is determined. This is the default method.
ONE-STEP (i.e. fixture-less, tip-to-tip) Æ The gun is closed and
re-mastered. The fixture-touch step is skipped so, only the combined
wear of both tips is determined. Each tip’s unique wear amount is then
estimated by applying the user-defined “wear ratio”.
TIP WEAR TASKS
With both methods, there are two main tasks for using tip wear
compensation:
INITIAL SETUP – do this once, to initialize tip wear reference data*
UPDATE– do this after initial setup, every time a new tip wear
measurement is needed
* Initial Setup must be run again if BZAL (Battery Zero Alarm) occurs, change in gun
geometry or change in gun friction when using Two-Step method. Read the Recovery
from Loss of Mastering Data section for more detail on running the initialization after
BZAL.
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6.2 STANDARD TIP WEAR PROGRAM LIST

The following TP programs are included in the TP program list when the
Servo Gun option is installed. Use these programs to perform the tip wear
initial setup and update tasks, as well as a few other common functions if
needed.
The TP programs are setup to perform a specific tip wear function on

gun #1. These programs can be copied or re-named by the user for
special cases such as:
Multi-gun systems
To support a customer specified TP program naming convention
To support indirect argument assignments
Etc.
The MACRO programs should generally not be re-named or deleted
since they are used as sub-routines of the main tip wear programs.
Default TP program Main Macro That is Function

name Run
The following programs are always loaded
TW_SET01 TW_SETUP Initialize tip wear data for the 2-step method on gun 1. Must specify the gun
number in the macro program call.
TW_UPD01 TW_UPDAT Measure the tip wear using the 2-step method for gun 1. Must specify the
gun number and the tip condition (new or used) in the macro program call.
TW_MV2PT N/A Move the robot to the positions required for each step in the 2-step method.
This is a sub-routine called by TW_SETUP and TW_UPDAT that is used to
specify positions and should not be re-named!
If $SGSYSCFG. $LOAD_TWD＝11 the following programs are loaded
WR_SET01 WR_SETUP Initialize tip wear data for the 1-step method on gun 1. Must specify the gun
number in the macro program call.
WR_UPD01 WR_UPDAT Measure the tip wear using the 1-step method for gun 1. Must specify the
gun number and tip condition (new or used) in the macro program call.
If $SGSYSCFG. $LOAD_TWD＝12, the following programs are loaded
TW_PRS01 TW_PRSRT Press new tips onto the gun tip holder by opening and closing the gun with
pressure several times. Please refer Appendix .F about more details.
The purpose of this document is to describe how to use the TP & macro
programs and Tip Wear UIF screens to properly measure and
compensate for tip wear.
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6.3 PREPARATIONS FOR TIP WEAR DOWN COMPENSATION
Preparations
• Complete servo gun autotune and pressure calibration
• Set Tip Wear Comp ’to ENABLE in Servo gun general setup
screen
• Install new tips before measurement setup
• Check the stroke limit and update it if necessary
NOTE
Robot and gun positions will change slightly from the
originally taught position at execution of the SPOT
and Press Motion with tip wear compensation. Be
sure robot arm and gun arms do not interfere with
tooling and fixtures when tip wear amount is large.
Preparation of TWO-STEP
Prepare a fixture for detecting the moving tip position in the
fixture-touch step of the measurement If the fixture deflects while the
tip presses against it, the measurement error may increase. Please
prepare make the fixture as rigid as possible (As a standard, movable tip
will press the fixture with 100-200 kgf of pressure.).
Movable tip
fixture
Confirmation of register & position register number

The macro programs for tip wear down measurement use R[10], R[11]
and PR[20],PR[21] as the default registers. Don’t use these registers for
another purpose. These registers can be changed in the macros,
however it is generally not necessary to change.
Macro Name Used Register Used Position Register

TW_SETUP R[10] PR[21]
TW_UPDAT R[10] PR [21]
WR_SETUP R[10] PR [20], PR [21]
WR_UPDAT R[10] PR [20], PR [21]
-58-
6.4 TWO-STEP MEASUREMENT METHOD
Procedures for TWO-STEP Measurement (ex. Gun =1)

The Two-Step measurement uses the macro programs TW_SETUP and
TW_UPDAT to perform the initial setup and update tasks respectively.
Two different positions are required. These positions are stored in the
template program TW_MV2PT.
Teaching Position
1. Teach two positions in TW_MV2PT
Label of gun number & teaching position
TW_MV2PT LINE 0 T2
ABORTED G1 JOINT 10% Shift + F5
31: LBL[11:P1/Tips_tch.Gun1]
32:L P[...] 250mm/sec FINE
33: END P1 - Approach position for fixture (Tips_tch)
34: LBL[21:P2/Fix_tch.Gun1]
35:L P[...] 250mm/sec FINE
36: END Shift + F5
37: >5mm
POINT SPOT TOUCHUP

P2 - Fixture touch position (Fix_tch)
NOTE：Notice the following for teaching positions.

1 TW_MV2PT is pre-installed in controller.
2 Please refer to the label comment of TW_MV2PT for gun number & teaching position
3 The positions should be taught such that movement from Posn[1] to Posn[2] or
vice-versa does not cause any collision
4 These are the same points the robot will move to for the measurement of tip wear
during production. Be sure to consider this when calling the tip wear update program
in production.
5 Robot and gun positions will change slightly from the originally taught position at
execution of the SPOT and Press Motion with tip wear compensation. Be sure robot
arm and gun arms do not interfere with tooling and fixtures when tip wear amount is
large.
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Initial Setup
1 Copy program TW_SET01、to a new program (name) if necessary,
and modify the instructions.
Ex) TW_SET02.TP : for setup gun 2
TW_SET01 LINE 0 T2
ABORTED G1 JOINT 10%
5: ;
6: !Use the following call for ;
7: !fixture-based wear measurement ;
8: !Parm1: gun number ;
9: !CALL TW_SETUP( 1 ) ;
10: CALL TW_SETUP(1) Set correct gun number
POINT SPOT TOUCHUP
2 Execute user program that was copied from TW_SET01.TP for

each gun. Check teaching positions and gun axis speed, then
execute it finally with override 100% (AUTO mode or T2 mode).
Position[1]:Tips touch position Position[2]:Fix touch position
Threshold value measurement Reference zero position calibration Reference open position measurement
Robot positions in TW_MV2PT
Update tip wear amount

1. Copy program TW_UPD01、to a new program (name) if necessary,
and modify the instructions.
Ex)TWUPD02 for update gun 2
TW_UPD01 LINE 0 T2

16: !fixture-based wear measuremt ;
18: !Parm2: new tips ;
19: !CALL TW_UPDAT( 1, 0 ) ;
20: CALL TW_UPDAT(1,0) ; Normally set ‘ 0 ’ for worn tip
Set ‘ 1 ’ after installing new tip
POINT SPOT TOUCHUP
Set correct gun number
2. Set the arguments correctly for the wear measurement that is

required. The arguments may be specified indirectly by using data
register.
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3. Run the TW_UPDAT macro any time an updated measurement is

needed:
-After tip change (set new tips parameter)
-After tip dress
-After pre-determined number of welds or parts
-Whenever an updated wear measurement is desired
Position[1]:Tips touch position Position[2]:Fix touch position
Reference zero position calibration Wear down amount measurement
Robot move to positions of TW_MV2PNT
NOTE
Teach position[1] and position[2] for each gun
NOTE
Execute SETUP & UPDATE program for each gun in
the system
The following is a sample for this function.
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Example of Tip wear down measurement

1. TP program”SAMPLE.TP” executes motion instruction and SPOT
instruction,then calls tip wear down measurement program
“TW_UPD01”.
2. When tip is replaced to new tip,new tip measurement is executed by turing
on DI[10].
User Program
SAMPLE _
5/5
： Tip wear down measurement program
3: L P[1] 250mm/sec FINE
SPOT[SD=1,P=1,S=1,ED=1] TW_UPD01 _
4: L P[2] 250mm/secFINE 20/20
SPOT[SD=1,P=1,S=1,ED=1] 15: !Use the following call for ;
5: L P[3] 250mm/secFINE 16: !fixture-based wear measuremt ;
SPOT[SD=1,P=1,S=1,ED=1] 17: !Parm1: gun number ;
5: IF DI[10]=ON, R[1]=1 18: !Parm2: new tips ;
6: IF DI[10]=OFF,R[1]=0 19: !CALL TW_UPDAT( 1, 0 ) ;
7: CALL TW_UPD01 20: CALL TW_UPDAT(1,R[1]) ;
8: WAIT DI[10]=OFF [END]
9: J P[5] 250mm/sec CNT100
： POINT SPOT TOUCHUP>
[END]
POINT SPOT TOUCHUP>
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6.5 ONE-STEP MEASUREMENT METHOD
Procedures for ONE-STEP Measurement (ex. Gun =1)

The One-Step measurement uses the macro programs WR_SETUP
and WR_UPDAT to perform the initial setup and update tasks
respectively.
Initial Setup
1. Copy WR_SET01、to a new program (name) if necessary, and
modify the instructions.
Ex) WR_SET02.TP : for setup gun 2
WR_SET01 LINE 0 T2
5: ;
7: !fixture-based wear measurement ;
9: !CALL WR_SETUP( 1 ) ;
10: CALL WR_SETUP(1) Set correct gun number
2. Execute the newly created program. Only the gun should move.
Check gun axis speed, and then execute it finally with override
100% (AUTO mode or T2 mode).
Update amount of Wear Down

1. Set wear ratio (This step is not necessary if default wear ratio (=0.5)
is used.).The wear ratio is defined as the fraction of total wear that
is assigned to the robot tip
a. Open the program WR_UPDAT
b. Find the line that calls twkcalc2, as shown (highlighted)
below
c. Set the 1st argument to the wear ratio you desire. (Default =
0.5, equal wear on each tip)
WR_UPDAT
60/66
53: LBL[1]
54:
55: !Update wear amounts
56: !Parm1: 0<=Robot wear ratio<=1.0
57: !RbtTipWear = ( rbtwr_ratio *
58: ! total wear )
59: !Parm2: New tip installed
60: CALL TWKCALC2(.5,AR[2])
61:
62: !Move gun to PR
63: ! Parm1: Velocity label 0: all wear is assigned to the moving tip
1:all wear is assigned to the robot tip
[ INST ] [EDCMD] 0<Wear ratio <1: wear is assigned to both tips
-63-
2. Copy WR_UPD01、to a new program (name) if necessary, and

modify the instructions.
Ex) WR_UPD02.TP : for update gun 2
WR_UPD01 LINE 0 T2

16: !fixture-based wear measuremt ;
18: !Parm2: new tips ;
19: !CALL WR_UPDAT( 1, 0 ) ;
20: CALL WR_UPDAT(1,0) ; Normally set ‘ 0 ’ for worn tip
POINT SPOT TOUCHUP Set ‘ 1 ’ after installing new tip
Set correct gun number
3. Set the arguments correctly for the wear measurement that is

required. The arguments may be specified indirectly by using a
data register.
4. Run the WR_UPDAT macro any time an updated

measurement is needed.:
-After tip change (set new tips flag)
-After tip dress
-After pre-determined number of welds or parts
-Whenever an updated wear measurement is desired
NOTE
Execute SETUP & UPDATE for each gun in the
system
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6.6 OPERATIONAL SETTING AND ALARM PROCESSING
6.6.1 Tip Wear Detect Setup screen

In this screen, user can setup about measurement and Alarm process
SETUP\Servogun\ SETUP\Spot\Weld\
GENERAL / EQ:1 Gun:1 1/16 TIP WEAR DETECT / EQ:1 Gun:1 1/11
1 Tip Wear Down Comp: DISABLE
2 Gun Sag Compensation: DISABLE 1 Common setup: <*DETAIL*>
4 Close Direction(Robot): UT: 1 [+Z ] 2 Detection type: LOAD
5 Max Motor Torque(%): 82.4 3 Margin of load(kgf): 35
6 Max Pressure(kgf): 500.0 4 Tip speed(mm/sec): 70
7 Max Part thickness: DISABLE 5 Mis-detect toler.(mm): 5.00
8 Thickness (mm): 0.0
9 Tip stick detect delay(ms): 0 Maximum wear down check(Gun)
10 Tip Wear Detection <*DETAIL*> 6 Max wear down value(mm): 5.00
11 Pressure Cal: COMP <*DETAIL*> 7 Inform signal: DO[ 0]
12 Tip Wear Standrd: COMP <*DETAIL*> 8 Increased error(mm): 1.00
13 Thickness check: <*DETAIL*> Maximum wear down check(Robot)
14 Servo Gun MWV: <*DETAIL*> 9 Max wear down value(mm): 5.00
15 Gun Stroke limit: <*DETAIL*> 10 Inform signal: DO[ 0]
16 OverTorque protection: <*DETAIL*> 11 Increased error(mm): 1.00
Setup for tip wear down measurement

These are items that are used in measurement. Basically, it is not
necessary to modify the default values. However, if these values are
changed, then re-execute SETUP again.
Items Description
Common Pressure Schedule Number of the pressure schedule to use for the re-master step of tip wear
setup (Default = 98) measurement. Do not use this schedule for other tasks or for welding
Start distance Schedule Number of the start distance schedule to use for the re-master step of tip
(Default = 98) wear measurement. Do not use this schedule for other tasks or for welding
Open Gun at Restart ENABLE/DISABLE, specifies whether the gun is opened to the start distance
(Default = ENABLE) before retry after a mis-detection.
Retry times no. of times the re-master step is re-tried when a mis-detection is observed.
Detection Type LOAD or DO are available. All the programs described in this document
( Default : LOAD) assumes the LOAD technique is used. DO (Digital Output) requires an
external visual sensor to measure wear instead of a fixture-touch.
Margin of Load This is the amount of force(load) in addition to the gun friction (measured
(Default = 30 kgf) during tip wear setup/initialization) that will be applied to detect the fixture
touch. This value is set automatically by the software based on the servo gun
max pressure, but the user can override this value.
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Setup Items Description

Tip Speed(mm/sec) set by default to 30mm/sec, this is the maximum speed the tip will close to the
(Default = 30 mm/sec) fixture at during the fixture-touch step of a two-step measurement. The user
can increase this value experimentally if needed. This value must be set
before running the TW_SETUP program, so that TW_SETUP uses the same
fixture touch speed that TW_UPDAT uses. Using the same tip speed for each
measurement is critical for accurate results.
Mis-detect toler(mm) set by default to 5mm. This is how much tip growth is acceptable between the
(Default = 5 mm ) “reference tips” and the present tips (“reference tips” are the tips that were
used during initialization).. If a tip growth in excess of this amount is observed
it will be deemed a mis-detection and the measurement will be re-tried by the
number of times listed in the “Common Setup” before posting a “Tip Wear
Down misdetection’ fault.
Setup for tip wear down alarm process

These are items that are used in alarm process for each tip.

Maximum Wear Down Value The user specifies the maximum wear that can be measured on either the gun
tip or the robot tip before the Maximum Wear Exceeded Warning and Inform
Signal [DO] is activated. Typical values are between 4-7mm
The error messages that occur when max wear down value is exceeded are:
SVGN-118 Max wear exceeded (Gun Tip).
SVGN-119 Max wear exceeded (Rbt Tip).
Inform Signal this is the digital output that is turned on when the measured wear exceeds
the specified Maximum Wear Down Value.
Increased error this is the maximum tip growth that can be observed (compared to the
previous tip wear measurement) before the Tip Increased Error fault is
asserted. The only case where a longer tip would be expected is at tip
change. Setting the new tip flag to 1in the TW_UPDAT or WR_UPDAT
program, prevents the Increased error from being checked so that no alarm is
posted when tips are changed. Typical settings for this item are 1-2mm.
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NOTE
The Tip Increased error informs the user that the tip wear program observed the tips
touching each other or the fixture before it did on the previous wear measurement
(by an amount >= tip increased error(mm) setting). When this happens consider the
following possible causes:
- A piece of metal from tip dressing operation remained on the tip making it longer.
Remove the excess metal.
- New tips were placed on the gun, but the new tips flag was not set in the update
program or the tips were not properly seated. Properly seat the tips, then set the
new tips flag and run the update program again.
- The fixture-touch tip speed was slower than it was during the previous wear
measurement. Keep the fixture-touch tip speed consistent.
- The fixture-touch or re-master position was mis-detected (sensed too soon). This
can happen if the fixture position has shifted relative to the robot, the gun friction has
changed or the Margin of Load is set too small. When using the two-step
measurement, increase the Margin of Load if the fixture does not bend. If this does
not work re-execute the Initialization Procedure and determine why the gun friction
has changed.
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6.6.2 Tip Wear Standard screen
User can see and check some data relating to tip wear compensation in
this screen.
SETUP\Servogun\ Fixture-based measurement (Two-step)

GENERAL / EQ:1 Gun:1 1/16 TIP WEAR STANDARD / EQ:1 Gun:1 1/2
2 Gun Sag Compensation: DISABLE 1 Tip Wear value(Gun) (mm) 0.00
3 Close Direction(Gun): PLUS 2 Tip Wear value(Robot) (mm) 0.00
5 Max Motor Torque(%): 82.4 Detect load(kgf): COMP 27
6 Max Pressure(kgf): 500.0 Standard tip
7 Max Part thickness: DISABLE Master count: COMP 34886729
8 Thickness (mm): 0.0 Opening (mm): COMP 13.7
9 Tip stick detect delay(ms): 0
10 Tip Wear Detection <*DETAIL*> [ TYPE ] EQUIP GUN END
12 Tip Wear Standrd: COMP <*DETAIL*>
13 Thickness check: <*DETAIL*> Fixture-less measurement (One-step)
14 Servo Gun MWV: <*DETAIL*>
15 Gun Stroke limit: <*DETAIL*> TIP WEAR STANDARD / EQ:1 Gun:1 1/2
16 OverTorque protection: <*DETAIL*>
1 Tip Wear value(Gun) (mm) 0.00
2 Tip Wear value(Robot) (mm) 0.00
Standard tip
COMP: tip wear setup is complete Master count: COMP 34886729
INCOMP: tip wear setup is incomplete [ TYPE ] EQUIP GUN END

Tip Wear Value displays the present wear amount of each tip (Warning: It is recommended to not manually
change these values)
Detect Load displays COMP if the fixture-touch setup/initialization has been executed and displays the load
measured during initialization to accurately detect the fixture
Master Count displays COMP if the tip wear reference master has been executed and displays the
pulsecoder count of that reference position
Opening (mm) displays COMP if the fixture-touch reference open position is valid and displays the opening
that was recorded as the reference open position during initialization.
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6.7 DATA RECOVERY
6.7.1 Recovery Mastering Data

When mastering data is lost for the servo gun, the tip wear reference
data gathered during the initial setup is invalidated and must be
recovered too. Mastering data is lost when the BZAL occurs, typically
caused when the pulse cable is disconnected or damaged.
Recovery by Gun Zero Master Utility
1. Gun zero master utility can recover mastering data.Please refer to

Appendix C for more details.
2. Re-run the tip wear Update program.(TW_UPD01 if the two-step
method is used.)
3. Confirm the robot tip locations. Touch-up position if it is requested
6.7.2 Recovery from Lost of Tip
If tip (s) is (are) lost or damaged during a program, it may be necessary

to change the tip (s) before the program completes. In this case, the tip
wear reset macro should be run, for each tip that was replaced.
The macro program must be created in advance (during tip wear set up
for example). The macro does not require motion and can be assigned
to a DIN via the macro table, if desired.
There is sample macro programs for gun 1 in the next page. Please refer
for your system.
Gun tip is broken ! Replace new tip Reset wear down amount of gun tip
Broken tip can not Continue
continue welding.
NOTE
Please update wear down amount after the welding
cycle.
Reset macro requests one register.It is no problem that the register is

same as one of other tip wear macro programs
Ex）
-69-
Reset target : Gun 1

・Register number : R[10]
Reset macro program for movable tip of gun 1: TWRSMV1.TP （Group mask[*,*,*,*,*]）
CALL TWKRSMOV( 1, 10 ) Reset wear down amount of movable tip
!arg1:Always 0.
CALL TWKSTROK( 0 ) Change stroke limit. Set 0 as argument
CALL TWKRSCLB( 10 ) Recovery mastering
Reset macro program for fixed tip of gun 1: TWRSFX1.TP （Group mask[*,*,*,*,*]）
CALL TWKRSFIX( 1, 10 ) Reset wear down amount of fixed tip
!arg1:Always 0.
CALL TWKSTROK( 0 ) Change stroke limit. Set 0 as argument
CALL TWKRSCLB( 10 ) Recovery mastering
NOTE
In case of using 1 step measurement (WR_SET01 and WR_UPD01), replace
both tips at the same time even if one of tips is normal. Then run both of reset
macro program for movable /fixed tip.
It is no problem about the order of running.
-70-
6.8 ACTIVE STROKE LIMIT PROTECTION
Tip Wear Compensation determines the servo gun stroke limits

automatically. Please notice the following about the stroke limit
protection:
1 The close stroke limit is the distance past the reference zero
position that the gun axis can advance (not the present zero
position)
2 If either robot tip or gun tip is worn, a tip opening distance larger
than the open stroke limit is not allowed.
3 When mastering data is lost, the gun stroke limits are invalid and
one of the procedures from the “Recovery from loss of mastering”
section must be used to recover the proper stroke limits
See the visual example below:
Open Stroke
Limit (60mm)
New Master Tips 10mm Worn Tips Servo Gun
60mm from 60mm from PLUS (+)
new tips worn tips
zero zero
direction
REFERENCE
ZERO LINE 20mm from Worn tips 10mm from reference zero
new tips zero Zero Line 10mm from
Close Stroke worn tips zero
Limit (20mm)
Summary of Stroke Limit behavior:

Wear value Stroke Limit value
Close Stroke Limit Open Stroke limit
Total Wear > 0 Original Close Stroke Limit MINUS total tip Original Open Stroke Limit (does not increase
wear with tip wear)
Total Wear < 0 (growth<= Original Close Stroke Limit (does not Original Open Stroke Limit (does not decrease
tipchgtol) increase with tip growth) with tip growth)
Total Wear < 0 (growth> Original Open Stroke Limit MINUS
tipchgtol) $sggun#.$sgtwd.$tipchgtol
Due to the active stroke limit protection that Tip Wear Compensation
provides, the following procedure should be followed to completely
disable the active stroke limit control when tip wear compensation is no
longer required, after it was already initialized:
Procedure to disable Tip Wear Compensation and active stroke limit protection:
1. Set Tip Wear Comp to DISABLE on Servo Gun General Setup
Page
2. Set the sysvar $SGGUN#.$SGTWD.$PHASE = 0 (where # is the
gun number)
3. Place New Tips on the gun and re-master
4. Set the Gun Stroke Limits to the proper value if they are not
already
-71-
6.9 USING TIP WEAR MEASUREMENT PROGRAMS from

R-J3iB
If you would like to use tip wear programs which have been created in
R-J3iB controller,choice one of the following 2 methods for using it in
R-30iA.
1: Modification of user programs

2: Loading subroutine programs which have been provided by default
in R-J3iB
Method１: Modification of user programs

Subroutine programs of R-J3iB are TP programs, however subroutine
programs of R-30iA are KAREL programs. KAREL programs can not
be deleted or edited by mis operation.KAREL program make Program
management useful and safe.
Please rename subroutine TP program of R-J3iB to subroutine KAREL
program of R-30iA in user programs for using R-J3iB user
program.Please refer to the following table for.
Name CALLING R-J3iB TP PROGRAM CALLING R-30iA KAREL PROGRAM

conversion
No.
1 CALL TW0THOLD( #1, #2, #3 ) CALL TWKTHOLD( #1, #2, #3 )
2 CALL TW1MTCLB( #1, #2, #3 ) CALL TWKZRCLB( #1, #2, #3 )
3 CALL TW1MTFIX( #1, #2, #3 ) CALL TWKFXTCH( #1, #2, #3 )
4 CALL TW2WDCLB( #1, #2, #3 ) CALL TWKZRCLB( #1, #2, #3 )
5 CALL TW2WDFIX( #1, #2, #3 ) CALL TWKFXTCH( #1,#2,#3,#4)
6 CALL TW3RSCLB( #2 ) CALL TWKRSCLB( #2 )
#1:Gun number
#2:Register number
#3:Position register number
#4:New tip flag
New tip : 1
Worntip : 0
-72-
NOTE
- The number of arguments is the same for R-J3iB and R-30iA, with the exception
of No.5.Please set the same number for the new tip flag. (See sample.)
- About No2,No4 and No3,No5, use common KAREL program.
- About No3, user does not have to add new argument.
SAMPLE
R-J3iB User Program R-30iA User program
TWDMST _ TWDMST _
：：
3: L P[1:TIPS TOUCH] 250mm/sec FINE 3: L P[1:TIPS TOUCH] 250mm/sec FINE
4: CALL TW0THOLD(1,10,20) 4: CALL TWKTHOLD(1,10,20)
5: CALL TW1MTCLB(1,10,20) 5: CALL TWKZRCLB(1,10,20)
6: L P[2:FIX TOUCH] 250mm/sec FINE 6: L P[2:FIX TOUCH] 250mm/sec FINE
7: CALL TW1MTFIX(1,10,20) 7: CALL TWKFXTCH(1,10,20)
：：
[END] [END]
POINT SPOT TOUCHUP> POINT SPOT TOUCHUP>
About New tip flag

Please add argument at renameing of No.5.
Added argument judges either new tips measuremnt or worn tip
measuremnt.
New tip measurement : CALL TWKFXTCH(1,10,20, 1 )

Worn tip measurement :CALL TWKFXTCH(1,10,20, 0 )
Ex1: Using register for new tip flag ( For example R[99] )
TWDUPD _ TWDUPD _
：：
4: CALL TW2WDFIX(1,10,20) 4: CALL TWKFXTCH(1,10,20,R[99])
：：
[END] [END]
POINT SPOT TOUCHUP> POINT SPOT TOUCHUP>
R[99]=1 : New tip measurement

R[99]=0 : Worn tip measurement
-73-
Ex1: Using register for new tip flag ( For example DI[1] )
TWDUPD _ TWDUPD _
：：
4: CALL TW2WDFIX(1,10,20) 4: IF DI[1]<>ON JMP LBL[100]
： 5: ﾖﾋﾞﾀﾞｼ TWKFXTCH(1,10,20, 1 )
[ｵﾜﾘ] 6: JMP LBL[200]
7: LBL[100]
POINT SPOT TOUCHUP> 8: ﾖﾋﾞﾀﾞｼ TWKFXTCH(1,10,20, 0 )
9: LBL[200]
：
[END]
POINT SPOT TOUCHUP>
DI[1]=ON : New tip measurement

DI[1]=OFF : Worn tip measurement
METHOD2 : Loading subroutine programs which have been provied by default in

R-J3iB
Please load the following rprograms when loadinng user program to R-30iA
controller from R-J3iB controller.
User do not have to modify your created programs.
TW0THOLD.TP
TW1MTCLB.TP
TW1MTFIX.TP
TW2WDCLB.TP
TW2WDFIX.TP
TW3RSCLB.TP
-74-
B-82634EN/01 7.GUN SAG COMPENSATION
7 GUN SAG COMPENSATION

Compensating for gun sag (deflection) that may occur at pressurization
will enable a spot welding sequence to always be performed at an
optimum position.
The gun sag compensation amount required is the deflection that occurs
in the robot tip during pressurization.
x Compensation method
Gun deflection is compensated for by setting up the gun sag comp
value in the Pressure Schedule and pushing up the robot tip by the
gun sag comp amount as pressure is applied.
x Gun Sag Compensation amount setting method:
State with no gun deflection compensation State with gun deflection compensation
Gun deflection
compensation amount h ｈ
DATA Registers G2 JOINT 10 %

1. Press the DATA key to display the DATA screen
R[ 1: ]=0 2. Press F1“[TYPE]” to display the pull-up menu.
__________________ ]=0 3. Select “Pressure”. The servo gun Pressure Schedule list screen
| 1 Registers | ]=0 appears.
| 2 Position Reg | ]=0
| 3 Pressure | ]=0
4. Press F4"DETAIL". The servo gun Pressure Schedule detail
| 4 Backup | ]=0 setting screen appears.
| +---------- 5. Input the gun deflection amount to the item " Gun Sag Comp
| TYPE |
Value (mm)" in the screen.
SERVO GUN DATA G2 JOINT 10 %

SERVO GUN DATA G2 JOINT 10 % PRESSURE / EQ:1 Gun:1 No:1 5/8
PRESSURE / EQ:1 Gun:1 1/99 1 Comment: [FRONT PNL ]
No. P (Kgf) Thick(mm) Manual Comment 2 Weld Pressure (Kgf) : 350.0
1 350.0 2.0 TRUE [ ] 3 Part Thickness (mm) : 2.0
2 180.0 2.0 TRUE [ ] 4 Gun Sag Comp Value (mm) : 1.2
3 0.0 0.0 FALSE [ ]
4 0.0 0.0 FALSE [ ] <*DETAIL*>
: : : :
-75-
8.EXT. TIP STICK SIGNAL DETECTION B-82634EN/01
8 EXT. TIP STICK SIGNAL DETECTION

An external sensor can be supplied to detect continuity or stuck tips.
This sensor can be mapped to an input specified by the tip stick detect
input. The state of this input will be checked after the weld complete
signal is received and the gun actuator reaches the position specified by
the tip stick detect distance. The robot will stop if the tips stick detect
signal is still on at this specified opening.
NOTE
The user is required to prepare the equipment for
detecting stuck tips and the tip stick detection input
signal.
Tip Stick Detect Input is the input from the external device that
indicates the tips are stuck. This input must be OFF when the gun opens
past the tip stick detect distance, otherwise the robot will stop and issue
I/O Weld In G1 JOINT 10 % the following alarm:
I/O SPOT / EQ:1 1/6 “SVGN-030 SVAL1 Tip Stick Detection”
5 Minor Alarm : DI [ 1] *****
6 Iso contactor on : DI [ 2] *****
7 Cap change request: DI [ 3] ***** x Tip Stick Detect signal setting method
8 Appr cap change: DI [ 4] ***** Display the I/O screen by executing the following procedure
9 Tip Dress Request: DI [ 5] ***** 1. Press the MENUS key to bring up the screen menu.
10 Tip Stick Detect : DI [ 6] *****
2. Select “I/O”.
[ TYPE ] EQUIP IN/OUT 3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Spot Equip”. The Spot I/O screen appears.
5. Specify the index of the “Tip stick detect” input on Spot
Input screen.
Tip Stick Detect Distance is the tip opening at which the tip stick detect
SETUP Spot Weld G2 JOINT 10 % input will be checked to determine if the tips are stuck. 1-5mm are
GENERAL / EQ:1 Gun:1 7/12 typical values for this item.
1 Tip Wear Comp : ENABLE
2 Gun Sag Compensation : ENABLE
3 Close Direction (Gun) : PLUS x Tip Stick Detect Distance setting method
4 Close Direction (Robot): UT: 1 [+Z] Display the General Setup screen by executing the following
5 Max Motor Torque (%) : 100.0 procedure
6 Max Pressure (Kgf) : 500.0
7 Tip stick detect distance (mm) : 5
8 Tip Wear Detection <*DETAIL*> 2. Select “SETUP”.
9 Pressure Cal : COMP <*DETAIL*> 3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Servo Gun”.
5. Select "General Setup". (Move the cursor on <*DETAIL*>
and press ENTER key.) General Setup screen for Servo Gun
setup appears.
6. Specify "Tip stick detect distance(mm)"
-76-
B-82634EN/01 8.EXT. TIP STICK SIGNAL DETECTION
Tip Stick Timing Output can be used to inform the PLC when the tip
stick check was performed. Each time the gun opens from the weld spot,
the tip stick timing output is turned on when the gun reaches the
I/O Weld Out G1 JOINT 10 %
I/O SPOT / EQ:1 1/6
opening specified by the Tip Stick Detect Distance. This output turns
6 Reset Stepper : DO [ 1] ***** on whether the tips are stuck or not.
7 Reset Welder : DO [ 2] *****
8 Iso Contactor : DO [ 3] ***** x Tip Stick Timing Output setting method
9 Cap Change Comp : DO [ 4] *****
10 Enable Cont. Saver : DO [ 5] ***** Display the I/O screen by executing the following procedure
11 Tip Stick Timing : DO [ 6] ***** 1. Press the MENUS key to bring up the screen menu.
2. Select “I/O”.
[ TYPE ] EQUIP IN/OUT
4. Select “Spot Equip”. The I/O Spot Input/Output screen
appears.
5. Specify the index of the “Tip stick Timing” output on Spot
Output screen.
The duration of the Tip Stick Timing output pulse is specified by

the following system variable (the time is specified in ms):
$Spotweldio[WC#].$stkdo_dwltm = 500 (default)
-77-
8.EXT. TIP STICK SIGNAL DETECTION B-82634EN/01
TIP STICK DETECTION DETAIL
Tip Stick Detect Distance is defined as the separation between the tips
and the part when the tip stick detect input shall be checked, see
the flow chart:
Tip stick detect distance = a + b
a
Thickness d
So, the servo gun position (d) at the time of tip stick check equals:
d = Tip Stick Detect Distance + Part Thickness
Since the gun is moving when the tip stick check is initiated, the
position when the servo gun stops with a tip stick detection may be
larger than the position at which the check is initiated.
NOTE
In the case that the tips are stuck, the gun actuator will move in the open direction,
but the tips will remain in contact with the part, causing deflection in the gun
mechanism. Be sure that the tip stick detect distance is set to a value less than the
maximum allowed deflection for the gun mechanism.
Gun Tries to
Gun Closed open – tips
– weld done stick
Opening the Gun after a Tip Stick

When a tip stick occurs the gun can be opened by pressing the
Shift+RESET key together, then still holding down the Shift key jog the
gun open with the +/- jog key (X for gun 1, Y for gun 2) or use the
BACKUP (BU 1/2) key.
-78-
B-82634EN/01 8.EXT. TIP STICK SIGNAL DETECTION
NOTE
Take great caution when using this jog method to release the tip stick. The
Shift+RESET key sequence will override the Overtorque Protection limit and jogging
the gun may place a large mechanical load on the servo gun and a large thermal
load on the servo motor. The Collision Guard function of the robot will also be
temporarily disabled. Release the Shift key to exit the Shift+RESET mode.
Weld complete
Gun Opening
YES
End distance
NO
Detect distance
NO Gun opening is larger than

Detect distance + Thickness
YES
NO
Detect signal is ON
YES
SVGN-030 Tip Stick Detection Next line
-79-
9.SERVO GUN MONITORING B-82634EN/01
9 SERVO GUN MONITORING

The state of the spot welding instruction being executed is displayed on
the servo gun monitoring screen at real-time on the teach pendant.
However, the refresh rate of the teach pendant may be such that the
information is only updated every few seconds.
Display the servo gun monitoring (status) screen by executing the

following procedure.
Procedure
2. Select “0 -- NEXT --“ and “4 STATUS”.
4. Select “Servo Gun”. The SERVO GUN Monitoring screen
appears.
STATUS Servogun G1 JOINT 100 %

SERVO GUN / EQ:1 Gun:1 1/11
1 Pressure schedule: 0
2 Start distance schedule: 0
3 End distance schedule: 0
4 Tip Wear value(Gun)(mm): 0.00
5 Tip Wear value(Robot)(mm): 0.00
6 Pressure value(kgf): 0.00
7 Current position(Gun)(mm): 0.00
8 Thickness check:
9 Prog, line: ********, *****
10 Specified thickness(mm): ******
11 Observed thickness(mm): ******
[ TYPE ] EQUIP GUN
-80-
B-82634EN/01 9.SERVO GUN MONITORING
Display items and Descriptions

Pressure schedule Indicates the pressure schedule number specified for the spot welding
instruction being executed. If no spot welding instruction is being executed, the
Pressure schedule for the most recently executed spot welding instruction is
indicated.
Pressure schedule number is specified by the P=#, in the spot instruction.
The pressure schedule contains all data for the pressure position: weld force,
thickness, gun sag compensation value, etc.
Start distance schedule Indicates the start distance schedule number for the spot welding instruction
being executed. This index defines an open distance for the movable tip and
stationary tip, enroute to the spot weld location.
End distance schedule Indicates the end distance schedule number for the spot welding instruction
being executed. This index defines an open distance for the movable tip and
stationary tip when opening from the spot weld location. However, there is no
end distance schedule for a press_motion instruction: end distance schedule= 0
for press_motion.
Tip Wear value Indicates the wear amount of the movable tip.
(Gun) (mm)
Tip Wear value Indicates the wear amount of the stationary tip.
(Robot) (mm)
Pressure value (kgf) Indicates the pressure applied during the execution of a spot welding instruction.
The indicated pressure is obtained by subtracting a dynamic friction portion from
the specified torque (corresponding to a disturbance torque) and multiplying the
difference by a pressure conversion coefficient. The indicated value is
therefore, a rough estimate of the pressure actually present between the tips.
Current position (Gun) (mm) Indicates the current gun position on the gun axis.
Thickness check: The following parameters provide thickness check status data. Thickness status
data is set at check (after force is achieved).
Thickness status data is cleared at:
Gun close
Task end
****** is displayed after thickness check data is cleared.
Prog, line: Program name and line number of spot/pressuring motion where thickness
check is being performed..
Specified thickness(mm) The expected (target) part thickness specified via pressure schedule or local
condition.
Observed thickness(mm) The measured (estimated) part thickness.
-81-
10.SOFT PANEL B-82634EN/01
10 SOFT PANEL
Test execution (test run) can be carried out to run the robot and servo
gun on a standalone basis before it is put into automatic operation on a
production line.
This section focuses on how to set the servo gun specific application
items related to running a test cycle. Please refer to the Soft Panel
STYLE1D LINE 0 T2 E1G1 JOINT10% section in the Spot Tool+ manual for more details on how to use the
SOFT PANEL Soft Panel.
1/4
1 Gun operation STROKE
2 Weld controller mode: WELD The Application Specific Soft Panel allows the user to specify the
3 Tryout mode: ENABLED operating conditions for the servo gun when executing a test cycle
4 Force process complete: DISABLED
[ TYPE ][ SHOW ] ENABLE DISABLE 1. Press the MENUS key to bring up the screen menu.
2. Select "8 SOFT PANEL". SOFT PANEL screen appears.
3. Press F2 “SHOW” then select 2 Applic.
Gun Operation Stroke – the gun will close and open at each weld spot. Passing of weld current depends on
the setting of the weld controller mode
(cannot be changed if a No Stroke – the gun stops closing for each weld spot at the specified Start Distance. The
program is running) pressurization motion is not executed. The gun then opens to the specified End Distance.
The weld controller mode must be set to NOWELD
Weld controller mode: WELD – when the gun closes the weld controller executes the appropriate schedule and
passes current through the gun
(cannot be changed if a NOWELD - no current passes through the gun when the weld controller executes the weld
program is running) sequence.
Tryout Mode: ENABLED – the robot will ignore the part present inputs and the servo gun will ignore the
specified part thickness so welding can be performed without a part.
NOTE: if tryout mode input on cell interface IO screen is not assigned, then it is not possible
to change tryout mode state to enable via soft panel screen.
DISABLED – The part present inputs and part thickness are handled normally.
If tryout signal is not assigned, tryout mode is DISABLE.
Weld IO sim ENABLED –Welding can be executed without setting weld schedule. Disable weld controller
mode for sim weld.
DISABLED – sim weld is disabled.
Weld Duration Specify sim weld time on this item.
Default : 500ms
Maximum: 32767ms
Minimum : 0ms
Inform out out to plc This signal inform to PLC that sim weld is ENABLE
Force Process ENABLED - Process Complete is turned on immediately. Process Complete will be cleared
Complete: at the start of the next style. The Process Alert signal is turned on whenever Force Process
Complete is enabled, and a warning error is displayed on the ALARMS screen to indicate
that this abnormal operation was performed.
DISABLED - Process Complete is turned off.
-82-
B-82634EN/01 11.PRESSURE RELATED I/O SIGNALS
11 PRESSURE RELATED I/O SIGNALS

Special signals can be set in the servo gun software to read and activate
I/O related to the pressuring operation of the servo gun. The use and
setup of these signal is optional. In the normal case, these signals do not
need to be used.
Pressure Enable Signal (input) set to enable the closing of the

servo gun to pressure
Next Step Enable Signal (input) set to enable execution of the

next step in the teach pendant program following the
completion of a spot welding instruction
Pressure Notification Signal (output) set to inform that

pressuring is active on the servo gun
-83-
11.PRESSURE RELATED I/O SIGNALS B-82634EN/01
11.1 PRESSURE ENABLE SIGNAL
When a spot welding instruction is issued, the robot checks the state of
the Pressure enable signal before starting pressurization. If the signal is
on, pressurization is started
Move to approach position
OFF/ time-out
Wait for Pressure enable signal
turn ON
ON
Pressurization Time-out alarm
SETTING
The user must specify both the Digital Input index and the time-out
value to activate this function.
The Digital Input index is specified by setting the following system

variable:
$SPOTEQIO[eq#].$DI_PEN_I
$SPOTEQIO[eq#].$DI_PEN_I = 62, would inform the software

verify that DI[62]is ON before pressurizing the gun in the
next spot weld instruction
The time-out value is defaulted to 5 seconds. To change the value,

update the following system variable (msec).
$SPOTEQSETUP[eq#].$PEN_TMOUT = 5000 (Change to

desired value)
Others
This function does not work with:
x Pressurization instruction
x Manual pressurization
x Manual welding
If a time-out condition occurs, the following alarm message

appears, causing the program to pause.
"SVGN-035 Pressure enable time out”
-84-
11.2 NEXT STEP ENABLE
When a spot welding instruction is issued, the robot checks the state of
the Weld completion signal between gun opening and the execution of
the next instruction. If the signal is on, the next instruction is started.
Gun opening position
OFF/ time-out
Wait for Next Step Enable signal to
turn ON
ON
Next instruction Time-out alarm
SETTING
The user must specify both the Digital Input index and the time-out
value to activate this function.
The Digital Input index is specified by setting the following system

variable:
$SPOTEQIO[eq#].$DI_NSE_I
$SPOTEQIO[eq#].$DI_NSE_I = 63, would inform the software

verify that DI[63]is ON before execution of the next
instruction
The time-out value is defaulted to 5 seconds. To change the value,

update the following system variable (msec).
$SPOTEQSETUP[eq#].$NSE_TMOUT = 5000 (Change to

desired value)
Others
This function does not work with:
x Pressurization instruction
x Manual pressurization
x Manual welding
If a time-out condition occurs, the following alarm message

appears, causing the program to pause.
"SVGN-036 Comp confirmation time out”
-85-
11.PRESSURE RELATED I/O SIGNALS B-82634EN/01
11.3 PRESSURIZATION NOTIFICATION SIGNAL

On the spot equip I/O screen, set the "gun pressurization notification"
signal.
This signal is output to external devices as the pressurization signal.
I I/O Spot Output G1 JOINT 10 %

I I/O SPOT / EQ:1 2/23
1 Reset water saver: DO [ 0] *****
2 Gun Pressure: DO\[ 0] *****
: : :
[ TYPE ] EQUIP IN/OUT RO DO
The pressurization signal is turned on or off as follows:

On: After the machine reaches the pressurization start position (this
position actually varies depending on the setting of the positioning
mode for the pressurization start position.)
Off: When welding is complete or after the machine reaches the
pressurization completion position (this position actually varies
depending on the setting of the positioning mode for the pressurization
completion position.)
When the program starts, restarts, pauses, or is forcibly terminated, this
signal is turned off.
The following system variable can be used to change the persistence of
the pressurization signal:
$SGSYSCFG.$PRES_SIGNAL
= 0 (default setting): Turns the signal off when welding is complete.
(A) in the following figure.
= 1: Turns the signal off after the machine reaches the pressurization
completion position. (B) in the following figure.
-86-
Start distance
Pressurization End distance
t
Pressure
(A) Pressurization notification

signal (OUT)
(B) Pressurization notification

signal (OUT)
Welding command (OUT)

Welding condition (OUT)
Welding completion (IN)
NOTE: The pressurization signal is not asserted when the

PRESS_MOTN instruction executes.
-87-
12.PRESSURE PROFILE CONTROL FUNCTION B-82634EN/01
12 PRESSURE PROFILE CONTROL

FUNCTION
-88-
B-82634EN/01 12.PRESSURE PROFILE CONTROL FUNCTION
12.1 OVERVIEW
It is possible to control pressure value with multi-step in servo gun spot

welding. This function can improve a welding quality. This function is
optional.
x Maximum 3 steps pressure can be specified for each step (Before
welding, In welding, After welding).
x Pressure profile can be specified for each pressure condition.
Enable pressure profile control
Pressure Before welding In welding After welding
Weld Start signal Weld complete signal
Process by weld timer
Disable pressure profile control (Standard)
Pressure Before welding In welding After welding
Weld Start signal Weld complete signal
Process by weld timer
-89-
12.2 PROFILE DATA
12.2.1 Operation
1. Select DATA menu. And select pressure condition menu.
SERVO GUN DATA G1 JOINT 100% SERVO GUN DATA G1 JOINT 100%
PRESSURE / EQ:1 Gun:1 1/99 PRESSURE / EQ:1 Gun:1 No:1 1/9
No. Press(Kgf) Manual Comment F4 DETAIL 1 Comment : [WORK A ]
1 250.0 FALSE [WORK A ] 2 Standard Pressure (Kgf) : 250.0
2 300.0 FALSE [WORK B ] 3 Part Thickness (mm) : 2.3
3 285.0 FALSE [WORK C ] 4 Pushing Depth (mm) : 5.0
4 0.0 FALSE [ ] 5 Gun Sag Comp Value (mm) : 0.0
: 6 Weld Delay Time(msec) 0
[ TYPE ] EQUIP GUN DETAIL COPY > 7 Auto Route : <*DETAIL*>
8 Stand Alone/Manual SPOT : <*DETAIL*>

SERVO GUN DATA G1 JOINT 100%
PROFILE / EQ:1 Gun:1 No:1 1/6
1 Pressure Profile Control : ENABLE
2 Standard Pressure (Kgf) : 250.0
3 Init Press : 300.0 [Kgf] (120.0[%])
(Pressure Control Start)
4 100 [msec] 200.0 [Kgf] ( 80.0[%])
(Weld Start)
5 50 [msec] 250.0 [Kgf] (100.0[%])
(Weld Complete) Return to previous menu by
6 50 [msec] 200.0 [Kgf] ( 80.0[%]) "PREV" key.
2. Move cursor to "3 Pressure Profile", and push ENTER key.
Please refer to the next page for the meaning of each items.
-90-
B-82634EN/01 12.PRESSURE PROFILE CONTROL FUNCTION
12.2.2 Meaning of each items
You can change a pressure value one time by one stage at each stage
(Pressure control start, weld start and weld complete) in standard.
Select ENABLE/DISABLE of profile control by each

SERVO GUN DATA G1 JOINT 100% pressure condition. Standard setting is DISABLE.
1 Pressure Profile Contro l: ENABLE Standard pressure value
2 Standard Pressure (Kgf) : Pbase This is standard value is for the following pressure
3 Init Press: Pf0 [Kgf] (PRf0[%]) ratio(%).
4 Tf1 [msec] Pf1 [Kgf] (PRf1[%])
(Weld Start) Specify target pressure value(P) and time(T). There are
5 Tw1 [msec] Pw1 [Kgf] (PRw1[%]) two input types that specify the target pressure value(P)
(Weld Complete) directly or specify the pressure ratio(%) to the above
6 Te1 [msec] Pe1 [Kgf] (PRe1[%]) standard pressure value.
Init Press Weld Start Weld Complete
Tf1 Tw1
Pressure Pf0
Pbase Pw1
Pe1
Pf1 Te1
Time
Weld start Weld complete signal
Welding
To change the target pressure value more than two times in each stage, a
following system variable should be changed.
$SGPPDCFG.$NUM_STEPS: Number of pressure change

(Standard:1, Maximum:3)
-91-
($SGPPDCFG.$NUM_STEPS=3)
SERVO GUN DATA G1 JOINT 100%

1 Pressure Profile Control :ENABLE
2 Standard Pressure (Kgf) : Pbase
3 Init Press : Pf0 [Kgf] (PRf0[%])
(Weld Start)
7 Tw1 [msec] Pw1 [Kgf] (PRw1[%])
(Weld Complete)
10 Te1 [msec] Pe1 [Kgf] (PRe1[%])
When target pressure value is 0, process in a stage will be completed.
SERVO GUN DATA G1 JOINT 100% Pe1 Pe2

1 Pressure Profile Control :ENABLE Pf0 Pf1
2 Standard Pressure (Kgf) : Pbase Pw3
3 Init Press: Pf0 [Kgf] (PRf0[%])
4 Tf1 [msec] Pf1 [Kgf] (PRf1[%]) Pw1 Pw2
5 Tf2 [msec] 0 [Kgf] ( 0[%])
6 Tf3 [msec] 0 [Kgf] ( 0[%])
(Weld Start)
9 Tw3 [msec] Pw3 [Kgf] (PRw3[%]) Tf1 Tw1 Tw2 Tw3 Te1 Te2
(Weld Complete)
10 Te1 [msec] Pe1 [Kgf] (PRe1[%]) W/Start W/Complete
12 Te3 [msec] 0 [Kgf] ( 0[%])
When weld completion signal is received in welding (Twi), welding

stage will move to processing of the weld completion.
12.2.3 Limitations
Please do not shorten a specified time in a profile data too much.
(10Kgf/msec is a standard)
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B-82634EN/01 13.GUN CHANGE FUNCTION
13 GUN CHANGE FUNCTION
-93-
13. GUN CHANGE FUNCTION B-82634EN/01
13.1 OUTLINE
13.1.1 Feature of function

It is possible to switch more than two servo guns without power
off.
13.1.2 Basic specification
The total number of 6 guns

changable gun Only one gun can be controlled at the same
The period of gun 0.4 sec (Battery type) / 0.4 sec(Battery less type) *1)
detach(standard)
The period of gun 4 sec(Battery type)/6 sec(Batteryless type) *1)
attach(standard)
Backup battery Both battery type and batteryless type can be available.
(*1) The period includes the internal processing period, not include the
period of robot motion for changing the guns.
13.1.3 Restrictions
Restrictions matters
The period of gun change of batteryless type gun is more than that
of battery less type gun.
The motor of the gun change must be controlled by the same amp.
The gun change instruction can not used by multi task. (The gun
change instruction can not be execute by pulral tasks at the same
time)
Prohibition matters
Do not force to detach the gun while the controller is off.
The line tracking can not used with gun change function.
When the batterless type is used,there are restrictions as follows:
When the calibration motion type 1 or 2 is selected,calibration cannot be
interrupted by a hold or emergency stop/(Program execution must not be
stopped during gun attach processing)
When the calibration motion type 1 ro 2 is selected,magnetic phase
detection cannot preformed.
When the calibration motion type 3 ro 4 is selected ,the stroke
limit must be expanded so that the gun axis touchs the open limit.
When the calibration motion type 5 or 6 is selected , a switch such
as a limit switch must be installed in the gun .
When the calibration motion type 7 or 8 is seleceted, calibration
preformed during gun attachment is disable if the tip wear amount
changed while the gun was detached.Therefore, tip replacement
must be performed for the attached gun.
For details of the calibration motion types, see Chapter
13.3,”GUN CHANGE SETTING”.
-94-
13.1.4 System Configuration

Servo gun change system is constructed as follows.
(Example : Servo gun is the 2nd group and the number of gun is four.)
Gun k
Detach/Attach
Gun 1 Gun 2 Gun 3 Gun 4
Robot = Motion group 1
J1 J2 J3 J4
（Max6）
EQ1
= Motion group 2
Robot
Controller
Y
ou can replace the servo gun with the air gun by switching on the
controller.
Servo gun: (example: controller = 1)
• Driven by servo motor
(motion group = 2)
• Any open position can be set.
Air gun: (example: controller = 2)

• Driven by air ON/OFF
(no motion group)
-95-
13.1.5 Outline of installation
Select “Servo gun” to the equipment

type.
Initial setup Enable the gun change. SETUP SERVO GUN
Set gun number configuration.
1 Equip number : 1
2 Equip type : [SERVO GUN]
Controlled
3 Motion Group (Gun) : 2
start
4 Motion Group (Robot) : 1
5 Gun Change : ENABLE
Set On to the battery type. [ TYPE ] EQUIP GUN_CFG
Execute gun attach
Provisional attach instruction.
Perform magnetic phase detection
Perform zero position SETUP GUN CHANGE G1 JOINT 10 %
mastering Gun Change / EQ:1 GUN:1 9/9
Perform calibration. 1 Comment : [ ]
2 Attach signal : SDI[ 1]
3 Indntify signal : SDI[ 2]
Gun change setup 4 Battery : OFF
5 Calibration motion type : [TYPE 3]
Calibration motion
Select correct battery type. 6 Calibration Speed (%) : 100
Select correct calibrate motion 7 Acc value : 100
type. 8 Position register index : PR[ 1]
9 Touch torque (%) : ( + ) 5.000
[ TYPE ] LIST
Perfrom reference position setup. System Master/Cal G2 JOINT 10 %

Refpos setup
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ‘ENTER’ or number key to select.
Teaching Check whether gun number is

correct or not.
1
2 GUN ATTACH [ 1 ]
Check whether gun status is :
Execution
correct or not. 10 GUN DETACH [ 1 ]
Do not stop the gun during the :
calibrate motion.
Verification Chech the attached gun and the

gun number of status screen is
same or not. STATUS GUN CHANGE G1 JOINT 10 %
Gun Change / EQ:1
AXS Comment Status
1 GUN[ 1:Part A ] ATTACH
2 GUN[ 2:Part B ] DETACH
3 GUN[ 3:Part C ] DETACH
4 GUN[ 4:Part D ] DETACH
-96-
13.2 INITIAL SETUP
The following initial setup is needed to install the servo gun change
system.
Motion parameter setup of servo gun axes

The configration setup of servo gun number
Enable the gun change function.
Provisional attach
NOTE
These setup must be done at the begining of system
installation.
These setup must be done only one time.
These setup is done at the controlled start.

See “Servo Gun Function Supplementary Manual”.
-97-
13.3 GUN CHANGE SETUP
The gun change setup must be done for each gun.
1. Press MENUS key.

SETUP GUN CHANGE G2 JOINT 10 % 2. Select “6 SETUP”.
Gun Change / EQ:1 3. Press F1[TYPE].
AXS Comment BatteryType
1 GUN [ 1: Part A ] ON[------]
4. Select “Gun change”
2 GUN [ 1: Part B ] ON[------] 5. Select gun from the list of guns, then press F3:DETAIL. The
3 GUN [ 1: Part C ] ON[------] detail screen is displayed.
[ TYPE ] EQUIP DETAIL
SETUP GUN CHANGE G1 JOINT 10 %

Gun Change / EQ:1 GUN:1 9/9
1 Comment : [Part A ]
2 Attach signal : SDI[ 1]
3 Indntify signal : SDI[ 2]
4 Battery : ON
[ TYPE ] LIST
Common setup
Comment Comment for each gun.
Attach signal This signal used for gun set verification.
Available I/O type = SDI / RDI
- This signal is check before gun attach/detach instruction. If
this signal is OFF, the error occurs.
- If the index is zero, the above checking is canceled.
Identify signal This signal used for gun identification.
Avaialble I/O type = SDI / RDI / GI
- This signal is check before gun attach/detach instruction. If
this signal is OFF, the error occurs.
- If the index is zero, the above checking is canceled.
Battery Select battery type.
ON = Battery backup type
OFF = Batteryless type
(Select the following when Battery is set to OFF in the common

settings.)
Calibration On battery-less guns, the position (pulse value) is lost when
Motion Type the gun is detached. So, calibration must be carried out when
gun is attached. Calibration involves the following two
operations:
Turning the motor two turns for positioning the pulse coder
(this operation is simply referred to as "positioning" from
here on)
Calibrating at a preset reference position
The user selects from the following types, 1 to 8, to suit the
user's particular system requirements.
(See Table 3.1 and Fig. 3.1.)
Calibration motion type Selection Criteria
-98-
Types 7, 8 ( Recommended type )

As with types 3 and 4 ,specify there types on systems
that are incapable of holding the gun detachment positon until the
gun is attachment next, because their servo gun axis motor does
not have a break. Types 7 and 8 use motor torque to detect the gun
axis touching the gun close position and set the positon as the
reference positon.The reference positon is set automatically before
the gun is detached.
The difference between type 7 and type 8 is in the operating
direction during calibration.(See Table 3.1 and Fig. 3.1)
Type 7: Specify this type when the gun is detected at a position
(near the 0 position) where the distance to the gun close
position is equivalent to less than two turns of the motor
at the time of gun attachment.
Type 8: Specify this type when the gun is detected at a position
(near the 0 position) where the distance to the gun close
position is equivalent to more than two turns of the
motor at the time of gun attachment.
NOTE
For types 7nad 8, calibration performed during
gunattachment is disabled if the tip wear amount changed
shile the gun was detected. Therefore tip replacement must
be performed for the attached gun.
NOTE
Types 7 and 8 can be used in 7D80/70 or later, or 7D82/18 or later.
Types 1, 2
Select these types on systems capable of holding the gun
detachment position as a result of braking the servo gun axis motor
up to the next servo gun attachment.
NOTE
With type 1 and 2 , if calibration is tnterrupted by a hold
or emergency stop,reference positon data is lost. In such a case ,see
Appendix C.2,”WHEN ROBOT IS STOPPED
DURING CALIBRATION”.
NOTE
With type 1 and 2,magnetic phase detection cannot be performed
When these types are set, the position where the gun is detached is
automatically memorized as the reference position, and calibration
is carried out at that position after the gun is attached. For this
reason, the position when the gun is attached must be the same as
position when it is detached.
The allowable errors of the detach and attach positions must fall
within the respective following ranges for the direct-acting axis
and rotary axis:
Direct-acting axis: ±(gear ratio/2)mm or less around the

detach position
Rotary axis: ±((360/gear ratio)/2)deg or less around the detach
position
-99-
Note that positional misalignment occurs during gun attachment if

the above ranges are exceeded.
The difference between types 1 and 2 is in the operating direction
during calibration. (See Table 3.1 and Fig. 3.1.)
Type 1: Specify this type when the gun is detached at a position

(near the 0 position) where operation is not possible in
the gun close direction
(near the open limit) where operation is not possible in
the gun open direction
Types 3, 4
Select these types on systems not capable of holding the gun
detachment position as a result of the servo gun axis motor not
having a brake up to the next servo gun attachment. On such a
system, the reference position must be set to another position as
the gun detachment position cannot be used as the reference
position.
With these types, contact of the gun axis with the open limit is
detected by using the motor torque, and the contact position is set
as the reference position. For details on how to set the reference
position, see "5. Setting the Reference Position."

(near the 0 position) where the distance to the open
limit is two or more turns of the motor.
Type 4: Specify this type when the gun is detached at a position (near
the open limit) where the distance to the open limit is two or
less turns of the motor.
NOTE
With types 3 and 4 , it is necessary to expand the storke limit
so that the gun axiz touches the open limit.
Types 5, 6
Like types 3 and 4, specify these types on systems not capable of
holding the gun detachment position as a result of the servo gun
axis motor not having a brake up to the next servo gun attachment.
With types 5 and 6, however, a detection signal must be provided
on the gun by means of a dog or limit switch, and the contact
position must be set as the reference position. For details on how
to set the reference position, see "5. Setting the Reference
Position."

(near the 0 position) where the distance to the position
-100-
where the detect signal turns ON is two or more turns of

the motor in the open direction.
(near the open limit) where the distance to the position
where the detect signal turns ON is two or less turns of
the motor in the open direction.
NOTE
With types 5 and 6, a switch suc as a limit switch must be
installed in the gun.
Table 3.1 Calibration Motion Type

Type Calibration Motion Set Position of Reference position
Type 1 The servo gun is opened by about two turns of the motor, Position when gun is detached
and then calibrated at the position where it is closed by about Reference position is not required. NOTE 2
two turns. NOTE 1
Type 2 The servo gun is closed by about two turns of the motor, and Position when gun is detached
then calibrated at the position where it is opened by about Reference position is not required. NOTE 2
two turns.
Type 3 The servo gun is opened to its open limit, and then Open limit position
calibrated. Arrival at the open limit is detected by motor
torque.
Type 4 The servo gun is closed by about two turns of the motor, Open limit position
opened to its open limit, and then calibrated. Arrival at the
open limit is detected by motor torque.
Type 5 The servo gun is opened until the detection signal turns ON, Position where detection signal turns ON
and then calibrated.
Type 6 The servo gun is closed by about two turns of the motor, Position where detection signal turns ON
opened until the detection signal turns ON, and then
calibrated.
Type 7 The servo gun is opened by about two turns of the Gun close positon
motor ,closed to its close positon ,then calibrated.Arrival at Reference positon setting is not
the close positon is detected by motor torque. required.NOTE3
Type 8 The servo gun is closed to its close positon ,then Gun close positon
calibrated.Arrival at the close positon is detected by motor Reference positon setting is not
torque. required.NOTE3
NOTE
1 Gun master data is lost if the operation is canceled due to a hold or an emergency
stop during calibration that is carried out during the gun change sequence when
types 1 or 2 are selected. If this happens, manually carry out zero position mastering.
2 With types 1 and 2, the system automatically memorizes the position where the
servo gun is detached as the reference position. This memorized reference position
is used in calibration when the same gun is next attached. For this reason, when
types 1 or 2 are selected, the detachment position and the attachment position must
be the same. Do not select types 1 or 2 when a motor with a brake is used for the
servo gun axis.
3 With types 7 and 8, the servo gun is closed during execution of the GUN DETACH
instruction ,and the system automatically memorizes the positon where the servo
gun is detached. The memorized reference position is used for calibration performed
when the same un is next attached.For reason ,ehrn the calibration motion type is
changed to type 7 or 8, the gun must have been attached.
Fig. 15.3 Calibration Motion Type
-101-
Type 1 Type 2
When the gun is detached near 0 position When the gun is detached near the open limit
About 2 turns
About2 turns
About 2 turns of motor Position when About 2 turns of motor Position when
(open direction) gun is detached (close direction) gun is detached
Type 3 Type 4
Torque Torqu
Detection Detection
Reference position setting About 2 turns of motor

Reference position
position during quick (close direction) setting position during
quick mastering
Type 5 Type 6
Input
ON signal ON
OFF OFF
Detection
Detection
Reference position setting About 2 turns of motor
position during quick
mastering (close direction)
Type 7 Type 8
When the gun is near 0 position at attachment When the gun is near the open limit at attachment
Torque Torque
Detection Detection
About 2 turns of motor Reference position Reference position

setting position setting position
(open direction) during quick mastering during quick mastering
-102-
Screen for Calibration Types 1, 2

Gun Change / EQ:1 Gun:1 5/7
1 Comment : [ ]
2 Attach signal : DI[ 1]
3 Identify signal : DI[ 2]
4 Battery : OFF
5 Calibarate motion type [TYPE 2]
Calibration Motion Setup
6 Calibration Speed (&) 100
7 Acc Value : ACC100
[ TYPE ] LIST
Screen for Calibration Types 3, 4, 7, 8 Screen for Calibration Types 5, 6
SETUP GUN CHANGE G1 JOINT 10 % SETUP GUN CHANGE G1 JOINT 10 %

Gun Change / EQ:1 Gun:1 5/9 Gun Change / EQ:1 Gun:1 5/9
1 Comment [ ] 1 Comment : [ ]
2 Attach signal : DI[ 1] 2 Attach signal : DI[ 1]
3 Identify signal : DI[ 2] 3 Identify signal : DI[ 2]
4 Battery : OFF 4 Battery : OFF
5 Calibration motion type : [TYPE 4] 5 Calibration motion type : [TYPE 6]
Calibration Motion Setup Calibration Motion Setup
6 Calibration Speed (%) 100 6 Calibration Speed (%) : 100
7 Acc Value : ACC100 7 Acc Value : ACC100
8 Position register index PR[ 1] 8 Position register index : PR[ 1]
9 Touch torque (%) : (-) 5.000 9 Detect signal : DI[ 0]
10 Detect speed (mm/s) 10 Detect speed (mm/s)
30 30
[ TYPE ] LIST [ TYPE ] LIST
(1) Open limit operation setting (Set the following when the
calibration motion type 1,2,4,6,or 7 is selected.)
Calibration speed Specify the motion speed of calibration (motion for about
two turns of the motor)
(2) Position register No. setting (Set the following for all the
Calibration motion Setup.)
Accelerate rate Specify the acceleration of calibration motion.
The standard value is 100(%).
(3) Position register No. setting (Set as follow when types 3 to 8 are
set in the Calibration Setup)
Position register Position register for holding the momentary position where
No arrival at the reference position (open limit or signal input
position) was detected
Set the position register specified here exclusively for
calibration. (Do not use the same position register in the
program, for example.)
(4) Open limit detection torque setting (Set as follows when types 3, 4 ,
7, and 8 are set in the Calibration Setup.)
Touch torque (%) Threshold value of the motor torque for detecting arrival at
the open limit
Set the value within range 0.0 to 100.0%.
-103-
(5) Detection signal setting (Set as follows when types 5 or 6 are set in
the Calibration Setup.)
Detection signal Type and No. of input signal for detecting arrival at the
reference position
•SDI
•RDI
Specify a No. available for each of the signals as the signal
No.
(6) Detection speed (Set the following ehwn the calibration motion
types 3 to 8 s set)
Detection speed Specify the speed of the motion to the reference posiotn.
-104-
13.4 SETTING THE REFERENCE POSITION
13.4.1 Battery-less type guns

On battery-less guns, the position (pulse value) is lost when the gun is
detached. So, calibration must be carried out when gun is attached.
The position taken as the reference for calibration is called the
"reference position."
On battery-less guns, the reference point must be set before the gun is
detached.
How the reference point is set differs according to the calibration
motion type.
SETUP Spot Weld G1 JOINT 10%

1 Tip Wear Down Comp : DISABLE
3 Close Direcrion(Gun): PLUS
4 Close Direction(Robot): UT:1 [+Z ]
5 Max Motor Torque(%): 100.0
6 Max Pressure(Kgf): 500.0
8 Count register: <*DETAIL*>
NOTE
Before you set the following reference positions, be
sure to set the correct direction at Close Direction
(Gun) in the Servo Gun Setup screen.
Types 1, 2
The system automatically sets the reference position when the
servo gun is detached.
Types 3, 4
Create a program for detecting the reference position using the
touch torque, and execute this program to calculate the reference
position.
For details, refer to "E-1-1 Reference Position Setup for
Calibration Types 3 and 4."
Types 5, 6
Create a program for detecting the reference position using the
detection signal, and execute this program to calculate the
reference position.
For details, refer to "E-1-2 Reference Position Setup for
Calibration Types 5 and 6."
Types 7, 8
The sysytem automatically sets the reference position when the
servo gun is detached.
-105-
13.4.2 Battery-mounted type guns

On battery-mounted type guns, the position (pulse value) is not lost
even if the gun is detached. Therefore, the reference position used for
calibration when the gun is attached need not be set as it needs to be on
a battery-less type gun. However, that we recommend setting a
reference position for quick mastering by marking a line or alignment
mark as shown in the figure below for extra safety in the event that the
battery comes loose. For details on how to set the reference position for
quick mastering, refer to "E-2 Quick Mastering Reference Position
Setup."
Line marking or alignment

mark
-106-
13.5 GUN CHANGE INSTRUCTION
13.5.1 GUN DETACH instruction

This instruction can detach the servo gun without power off. When the
calibration motion type 7 or 8 is selected , before the servo gun is
detached, the servo gun is closed automatically,and the gun close
position is set the reference position.
Format :
GUN DETACH[i]
i: Gun number (1 ∼ 6)
Specify the gun number which you want to detach.
R[ ] and AR[ ] can be used.
Ex) GUN DETACH[1]
GUN DETACH[R[2]]
GUN DETACH[AR[1]]
13.5.2 GUN ATTACH instruction

This instruction can attach the servo gun without power off. In case of
batteryless gun, the mastering and calibration are performed
automatically.
Format :
GUN ATTACH[i]
i: Gun number (1 ∼ 6)
Specify the gun number which you want to detach.
R[ ] and AR[ ] can be used.
Ex) GUN ATTACH[5]
GUN ATTACH[R[3]]
GUN ATTACH[AR[1]]
After servo gun is attached, the tool number is changed to the same
number which is specified as a gun close direction of fixed side in the
servo gun setup screen.
Setup Spot Weld G1 JOINT 10%

Genral / EQ:1 GUN:1 8/11
-107-
13.5.3 Sample program

Sample Program
[Explanation]
1: J P[1:Approach] 100% FINE 1: Move to approach position
2: L P[2:GUN1 SET] 100mm/sec 2: Set gun axis to 0 positio n
FINE
3: GUN DETACH[1] 3: Gun 1 detach sequence executed
4: L P[1:Approach] 100mm/sec 4: Mechanical detachment operation
FINE
:
11: J P[11: Approach] 100% FINE
12: L P[12:GUN2 SET] 100mm/sec
FINE
13: GUN ATTACH[2] 13: Gun 2 attach sequence executed.
14: L P[13: Approach] 100mm/sec
FINE
:
99: END 99: Normal end
NOTE
The above is merely a sample program. Create
programs to suit the requirements of your system
13.5.4 Foward execution

It is necessary to check that the gun number of instruction is same as the
actual gun. And in the case of attach instruction, the calibration motion
type must be set correct type.
In the case of batteryless gun, the calibration motion(3 in the following
figure) is done.
1. Move to the attached

position Mastering and
2. Gun attach Calibration are
finished
3. Calibration motion
4. Move to the SPOT position
-108-
NOTE
In the case of calibration motion type is Type 1 or Type 2, if the motion is stopped by
e-stop or HOLD during the calibration motion, the mastering data is lost.
If the mastering data is lost, please do the zero mastering and calibration by manual
again.
Otherwise,
1) The current position on TP is not matched to the actual position.
2) If the motion instruction is executed, the following alarm is occurred.
“MOTN-049 Attempt to move w/o calibrated”
3) The GUN DETACH instruction does not work until manual mastering and calibration
are finished.
13.5.5 Backward execution

Both GUN ATTACH and GUN DETACH instruction can not be
execute by backward execution.
-109-
13.6 GUN CHANGE SEQUENCE
GUN DETACH GUN ATTACH

Detach Attach
Robot motion
moving STOP STOP
ON
Robot lock of servo gun OFF
motion group is ON
SRDY of servo gun motor
ON
OFF
Gun attach signal

ON
OFF
Gun attach verification signal
ON
OFF
Motor power line(MCC)

Attach
Detach
Motor power line
GNDline Attach
Detach
Pulse coder line

+5V Attach
Detach
Pulse coder line

0V Attach
Detach
Detach/Attach status Gun1 Attach Non gun Non gun Gun2 attach
Gun1 Gun2
Detaching Attaching
-110-
13.7 GUN CHANGE STATUS
On the gun change status screen, verify that which gun is attached or
detached now.
1. Press MENUSkey.
2. Select “0 next page”, ”4 STATUS”.
3. Press F1[TYPE].
4. Select “Gun change”.
STATUS GUN CHANGE G1 JOINT 10 %

Gun Change / EQ:1
AXS Commen Status
1 GUN[ 1:Part A ] ATTACH
2 GUN[ 2:Part B ] DETACH
3 GUN[ 3:Part C ] DETACH
4 GUN[ 4:Part D ] DETACH
The following status are displayed.

AXS The axis number of the motion group which is assigned to the
current equipment.
Gun The gun number which is assigned to the above axis.
Status Gun status
ATTACH : The gun is attached.
DETACH : The gun is detached.
Comment The comment of each gun.
-111-
13.8 SERVO GUN SETUP
On gun change systems, the following settings must be carried out each
time that the gun is changed.
For details on how to set each item, refer to the "Servo Gun Function
Instruction Manual."
Servo gun initial setup

Servo gun general setup
Pressure conditions setup
Backup conditions setup
Manual operation (manual pressuring, manual stroke, manual
welding) setup
Tip wear down value compensation setup
To select the gun to be set in each screen, use F3 GUN.

When setting the above items, the gun to be set need not necessarily be
attached. (Note, however, that the gun to be set must be attached when
the gun is actually operated by manual pressuring, pressure adjustment
and tip wear down detection.)
Example) Servo Gun General Setup Screen
Currently selected gun No

8 Weld Timing Torque Rate(%) 0
9 Counter register: <*DETAIL*>
10 Max wear down check <*DETAIL*>
11 Pressure Cal: INCOMP <*DETAIL*>
12 Wear Down Cal: INCOMP <*DETAIL*>
Key for switching gun No
-112-
13.9 TEACHING
In the gun change system, the normal spot instruction can be used. But,
in the gun change system, please note the folloiwng points.
13.9.1 Notice for teaching
Position data
In the gun change system, the each gun is assigned to the each axis of
the servo gun motion group. For example, if three kinds of gun are
assiged to gun change system, the servo gun motion group has three
axes data. This means three axes data are recorded when servo gun
position is tought.
(Ex. The position data of gun1 which is assigned to first axis)
GP1: UF : 0, UT : 1, Config : 'N, 0, 0, 0',

X = 1879.25 mm, Y = -1035.37 mm, Z = 162.65 mm,
W = -178.67 deg, P = -13.68 deg, R = -37.32 deg
GP2: UF : 0, UT : 1,
J1 = 10.00 mm J2 = 0.00 mm J3 = 0.00 mm
Please note that this position data has not only gun1 data but also gun2
and gun3 data. This means this position data can move gun2 and gun3.
If gun2 is attached, gun2 moves to 0mm position. This specification is
for the flexibility of the program. But, if the user attaches different gun,
it may cause interfer of gun. To prevent this problem, please specify
different tool number to the gun close direction for each gun. Because
gun attach instruction changes the tool number to specified number of
the gun close direction.

GENERAL / EO:1 Gun:1 4/11
1 Tip Wear Down Comp: ENABLE
2 Gun Sag Compensation: ENABLE
3 Close Direction(Gun) : PLUS Specify this number to each gun
4 Close Direction(Robot) : UT: 1 [+Z]
6 Max Pressure(Kgf) : 500.0
8 Weld Timing Torqe Rate(%): 0
9 Count register : <∗DETAIL>
10 Max wear down check : <∗DETAIL>
11 Pressure Cal : INCOMP <∗DETAIL>
12 Wear Down Cal INCOMP <∗DETAIL>
[TYPE] EQUIP GUN ENABLE DISABLE
-113-
By this function, the position data for each gun has the different tool
number. Becuse of this, even if the user execute the program with
different gun, the program is stopped by “INTP-253 Tool frame number
mismatch”.
When the gun attach instruction is executed, the currently selected
coordinate system No. is automatically switched to the coordinate
system No. of the attached gun. So, the trouble of manually switching
the coordinate system No. does not arise even if the above settings are
made.
SPOT instruction
The gun number is not specified in SPOT instruction. This means SPOT
instruction does not care which gun is attached. So, same SPOT
instruction can control plural guns.
1 : J P[1] 100% FINE SPOT[P=1,S=1,BU=1]
<- Gun number is not specified.
But, in other word, the SPOT instruction tought with gun1 can be
executed with gun2. To prevent this problem, please specify different
tool number to the gun close direction for each gun. This is the same
reason in the case of position data. “INTP-253 Tool frame number
mismatch” stops the program execution.
13.9.2 Sample program

Sample program
: [Explanation]
11:J P[11] 100% FINE SPOT[P=1,S=1,BU=1] 11:Spot weld with gun1
12:L P[12] 100mm/sec FINE 12:Spot weld with gun1
: SPOT[P=1,S=1,BU=1]
13:J P[13:Approach pos] 100% FINE 13:Move to approach position
14:L P[14:Gun1 set] 100mm/sec FINE 14:Set gun1 to gunchanger
Move with tool number 1
15: GUN DETACH[1] 15:Detach gun1
16:L P[13:Approach pos] 100mm/sec FINE 16:Release gun1
: :
21:J P[21:Approach pos] 100% FINE
22:L P[22:Gun2 set] 100mm/sec FINE
23: GUN ATTACH[2] 23:Attach gun2. Tool number is changed to 2
24:L P[23:Approach pos] 100mm/sec FINE
25:J P[24] 100% FINE SPOT[P=1,S=1,BU=1] 25:Spot weld with gun2
26:L P[25] 100mm/sec FINE 26:Spot weld with gun2
Move with tool number 2
: SPOT[P=1,S=1,BU=1]
:
99: END 99:Normal end
NOTE
This is sample program. Create the program related
to your system.
-114-
13.9.3 Guidelines for gun change with multi-tasking

Multi-tasking allows you to execute a motion instruction and a gun
change instruction simultaneously. Executing gun change instructions
during robot motion can improve cycle time. Follow the guidelines
below to teach gun change with multi-tasking.
• Set the group mask of the main task so that the target group of gun
change is disabled. (1)
• Set the group mask of the subtask so that only the target group of
gun change is enabled. (2)
• Set the ignore pause attribute of the subtask to OFF. (3)
• Synchronize the execution of the main task and subtask using
registers.
- The gun detach instruction in the subtask must be completed
before the gun is physically disconnected. (4)
- The gun attach instruction in the subtask must be completed
before welding is started. (5)
• Teach the frame instruction in the main task so that the frame of
Close Direction (Robot) becomes active just before the subtask
including the gun attach instruction starts. (6)
- As described in the previous section, the tool frame number
is set when the gun attach instruction is executed. The tool
frame number should be set in advance in case it is set during
robot motion (7).
Sample programs (Target group number of gun change=2)
Main task
Group mask : [1,*,*,*,*] (1) Subtask
Program name: GUN1DTCH
Group mask : [*,1,*,*,*] (2)
: Ignore pause :OFF (3)
11: CALL WELD1
12: R[51:Flag1]=1
13: RUN GUN1DTCH 1: GUN DETACH[1]
14:J P[13:Approach pos] 100% FINE 2: R[51:Flag1] = 0 (4)
15:L P[14:Gun1] 100mm/sec FINE [End]
(4) 16: WAIT R[51:Flag1]=0
17: RO[1:Unchuck]=ON
18: WAIT RI[1:Unchuck]=ON
19:L P[13:Approach pos] 100mm/sec FINE
：
31:J P[21:Approach pos] 100% FINE
32:L P[22:Gun2] 100mm/sec FINE Subtask
33: RO[1:Unchuck]=OFF Program name: GUN2ATCH
34: WAIT RI[1:Unchuck]=OFF Group mask : [*,1,*,*,*] (2)
35: R[52:Flag2]=1 Ignore pause :OFF (3)
(6) 36: UTOOL_NUM=2
37: RUN GUN2ATCH
1: GUN ATTACH [2]
(7) 38:L P[23: Approach pos] 100mm/sec FINE
2: R[52:Flag2] = 0 (5)
(5) 39: WAIT R [52:Flag2]=0
[End]
40: CALL WELD2
:
-115-
14.OVERTORQUE PROTECTION FEATURE B-82634EN/01
14 OVERTORQUE PROTECTION FEATURE

NOTE
No special hardware/software is required. This
function is included in Enhanced Servo Gun option.
-116-
B-82634EN/01 14.OVERTORQUE PROTECTION FEATURE
14.1 Overview
Servo Gun OverTorque Protection is part of the Enhanced Servo Gun

Software Option. OverTorque Protection is designed to reduce the
damage to servo guns and servo gun actuators caused by driving
Over the gun open to its hard stop or closed to where tips collide at
Torque
excessive force. OverTorque Protection monitors the motor
current on the servo gun axis to determine if an unexpected
disturbance, such as the gun being jogged to its end of stroke, has
occurred. It will remove servo power from the motor and post a
“Collision Detect Alarm” if a potential OverTorque condition is
captured. There is no guarantee that OverTorque Protection will
prevent a gun from being damaged. It is available to provide
additional protection in the case of operational and axis setup
errors. The best protection for any servo gun is still careful setup
Over and operation of the servo gun axis by a user that respects the
Torque mechanical limitations of the gun.
There are no additional setup tasks required to activate and use

OverTorque Protection. It is enabled by default. However, proper
setup of the servogun axis and sometimes, adjustments to the
standard settings of OverTorque Protection are needed to optimize
its performance. This Chapter explains how to do this.
Setup tasks important to OverTorque Protection includes selecting the

proper motor and defining the tool as a servo gun at Controlled
Start. Then set the correct max gun pressure, tip displacement
ratio and complete autotuning and calibration before proceeding
with teaching operations.
Before the Servo Gun setup is complete, the OverTorque Protection is

an estimate, based on theoretical data. However, as the setup is
completed, the parameters are optimized to best protect the gun.
-117-
14.2 OVERTORQUE PROTECTION SETUP
Before autotuning: motor torque is limited to a torque corresponding

to the max gun pressure based on the selected motor and tip
displacement ratio. In this case a “Collision Detect Alarm” will not be
posted, but a “Move Error Excess” or “Stop Error Excess” may be
indicators that the gun could not reach the commanded position because
OverTorque Protection limited the motor torque available.
After autotuning: motor torque is not limited, but actual OverTorque
monitoring is active. In this case, a “Collision Detect Alarm” will
indicate a detected OverTorque condition.
Step 1: Proper Motor and Axis Setup at Control start

1. Add nobot axis
2. Setup nobot axis
3. Make sure that motor selection is correct.
4. Also, provide the proper gear ratio (tip displacement). If you don’t
know it, then the gear ratio can be found experimentally via the
Servo Gun Autotuning Utility.
5. Go to Cold start ( function + start cold )
Step 2: OverTorque Protection Screen Basic Settings

1. Get to this menu through setup servogun
Menu-Setup-Servo Gun-General Setup –OverTorque
Protection<DETAIL>
Servogun Setup _
Eq: 1 Gun: 1
SETUP Servogun G1 WORLD 10 %

Max gun torque: 22.5
7 Tip stick detect distance: 0
8 Max wear down check: <*DETAIL*>
10 Wear Down Cal: INCOMP <*DETAIL*>
11 Thickness check: <*DETAIL*>
12 Gun Stroke Limit: <*DETAIL*>
13 Overtorque protection: <*DETAIL*>
[ TYPE ] EQUIP GUN
-118-
Before autotuning
The following message is displayed. Press F4 OK to go setting screen.
OverTorque protect status: ACTIVE
Collision thresholds are not

available yet, autotuning status
is not complete. But, torque%
has been reduced to protect gun.
Please perform autotuning.
[OK]
After autotuning
When autotuning is complete, the following message is displayed.
Press F4 OK to go setting screen.
OverTorque protect status: ACTIVE
Autotuning status is complete, and

Overtorque detection thresholds
have been set.
[OK]
2. Make sure that OverTorque Protection is enabled. The software

default is enabled.
3. Reduce the jog velocity limit to get more response time during
jogging. This is optional.
NOTE: OverTorque sensitivity adjustment is not available
prior to completion of autotuning
4. Digital Outputs can be set to inform if OverTorque Protection is
enabled or an OverTorque “collision” is detected
SETUP servo gun G1 JOINT 100 %

OVERTORQUE PROT MAIN / EQ:1 Gun:1 1/5
Sensitivity not
1 OverTorque protection: ENABLE displayed until
2 Sensitivity: 100.000% autotuning is
3 Parameter Summary <*DETAIL*> complete
4 OverTrq protection enabled: DO[ 0]
5 OverTrq condition detected: DO[ 0]
6 Jog velocity limit (mm/sec): 250
-119-
Step 3: Max Pressure Setting at Servogun setup screen

Overtorque Protection will prevent torque in excess of what generates
Max Pressure as defined on the servo gun setup screen and calculated
from the user provided calibration data for the servo gun.
1. Get to this menu through setup servogun.

2. Set Max Pressure to the actual maximum allowable tip force for the
weld gun (NOTE: the default value is 500kgf).
The present gun torque limit can be seen beneath the max pressure item.
This is % of max amplifier current. You will also see the message: Gun
torque limit is in effect. You cannot directly specify the gun torque %
on this screen .

Max Gun torque: 22.5
9 Tip stick detect distance: 0
10 Tip Wear Detection: <*DETAIL*>
Step4: Perform Autotuning

See Servo Gun Autotuning section for detail on how to complete
autotuning
Step 5: Perform Pressure Calibration

After autotuning, the Max Gun Torque % is still based on theoretical
data, before force calibration is completed. This theoretical limit is
conservative since it assumes the weld gun is 100% mechanically
efficient. If motor torque is limited to a value based on this 100%
efficiency, then the actual max pressure won’t likely be achievable. A
system variable is provided to deal with this, as described below. The
following information is displayed at pressure calibration.
ALT_PGO4 LINE 2 AUTO PAUSED ALT_PGO4 LINE 2 AUTO PAUSED

_ G2 JOINT 100 % _ G2 JOINT 100 %
NOTE: NOTE:
$SGSYSCD.$CAL_TRQ_SEV = 0 $SGSYSCD.$CAL_TRQ_SEV = 1
If torque% exceeds the Overtorque If torque% exceeds the Overtorque
limit: ( 15.2%), a warn prompt is limit: ( 15.2%), a fault prompt is
is posted. However, pressure is posted. Pressure calibration
calibration can still be performed cannot be performed in this
in this condition. condition.
OK OK
-120-
NOTE
The torque limit during calibration is determined by the setting of the system variable
$SGSYSCD.$CAL_TRQ_SEV as follows:
$SGSYSCD.$CAL_TRQ_SEV = 0, the user will be able to command torque
percentages during calibration up to the maximum motor torque. High torques may
damage the gun.
$SGSYSCD.$CAL_TRQ_SEV = 1, the user will be able to command torque
percentages during calibration up to the percentage displayed on the above prompt.
This percentage is the torque that corresponds to max pressure based on present
calibration data or theoretical limit if no calibration data is available.
Procedure
Perform force calibration as usual.
If max gun torque is exceeded, then a prompt is displayed, as shown
below

PRESSURE CALIB PARMS / EQ:1 Gun:1 1/15
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 2.0
3 Thickness of Gauge(mm): 0.0
4 Pushing Depth(mm): 5.0
5 Gun Open Value(mm): 10.0
Torque(%) Speed(%) Pressure(Kgf)
6 5.0 % 100 % 120.0 Kgf
7 11.0 % 100 % 230.0 Kgf
8 16.0 % 100 % 365.0 Kgf
9 0.0 % 100 % 0.0 Kgf
Warn torque limit is 15.2%
Decrease torque% or disable overtorq prot
[ TYPE ] CANCEL PRESSURE COMP INCOMP
-121-
Step 6: Adjustment and Description of OverTorque Protection parameters

The parameter settings can be viewed from the OverTorque Protection
line item seen on the Servo Gun General Setup Screen. By default,
OverTorque Protection will be enabled and set to a sensitivity of 100%.
If you wish to adjust the OverTorque Protection settings for program
open motion and jogging, change the sensitivity on the OverTorque
Protection main screen:
- 100% is what the servo gun software perceives to be the optimal
setting for the mechanical gun, now defined.
- The limit can usually be increased to 200% (twice as sensitive) or
decreased to a value that varies based on the Max Pressure for the
gun.
- 50% would be ½ the collision sensitivity of 100%. The sensitivity
can never be decreased to a value that would allow a collision
above the gun’s Max Pressure.
- Disabling OverTorque Protection, completely disables the
OverTorque Protection feature.
OVERTORQ PARAM SUMRY / EQ:1 Gun:1 1/1
1 Display unit: TorqCt

This is a display of the Parameter Summary <DETAIL>.
The values on this page are for display only. They can be
Max Gun torque: 1106 used to better understand how the Sensitivity adjustment will
Std OverTorque value: 692 actually effect the collision detection capability and level of
Max Motor torque: 7282 protection for the servo gun. The parameters can be
OverTorque thresholds: displayed in units of torque counts (TorqCt) or Units Force,
based on the results of the Pressure Calibration for the gun.
Program close stroke(trq): 1106
Program open stroke(trq): 692 Torque counts can be converted into amplifier current by the
Jog close stroke(trq): 692 following equation:
Jog open stroke(trq): 692 Amps (Pk) = TorqCt/7282 * Amplifier max current
output
Item Description / notes

Display Units The user can specify the display units for the Overtorque Parameters
TorqCt = Torque counts are the internal operating units for the software. Torque Counts can be
converted to motor current based on the preceding equation
Force = the TorqCt is converted to a unit of force based on the existing Pressure Calibration data
Max Gun Torque This is the maximum collision torque that OverTorque Protection will allow for the servo gun
axis. This value corresponds to the torque that will yield the Max Pressure, as specified on the servo
gun general setup screen, plus a small margin. Max gun torque is the value at which the overtorque
alarm triggers. Therefore, the margin should be specified so that Max gun torque is slightly larger than
the max torque observed during close (transient torque) and hold (static torque).. The magnitude of the
margin is specified by the system variable $sggun#.$chk_prs.$margin_p and is in units of kgf
Std OverTorque This is the standard collision detection torque. This value is derived from measurement of the
Value static friction during autotuning. When sensitivity is set to 100%, all OverTorque thresholds except the
program close stroke (used for pressuring) will be set to this value. Sensitivity adjustment will adjust the
OverTorque thresholds around the Std OverTorque value. See the equation for how sensitivity
adjustment affects the Overtorque thresholds.
Max Motor This is NOT an OverTorque limit. This value represents the maximum motor torque available from the
Torque amplifier for standard motion, such as acceleration and deceleration.
-122-
Item Description / notes

OverTorque The following values display the actual OverTorque parameters for the (4) different types of servo gun
thresholds motion. These represent the actual torque value at which a Collision Alarm will be issued.
Program Close This is the limit for program close motion, which is for performing pressuring operations. The value
Stroke corresponds to the torque that yields the Max Pressure specified for the gun. This value can only be
adjusted by changing the Max Pressure. Since pressuring operations require large torque, this value is
always equal to the Max Gun Torque.
Program Open This is the limit for open motion of the gun during program operation. This is based on the Std
Stroke OverTorque Value and the Sensitivity
Jog Close This is the limit for close motion of the gun during jogging operation. This is based on the Std
Program Open This is the limit for open motion of the gun during jogging operation. This is based on the Std
NOTE
After Sensitivity Adjustment, it is good to check the Parameter Summary screen in
OverTorque Protection to confirm that the open stroke torque limits are still set below
the mechanical limit of the gun’s open hard stop.
NOTE
- Largest allowed gun torque = Max Gun Torque
- Sensitivity adjusts the OverTorque thresholds as follows:
Threshold = 100 / sensitivity * Std OverTorque value.
- Program Close Stroke threshold does not change with Sensitivity adjustment, it is
always equal to Max Gun Torque
- Minimum sensitivity depends on the ratio between Max Pressure and Std
OverTorque value
- If the “Std OverTorque value” is higher than “Max Gun Torque”, the OverTorque
Protection function may return an error status message. Countermeasures to this
condition include:
- Increase Max Pressure until the error status is eliminated
- NOTE: Reducing the Max Pressure after this will still reduce the Max Pressure that
can be commanded for pressuring. Only the torque limit for “Program Close Stroke”
won’t get updated. Overtorque Protection for jogging and program open motion will
still be maximized
- Stroke the gun many times to reduce the friction in the drive mechanism then
Autotune the gun again to re-measure the Std OverTorque value
Effect of Tip Sticking on OverTorque Protection

Since OverTorque Protection provides for detection of unexpected
motor current disturbances that are relatively small, there is a
possibility that heavy tip sticking following a spot weld will trigger
collision alarms for the servo gun axis. If these alarms are troublesome,
attempt the following countermeasures (in recommended order) to
reduce the occurrence of these alarms:
1. Reduce the tip sticking. Only excessive tip sticking will cause a
fault in most guns.
-123-
2. Reduce the sensitivity of OverTorque Protection. Sensitivity

may be reduced to the minimum percentage, but it is best to only
reduce to a level that prevents unwanted alarms from tip sticking.
Reducing sensitivity will remove unwanted alarms in most cases
and OverTorque Protection will still be active.

OVERTORQUE PROT MAIN / EQ:1 Gun:1 1/5
1 OverTorque protection: ENABLE

2 Sensitivity: 15.000%
3 Parameter Summary <*DETAIL*>
4 OverTrq protection enabled: DO[ 0]
5 OverTrq condition detected: DO[ 0]
6 Jog velocity limit (mm/sec): 250
3. Disable OverTorque Protection. Do this only as a last

resort, especially when users expect to have OverTorque
Protection enabled.
-124-
B-82634EN/01 15.PART THICKNESS CHECK FUNCTION
15 PART THICKNESS CHECK FUNCTION

Part Thickness checks can be carried out with the servo gun during
execution of motion option and standalone SPOT instructions and the
Press_Motion instruction.
The part thickness check compares measured part thickness to the

Expected part thickness. When the measured value exceeds the
user-specified tolerance a warning or fault can be issued, and an output
can be asserted. The thickness check function can be configured to
check:
a Every spot/press_motn instruction
OR
b Specify spot/press_motn instructions (When requested within the
tp program)
Thickness checks can be enabled for all spot and press_motion
instructions or only when directly specified.
Target applications for Part Thickness check include detection of:

- Missing part
- Incorrect part
NOTE
Compensation for wear on the welding tips (Tip wear
compensation) and bending in the gun arms (Gun
Sag compensation) are required for accurate part
thickness measurement. See the appropriate
sections for details on each of these compensation
functions.
The user must complete the “Thickness Check Calibration” item on the
Servogun Autotune Utility for the part thickness function to be enabled.
In addition, the user is required to:
1. Accurately set the tip displacement ratio for the gun (mm/motor
revolution).
2. Keep gun tips accurately mastered so tips touch exactly at zero
position. Tip wear compensation programs are typically used to
achieve this.
3. Fixed tip of gun must be in gentle contact with the metal surface
during thickness check. Accurate teaching and gun sag
compensation are typically required.
-125-
15.PART THICKNESS CHECK FUNCTION B-82634EN/01
DEFINITIONS
Estimated (Measured) Part Thickness = position of the gun tips minus expected
gun deflection when the thickness check is performed.
Expected Part Thickness = part thickness from the specified pressure schedule (or
THK_VAL condition if used). This is compared to the Measured Part Thickness to
determine if the measured thickness is out of tolerance.
15.1 THICKNESS CHECK CALIBRATION
Gun Deflection Calibration Procedure

1. Press MENUS.
2. Select UTILITIES.
3. Press F1, [TYPE] and select SG Auto Tune. You will see a screen
Servogun TUNE G2 JOINT 10 %

EQ:1 Gun:1 15/15
Press F2 to tune gun on other equipment

Press F6 to select gun in dual gun case
1. Set gun motion sign: COMP

2. Set gun specs master gun COMP
Tip Displacement: 7.5 (mm/rev)
Open Stroke Limit: -110.00(mm)
Close Stroke Limit: 20.0(mm)
3. Auto Tune: COMP
4. Thickness Check Calibration:INCOMP
[ TYPE ] EQUIP# RESTART HELP>
4. Complete Steps 1-3 of the Servogun Autotune utility.

Refer to the Autotuning Utility sections in the Servo Gun Manual
5. Complete Pressure Calibration. Refer to the Pressure Calibration
section in the Servo Gun Manual.
6. Be sure that the tips touch at the zero position exactly (+/- 0.1mm).
It is best to complete Tip Wear Compensation Setup/Initialization
since tip wear compensation is needed, and provides for accurate
zero position mastering of the gun tips.
7. Select the appropriate equipment and gun number using the
F-keys.
-126-
8. Move the cursor to select Step 4, “Thickness Check Calibration”.
NOTE
Before starting the calibration the following items
must be confirmed:
- The gun tips must be accurately mastered. Use Tip
Wear Compensation Setup program to achieve this.
(any error in mastering will lead to a direct error in part
thickness measurement)
- Items 1-3 of the Autotune Utility must be complete
- Pressure Calibration must be complete
Robot may have to be placed in AUTO or T2 and all
faults cleared
9. Press Shift + F3 (EXEC) to initiate the calibration. The following

prompt box may appear when you do this.
Deflection calibration exercises will begin
This is only used for part thickness estimation.
Are you sure you want to do this?
[YES] NO
10. Select YES and press enter. The selected gun will open and close
4 times to perform the calibration. The robot will not move during
this process.
Once the deflection calibration is complete, part thickness

checking can be used. The next step is to setup and define the part
thickness operation desired.
-127-
15.2 THICKNESS CHECK GENERAL SETUP
Thickness Check General Setup Procedure

1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE] and select Servo Gun. Then select the General
SETUP Spot Weld G2 JOINT 10 % Setup page.
3 Close Direction (Gun) : PLUS 4. Scroll to the Thickness check item and press enter to see the
4 Close Direction (Robot): UT: 1 [+Z] Thickness Check screen.
5 Max Motor Torque (%) : 100.0
6 Max Pressure (Kgf) : 500.0
7 Tip stick detect distance (mm) : 5
SPOT_1A2 LINE 0
8 Tip Wear Detection <*DETAIL*>
SETUP\Servo\gun
9 Pressure Cal : COMP <*DETAIL*> THICKNESS CHECK / EQ:1 Gun:1 1/8
10 Tip Wear Standard: COMP <*DETAIL*>
11 Thickness Check <*DETAIL*> 1 Thickness check: DISABLE
2 Thickness check mode: ON RQST
3 Check at 0kgf: DISABLE
[ TYPE ] EQUIP GUN ENABLE DISABLE 4 Settling time delay (ms): 0
5 Alarm severity: WARN
6 Under thickness limit (mm): 0.2
7 Over thickness limit (mm): 0.2
8 Thickness out of tolerance: DO[ 0]
5 Using the table below as a guideline, setup each item on the

Thickness Check page to specify the part thickness check
operation that you desire.
Item Description / notes Values

Thickness check This setting specifies whether thickness ENABLE Æ checking is done based on thickness
checking is enabled. In the case of on request check mode selected below
mode, this becomes thickness check DISABLE Æ (default) checking is globally disabled
permissive. and never done.
Thickness check Specify whether every spot should be ALL Æ if thickness check is set to ENABLE, checks
Mode checked or only those spots that are preceded are done for every spot and press motion that is not
by the condition, TCHK_RQD preceded by the TCHK_SKP condition.
ON_RQST (“on request”) Æ (default) if thickness
check is set to ENABLE, checks are done only for
each spot and press motion that is preceded by the
TCHK_RQD condition.
Check at 0kg Specify whether thickness should be checked ENABLE Æ the weld pressure will be set to a
with no pressure in the gun. An additional minimum value (i.e. the gun is relaxed) prior to
step is added to relax the gun in this case. checking thickness, after the measurement is done
the gun will close to weld pressure before welding.
DISABLE Æ (default) check is performed when
gun reaches the specified weld pressure, this is the
faster of the two measurement styles.
Settling time Delay after achieving pressure, before 0-9999 Æ (default = 0) time in ms that system will
delay(ms) reading thickness value. Adding a delay may wait after pressure is achieved before checking the
improve the repeatability of the measurement part thickness.
but will increase the time required to complete
the measurement
-128-
Item Description / notes Values

Alarm severity Severity level of message that is posted when WARN Æ (default) if thickness check yields an
out of tolerance condition is detected. out-of-tolerance value, a warning message is
posted but the program and weld will execute
normally
FAULT Æ if thickness check yields an
out-of-tolerance value, a fault will be issued that will
immediately stop the robot and pause the program.
No welding will be done.
Under thickness Maximum deviation from specified thickness 0-99.9mm Æ (default = 0.5mm) A value of 0.0
limit (mm) in the negative direction. For example, if: disables the tolerance check. A value of 0.5mm or
Expected thickness = 2.0 higher is recommended for most users.
under thickness limit = 0.5
Measurements < 1.5mm are out of tolerance
Over thickness Maximum deviation from specified thickness, 0-99.9mm Æ (default = 0.5mm) A value of 0.0
limit (mm) in the positive direction. For example, if: disables the tolerance check. A value of 0.5mm or
Expected thickness = 2.0 higher is recommended for most users.
Over thickness limit = 0.5
Measurements > 2.5mm are out of tolerance
Thickness out of The output number (DO index) asserted, The output pulses for the duration specified by
tolerance DO when a thickness alarm occurs. $sggun#.$setup. $tc_almiopls (default=500ms).
0 -> 999 Æ (default = 0)
Program-Based Thickness Check Conditions

Thickness checking conditions can be set locally in the teach pendant
programs to override certain items from the Thickness Check setup
page.
The TCHK_RQD condition must be used to enable a thickness check
when the Thickness Check mode is set to “On Request”.
These special conditions are activated by placing the condition
statement directly before the pressuring instruction (SPOT or
Press_motion) when the thickness check is to be done. The condition is
only active for the next pressuring motion.
Conditions Comment
TCHK_RQD Used to activate a thickness check when the
thickness check mode is set to On Request
(ON_RQST)
TCHK_SKP Used to skip a thickness check when the
thickness mode is set to ALL
Override Conditions (parameters)
THK_VAL(thickness, gun index ) Used to override the expected thickness from
the Pressure Schedule. Thickness is entered in
mm and must be >0.0
THK_TOL(under, over, gun index ) Used to override the under and over tolerance
settings from the Thickness Check setup page,
values are in mm and must be >0.0
THK_SEV(severity , gun index ) Used to override the Alarm Severity from the
Thickness Check setup page.
Settings for the severity parameter are:
1 = Warning (message only)
2 = Fault (pause program)
-129-
The optional parameter - gun index - is common to all override

conditions. It is only significant when the gun is part of a dual-gun.
1 = gun A
2 = gun B
A value of 3 (both guns) is assumed by default.
The conditions are added to teach pendant programs by inserting a

CALL instruction. Each condition is acutally a MACRO program that
is found in the macro program list.
Sample program demonstrating use of Thickness Check Conditions
TP Program instruction Comments:

1: L P[1] 2000mm/sec CNT100 Expected thickness =
PRESS_MOTN[ 1 ] Part Thickness from Pressure Schedule #1
SPOT[ P=1,S=1,BU=1] Part Thickness from Pressure Schedule #1
3: CALL THK_VAL[1.5] Thickness value override condition is set
4: CALL THK_TOL[0.3,0.3] Under/Over limit override condition is set
5: CALL THK_SEV[2] Alarm Severity override condition is set
6: L P[1] 2000mm/sec CNT100 Expected thickness = 1.5mm
SPOT[ P=1,S=1,BU=1] If measurement is greater than 1.8mm or less
than 1.2mm, the program will stop.
PRESS_MOTN[ 1 ] Part Thickness from Pressure Schedule #1
SPOT[ 1 ] Part Thickness from Pressure Schedule #1
-130-
B-82634EN/01 16.GUN OPEN FUNCTION at WELD FAULT
16 GUN OPEN FUNCTION at WELD FAULT
This function automatically opens servo gun when weld major fault or
weld complete time-out is occurred, then movable tip and fixed tip is
removed from panel. (In case of fixed servo gun, panel is removed from
fixed tip)
Executed program is paused, however user can restart welding as soon

as release occurred alarm.
Curried Gun
Major fault! Auto-open
Fixed Gun
Major fault! Auto-open
WARNING
Robot move during opening fixed tip. Don't approach
a robot during welding and production.
-131-
16.GUN OPEN FUNCTION at WELD FAULT B-82634EN/01
16.1 Conditions of Gun Open
When fulfilling all the following conditions, gun is opened.
・ Teach pendant is disable

・ Weld retry have finished specified time.
・ Weld major fault or weld complete time-out is occurred with
closing servo gun.
But gun is not opened when the following errors are occurred.
・ Errors of except weld major fault or weld complete time-out

・ Receive HOLD signal during welding.
NOTE
This function is DISABLE by default. Please set
$SGGUN#.$FLTOPN.$ENBLE=TRUE, if you want to
use this function.( # =gun number)
NOTE
If any error is occurred during opening gun, opening
gun is aborted.
-132-
B-82634EN/01 16.GUN OPEN FUNCTION at WELD FAULT
16.2 GUN OPENING MOTION
When major fault occuers, gun and robot moves so that their tips
remove form panel.
This offset is the following.
Movable tip: Offset 10mm from panel

Fixed tip: Offset 5mm from teaching point
(In case of fixed gun,offset panel)
Movable tip
Part thickness Curried servo gun:

Fixed tip removes form panel
10mm
Fixed servo gun
Panel Panel removes form fixed tip.
Teaching point 5mm
Fixed tip
WARNING
TCP of Robot moves forward gun open direction at
weld fault if this function is ENABLE.
Please make sure of setup of the servo gun
coordinate (ref. 2.2) and gun close direction (ref.2.3)
for your system before welding.
WARNING
In case of standalone SPOT instruction, robot offsets
current position, but not teaching position.
-133-
17.ALARM CODE LIST B-82634EN/01
17
SVGN Alarm Code List
ALARM CODE LIST
SVGN-001 STOP Serious Internal error

Cause: Internal Servo Gun error
Remedy: Record error and report to hotline.
SVGN-002 STOP No sysvar pointer

Cause: This is an internal system error.
SVGN-003 STOP No global variables

SVGN-004 STOP Unable to Allocate Memory

Cause: A failure occured while allocating memory.
Remedy: Check amount of memory being used by the system. Perform a cold start on the controller.
Record error and report to hotline.
SVGN-005 STOP Wrong TPP inst. format

Cause: This SPOT instruction format is not correct. This SPOT instruction is not available.
Remedy: Reteach this instruction with current configulation.
SVGN-006 STOP Another TASK used this equip.

Cause: Another TPP specified this equipment and now executing or paused.
Remedy: Force abort another TPP.
SVGN-007 STOP Pre execution failed

Cause: Pre-execution has some trouble and system pauses the program execution for safety.
Remedy: Press RESET to clear the error and continue the program. If this error continues to occur,
perform a cold start by turning off the robot, then while pressing SHIFT and RESET on the
teach pendant, turn the robot back on. If the error is not cleared, document the events that led to
the error and call your FANUC Robotics technical representative.
SVGN-008 STOP Syntax error

Cause: Instruction syntax error. This instruction is for air gun spot.
Remedy: Reteach the instruction. Reteach servo gun SPOT instruction.
SVGN-009 STOP Motion Group config. mismatch

Cause: Robot group and/or gun group are not enabled, in the group mask of this tp program.
Remedy: Determine the robot group number and gun group number for this equipment, then re-create the
program, with these groups enabled.
－134－
B-82634EN/01 17.ALARM CODE LIST
SVGN-010 STOP Invalid SG group config.

Cause: Invalid servo gun group number (greater than total number of groups).
Remedy: Check the group number assigned to this servogun (equipment).
SVGN-011 STOP Can not execute instruction(s).

Cause: Incremental, offset or tool offset instructions can not execute with servo gun SPOT instruction
at the same program line.
Remedy: Reteach this SPOT instruction to another line stand alone.
SVGN-012 STOP Invalid value for index

Cause: The register index specified in the instruction is invalid.
Remedy: The register index specified in the instruction is invalid.
SVGN-013 STOP Pressure exceeds limit

Cause: The Pressure specified in the pressure schedule, or pressure instruction, exceeds Max Pressure
for the gun.
Remedy: Reduce the Pressure in the pressure schedule / program. Or increase the Max Pressure item on
the Servo Gun General Setup screen. Confirm that the new pressure value does not exceed the
mechanical limitation of the gun.
SVGN-014 STOP Associate TID not found

SVGN-015 STOP Setup Configuration error

Cause: Pointer to gun, schedule, backup or distance data is invalid.
Remedy: Check servo gun configuration data. Record error and report to hotline.
SVGN-016 STOP Specified pressure too low

Cause: The pressure specified in the pressure schedule or pressure instruction is lower than the lowest
reachable pressure on the calibration curve.
Remedy: Higher pressure. Lower Pressure coefficient-B.
SVGN-017 STOP Invalid pressure coefficient

Cause: Single-segment calibration method is enabled and prm_a1 is invalid ( less than 0.0001 OR
greater than 100.0 )
Remedy: Change the calibration method to the multi-linear segment method if possible. Do this by setting
the sysvars $sgsyscfg.$cal_model = 12 and $sgsyscfg.$frc2spd_cnv = 3, then perform the
pressure calibration again.
SVGN-018 STOP Illegal torque limit value

Cause: Torque value is illegal ( less than $sgsyscfg.$minimum_trq OR greater than max rated torque ).
This alarm can occur at the following times:SPOT[], PRESS_MOTN[], or PRESS[]kgf
execution
Remedy: Confirm that pressure calibration data is valid.
SVGN-019 WARN Pressure shortage

Cause: Same as SVGN-020, but severity is WARN. Note:SVGN-019 can occur during autotuning or if
$sgsyscfg.$pst_ertype = 1; SVGN-020 occurs otherwise.
Remedy: See Remedy for SVGN-020.
－135－
SVGN-020 STOP Pressure shortage

Cause: The pressure specified in the SPOT or PRESS_MOTN instruction could not be achieved in the
expected time ($sgpxdata.$info[eq#].$lim_time [ms]). There are 2 Causes:
1) Gun close was not detected: the moving tip did not press into the part (or fixed tip, if no part).
2) The pressure (force) setpoint could not be reached and/or was unstable.
Remedy:"1A) If a welding part is expected then confirm that a part for welding is present. If no part is expected
set the Part Thickness value to zero for the Pressure Schedule being used. If there is no part
beCause this is a test cycle or dry-run, then set the Soft Panel to TRYOUT mode to ignore the
missing part.
1B) Verify that the tips touch at the zero position. If they do not: a. if tip wear update is used: run the tip
update program b. if tip wear update is not used, perform mastering with the gun zero master
screen.
1C) Adjust the Pressure Schedule data as necessary to close the tips to pressure:
1. Press the DATA key
2. Press F1 - TYPE and select PRESSURE from the list
3. Select the Pressure Schedule # that is being used and press F4 – DETAIL
Confirm that the Part Thickness value is correct. Adjust the Part Thickness value if necessary. If Part Thickness
is correct, increase the Pushing Depth to allow the moving tip to extend further to achieve
pressure. If the pushing depth does not appear in the pressure schedule detail, add it to the form
by setting $sgsyscfg.$sho_pshdpth=TRUE. If tip wear compensation is NOT used, increase the
Pushing Depth up to the Close Stroke limit of the gun.
2) If the gun is closing too slowly, then try to increase speed with the following measures:
- Increase the General Override
- Reduce the opening used in the Distance Schedule
- Increase the Contact speed in the Pressure Calibration screen or change it directly in the r ssure schedule
screen. Set $sgsyscfg.$sho_prs_spd=TRUE then return to the pressure chedule screen to adjust
the value. It may be necessary to perform the Pressure Calibration again if the tip pressure
changes.
- Autotune the gun again to compensate for mechanical changes in the gun
SVGN-021 STOP Uninitialized BU condition

Cause: Servo gun condition BU is not initialized.
Remedy: Add a servo gun condition instruction.
SVGN-022 STOP Uninitialized Pres. condition

Cause: Pressure condition is not initialized. Pressure condition value is invalid.
Remedy: Add a servo gun condition instruction.
SVGN-023 STOP Incomplete Pressure calibration

Cause: Incomplete pressure calibration.
Remedy: Go to the Servo Gun General Setup screen, select Pressure calibration, and perform pressure
calibration procedure
SVGN-024 STOP Incomplete Wear Down calibration

Cause: Tip Wear Compensation setup (calibration) is not complete.
Remedy: Perform the Tip Wear Setup procedure. Consult the Servo Gun Manual for details on this
procedure.
－136－
SVGN-025 STOP Illegal BU condition number

Cause: Invalid BU condition number ( greater than $sgsyscfg.$back_elm, or less than 1 ).
Remedy: Specify a backup condition condition number within the range above.
SVGN-026 STOP Illegal P condition number

Cause: Invalid P condition number ( greater than $sgsyscfg.$sch_elm, or less than 1 ).
Remedy: Specify a pressure condition condition number within the range above.
SVGN-027 STOP Untaught element encountered

Cause: Some program elements (like positional data for example) have not been recorded.
Remedy: Enter data for the missing program elements.
SVGN-028 STOP Pos. type is JOINT

Cause: Position type is JOINT.
Remedy: Change position type to XYZWPR.
SVGN-029 STOP Over max motor torque value

Cause: The convert value from specified pressure value to torque limit value exceeds the max torque
value.
Remedy: Check the specied pressure value. Check the max torque value.
SVGN-030 SVAL1 Tip Stick detection

Cause: Tip stick detection DI is ON
Remedy: Check the specied pressure value. Check the max torque value.
SVGN-031 STOP Tear Off is executing

Cause: When tear off function is executing, program cannot be started.
Remedy: Restart program after tear off function finished.
SVGN-032 STOP Tip increased error(Gun)

Cause: The measured tip wear on the gun side (moving tip) indicates that the tip has grown by an
amount greater than the Gun Increased Error(mm) setting
Remedy: First confirm the condition of the tip. If the tip is not ok, then replace it, and perform tip wear
measurement again. If a chip from tip dressing remains on the tip, remove this chip then
re-measure the tip wear.If new tips were installed after the previous tip wear measurement, be
sure the tip wear update program was run with the New Tips Parameter set to (1) in the Call
instruction for the tip wear macro. If this parameter was not set correctly, then press fault reset
and run the tip wear update program again with the New Tips Parameter set to (1).
If the tip is OK and the new tip parameter was set correctly, then perform the tip wear
measurement again. Observe the gun closely during this operation. Be sure the tips touch
during the 1st step of the tip wear measurement and be sure the gun tip touches the fixture
during the 2nd step (if used). If the gun tip does not close fully during either step, then the gun
friction has probably increased. To compensate, run Autotuning then Pressure Calibration and
perfrom the tip wear setup procedure again with new tips. Inspect the gun to find the reason
for the increase in friction.
If both steps of the measurement perform correctly then it may be necessary to increase the
value of the Increase Error(mm) setting for the robot side tip. Do this on the Tip Wear
Detection screen (SETUP-SERVO GUN-GENERAL SETUP).
－137－
SVGN-033 STOP Tip increased error(Robot)

Cause: The tip wear down value of robot side exceeds the increased error.
Remedy: Some chips may stick to the robot side tip. Please check the tip.
SVGN-034 STOP Excessive robot tip difference.

Cause: The Tip Wear difference between the robot tips on the dual gun exceeds the specified tolerance.
Remedy: Replace or dress the tips (and tip holder if necessary) and run the tip wear update program for
each gun. Alternatively, increase the difference tolerance in the Tip Wear Detection screen
(SETUP-SERVO GUN-GENERAL).
SVGN-035 STOP Pressure enable time out

Cause: Pressure enable signal (input) did not turn on, before wait time expired.
Remedy: Determine why the pressure enable signal did not turn on. Or increase the value of time
out($SPOTEQSETUP[].$PEN_TMOUT).
SVGN-036 STOP Comp confirmation time out

Cause: Comp confirmation signal (input) did not turn on, before wait time expired.
Remedy: Check the reason of comp confirmation signal off. Or Fix the value of time out
($SPOTEQSETUP[1].$NSE_TMOUT).
SVGN-037 STOP Illegal pressure enable signal

Cause: Pressure enable signal number is illegal.
Remedy: Map pressure enable input to a valid input index via ($SPOTEQIO[1].$DI_PEN_I).
SVGN-038 STOP Illegal comp confirmation signal

Cause: Comp confirmation signal number is illegal.
Remedy: Map comp confirmation input to a valid input index via ($SPOTEQIO[1].$DI_NSE_I).
SVGN-039 WARN Thickness out of tolerance

Cause: Same as SVGN-040, but warn severity.
Remedy: See SVGN-040.
SVGN-040 STOP Thickness out of tolerance

Cause: The Measured part thickness deviates from the specified value more than the Under or Over
thickness limit(mm). The part may be out-of-tolerance.
Remedy: Check the master position for the gun axis and make sure the tips touch at the zero position (+/-
0.1mm). Confirm that tip wear and gun sag compensation are enabled and that the compensation
values are correct. Check the part or re-enter the part thickness in the pressure schedule.
Alternatively, increase the Under and Over thickness limits in the Part Thickness check screen
found on the Servo Gun General Setup screen. Resume the program, to retry the measurement.
Perform deflection calibration again, if the problem persists.
SVGN-041 WARN No more available memory(PERM)

Cause: The number of $SGGUN is less than the total axis number of servo gun group.
Remedy: Please increase $SGSYSCFG.$M_GUN_NUM to be larger than the total axis number of servo
gun group.
－138－
SVGN-042 WARN Lack of $SGGUN

Cause: The number of $SGGUN is less than total number of axes in the servo gun group(s).
Remedy: Reduce $SGSYSCFG.$M_GUN_NUM to the minimum value required to accomodate all servo
gun axes. After changing this sysvar, go to control start, and then cold start, to make the change
effective.
SVGN-043 WARN AutoTuning Started

Cause: User has started Servo Gun autotuning.
Remedy: No Remedy required. This is a warning message to log the event.
SVGN-044 WARN AutoTune Successfully Complete

Cause: User has successfully completed auto tuning.
Remedy: User should cycle power to use servo gun.
SVGN-045 WARN AutoTuning Failed

Cause: Auto Tuning Could not be completed.
Remedy: Restart on tuning menu and try again.
SVGN-046 FAULTS must be reset

Cause: User executed autotuning, while the system was faulted.
Remedy: Clear ALL FAULTS and start tuning again.
SVGN-047 WARN Step mode must be disabled

Cause: STEP mode is enabled.
Remedy: Disable STEP mode and start tuning again.
SVGN-048 WARN Machine lock must be disabled

Cause: Machine Lock is enabled for servo gun group.
Remedy: Disable Machine lock from TEST CYCLE Menu and start tuning again.
SVGN-049 WARN Hold must be cleared

Cause: Hold is active.
Remedy: Clear HOLD and start tuning again.
SVGN-050 SYSTEM Autuning: Re-power required

Cause: Cycle power.
Remedy: Cycle power before proceeding.
SVGN-051 WARN Backup stroke is not selected.

Cause: Shift + backup (hardkey) was pressed, but no Backup Schedule schedule was selected.
Remedy: Select a backup schedule, by pressing the backup hardkey, (without the shift key).
SVGN-052 WARN Motion group mismatch.

Cause: The motion group number of the user program for manual pressure or manaul backup is not
matched to the Servo Gun group.
Remedy: Change the motion group number of the program to match the Servo Gun
SVGN-053 WARN Backup stroke is not set.

Cause: Specified backup stroke index is not set the valid stroke value.
Remedy: Set the valid backup stroke to the specified backup stroke index.
－139－
SVGN-054 STOP $EQNUM is invalid number.

Cause: $EQNUM is not use in the system.
Remedy: Set the valid equipment number to $EQNUM.
SVGN-055 STOP $EQNUM is not Servo Gun.

Cause: The equipment specified by $EQNUM is not assigned to the Servo Gun
Remedy: Set the equipment number which is assigned to Servo Gun to $EQNUM.
SVGN-056 STOP $GUNNUN is invalid number.

Cause: Specified number is not valid for $GUNNUM.
Remedy: $GUNNUM can be set only 1 or 2 which is corresponding to GUN1 or GUN2
SVGN-057 STOP Tip Wear Down Cal. is INCOMP.

Cause: Tip Wear Compensation setup is not complete.
procedure.
SVGN-058 STOP UT or UF is different.

Cause: The tool frame number or user frame number is different from the standard position.
Remedy: Change the frame number to same number of standard position.
SVGN-059 STOP Cannot read specified PR[].

Cause: System cannot read the position register which is specified by $PRINDEX.
Remedy: Check the number of $PRINDEX.
SVGN-060 WARN Pressure program is not set.

Cause: The pressure program name is not set correctly.
Remedy: Set correct program name in manual operation setup screen.
SVGN-061 WARN Backup program is not set.

Cause: The backup program name is not set correctly.
Remedy: Set correct program name in manual operation setup screen.
SVGN-062 WARN Pressure data is not selected.

Cause: Shift + GUN hardkey was pressed, but no Pressure Schedule was selected.
Remedy: Select a pressure schedule, by pressing the backup hardkey, without the shift key.
SVGN-063 WARN Pressure data is not set.

Cause: GUN hardkey was pressed (to select pressure), but no Pressure Schedule was enabled.
Remedy: Enable Pressure Schedule(s) for Manual Operation by setting the Manual item to TRUE in the
Pressure Schedule data table.
SVGN-064 WARN Manual Weld Verif. Enabled

Cause: Manual Weld Verification feature was enabled.
Remedy: Just a notification, no action neccessary.
SVGN-065 WARN Manual Weld Verif. Disabled

Cause: Manual Weld Verification feature was disabled.
Remedy: Just a notification, no action neccessary.
－140－
SVGN-066 WARN Manual Weld Verif. Activated

Cause: Manual Weld Verification feature was activated.
Remedy: Just a notification, to let user know he is in this modeand that groups may be disabled
automatically for him
SVGN-067 WARN Manual Weld Verif. De-Activated

Cause: Manual Weld Verification feature was activated.
Remedy: Just a notification, to let user know he is in this mode and that groups may be enabled
automatically for him
SVGN-068 WARN Could not load program %s

Cause: Could not load tp program for tip wear measurmenet. See Cause code for reason.
Remedy: Resume the program, to re-attempt the load. If the load is successful, then the tip wear
measurement will contine.
SVGN-070 PAUSE Gun Change is DISABLED.

Cause: This equipment is set to Air Gun. Or the gun change function is disabled.
Remedy: Set the equipment type to Servo Gun in initial setup screen, and Enable Gun change.
SVGN-071 PAUSE Machine lock is ENABLE.

Cause: Machine lock for robot axes is enabled at gun attach instruction.
Remedy: Release machine lock.
SVGN-072 PAUSE Illegal assignment of gun axis.

Cause: Gun number assignment are wrong .
Remedy: Confirm Gun number assignment.
SVGN-073 PAUSE Gun not detatched (AXISORDER).

Cause: Gun is not detached. Some AXISORDER are not 0.
Remedy: GUN ATTACH instruction can be executed only when no gun is attached.
SVGN-074 PAUSE Gun not detatched.

Cause: Gun is not detached. Gun attach input signal is OFF.
Remedy: GUN ATTACH instruction can be executed only when no gun is attached.
SVGN-075 PAUSE Gun not attached.

Cause: Gun is not attached. Gun attach input signal is ON.
Remedy: GUN DETACH instruction can be executed only when a gun is attached.
SVGN-076 PAUSE Another process is executing.

Cause: Another program is executing GUN ATTACH or GUN DETACH instruction. $CHG_PHASE
is not 0 at executing the instruction.
Remedy: Wait until another program end GUN ATTACH/DETACH instruction.
SVGN-077 PAUSE Gun identify signal is OFF.

Cause: Gun identify signal is OFF.
Remedy: Confirm the setting for Gun identify signal.
SVGN-078 PAUSE Gun set signal is OFF.

Cause: Gun set signal is OFF.
Remedy: Confirm the setting for Gun set signal.
－141－
SVGN-079 PAUSE Gun change canceled.

Cause: GUN ATTACH or GUN DETACH instruction is canceled while executing the instruction.
Remedy: Do COLD START the system.
SVGN-080 PAUSE Gun change timeout.
Cause: GUN ATTACH or GUN DETACH instruction become timeout while executing the instruction.
Remedy: Do COLD START the system.
SVGN-081 SYSTEM Gun mastering data is lost.

Cause: Mastering data of the gun is lost by a pause while mastering.
Remedy: Do COLD START the system. Then master the gun by manual operation.
SVGN-082 PAUSE Gun mastering is failed.

Cause: Gun mastering is failed by a pause while mastering.
Remedy: Continue to retry mastering.
SVGN-083 PAUSE GUN ATTACH is failed.

Cause: GUN ATTACH instruction failed. Please see Cause code.
Remedy: Please see Cause code.
SVGN-084 PAUSE GUN DETACH is failed.

Cause: GUN DETACH instruction failed. Please see Cause code.
Remedy: Please see Cause code.
SVGN-085 PAUSE Robot not mastered(Gun axis).

Cause: The mastering of servo gun axis has not been performed yet. System variable $master_done set
FALSE.
Remedy: Please perform the mastering of the servo gun axis.
SVGN-086 PAUSE Robot not calibrated(Gun axis).

Cause: The calibration of servo gun axis has not been performed yet. System variable $calibrate set
FALSE.
Remedy: Please calibrate the servo gun axis.
SVGN-087 PAUSE Ref pos not set(Gun axis).

Cause: Reference position has not been set when quick mastering.
Remedy: Quick mastering may not be possible. Fixture or zero master.
SVGN-088 PAUSE Another gun is attached.

Cause: The another gun which is different from the gun number specified by GUN DETACH
instruction is attached.
Remedy: Verify the gun number of GUN DETACH instruciton.
SVGN-089 PAUSE Calibrate motion is failed.

Cause: While the calibrate motion, the detect condition was not triggered.
Remedy: Verify the detect condition in the gun change setup screen.
SVGN-090 PAUSE PR[] index is not set.

Cause: The PR[] index for the calibrate motion is not set.
Remedy: Please set PR[] index for the calibrate motion in the gun change setup screen.
－142－
SVGN-091 PAUSE Touch torque is not set.

Cause: The Touch torque for the calibrate motion is not set.
Remedy: Please set Touch torque for the calibrate motion in the gun change setup screen.
SVGN-092 PAUSE Detect signal is not set.

Cause: The Detect signal for the calibrate motion is not set.
Remedy: Please set Detect signal for the calibrate motion in the gun change setup screen.
SVGN-093 PAUSE Gun does not stop.

Cause: At the Gun Zero Master[] instruction, Servo gun axis does not stop.
Remedy: After servo gun axis stops, execute the Gun Zero Master[] instruction.
SVGN-094 PAUSE GUN EXCHANGE failed

Cause: At the Gun exhange[] instruction, the new gun could not be activated.
Remedy: Make sure that the each servogun has valid axisorder
SVGN-095 PAUSE Gun type is not opposable.

Cause: Opposable gun type is required for target gun.
Remedy: Set gun type as opposable, if appropriate.
SVGN-096 PAUSE Gun Close is disabled.

Cause: Cannot perform this operation while Gun Close (stroke enable) is disabled.
Remedy: Set Gun operation to stroke (stroke enable) on softpanel screen. Note: softpanel screen is
accessed from the TEST CYCLE menu.
SVGN-097 PAUSE Tip wear misdetection.(CLB)

Cause: The tips did not touch during the 1st step of tip wear measurement due to an increase in gun
friction or the tips touched but they are now longer than the reference tips by an amount greater
than the Mis-Detect Toler.(mm)
Remedy: If the tips are not fully closed when the alarm occurs, then the re-master operation failed during
tip wear measurement. This usually happens beCause the gun friction has increased since the
gun was last Autotuned. Autotune the gun again and/or inspect the Cause of the friction
increase. After this, put new tips on the gun and perform the tip wear setup procedure again. If
the tips are closed when the alarm occurs, then the tips are longer than allowed. The tips
measured during tip wear setup are the reference tips. New tips can only be longer than the
reference tips by an amount equal to the Mis-Detect Toler.(mm) specified in the Tip Wear
Detection screen (within the Servo Gun SETUP screen). Either increase the Mis-Detect
Toler.(mm) or replace the tips with shorter tips. If the tips seem to be the correct length, then
perform the tip wear setup procedure again to establish new reference tips.
SVGN-098 PAUSE Invalid inform signal(Gun).

Cause: The Digital Output assigned to Maximum Gun Tip Wear (amount) exceeded is invalid.
Remedy: Check the present setting of the Inform Signal for the Maximum Wear Check (gun) found on
the Tip Wear Detection screen (within the Servo Gun SETUP screen). Change the DO number
to one that is configured and unused. Check the Digital Output list
(I/O-Type-DIGITAL-OUTPUTS) to find an available DO point to use.
SVGN-099 PAUSE Invalid inform signal(Robot).

Cause: The Digital Output assigned to Maximum Robot Tip Wear (amount) exceeded is invalid.
Remedy: Check the present setting of the Inform Signal for the Maximum Wear Check (robot) found on
the Tip Wear Detection screen (within the Servo Gun SETUP screen). Change the DO number
－143－
to one that is configured and unused. Check the Digital Output list
(I/O-Type-DIGITAL-OUTPUTS) to find an available DO point to use.
SVGN-100 PAUSE Invalid register number.

Cause: Specified register number is out of range.
Remedy: Set a valid register number.
SVGN-101 PAUSE Invalid position reg number.

Cause: Specified position register number is out of range.
Remedy: Set a valid position register number.
SVGN-102 WARN Increased err. not set(Gun).

Cause: Increased error limit for Gun(movable) tip is set to 0.0mm
Remedy: Set the Increased error to a value greater than 0.0mm if Increased Error checking is needed. This
item is set on the Tip Wear Detection screen (within the Servo Gun SETUP screen)
SVGN-103 WARN Increased err. not set(Robot).

Cause: Increased error limit for Robot(stationary) tip is set to 0.0mm.
Remedy: Set the Increased error to a value greater than 0.0mm if the Increased Error checking is needed.
This item is set on the Tip Wear Detection screen (within the Servo Gun SETUP screen)
SVGN-104 PAUSE Excessive load detected.

Cause: Excessive load is detected, during tip wear setup or tip wear update. Gun zero position may be
incorrect.
Remedy: Remove any foreign object between the tips, and/or re-master the gun. Resume the tip wear
setup or update operation. If the alarm still occurs, then the gun friction has increased since it
was last Autotuned. Autotune the gun again and/or inspect the gun to determine the Cause of
the friction increase.
SVGN-105 PAUSE Failed to reset pulse coder.

Cause: Failed to reset pulse coder alarm.
Remedy: Reset pulse coder alarm again.
SVGN-106 PAUSE Tip wear uninitialized.

Cause: Tip Wear Compensation is uninitialized.
procedure.
SVGN-107 PAUSE Tip wear no load threshold.

Cause: The load threshold used to detect contact with the fixture for the 2nd step of tip wear
measurement has not been set.
procedure.
SVGN-108 PAUSE Tip wear no standard pulse.

Cause: The reference zero position (i.e. standard pulse) used for tip wear measurement has not been set.
procedure.
－144－
SVGN-109 PAUSE Tip wear no standard opening.

Cause: The reference open position (i.e. standard opening) used for the 2nd step of tip wear
measurement has not been set.
procedure.
SVGN-110 PAUSE Tip wear no detect DI index.

Cause: The Tip wear Detection Type is set to DI, but no DI index is specified.
Remedy: Confirm that DI detection is the desired type (LOAD detection is default type). If so, then
assign an available DI point to the tip wear dectection sensor and set that index value into the
Detect Signal item on the Tip Wear Detection Screen.
SVGN-111 PAUSE Failed to touch fixture.

Cause: The gun tip reached the master position without detecting the fixture (i.e. tip wear plate) during
the 2nd step of tip wear measurement.
Remedy: Confirm that zero position is correct, then confirm that a rigid fixture is between the tips during
the 2nd step of tip wear measurement.
SVGN-112 PAUSE Incomplete Servo tuning.

Cause: Tip wear measurement or deflection calibration started, but Servo tuning is incomplete.
Remedy: Complete servo auto-tuning. Go to the Gun Setup Utility (UTILITIES-GUN SETUP) and select
the Auto Tune item. The Auto Tune program can be started after completeing the previous steps
in the utility.
SVGN-113 PAUSE Gun must be open.

Cause: Tip wear setup or update program started with the gun closed.
Remedy: pen the tips, then execute the tip wear measurment program again. If the problem persists,
master the gun, then execute the tip wear measurment program again.
SVGN-114 PAUSE Tip wear misdetection.(FIX)

Cause: The moving tip did not touch the fixture during the 2nd step of tip wear measurement due to an
increase in gun friction, or the fixture and/or robot master position has changed since tip wear
was initialized.
Remedy: If the moving tip is not pressing into the fixture when the alarm occurs, the fixture touch load
(i.e. pressing force) was reached without actually touching the fixture. This usually happens
beCause the gun friction has increased since the tip wear setup program was run. Increase the
Margin of Load item in the Tip Wear Detection Screen to overcome the increase in friction.
Doing this can affect the tip wear measurement, so the tip wear setup procedure should be
performed again. It may be wise to autotune the gun again and/or inspect the gun for the
Cause of the friction increase. If the moving tip is pressing into the fixture when the alarm
occurs then the fixture position has moved relative to the robot master position, the robot master
data has changed, or the points in the program TW_MV2PT.tp have changed. Perform the tip
wear setup procedure again.
SVGN-115 PAUSE MP detection failed.

Cause: Magnet Phase detection failed.
Remedy: Retry the operation. Make sure that there is some separation (at least a few mm between),
between guntip/fixedtip and drive mechanism/open_hardstop.
－145－
SVGN-116 PAUSE MP detection unavailable.

Cause: Magnet Phase detection is unavailable with the current calibration motion type.
Remedy: Change the calibrating motion type (to 7 or 8) on the Gun change SETUP screen. Magnet phase
detection is only supported for battery-less gun change types 7, 8.
SVGN-117 PAUSE Ref pos auto-setup failed.

Cause: The Gun closing motion to set the reference position failed.
Remedy: Confirm that the Touch torque(%) on the Gun SETUP screen is set appropriately.
SVGN-118 WARN Max wear exceeeded (Gun Tip).

Cause: The maximum tip wear amount has been exceeded on the gun tip.
Remedy: Replace the gun tip or re-run tip wear setup.
SVGN-119 WARN Max wear exceeded (Rbt Tip).

Cause: The maximum tip wear amount has been exceeded on the robot tip.
Remedy: Replace the robot tip or re-run tip wear setup.
SVGN-120 WARN Skipped max gun torque update: Gun%d.

Cause: Max gun torque was not updated due to an invalid parameter.
Remedy: Please see the Cause code to identify the reason for the update failure. Correct the problem as
described by Remedy for the alarm specified in the Cause code.
SVGN-121 WARN Illegal disturbance threshold.

Cause: Over torque detection thresholds were not updated to invalid parameter.
Remedy: Check the pressure limit, force calibration, and event map. Update the pressure limit value, if it
is not correct. For example, the pressure limit (torque) must greater than the gun friction;
otherwise, this alarm will occur. After autotuning is complete, overtorque protection is provided
via the collision threshold. If this alarm is present, the collision threshold could not be set.
SVGN-122 STOP Pressure is not invertible.

Cause: The specified pressure cannot be used, it does not lie on the calibration curve (2nd order).
Remedy: Change the calibration method to the multi-linear segment method if possible. Do this by setting
the sysvars $sgsyscfg.$cal_model = 12 and $sgsyscfg.$frc2spd_cnv = 3, then perform the
pressure calibration again. Alternatively, perform pressure calibration again, or reduce max
pressure.
SVGN-123 WARN Gun ovrtrq protection disabled.

Cause: Overtorque protection has been disabled. This is merely a warning to notify the operator.
Remedy: Enable overtorque protection, if desired.
SVGN-124 WARN Max gun torque limit must be > floor.

Cause: The Max Gun Torque parameter in OverTorque Protection is less than the Standard OverTorque
Value. The Max Gun Torque is the torque required to achieve the Max Pressure of the gun
(according to the Pressure Calibration data). The Standard OverTorque Value is the lowest
torque (i.e. floor) where an abnormal torque condition can be accurately observed due to gun
friction.
Remedy: To eliminate this alarm either the Max Gun Torque must be increased or the Standard
OverTorque Value needs to be lower. If OverTorque Protection is still enabled, there may be no
action necessary. View the Parameter Summary in OverTorque Protection to judge whether
the values are acceptable. The Max Gun Torque can be increased by increasing the Max
Pressure on the Servo Gun General Setup Screen. If OverTorque Protection is presently
－146－
disabled, be sure to enable it after this. If the Pressure Calibration is not complete or the data is
old, perform the Pressure Calibration again.
SVGN-125 WARN Max gun torque limit must be < ceil.

Cause: The Max Gun Torque parameter in OverTorque Protection is set higher than the maximum
torque of the servo motor.
Remedy: Make sure Pressure Calibration of the gun is complete and the data is entered correctly. Perform
Pressure Calibration again if possible. Decrease The Max Gun Torque by decreasing the Max
Pressure of the gun via the Servogun General Setup Screen.
SVGN-126 STOP Servo parameters exceed max gun torque.

Cause: Overtorque protection is enabled, but one or more of the parameters responsible for limiting
torque exceed max gun torque.
Remedy: Disable, then re-enable overtorque protection, in order to re-write servo parameters.
Alternatively, disable overtorque protection OR enable machine lock on the servogun group to
disable this alarm.
SVGN-127 STOP DSP max gun torque update timeout.

Cause: Timeout, getting acknowlegement for new overtorque parameters.
Remedy: Cycle power or toggle overtorque protect enable to write parameters again.
SVGN-128 STOP Invalid thickness value specified.

Cause: A string parameter or a value less than 0.0 was passed into the THK_VAL macro.
Remedy: Re-enter a parameter value greater than or equal to 0.0 into the thickness value macro.
SVGN-129 STOP Invalid thickness tolerance specified.

Cause: A string parameter or a value less than 0.0 was specified for the THK_TOL macro.
Remedy: Re-enter a parameter value greater than or equal to 0.0 into the thickness value macro.
SVGN-130 STOP Invalid thickness severity specified.

Cause: A string parameter or a value other than 1 or 2 was specified for the THK_SEV (thickness
severity) macro.
Remedy: Re-enter a parameter value of 1 or 2 into the THK_SEV (thickness severity) macro.
SVGN-131 STOP Invalid gun index specified.

Cause: A string parameter or a value other than 1, 2, or 3 was specified for gun index in a THK_ macro.
Remedy: This parameter is optional but if it is specified, set it as follows: 1: Gun.A only 2:
Gun.B only (dual gun case) 3: Gun.A+B (dual gun case)
SVGN-133 STOP Encoder scale is NULL.

Cause: An encoder scale value of 0.0 was detected.
Remedy: Go to the nobot maintenance menu and re-enter the gear ratio.
SVGN-134 STOP Thickness Check Calibration Incomplete.

Cause: Thickness Check Calibration was never performed or did not complete successfully.
Remedy: Go to Gun Setup Utility screen (UTILITIES-GUN SETUP) and re-execute the Thickness Check
Calibration.
－147－
SVGN-135 STOP Thickness check cal err: bad torque

Cause: A deflection calibration point has a torque value that is not greater than 0.0, or is not in
ascending order.
Remedy: Go to the Gun Setup Utility Screen (UTILITIES-GUN SETUP) and re-execute the Thickness
Check Calibration.
SVGN-136 STOP Thickness check cal err: bad deflection

Cause: A deflection calibration point has a distance value that is not greater than 0.0, or is not in
ascending order.
Remedy: Go to the Gun Setup Utility Screen (UTILITIES-GUN SETUP) and re-execute Thickness
Check Calibration. If error still occurs, re-master and re-execute Thickness Check Calibration.
SVGN-137 STOP Invalid number of deflection cal pts.

Cause: The number of Thickness Check calibration points is less than 2 or greater than 4.
Remedy: Go to the system variable screen and enter a value of 2, 3, or 4 into
$sgthkset#.$num_cal_pts,where # = gun number.
SVGN-138 STOP Invalid tipwear ratio.

Cause: The tip wear ratio for one step wear measurement is invalid ( less than 0.0 OR greater than 1.0 ).
Remedy: "Set the wear ratio in the Tip Wear measurement macro program to a value between 0 and 1.The
macro program WR_UPDAT is used to perform the Tip Wear measurement with the 1-Step
Method. Set the wear-ratio which is found as a parameter in a CALL instruction to the program
TWKCALC2, or similar name. Follow the program comments to find the proper parameter to
adjust: CALL TWKCALC2(wear-ratio,AR[2])
SVGN-139 STOP Could not read tip stick detect input.

Cause: Tip stick detect input could not be read, due to an I/O error.
Remedy: Check the I/O mapping/configuration and I/O device status.
SVGN-140 STOP Uninitialized start distance number.

Cause: The specified start distance number is not valid.
Remedy: Specify a start distance number greater than or equal to 1 and less than or equal to
$sgsyscfg.$dst_elm..
SVGN-141 STOP Uninitialized end distance number.

Cause: The specified end distance number is not valid.
Remedy: Specify an end distance number >= 1 and <= $sgsyscfg.$dst_elm.
SVGN-142 STOP Illegal decel option.

Cause: The decel rate option setting is incompatible with the speed calibration specification.
$sgsyscfg.$change_spd indicates that the robot should decelerate by a % during move to the
pressure position. However, absolute speed calibration has been specified
($sgsyscfg.$cal_method = 2).
Remedy: Reset the bit corresponding to 0x8 in $sgsyscfg.$change_spd.
SVGN-143 STOP Min press speed > max press speed.

Cause: The Minimum speed ($sggun#.$setup.$prs_spd_min) cannot be larger than the maximum speed
($sggun#.$setup.$prs_spd_max).
Remedy: Re-perform force calibration to update $sggun#.$setup.$prs_spd_min automatically AND/OR
manually set $sggun#.$setup.$prs_spd_min, $sggun#.$setup.$prs_spd_max to valid values.
－148－
SVGN-144 STOP Min press speed < 1mm/sec.

Cause: The Minimum speed must be greater than 1mm/sec.
Remedy: Re-perform force calibration to update $sggun#.$setup.$prs_spd_min automatically AND/OR
manually set $sggun#.$setup.$prs_spd_min to a valid value.
SVGN-145 STOP Max press speed > joint velocity lim.

Cause: Maximum speed must be less than or equal to the joint velocity limit.
Remedy: Manually set $sggun#.$setup.$prs_spd_max to a valid value.
SVGN-146 STOP Joint velocity limit too low.

Cause: Joint velocity limit must be greater than zero, for mm/sec pressure calibration speed
specification.
Remedy: Go to nobot maintenance menu and set speed or manually set $param_group[].$jntvellim[] and
repower.
SVGN-147 WARN Sync/speed min distance =%s.

Cause: The minimum gun opening distance required to achieve the specified contact speed for this
Pressure Schedule is larger than the opening specified by the Start Distance schedule used in the
SPOT or Press_Motion instruction. The correct contact speed may not have been achieved
during execution of this instruction.
Remedy: Increase the Start Distances assigned to the Distance Schedule that is used when this alarm
occurs. Go to the Distance Schedule data table (DATA-DISTANCE) and increase the gun
and/or robot distances.
SVGN-148 WARN Invalid gun index specified.

Cause: Can't identify routine name corresponding to the standalone instruction. Refer to Cause code for
root Cause.
Remedy: See Remedy for Cause error.
SVGN-149 STOP CP enable is required.

Cause: CP mode is not enabled, but synchronize move to pressure position is enabled AND/OR linear
distance is enabled.
Remedy: Enable CP mode ($cpcfg.$cp_enable=TRUE) OR disable synchronize move to pressure
position ($sgsyscfg.$sync_mv2prs=FALSE) AND linear distance
($sgsyscfg.$lin_dst_enb=FALSE).
SVGN-150 STOP Synchronization enable is required.

Cause: Linear distance function is enabled, but synchronize move to pressure is not enabled.
Remedy: Enable synchronize move to pressure position($sgsyscfg.$sync_mv2prs=FALSE) OR disable
linear distance ($sgsyscfg.$lin_dst_enb=FALSE).
SVGN-151 WARN Cannot add file to backup/restore list.

Cause: The Servogun sysvar file(s) could not be added to the backup/restore list.
Remedy: Document the events that led to the error and call your FANUC Robotics technical
representative.
SVGN-160 STOP Invalid calibration point: bad torque.

Cause: A pressure calibration point has a torque value that is not greater than 0.0, or is not in ascending
order.
Remedy: Perform Pressure Calibration again. Make sure that both torque and pressure increase, at each
successive calibration point.
－149－
SVGN-161 STOP Invalid calibration point: bad speed.

Cause: A Speed value in the Pressure Calibration table is less than min speed or greater than max
speed.
Remedy: Perform Pressure Calibration again. Make sure that the Speed for each point in the Pressure
Calibration table is within the operating range of the gun.
SVGN-162 STOP Invalid calibration point: bad pressure.

Cause: A pressure calibration point has a pressure (force) value that is not greater than 0.0, or is not in
ascending order.
Remedy: Perform Pressure Calibration again. Make sure that both torque and pressure increase, at each
successive calibration point.
SVGN-163 STOP Invalid calibration model setting.

Cause: The calibration model setting ($sgsyscfg.$cal_model) is not supported. The following settings
are supported:
3: Single linear segment pressure and speed model
12: Multiple linear segment pressure and speed model piece-wise pressure calibration.
Remedy: Change setting to one of the settings above, and reperform calibration if necessary.
SVGN-164 STOP Invalid force/speed convert setting.

Cause: "Pressure to speed conversion specification ($sgsyscfg.$frc2spd_cnv) is not supported. The
following setting combinations are supported:
$sgsyscfg.$cal_model = 3 and $sgsyscfg.$frc2spd_cnv = 0: Single linear segment, JNT%.
$sgsyscfg.$cal_model = 3 and $sgsyscfg.$frc2spd_cnv = 3, Single linear segment, mm/sec
converted at spot.
$sgsyscfg.$cal_model = 12 and $sgsyscfg.$frc2spd_cnv = 3, Multiple linear segments, mm/sec
converted at spot.
Remedy: Change setting to one of the settings above, and reperform calibration if necessary.
SVGN-165 WARN Gun opened < equalizer trigger distance.

Cause: The open distance condition for equalization pressure trigger, was not met before start of motion
to pressure position, for the next spot. The equalization trigger state for the next spot may have
been delayed, in this case.
Remedy: Increase the end and/or start distance value on the distance schedule screen, or decrease the
open distance for the after equalization pressure trigger.
SVGN-166 STOP Invalid equalizer trigger type.

Cause: The specified equalization pressure trigger type is not supported. The following settings are
supported: $spoteqsetup[].$epb4_trgtyp = 1(time), 2(event) AND $spoteqsetup[].$epaf_trgtyp
= 1(time), 3(distance).
Remedy: Select a valid trigger, on the spot equipment setup screen.
SVGN-167 STOP Invalid equalizer trigger event.

Cause: The specified equalization pressure trigger event is undefined.
Remedy: Go to the spot equipment setup screen, and select a valid trigger event.
－150－
SVGN-168 WARN Push depth %s[mm] exceeds strokelimit

Cause: The pushing depth specified in the pressure schedule or the minimum pushing depth, exceed the
strokelimit. Contact speed may be slightly lower than specified as a result of this alarm.
Remedy: Update one or more of the parameters used to specify pushing depth: $sgsch#[].$push_depth
and $sggun.$setup.$push_margin. If these parameters cannot be reduced, then increase the
strokelimit, if possible. Please note that this is only a warning.
SVGN-201 PAUSE.L Gun index 1

Cause: The posted error occurred on gun index 1 of the dual gun.
Remedy: Correct the error on the gun number corresponding to gun index 1.
SVGN-202 PAUSE.L Gun index 2

Cause: The posted error occurred on gun index 2 of the dual gun.
Remedy: Correct the error on the gun number corresponding to gun index 2.
SVGN-203 PAUSE.L GunA, GunB contact speed is different

Cause: The contact speed used in this Pressure Schedule is different for Gun A and Gun B -but contact
speed must match to achieve syncronized contact with the part.
Remedy: Set the contact speed of the Pressure Schedule to the same value for both guns. This is done by
must be the same for both guns. It is recommended to use matching Pressure and Speed values
for each calibration point for both guns. Then, find the unique torque% required to achieve the
pressure for each gun. OR, just set the contact speed for all points in the Pressure Calibration
table for both guns to the same value.
SVGN-204 PAUSE.L GunA, GunB pushing depth is different

Cause: Pushing depth is different for GunA and GunB. Equal pushing depth is required, for
synchronized move to pressure position.
Remedy: Set $sgsch#[].$pushing depth, and $sggun#.$setup.$push_margin to same value, for both guns.
SVGN-205 PAUSE.L GunA, GunB creep distance is different

Cause: The Creep distances are different for GunA and GunB. Equal creep distance is required to
achieve syncronized contact with the part.
Remedy: Set the system variable $sggun#.$setup.$creep_dst to same value, for both guns on this
dual-gun (# represents the gun number).
SVGN-206 PAUSE.L GunA, GunB part thickness is different

Cause: Creep distance is different for GunA and GunB. Equal thickness is required, for synchronized
move to pressure position.
Remedy: Set thickness to same value, for both guns.
SVGN-207 PAUSE.L GunA, GunB sag settings are different

Cause: Gun sag values are different for GunA and GunB. Gun Sag value must be equal, for
synchronized move to pressure.
Remedy: Set gun sag compensation values the same.
SVGN-208 PAUSE.L GunA, GunB linear distance is different

Cause: Linear distance values are different
Remedy: Specify same linear distance value for GunA and GunB.
－151－
SVGN-209 PAUSE.L GunA, GunB joint velocity limits differ.

Cause: Joint velocity limits are different for gunA and gunB. Joint velocity limit must be equal to
Remedy: Use the Gun Setup Utility to set the Maximum Speed (i.e. joint velocity limit) of both Gun
A&B to the same value.
- Go to UTILITIES - GUN SETUP
- Press the F6 key, DG_CHECK
- Press the F4 key, SETSPD and reply YES to the prompt to set the speed to same value
- Cycle Power to activate the change
SVGN-210 PAUSE.L GunA, GunB accel times differ

Cause: Acceleration Times are different for gunA and gunB. The acceleration times must be equal to
Remedy: Use the Gun Setup Utility to set the Acceleration Times of both Gun A&B to the same value.
- Go to UTILITIES - GUN SETUP
- Press the F6 key, DG_CHECK
- Press the F5 key, SETACC and reply YES to the prompt to set the accel time to same value
- Cycle Power to activate the change
－152－
APPENDIX
B-82634EN/01 A.GUN CHANGE REFERENCE POSITION SETUP METHOD (BATTERY-LESS TYPE)
A GUN CHANGE REFERENCE POSITION

SETUP METHOD (BATTERY-LESS TYPE)
- 155 -
A.GUN CHANGE REFERENCE POSITION SETUP METHOD (BATTERY-LESS TYPE) B-82634EN/01
A.1 REFERENCE POSITION SETUP OF EACH POSITION TYPE
A.1.1 REFERENCE POSITION SETUP FOR CALIBRATION TYPES 3

AND 4
♦Reference Position Setup Program
Create the following program to calculate the reference position based
upon the sign of the calculated touch torque.
NOTE
Only the servo gun axis operation group can be used
as the operation group of the program to be used for
setting the reference position.
Example) When the servo gun axis operation group is
the 2nd group:
The operation group becomes [*,1,*,*,*].
Sample Program Operation Group=[*,1,*,*,*]

1: J P[1:ZERO POS] 10% [Explanation]
positioning 1: Servo gun axis 0 position
(when sign of touch torque is 2: Set the torque at which contact with
plus) the gun open limit is detected and its
2: SKIP CONDITION threshold as the skip conditions. Pay
$MISC[g].$HPD_TRQ[ga] > 2 *1) attention to the sign of the touch
(when sign of touch torque is torque.
minus)
2: SKIP CONDITION
$MISC[g].$HPD_TRQ[ga] <-2 *1) 3: Move gun to open limit. (Jump to
3: J P[2:GUN OPEN END] 1% *2) LBL[1] if gun open limit cannot be
FINE ACC 100 *3)SKIP, detected.)
LBL[1],PR[1]=JPOS 4: Normal end
4: END 5: Jump to here if gun open limit cannot
5: LBL[1] be detected.
6: UALM[1] 6: Generate user alarm.
NOTE
programs to suit the requirements of your system.
g: Operation group number of currently attached gun
ga: Axis number of currently attached gun
If the currently attached servo gun axis is taken as the
1st axis of the 2nd group, then g and ga are as
follows: g=2, ga=1
x Program Operation Adjustment Method

Adjust the value at the shaded section in the sample program to
adjust program operation.
Operation adjusted here is used as calibration motion that is
carried out when attaching the gun.
- 156 -
*1) Touch torque

Increase the value from about ±2, and calculate the value at
1 Comment [ ] which erroneous detection of contact occurs.
2 Attach signal: DI[ 1] The sign of touch torque is the sign that is currently displayed
3 Identify signal DI[ 2] at Touch torque at the Calibration Setup screen on the right.
4 Battery: OFF
5 Calibration motion type: [TYPE 3]
Calibration Motion Setup NOTE
6 Calibration Speed(%) 100
7 Acc Value: ACC100
After confirming the sign in this screen, teach it to the
8 Position register index PR[ 1] program. Do not make a mistake when entering the
9 Touch torque(%): ( + ) 5.000 sign. If you do so, contact with the open limit may not
[ TYPE ] LIST be detected.
*2) Program operation speed

To set the same calibration motion that is carried out when
attaching the gun, execute this program at the same override
(normally, 100%) as when the attach instruction is executed
for the gun used during actual production. For this reason,
reduce the program operation speed so that contact is made
with the open limit at a safe speed even if the program is
executed at a high override.
For added safety, increase the program operation speed value
successively from 1%.
*3) Accelerate rate
Decrease the accelerate rate if motion is sluggish even if the
program operation speed is 1%.
♦Reference Position Setup
After you have adjusted operation in the program, execute the
program to bring the servo gun axis into contact with the open limit.
Set up the reference position according to the procedure described in
Appendix A.2 Quick Mastering Reference Position Setup with the
servo gun contacting the open limit.
♦Gun Change Setup
To set operation in the newly adjusted program to the same motion
as calibration motion that is carried out when attaching the gun,
reflect the program operation speed, accelerate rate and touch torque
adjustment values in the gun change setup.
1. Press the SELECT SCREEN key to display the Screen menu.
2. Select 6 SETUP.
4. Select GUN CHANGE. The Gun Change Setup List screen
appears.
5. Select the gun to be adjusted from this list, and press F3
DETAIL to display the Gun Change Details Setup screen.
6. Set the operation speed, accelerate rate and touch torque
adjustment values at the shaded sections in the following
screen:
- 157 -

1 Comment [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
6 Calibration Speed(%) 1
7 Acc Value: ACC100
8 Position register index PR[ 1]
9 Touch torque(%): ( + ) 2.000
[ TYPE ] LIST
A.1.2 Reference Position Setup for Calibration Types 5 and 6
♦Provision of Detection Signal

With calibration types 5 and 6, the position where the detection
signal is input is taken as the reference position during quick
mastering.
The user must install a limit switch for providing the detection signal
capable of assuring the absolute position of the gun.
♦Reference Position Setup Program
Create the following program to calculate the reference position
based upon the sign of the calculated touch torque.
NOTE
Only the servo gun axis operation group can be used
as the operation group of the program to be used for
setting the reference position.
Example) When the servo gun axis operation group is
the 2nd group: The operation group becomes
[*,1,*,*,*].
Sample Program Operation Group=[*,1,*,*,*]

[Explanation]
1:J P[1:ZERO POS] 10% 1: Servo gun axis 0 position
FINE 2: Set turning ON of the provided detection
2:SKIP CONDITION DI[ 1*1)] signal as the scan condition.
=ON 3: Move gun to position where detection signal
3:J P[2:SWITCH POS] 1% *2) turns ON. (Jump to label[1] if the detection
FINE ACC100 *3)SKIP, signal does not turn ON.)
LBL[1],PR[1]=JPOS 4: Normal end
4:END 5: Jump to here if detection signal does not
5:LBL[1] turn ON.
6:UALM[1] 6: Generate user alarm
NOTE
programs to suit the requirements of your system.
x Program Operation Adjustment Method
- 158 -
Adjust the value at the shaded section in the sample program to

adjust program operation.
Operation adjusted here is used as calibration motion that is
carried out when attaching the gun.
*1) Detection Signal
Assign the provided detection signal to SDI[ ] or RDI[ ].
*2) Program Operation Speed
To set the same calibration motion that is carried out when
attaching the gun, execute this program at the same override
(normally, 100%) as when the attach instruction is executed
for the gun used during actual production. For this reason,
reduce the program operation speed so that the switch will
not be broken even if the program is executed at a high
override.
For added safety, increase the program operation speed value
successively from 1%.
*3) Accelerate rate
Decrease the accelerate rate if motion is sluggish even if the
program operation speed is 1%.
♦Reference Position Setup
After you have adjusted operation in the program, execute the
program to stop the servo gun axis at the position where the detection
signal turns ON.
Set up the reference position according to the procedure described in
Appendix A.2 Quick Mastering Reference Position Setup with the
servo gun contacting the open limit.
♦Gun Change Setup
To set operation in the newly adjusted program to the same motion as
calibration motion that is carried out when attaching the gun, reflect
the program operation speed, accelerate rate and detection signal
adjustment values in the gun change setup.
1. Press the SELECT SCREEN key to display the Screen menu.
2. Select 6 SETUP.
4. Select GUN CHANGE. The Gun Change Setup List screen
appears.
5. Select the gun to be adjusted from this list, and press F3
DETAIL to display the Gun Change Details Setup screen.
6. Set the operation speed, accelerate rate and detection signal
adjustment values at the shaded sections in the following
screen:
- 159 -

1 Comment: [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
6 Calibration Speed(%): 1
7 Acc Value: ACC100
8 Position register index: PR[ 1]
9 Detect signal: DI[ 0]
[ TYPE ] LIST
A.2 QUICK MASTERING REFERENCE POSITION
Calibration (quick mastering data) is automatically carried out when the

servo gun is changed. However, the reference points must be set to each
of the guns to enable automatic calibration. The reference points are set
with the robot in a cold start state.
Be sure to set the group of Follow the procedure below to set the reference points:
Servo gun axis
1. Press the AUX key to select 3 CHANGE GROUP. Change the

SYSTEM Master Cal G2 JOINT 10 %
operation group to the desired servo gun group (e.g. 2nd group).
TORQUE = [ON ] 2. Press the SELECT SCREEN key to display the Screen menu.
1 FIXTURE POITION MASTER 3. Press 0 NEXT and 6 SYSTEM.
2 ZERO POSITION MASTER 4. Press F1 TYPE to display the Screen Selection menu.
3 QUICK MASTER
4 SINGLE AXIS MASTER 5. If CALIBRATE is not displayed in the menu, select Variables to
5 SET QUICK MASTER REF display the System Variables screen. Set the $MASTER_ENB
6 CALIBRATE system variable to "1".
Press 'ENTER' or number key to select.
6. Select CALIBRATE at 4. to display the Calibration screen.
7. Select 5 SET QUICK MASTER REFERENCE and F4 YES.
[ TYPE ] LOAD RES_PCA DONE 8. The message "Quick master reference point is set." is displayed.
This indicates that setting of the reference point is completed.
- 160 -
B-82634EN/01 B.TROUBLESHOOTING (GUN CHANGE)
B TROUBLESHOOTING (GUN CHANGE)
- 161 -
B.TROUBLESHOOTING (GUN CHANGE) B-82634EN/01
B.1 The attach instruction is executed when the gun is not

attached.
xPhenomenon
The gun is not actually attached. So, a communications alarm such as
"SRVO-068 DTERR alarm" occurs on the pulse coder. Correct this by
Remedy 1 or Remedy 2 below according to the present conditions.
xRemedy 1
1. Turn the machine lock ON in the servo gun operation group
(normally, group 2) in the Test Cycle screen.
2. Move the robot by manual feed so that the robot and gun are
physically attached.
3. Turn the controller OFF then ON again.
Battery-less gun (calibration motion types 1, 2)

4. The gun pulse values and mastering data are lost. So, first move
the gun by manual feed to cancel the "SRVO-075 Pulse not
established" alarm.
5. Then, carry out gun 0 position mastering and calibration manually.
Battery-less gun (calibration motion types 3, 4, 5, 6)

6. The gun pulse values and mastering data are lost. So, move the gun
by manual feed to cancel the "SRVO-075 Pulse not established"
alarm.
7. Carry out gun 0 position mastering and calibration manually. The
gun 0 position may be an approximate position.
8. Execute the detach instruction to temporarily detach the gun. Also,
physically detach the gun from the robot. Otherwise, the gun will
not be calibrated at the next attach operation.
9. Execute the attach instruction again to attach the gun. Calibration
this time is carried out at the reference position to restore the
position.
Battery mounted gun

10. The gun is attached and positioned, so it can be used as it is.
xRemedy 2
1. Directly change the system variable to detach the gun. To do this,
set the following system variable to "0":
$SCR_GRP[servo gun operation group No. (normally,
2)].$AXISORDER[all 1 to 9] = 0
2. Turn the controller power OFF then back ON.
3. The robot starts up with the gun in a detached state. Move the
robot by manual feed to physically attach the robot and gun.
4. Execute the attach instruction to attach the gun.
5. The gun can be used as it is after it is attached regardless of the
battery type.
- 162 -
B.2 THE ROBOT STOPPED DURING CALIBRATION
xPhenomenon
This phenomenon occurs only on battery-less guns. Note that the
phenomenon and remedy vary according to the preset calibration type.
Battery-less gun (calibration motion types 1, 2)

The "SVGN-081 Gun mastering data is lost" alarm has occurred.
Battery-less gun (calibration motion types 3, 4, 5, 6)

Alarm has not occurred.
･Remedy
Calibration motion types 1, 2
1. The gun pulse values and mastering data are lost. So, first move
the gun by manual feed to cancel the "SRVO-075 Pulse not
established" alarm.
This alarm may not be occurring. If so, skip this step and proceed
to step 2.
2. Then, carry out gun 0 position mastering and calibration manually.
Calibration motion types 3, 4, 5, 6

1. Gun operation can be resumed as it is.
- 163 -
B.3 CALIBRATION MOTION FAILED
xPhenomenon
The "SVGN-089 Calibrate motion is failed" alarm occurred.
This phenomenon occurs only when the calibration motion type is 3, 4,
5 or 6 on a battery-less gun.
This alarm occurs when the touch torque or detection signal conditions
are not satisfied during calibration.
In both of the following Remedies 1 and 2, the gun is calibrated again.
So, calibration motion will fail again if the touch torque or detection
signal conditions are not satisfied. Before you remedy this phenomenon,
make sure that the touch torque or detection signal conditions are
correct.
xRemedy 1
Carry out steps 6 to 9 of G-1 Remedy 1.
xRemedy 2
Same as Remedy 2 of G-1.
- 164 -
B.4 A DIFFERENT GUN FROM THAT SPECIFIED BY THE

ATTACH INSTRUCTION IS ATTACHED.
xPhenomenon
The gun is attached to the robot, but the gun's current position is the
wrong value. On a battery-less gun, an alarm may cause the robot to
stop during calibration.
xRemedy
The following describes an example where gun 2 (actually attached
gun) is attached to gun 1 (gun No. taught by the attach instruction).
1. In this state, the gun cannot be detached from the robot by the
detach instruction. So, directly change the system variable to
detach the gun. To do this, set the following system variable to
"0":
$SCR_GRP[servo gun operation group No. (normally,

2)].$AXISORDER[all 1 to 9] = 0
2. Turn the controller power OFF then back ON.

3. The gun starts up in a detached state.
4. Execute the attach gun[2] instruction to attach gun 2. (In this state,
gun 2 should be physically connected to the robot.)
When gun 2 is a battery-less gun and the calibration motion type is

1 or 2:
If gun 2 is moved when attached by mistake instead of gun 1, gun
2 will move and be at a position different to when it was detached.
So, gun 2 may be calibrated to the wrong position by the attach
instruction executed in step 4 above, resulting is misalignment
between its actual and desired positions. In this case, carry out gun
0 position mastering and calibration manually.
When gun 2 is other than the above:

Gun 2 can be used as it is.
5. Gun 1 can be used as it is by executing the attach instruction to

attach the gun.
- 165 -
B.5 THE ATTACHED GUN HAS BEEN DETACHED BY

MISTAKE (WITHOUT USING THE DETACH
INSTRUCTION).
xPhenomenon
The gun is not actually attached. So, a communications alarm such as
"SRVO-068 DTERR alarm" occurs on the pulse coder. Correct this by
Remedy 1 or Remedy 2 below according to the present conditions.
xRemedy 1
Same as Remedy 1 of B-1
xRemedy 2
Same as Remedy 2 of B-1
B.6 THE GUN AXIS OF A DETACHED GUN HAS MOVED.
xPhenomenon
Battery-less gun (calibration motion types 1, 2):
Misalignment has occurred. Misalignment occurs as a result of
calibration at the wrong position when the gun is attached with the gun
axis having moved to a different position. Note, however, that
misalignment does not occur when gun axis movement is within the
allowable errors indicated below.
The allowable error must fall within the respective following ranges for
the direct-acting axis and rotary axis:
Direct-acting axis: ±(gear ratio/2)mm or less around the detach

position
Rotary axis: ±((360/gear ratio)/2)deg or less around the detach position
Other instances:
No problem has occurred.
xRemedy
Battery-less gun (calibration motion types 1, 2):
1. Execute the attach instruction to attach the gun.
2. If misalignment occurs, carry out gun 0 position mastering and
calibration manually.
B.7 THE BATTERY VOLTAGE HAS FALLEN.
xPhenomenon
The "SRVO-065 BLAL" alarm has occurred with the gun in an attached
state.
xRemedy
1. Change the battery with the gun attached.
2. The gun can be used as it is.
- 166 -
B.8 THE BATTERY RAN LOW WHILE THE GUN WAS

DETACHED.
xPhenomenon
The "SRVO-062 BZAL" and "SRVO-075 Pulse not established" alarms
occurred when the gun was attached.
xRemedy
When the reference position has not been set:
1. Press F3:RESET_PULSE in the Calibration screen, and select
YES.
3. Move the gun by manual feed to cancel the "SRVO-075 Pulse not
established" alarm.
4. Carry out gun 0 position mastering and calibration manually.
When the reference position has been set:

1. Press F3:RESET_PULSE in the Calibration screen, and select
YES.
3. Move the gun by manual feed to cancel the "SRVO-075 Pulse not
established" alarm.
4. Move the gun by manual feed to the reference position marked by
a line marking or alignment mark.
5. Execute 3 QUICK MASTERING in the Calibration screen.
Carry out simple mastering at the reference

position marked by a line marking or alignment
mark.
*1) Touch torque

ncrease the value from about ±2, and calculate the value at which
erroneous detection of contact occurs.
The sign of touch torque is the sign that is currently displayed at
Touch torque at the Calibration Setup screen on the right.
NOTE
After confirming the sign in this screen, teach it to the
program. Do not make a mistake when entering the
sign. If you do so, contact with the open limit may not
be detected.
- 167 -
C.GUN ZERO MASTERING B-82634EN/01
C GUN ZERO MASTERING
- 168 -
B-82634EN/01 C.GUN ZERO MASTERING
C.1 GUN MASTER UTILITY
You can use the Gun Master screen to reset BZAL (Battery Zero
Alarm), perform the Magnet Phase
Detection function, and perform mastering of the gun axes.
The following lists and describes the items on the GUN MASTER
screen.
Function Key Description

EQUIP ress this key to change the equipment number. If you have multiple equipment, it
will also set the correct group for the selected equipment.
BZAL Press this key to reset a Battery Zero Alarm (BZAL) for the servo gun axis after loss of
battery power. This key does not appear if the alarm is not present
EXEC Press this key to zero position master the selected servo gun. Be sure that new tips
are on the gun and that the gun tips touch. Important: The tip wear values are rest to
0.0, when mastering executes. Touchup is only necessary if tw_setup is run. Execute
master does not clear out the reference data relating to the fixed tip.
However, execute master does clear out zero reference, so there can be some error
in the gun tip wear and stroke limit error if tw_setup is not run.
MPDT Press this key to execute the Magnet Phase Detection function if the message
“Execute MPDT(Magnetic Phase Detection)” is displayed. If displayed, the gun
cannot be jogged until the function is performed. The gun will move slightly during
execution so be sure gun tips are free to move. Note: this key is only displayed if a
non-8 pole motor ( i.e. 4 pole or 6 pole ) motor is selected.
DGIDX You must press NEXT to see this function key. Press this key to select the correct gun
for mastering when using a dual-gun. Pressing this key will switch between the 1st
and 2nd gun of the dual-gun. The correct gun must be selected before performing the
mastering operation, otherwise the wrong gun will be mastered.
RECALIB You must press NEXT to see this function key. Press this key to re-calibrate the
master position of the servo gun axis. This key will master the selected servo gun
and maintain the existing tip wear amounts. Be sure that tips have not been changed
since the last tip wear measurement was done and be sure the tips touch before
pressing this key.
GUN MASTER _
SERVO GUN Zero position master 1/1
Equip number: 1 (Group: 2)

AXS MASTER
1 Gun 1 (J1, INCOMP) 0 MASTER
Change to new tips for gun master.

[ TYPE ] EQUIP BZAL EXEC MPDT
NOTE
If the tip holder or gun arm is changed, you must change the stroke
limit in the Stroke limit
setup screen before you execute Zero position mastering.
- 169 -
C.2 Reset Alarm

Procedure C-1 Resetting BZAL (Battery Zero) and “Pulse Not Established” Alarms
1 Connect pulsecoder cable and Power Up controller.
2 Display Gun Master screen.
[MENUS] key -> SYSTEM -> F1[TYPE] -> Gun Master
3 Press F3 “BZAL”. The system displays the following message.
“Reset BZAL alarm.”
“Please power OFF/ON.”
4 Turn OFF/ON the power of the robot controller.
5 SRVO-075 Pulse not established will be displayed.
6 Establish the Pulse
a For 8-pole motors (all FANUC motors) jog motor more than
1 revolution using jog keys,then press the RESET key to
reset this alarm
b For less than 8-pole motors, Execute the MPDT routine (see
procedure below)
- 170 -
C.3 Magnet Phase Detection (MPDT)

Procedure C-2 Establishing Pulse for Less than 8-pole Motor Using the Magnet Phase
Detection(MPDT) Feature
The MPDT softkey (F5) is displayed on the Gun Master screen when
MPDT is required. The message
“Execute MPDT(Magnetic Phase Detection)” will be displayed. MPDT
is required when the servo
motor connected to the servo gun axis, has fewer that 8 magnetic poles,
and the home position of
the magnets has not yet been located.
NOTE
A motor that requires MPDT cannot be jogged prior to
completing this procedure.
Before executing MPDT, be sure the tips are not fully closed or fully
opened. During MPDT, the
tips may move slightly so, be sure that the tips are free to move a few
mm in either direction before
starting MPDT.

[MENUS] key -> 0 NEXT PAGE -> 6 SYSTEM -> F1[TYPE] ->
Gun Master
2 Press the MPDT softkey. The system displays the following
messages.
“Execute MPDT. Are you ready? “
“ YES NO “
3 With the system in teach, press the deadman switch, reset faults
and press F4 “YES.”
4 Magnet Phase Detection will commence. If MPDT completed
successfully, the followingmessage is displayed
“Completed MPDT.”
5 If MPDT failed, the following message is displayed
“Failed MPDT.”
“Execute MPDT(Magnetic Phase Detection).”
If MPDT failed, the motor will need to be manually turned to
establish the magnet phase. Todo this, locate the manual override
key/gear on the servogun actuator (if included) to drive thetips
open/closed at least (1) full motor revolution. This must be done
until the “CompletedMPDT” message is posted.
6 The servogun can now be jogged using the jog keys.
- 171 -
C.4 MASTERING
Procedure C-3 Executing Zero Position Mastering

Two (2) methods are available to master the gun.
• Standard Master - Press EXEC; tip wear amounts will be set to zero
• Re-Calibration Master - Press RECALIB; tip wear amounts will not
be changed
1. Decide whether to change to new tips according to the information

below:
Standard Master is performed when the F4 key, EXEC is
pressed. This operation will set thetip wear amount to zero for both
tips. Therefore, new tips must be placed on the gun
beforeperforming this operation.
Re-Calibration Master is performed when the F9 key,
RECALIB is pressed. This operation isused to master a gun with
worn tips. Only use this operation when the tip wear amounts
arecorrect, since they will not be changed. Therefore, do not place
new tips on the gun whenperforming this operation.
2 Jog the gun axes until both tips touch each other.
[MENUS] -> 0 NEXT PAGE -> 6 SYSTEM -> F1[TYPE]
-> Gun Master
GUN MASTER _

AXS MASTER
1 Gun 1 (J1, INCOMP) 0 MASTER
Change to new tips for gun master.

4 You can use F2 ”EQUIP” to select the equipment number when

multiple equipment exists.
GUN MASTER _

Equipment E2 is assigned
to Air Gun.
Press F2’EQUIP’
to select Servo Gun equipment.
- 172 -
5 Execute the gun axis mastering by pressing EXEC (F4) or

RECALIB (F9). Make the choiceaccording to the descriptions
above.
a If this is the initial master attempt for the gun with new tips
Press F4 “EXEC”.
b If this is a re-master operation and the tips are worn and have
a measured wear value from Tip Wear Compensation, press
NEXT then press “RECALIB”.
6 If you press F4 “YES” now, the system will master the gun axis
and either reset the tip wearvalues to 0.0 for EXEC or maintain the
existing wear data for RECALIB
- 173 -
D.SETTING GUN STROKE LIMITS B-82634EN/01
D SETTING GUN STROKE LIMITS
The axis limits for the servo gun, are referenced from the master
position. The master position is set where the tips touch. The Gun
stroke limit screen allows the user to directly specify the maximum
allowable stroke in each direction OPEN and CLOSE from the master
position. The stroke limits may have been set correctly during the axis
configuration as Controlled start. However, it is good to confirm the
proper setting before starting the autotuning program.
Open Stroke
Master Limit (mm)
Position Close Stroke
Limit (mm)
The Open Stroke Limit (mm) is the maximum open distance for the
gun. This may be directly specified by the gun manufacturer, or it may
need to be measured.
The Close Stroke Limit (mm) is the maximum gun tip extension
allowed past where the tips touch. This must be enough to allow for tip
wear and bending of the gun arms during pressurization. But, it cannot
be larger than the physical stroke limit of the gun’s moving mechanism.
Consult with the gun manufacturer to determine the appropriate setting
for the Close Stroke Limit. Typical range for the value is 15-30mm.
If you would rather set the OPEN stroke limit by directly recording the
position, use the Gun Setup Utility discussed earlier. This is
recommended for most users.
PROCEDURE
1. Go to the Servo Gun General Operations Setup screen
2. Scroll to the Gun Stroke Limit item and press ENTER. You will
see a screen similar to the following.
3. Adjust the Open and Close stoke limit as needed.
- 174 -
B-82634EN/01 D.SETTING GUN STROKE LIMITS
SETUP Servogun _
STROKE LIMIT 1/2
Gun 1 ( J1 )
1 Open stroke limit(mm): 115.0

2 Close stroke limit(mm): 20.0
NOTE
Both OPEN and CLOSE stroke limit should be
entered as positive values. The magnitude of stroke
distance from the master position is the required
value.
- 175 -
E.AUTOTUNE MACRO PROGRAM B-82634EN/01
E AUTOTUNE MACRO PROGRAM

Autotuning via the macro program AUTOTUNE, executes the same
gun exercises that are performed when autotuning is started with the
EXEC key from the Gun Setup Utility.
CAUTION
The Servo gun axis moves at max speed, during
autotuning.Autotuning can be performed with the
teach pendant enabled or disabled.
Please make sure that no personnel are in the vicinity
of the gun, whenyou execute autotuning.
Autotune macro program

Program name: AUTOTUNE (There is in the macro list)
The user has to set up the following prior to running the AUTOTUNE
macro program.
- Tip displacement ratio
- Mastering
- Stroke limit
- Gun closing direction & motion sign
- Max gun pressure
Furthermore, the user may need to set parameters in the program call to
AT_KLTUN to ensure that the proper exercises are initiated.
1. Press the Select key

2. Press the F1 key <TYPE>
3. Select MACRO
4. You should now see the list of macro programs. Scroll to the
program AUTOTUNE and press ENTER to select it.
5. You should see a screen similar to the following:
- 176 -
B-82634EN/01 E.AUTOTUNE MACRO PROGRAM
AUTOTUNE LINE 0 G2 JOINT 50%

AUTOTUNE
1/18
1: !Autotuning Main Program
2:
3: !Input parameters for autotuning
4: !P1: Equipment number(1 to 5)
5: !P2: Dual gun index(1 or 2)
6: !P3: Enable debug msg(0 or 1)
7: !P4: Reload parameters(0 or 1)
8: !P5: Starting load ratio(1 to 5)
9: !P6: Pushing depth(1 to strklim)
10: !P7: Acc estimation method
11: !(1: determine automatically)
12: !(2: use specified values)
13: !(3: use previous values)
14: !P8: Accel time1(100 to 384)
15: !P9: Min acc shm(100 to 384)
16: !P10: Initial Filter (Hz)
17: CALL AT_KLTUN
[End]
6. If default settings are not sufficient, enter custom parameters in the

program line
17: CALL AT_KLTUN(P1,P2,P3…,P10)
Descriptions and Default setting for the parameters are as

follows:
P1 – Equipment Number
Default = 1
P2 – Dual Gun Index: defines if gun 1or 2 in the case of a
dual gun is to be tuned
Default = 1
P3 – Enable Debug messages
Default = 0 (false)
P4 – Reload default servo parameters
Default = 0 (false)
P5 – Starting load ratio
Default = 1
P6 – Pushing Depth (mm)
Default = 5
P7 – Acceleration estimation method
Default = 1 (determine automatically)
P8 – Accel Time 1 (ms)
Default = 100
P9 - Min acc shm
Default = 100
P10 – Initial Filter Frequency (Hz)
Default = 30
- 177 -
E.AUTOTUNE MACRO PROGRAM B-82634EN/01
7. Place the control reliable switch to T2 mode hold down the Shift
key and Press FWD. The shift key must be held down until the
autotuning program is completed. If the shift key is released, the
program will have to be restarted.
If autotuning did NOT complete successfully (indicated by status
NOTE
After Autotuning is started, the servo gun will perform the following by opening and
closing the gun:
- Acceleration settings
- Inertia measurements
- Friction measurements
- Spring constant measurements
- Force control gain settings
NOTE
If acceleration times were changed during autotuning, then an SVGN-050 “Autuning:
Re-power required” is posted. Repower the controller makes the new acceleration
effective, and clears the SVGN-50 message.
FAILED instead of COMP), then try the following:

• Make sure axis limits are set properly.
• Check motor selection.
• Re-perform autotuning until it completes successfully.
- 178 -
B-82634EN/01 F.PRESS ON NEW TIPS
F PRESS ON NEW TIPS

After changing to new tips, it is good practice to be sure the tips are
fully pressed on the tip holder before returning to welding or updating
the tip wear amount. The macro program TW_PRSRT can perform this
function automatically. This macro and the TW_PRS01 template
program are loaded with the load-option by setting
$sgsyscfg.$load_twd=12 .
The program will squeeze the tips together several times, so the tips are
pressed fully onto the tip holder.
The user must specify (8) parameters for TW_PRS01 to define how the
routine executes. Below is a description of each parameter and a few
examples of the pressing operation with different parameters. This
macro or template program can be run anytime, but is best to run after
changing tips and before getting an updated tip wear measurement.
TW_PRS01
1: !PROGRAM NAME: TW_PRSRT;
2: !Program function: ;
3: ! Compress caps after tip change ;
:
8: !Parameters supplied to TW_PRESS ;
9: !1: Equipment number ;
10: !2: Force end value (Kgf) ;
11: !3: Number of steps ;
12: !4: Number of repititions ;
13: !5: Dwell time (ms) ;
14: !6: Register number R[#] ;
15: !7: PrePress margin ;
16: !8: Max growth ;
17: CALL TW_PRSRT(1,500,2,4,1,10,5,15) ;
Parameter 1 – Equipment Default = 1 Create a CALL instruction for each equipment if there are multiple ones.
Number
Parameter 2 – Force End Default = 500 The maximum force that will be applied during the tip pressing operation.
Value (kgf) If the value specified here exceeds the max pressure for the gun, the
software will limit the pressure to the Max Pressure, automatically.
Parameter 3 – Number of Default = 2 Specifies how many sets of squeezing repetitions will be performed.
Steps The force during step n, will be equal to:
(Parameter 2) * [n/(Parameter 3)]
Parameter 4 – Number of Default = 4 The number of repetitions performed during each step. The total
Repetitions number of squeezing repetitions is equal to:
(Parameter 3) * (Parameter 4)
Parmeter 5 – Dwell Time Default = 1 Squeezing time of each repetition.
(ms) (ms)
Parameter 6 – Register Default = 10 Register used to track program status internally. R[10] is the standard
Number register for tip wear measurement, so it is generally unnecessary to
change this
- 179 -
F.PRESS ON NEW TIPS B-82634EN/01
Parameter 7 – PrePress Default = 5 Defines an extra open distance required to reach the pressing speed
Margin (mm)
Parameter 8 – Max Growth Default = 15 Defines the maximum expected increase in length between (2) worn tips
(mm) and (2) new tips. The actuator position between repetitions is equal to:
Worn tips zero position + (Parmater 7) + (Parameter 8)
Movable Tip
PrePress Margin
Mastering position of New tip (Unknown before update)
Mastering position of Worn tip
Growth
Fixed Tip
TIP PRESSING EXAMPLE SEQUENCES

Pressing sequence with default settings [CALL TW_PRSRT(1,500,2,4,1,10,5,15)]
Step # Operation Critical Parameters
Step 1 Gun Closes to pressure, 250kgf Parameter 2 * (1/Parameter 3)
Pressure is help for 1ms Parameter 5
Gun opens to 20mm compared to worn tips zero position Parameter 7+8
Above steps are repeated (4) times Parameter 4
Above steps are repeated (4) time Parameter 4
Pressing sequence with custom settings [CALL TW_PRSRT(1,300,1,6,1,10,5,10)]

Step # Operation Critical Parameters
Above steps are repeated (6) times Parameter 4
- 180 -
B-82634EN/01 INDEX
INDEX
GUN CHANGE REFERENCE POSITION
A
SETUP METHOD (BATTERY-LESS TYPE)
A DIFFERENT GUN FROM THAT
................................................................. 155
SPECIFIED BY THE ATTACH
GUN CHANGE SEQUENCE..................... 110
INSTRUCTION IS ATTACHED.............165
GUN CHANGE SETUP ............................... 98
ACTIVE STROKE LIMIT PROTECTION ...71
GUN CHANGE STATUS ........................... 111
ALARM CODE LIST...................................134
GUN DETACH instruction ........................ 107
AUTOTUNE MACRO PROGRAM .............176
GUN JOG OPERATION .............................. 41
B GUN MASTER UTILITY........................... 169
GUN OPEN FUNCTION at WELD FAULT131
Backward execution....................................109
GUN OPENING MOTION......................... 133
BASIC SPECIFICATION .........................2, 94
GUN SAG COMPENSATION...................... 75
Battery-less type guns ................................105
Gun Zero Master Instruction....................... 54
Battery-mounted type guns........................106
GUN ZERO MASTERING ......................... 168
C
H
CALIBRATION MOTION FAILED ...........164
Hold............................................................... 49
Conditions of Gun Open .............................132
CONTROL METHOD (MULTI-GROUP) ..... 4 I
Ｄ INITIAL SETTING ........................................ 5

INITIAL SETUP........................................... 97
DATA RECOVERY .......................................69
L
E
Limitations ................................................... 92
E-Stop ............................................................50
EXT. TIP STICK SIGNAL DETECTION ...76 M
F Magnet Phase Detection (MPDT) .............. 171

MANUAL BACKUP (Shift+BU) .................. 38
Feature of function .......................................94
MANUAL OPERATIONS ............................ 33
FEATURES OF FANUC SERVO GUN ........ 2
MANUAL PRESSURIZATION (Shift+GUN)34
Foward execution ........................................108
MANUAL WELDING................................... 40
G
MASTERING.............................................. 172
Guidelines for gun change with multi-tasking Meaning of each items ................................. 91
..................................................................115
N
GUN ATTACH instruction .........................107
NAMES OF MAJOR SERVO GUN
GUN CHANGE FUNCTION ........................93
COMPONENTS .......................................... 3
GUN CHANGE INSTRUCTION................107
i-1
INDEX B-82634EN/01
NEXT STEP ENABLE..................................85 Recovery Mastering Data............................. 69

Notice for teaching ......................................113 REFERENCE POSITION SETUP FOR
CALIBRATION TYPES 3 AND 4........... 156
O
Reference Position Setup for Calibration Types
ONE-STEP MEASUREMENT METHOD ...63
5 and 6 ..................................................... 158
Operation.......................................................90
REFERENCE POSITION SETUP OF EACH
OPERATIONAL SETTING AND ALARM
POSITION TYPE.................................... 156
PROCESSING ...........................................65
Reset Alarm ................................................ 170
OTHER INSTRUCTIONS ............................52
Restrictions................................................... 94
OUTLINE......................................................94
Outline of installation...................................96
S
OVERTORQUE PROTECTION FEATURE116
OVERTORQUE PROTECTION SETUP ...118 Sample program ................................. 108, 114
OVERVIEW....................................1,56,89,117 SERVO GUN AXIS INITIALIZATION ......... 6
SERVO GUN GENERAL SETUP SCREEN31
P
SERVO GUN MAIN SETUP SCREEN ....... 29
PART THICKNESS CHECK FUNCTION 125
SERVO GUN MONITORING ...................... 80
PREPARATIONS FOR TIP WEAR DOWN
SERVO GUN SETUP................................. 112
COMPENSATION.....................................58
SERVO GUN SETUP AND AUTOTUNING
Press Motion Instruction ..............................52
UTILITY.................................................... 18
PRESS ON NEW TIPS ...............................179
SERVO GUN SETUP SCREEN .................. 30
PRESSURE CALIBRATION ........................26
SETTING GUN STROKE LIMITS............ 174
PRESSURE ENABLE SIGNAL ...................84
SETTING THE COORDINATE SYSTEM .. 14
Pressure Instruction .....................................52
SETTING THE GUN CLOSE DIRECTION 16
PRESSURE PROFILE CONTROL FUNCTION
SETTING THE MAX PRESSURE .............. 17
....................................................................88
SETTING THE REFERENCE POSITION 105
PRESSURE RELATED I/O SIGNALS ........83
Single-Step.................................................... 50
PRESSURIZATION NOTIFICATION SIGNAL
SOFT PANEL ............................................... 82
....................................................................86
SPOT Instruction Format ............................ 44
PROFILE DATA ...........................................90
SPOT WELDING INSTRUCTIONS............ 43
PROGRAMMING..........................................42
STANDARD TIP WEAR PROGRAM LIST . 57
Q System Configuration .................................. 95
QUICK MASTERING REFERENCE T

POSITION ...............................................160
TEACHING ................................................ 113
R Teaching Position ......................................... 49
The attach instruction is executed when the
Recovery from Lost of Tip.............................69
gun is not attached. ................................ 162
i-2
B-82634EN/01 INDEX
THE ATTACHED GUN HAS BEEN

DETACHED BY MISTAKE (WITHOUT
USING THE DETACH INSTRUCTION).166
THE BATTERY RAN LOW WHILE THE GUN
WAS DETACHED. ..................................167
THE BATTERY VOLTAGE HAS FALLEN.166
THE GUN AXIS OF A DETACHED GUN HAS
MOVED....................................................166
THE ROBOT STOPPED DURING
CALIBRATION .......................................163
THICKNESS CHECK CALIBRATION .....126
THICKNESS CHECK GENERAL SETUP128
Tip Wear Detect Setup screen......................65
TIP WEAR DOWN COMPENSATION........55
Tip Wear Standard screen............................68
TROUBLESHOOTING (GUN CHANGE) .161
TWO-STEP MEASUREMENT METHOD...59
USING TIP WEAR MEASUREMENT

PROGRAMS from R-J3iB .........................72
Welding Sequence .........................................48
i-3
Revision Record
FANUC Robot series R-30iA CONTROLLER Servo Gun Function

OPERATOR’S MANUAL (B-82634EN)
01 Mar.,
2007
Edition Date Contents Edition Date Contents

FANUC Robot Series R-30iA CONTROLLER Servo Gun Function OPERATOR'S MANUAL PDF

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FANUC Robot Series R-30iA CONTROLLER Servo Gun Function OPERATOR'S MANUAL PDF

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Servo Gun Function

• No part of this manual may be reproduced in any form.

1.1 OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is

The following lists the general safety precautions. Careful

(4) Provide the peripheral devices with appropriate grounding (Class

The circuit breaker installed in the controller is designed to disable anyone

(9) When adjusting each peripheral device independently, be sure to

Limit switch which operates when the gate

Panel board Note) Terminals FENCE1 and FENCE2

Limit switch which operates when the gate is

Fig.1.1(b) Safety Fence and Safety (For R-30iA CONTROLLER)

1.1.1 Operator Safety

Note) Connect between EMGIN1 and EMGIN 2.

Fig.1.1.1(a) Connection Diagram for External Emergency Stop Switch

Fig.1.1.1(b) Connection Diagram for External Emergency Stop Switch

1.1.2 Safety of the Teach Pendant Operator

(1) Unless it is specifically necessary to enter the robot work area,

The teach pendant supplied by FANUC is provided with a teach pendant

The teach pendant, operator panel, and peripheral device interface

Operator ‘s panel Teach pendant Software remote Teach Operator’s Peripheral

1.1.3 Safety During Maintenance

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1 Precautions in Programming

1.2.2 Precautions for Mechanism

1.3 SAFETY OF THE ROBOT MECHANISM

1.3.1 Precautions in Operation

1.3.2 Precautions in Programming

1.3.3 Precautions for Mechanisms

1.4 SAFETY OF THE END EFFECTOR

1.4.1 Precautions in Programming

1.5 SAFETY IN MAINTENANCE

1.6 WARNING LABEL

(1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

1) When greasing, be sure to keep the grease outlet open.

(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

(3) High-temperature warning label

Fig. 1.6 (c) High-temperature warning label

6 TIP WEAR DOWN COMPENSATION................................................... 55

13 GUN CHANGE FUNCTION................................................................... 93

13.1.4 System Configuration.............................................................................................95

14 OVERTORQUE PROTECTION FEATURE ......................................... 116

A.1.2 Reference Position Setup for Calibration Types 5 and 6 .....................................158

1.1 FEATURES OF FANUC SERVO GUN

• Many dedicated servo gun functions (such as manual operation,

1.2 BASIC SPECIFICATION

Pressure setting range 0.0-9999.9[N, kgf, lbf] (*1)

Stroke limit range 0.0-9999.9[mm] (*1)

1.3 NAMES OF MAJOR SERVO GUN COMPONENTS

1.4 CONTROL METHOD (MULTI-GROUP)

Control method for servo gun system

Motion Group 1 Motion Group 2

6 Axes for Robot Axis for Servo gun

Extended axis Control

6 Axes for Robo Axis for Servo gun

2.1 Servo gun axis initialization

2.1 SERVO GUN AXIS INITIALIZATION

If extended axis control or multi-group control is being used or

Servo Gun Axis Initialization

[1] Controlled Start

* SETUP TYPE *