SVGunOpManual PDF

B-80954EN/01 Table of Contents
1. OUTLINE ............................................................................................................................................ 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
3. SPOT WELDING SETTING .................................................................................................... 6

3.1 SPOT WELDING SEQUENCE SETUP SCREEN ...........................................................................7
3.2 SERVO GUN SETUP ............................................................................................................................8
4. MANUAL OPERATIONS ........................................................................................................ 11

4.1 MANUAL PRESSURIZATION AND MANUAL PRESSURE CONDITION
CHANGE-OVER ..................................................................................................................................12
4.2 MANUAL STROKE AND MANUAL STROKE CHANGE-OVER ...........................................16
4.3 USER PROGRAM-BASED OPERATION (SPECIAL OPERATION) .......................................19
4.4 MANUAL WELDING .........................................................................................................................21
4.5 JOG OPERATION (GROUP 2 MANUAL OPERATION) ............................................................22
4.6 SIMPLIFIED TEACHING ..................................................................................................................23
5. PROGRAMING ............................................................................................................................. 26
5.1 SPOT WELDING INSTRUCTIONS .................................................................................................27
5.1.1 Instruction format.........................................................................................................................27
5.1.2 Pressure Condition Setting...........................................................................................................29
5.1.3 Welding Sequence .......................................................................................................................38
5.1.4 Backup Condition Setting ............................................................................................................39
5.1.5 Teaching Position.........................................................................................................................40
5.1.6 The detail of positions generated by taught position and auto route setup...................................41
5.1.7 Hold .............................................................................................................................................43
5.1.8 E-Stop ..........................................................................................................................................43
5.1.9 Single-Step Testing ......................................................................................................................43
5.1.10
Backward Execution (BWD) .......................................................................................................44
5.2 OTHER INSTRUCTIONS...................................................................................................................45
5.2.1 Servo Gun Condition Instruction .................................................................................................45
5.2.2 Pressurization Instruction.............................................................................................................46
5.2.3Pressure Instruction......................................................................................................................47
5.3 STROKE SWITCHING .......................................................................................................................49
6. TIP WEAR DOWN COMPENSATION............................................................................ 50
6.1 FLOW OF TIP WEAR COMPENSATION ......................................................................................51
6.2 WEAR DOWN VALUE DETECTION METHODS ......................................................................53
6.3 CREATING A WEAR DOWN VALUE DETECTION PROGRAM...........................................55
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TABLE OF CONTENTS B-80954EN/01
6.3.1 Incremental operation method......................................................................................................55

6.3.2 Teaching position operation method ............................................................................................57
6.3.3 Register operation method ...........................................................................................................59
6.4 WEAR DOWN VALUE RESET PROGRAM .................................................................................64
6.5 DETECTION OF ABNORMAL WEAR AMOUNT ......................................................................65
6.6 CHECKING THE REFERENCE POINT AND WEAR DOWN VALUE...................................68
6.7 TIP WEAR DOWN COMPENSATION FOR STATIONARY ARM MOVING WITH
MOVABLE ARM (X GUN) .....................................................................................................................................70
7. GUN DEFLECTION COMPENSATION......................................................................... 73
8. TIP STICK SIGNAL DETECTION FUNCTION ......................................................... 74
9. DEPOSITION REMOVAL FUNCTION ........................................................................... 76
10. SERVO GUN MONITORING................................................................................................ 78
11. TEST EXECUTION..................................................................................................................... 81
12. INDEPENDENT MOTION ...................................................................................................... 82
13. PRESSURE ENABLE AND COMPLETION CONFIRMATION

SIGNALS .......................................................................................................................................... 83
13.1 PRESSURE ENABLE SIGNAL .........................................................................................................84
13.2 WELD COMPLETION CONFIRMATION SIGNAL ....................................................................85
14. PRESSURE PROFILE CONTROL FUNCTION ....................................................... 86

14.1 OVERVIEW ..........................................................................................................................................87
14.2 PROFILE DATA ...................................................................................................................................88
14.2.1 Operation .....................................................................................................................................88
14.2.2
Meaning of each items .................................................................................................................89
14.3 LIMITATIONS......................................................................................................................................90
15. GUN CHANGE FUNCTION ................................................................................................. 91

15.1 OUTLINE ...............................................................................................................................................92
15.1.1 Feature of function .......................................................................................................................92
15.1.2 Basic specification .......................................................................................................................92
15.1.3 Restrictions ..................................................................................................................................92
15.1.4 System Configuration...................................................................................................................93
15.1.5
Outline of installation ..................................................................................................................94
15.2 INITIAL SETUP ...................................................................................................................................95
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B-80954EN/01 TABLE OF CONTENTS
15.3 GUN CHANGE SETUP ......................................................................................................................96

15.4 SETTING THE REFERENCE POSITION .....................................................................................102
15.4.1 Battery-less type guns ................................................................................................................102
15.4.2
Battery-mounted type guns ........................................................................................................103
15.5 GUN CHANGE INSTRUCTION .....................................................................................................104
15.5.1 GUN DETACH instruction........................................................................................................104
15.5.2 GUN ATTACH instruction........................................................................................................104
15.5.3 Sample program .........................................................................................................................105
15.5.4 Foward execution.......................................................................................................................105
15.5.5
Backward execution...................................................................................................................106
15.6 GUN CHANGE SEQUENCE ...........................................................................................................107
15.7 GUN CHANGE STATUS .................................................................................................................108
15.8 SERVO GUN SETUP ........................................................................................................................109
15.9 TEACHING .........................................................................................................................................110
15.9.1 Notice for teaching.....................................................................................................................110
15.9.2 Sample program .........................................................................................................................111
16. SAVING THE SERVO GUN SETTINGS ..................................................................... 112
17. ALARM CODE TABLE .......................................................................................................... 113
APPENDIX
A. Construction of Servo gun screen ............................................................................. 127
B. Construction of Servo gun gun change screen ............................................... 129
C. Recommendatory Setting ................................................................................................. 130
D. List of servo gun instructions ....................................................................................... 133
E. Gun Change Reference Position Setup Method

(battery-less type) .................................................................................................................. 134
E.1.1 Reference Position Setup for Calibration Types 3 and 4 ...........................................................134
E.1.2 Reference Position Setup for Calibration Types 5 and 6 ...........................................................136
E.2 Quick Mastering Reference Position Setup.....................................................................................139
F. Troubleshooting....................................................................................................................... 140
F.1 Insufficient pressure............................................................................................................................140
F.2 Pressure is too high, or fluctuates .....................................................................................................142
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TABLE OF CONTENTS B-80954EN/01
F.3 The wear down value cannot be detected correctly .......................................................................142

F.4 Pressure cannot be output manually. ................................................................................................145
F.5 The end signal is ignored and welding is ended .............................................................................147
F.6 The next line is executed without Pressuring carried out. ............................................................148
F.7 The next line is executed without welding carried out ..................................................................148
F.8 The reference point for tip wear compensation can no longer be found.....................................149
F.9 The gun has bent..................................................................................................................................151
G. Troubleshooting (Gun Change).................................................................................... 156

G.1 The attach instruction is executed when the gun is not attached. ................................................156
G.2 The robot stopped during calibration. ..............................................................................................157
G.3 Calibration motion failed. ..................................................................................................................157
G.4 A different gun from that specified by the attach instruction is attached. ..................................158
G.5 The attached gun has been detached by mistake (without using the detach instruction) .........159
G.6 The gun axis of a detached gun has moved .....................................................................................159
G.7 The battery voltage has fallen ...........................................................................................................160
G.8 The battery ran low while the gun was detached............................................................................160
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B-80954EN/01 1. OUTLINE
1 OUTLINE
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1. OUTLINE B-80954EN/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
Pressure setting range 0.1-9999.9[Kgf](in 0.1-kgf steps) (*1)

Stroke setting range 0.1-9999.9[mm] (in 0.1-mm steps) (*1)
Gun axis speed setting 0-2000[mm/sec]
range (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 (*2)
Gun type C gun, X gun
Single gun(*2)
Other One control unit can be used for both air and
servo guns.
*1 Practical values are determined according to the specification of the
servo gun main unit.
*2 A double gun is not supported for the time being.
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B-80954EN/01 1. OUTLINE
1.3 NAMES OF MAJOR SERVO GUN COMPONENTS
Servo gun motor

Controls movable tip.
Movable tip
Controlled using servo gun motor
Stationary tip
Controlled using six robot axes.
Stationary arm
The term "arm" herein refers to the stationary arm
unless otherwise stated.
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1. OUTLINE B-80954EN/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 handles robot and servo gun axes in separate
motion groups, enabling separate the robot and the gun
control.
Control method in the new servo gun system
Multi-group control
Motion group 1 Motion group 2
Six robot axes Servo gun axis

(The first axis in group 2)
Control method in the old servo gun system
Extended axis control
Motion group 1
Six robot axes Servo gun axis

(seventh axis in group 1)
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B-80954EN/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. Please refer to the “Servo
Gun Function Supplementary Manual”.
1. Servo gun motor initialization

Initialize the settings related to the servo gun motor
(such as motor size, gear ratio, and maximum speed).
2. Equipment type setting
Assign a welding machine.
3. Mastering
Perform zero position mastering for the servo gun axis.
4. Tool coordinate system setting
Define a tool coordinate system at the end of the
stationary tip.
5. Closing direction setting
Specify the direction in which the stationary and
movable tips are closed.
6. Servo adjustment
When high-precision pressure control is used, the servo
parameter must be adjusted.
This adjustment is not necessary if conventional control
methods are used.
7. Pressure calibration
Calibrate the pressure applied to the tips using a
commercial pressure gauge (load cell).
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3. SPOT WELDING SETTING B-80954EN/01
3 SPOT WELDING SETTING

This section explains the settings necessary for
pressurization, welding, and opening.
･ Spot I/O setting (I/O menu → “Spot welding”)

Set up welding, schedule, and welding completion signals.
This section explains only "Pressure Enable Signal" and
"Weld Completion Signal" in the Section 13. Please refer to
"FANUC Robot series (R-J3 Controller) SPOT TOOL
OPERATOR'S MANUAL" for details of other I/O signals.
･ Spot weld sequence Setup (SETTING menu → “Spot welding”)

Specify details of servo gun-based spot welding (see
Section3.1).
･ Servo gun Setup(SETTING menu → “Spot welding”)

Specify details of servo gun feature（see Section 3.2）
･ Pressure Condition setting (DATA screen → “Pressure”)

Specify conditions related mainly to pressurization (see
Section 5.1.2).
･ Stroke condition setting (DATA screen → “Backup”)

Specify the opening amount (stroke amount) (see Section
5.1.4).
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B-80954EN/01 3. SPOT WELDING SETTING
3.1 SPOT WELDING SEQUENCE SETUP SCREEN
Specify details of settings related to servo gun-based spot

SETUP Spot Weld
SERVO GUN SETUP
G2 JOINT 10 %
3/9
welding by referring to the descriptions of the corresponding
1 Equip number: 1 items (listed on the subsequent pages) so that the actual use
2 Gun select: SINGLE conditions can be satisfied.
3 Weld completion signal:
4 weld complete delay:
ENABLE
420
1 Press the MENUS key to bring up the screen menu.
5 detect condition: LEVEL 2 Select “6 SETUP”.
6 Detect weld done: DISABLE 3 Press F1“[TYPE]” to display the pull-up menu.
7 weld done timeout(ms):
8 General Setup:
100
<*DETAIL*>
4 Select “Spot welding” to display the SERVO GUN
9 Manual Operation Setup: <*DETAIL*> SETUP screen.
[ TYPE ] EQUIP ENABLEDISABLE
Descriptions of items for spot weld sequence setup

Equip number Equipment number shows the number of the selected weld controller is displayed.
GUN GUN shows the spot gun type. When there is 1 axis in the motion group for the spot gun,
GUN is set to SINGLE automatically. When there are 2 axes in the group, GUN is set to
DOUBLE automatically
This item is provided for reference purposes. You cannot change it.
SINGLE = the target gun is a single gun.
DOUBLE = the target gun is a double gun.
Weld completion signal: Weld completion signal specifies if the Weld completion signal (input) is used or not. If the
Default value: signal is used, the welding is performed for the time specified by the next item.
ENABLE DISABLE = a signal for indicating the completion of welding (welding completion signal) is
not detected. (Welding is not interlocked with the welding timer. Welding is terminated,
when the time specified in the following item (welding time) elapses.
ENABLE = a welding completion signal is detected. (The number of the welding
completion signal must be specified on the spot signal input screen, which is one of the I/O
screens.
Weld complete delay: Weld complete delay specifies the time to do a welding process. This value is only used
when the Weld completion signal is set “DISABLE”.
It is also used as pressuring time when Gun welding is set DISABLE on the CYCLE TEST
screen.
Detect condition Detect condition specifies a condition for detecting the Weld completion signal.
Default value: LEVEL The detection condition for the Weld completion signal can be set as described below.
LEVEL= Completion of spot welding is assumed when the Weld completion signal is ON.
EDGE = Completion of spot welding is assumed when the Weld completion signal is
changed from Off to On (at rise time).
Detect weld done: Detect weld done specifies if the timeout value for the Weld completion signal is used or not
Default value: DISABLE = does not detect timeout.
DISABLE ENABLE = detects timeout if Weld completion signal does not come back within the
specified time. (See Weld done timeout)
Weld done timeout Weld done timeout specifies the timeout value for the Weld completion signal (input) after
(ms): Weld signal is output.
Default value: 100 This value is only used if Detect weld done is set to ENABLE. And when timeout is occurred,
a Spot weld alarm is displayed then spot welding signals are turned off.
General setup The features of the servo gun are set in General setup screen.
Put the corsor on the <*DETAIL*>, then press enter key to display the General setup
screen.
Manual Operation setup The setup related to the manual opration are set in Manual Operation setup screen.
Put the corsor on the <*DETAIL*>, then press enter key to display the Manual Operation
setup screen.
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3.2 SERVO GUN SETUP
Specify details of settings related to servo gun by referring to

the descriptions of the corresponding items (listed on the
subsequent pages) so that the actual use conditions can be
satisfied.
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 “Spot welding” 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 Spot Weld G2 JOINT 10 % SETUP Spot Weld G2 JOINT 10 %

SERVO GUN SETUP 8/9 GENERAL / EQ:1 Gun:1 1/12
1 Equip number: 1 1 Tip Wear Down Comp: ENABLE
2 Gun select: SINGLE 2 Gun Sag Compensation: ENABLE
3 Weld completion signal: ENABLE 3 Close Direction(Gun): PLUS
4 weld complete delay: 420 4 Close Direction(Robot): UT: 1
5 detect condition: LEVEL [+Z]
6 Detect weld done: DISABLE 5 Max Motor Torque(%): 100.0
7 weld done timeout(ms): 100 6 Max Pressure(Kgf): 500.0
8 General Setup: <*DETAIL*> 7 Tip stick detect delay(ms): 0
9 Manual Operation Setup: <*DETAIL*> 8 Weld Timing Torque 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
[ TYPE ] EQUIP GUN ENABLE DISABLE
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B-80954EN/01 3. SPOT WELDING SETTING
Descriptions of items for servo gun setup

Tip Wear Down Comp Tip Wear Down Comp specifies whether to perform tip wear completion.
Default value: DISABLE = tip wear completion is not performed.
DISABLE ENABLE = tip wear completion is performed.
To use the tip wear completion function, it is necessary to acquire a reference position and
calculate a compensation value. See section 6 for details.
Gun Sag Compensation Gun Sag Compensation specifies whether to perform the spot gun deflection compensation.
Default value: DISABLE = gun deflection compensation is not performed.
DISABLE The amount of gun deflection compensation is specified as Pressure Condition data. See
Section 7 for details.
ENABLE = the gun deflection compensation is performed.
Close Direction (Gun) Close Direction specifies the direction in which the movable tip is to be closed.
Default value: PLUS Please refer to separate-volume “Servo Gun Function Supplementary Manual
(B-80954EN-1)”.
Close Direction (Robot) Close Direction specifies Tool Frame Number specifies a tool coordinate system number
Default value: UT:1 +Z and which axis of the tool coordinate system specified the direction in which the stationary
tip is closed.
Please refer to separate-volume “Servo Gun Function Supplementary Manual
(B-80954EN-1)”.
Max Motor Torque (%) Max Motor Torque specifies a limit to the maximum torque of the servo gun motor in usual
Default value: 100.0 motion if necessary. The torque specified here is applied to the servo gun axis when
pressurization is not taking place. Usually, the limit should be set to 100.
The valid data range is between 1.0 and 100.
Max Pressure (Kgf) Max Pressure specifies a limit to the pressure to be applied during pressurization. Any
Default value: 500.0 pressure higher than specified here will not be generated. A similar limit is also placed
kg during pressure input.
This value should match the allowable maximum pressure of the gun to be used. The valid
data range is between 1.0 and 9999.9.
Tip stick detect delay Sets the time in the welding sequence up to start of the tip stick detection signal check after
[msec] arrival to the pressure end position. Set the tip stick detection signal in the I/O screen.
Default: 0
Weld instruction timing Weld instruction timing specifies the timing by which the weld instruction and weld condition
(%) signals are output in the welding sequence as a percentage of the actual pressure with
Default: 0 respect to the target pressure. These signals are output when the actual pressure falls
within the percentage (+/-) range specified for the target pressure.
This item is used to output the weld instruction early on.
For details, see the description for "weld instruction lag time" in "5.1.2 Pressure Condition
Setting."
Counter register Open the conter register setup screen. The registers used for spot counter are assigned in
this screen.
Put the cousor on the <*DETAIL*>, then press the enter key to bring up this screen.
Max wear down check Open the maximum tip wear down check setup 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.
Wear Down Cal Open tip wear down calibration screen. Wear Down Cal is for setting the reference position
of Tip wear compensation. When the reference position is set, the display changes from
INCOMP to COMP
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Counter register setup
SETUP Spot Weld G2 JOINT SETUP Spot Weld G2 JOINT 10 %

10 % COUNT REGISTER / EQ:1 Gun:1 1/3
GENERAL / EQ:1 Gun:1
9/12 1 Spot count register: 0
1 Tip Wear Down Comp: 2 Tip dress count register: 0
ENABLE 3 Tip change count register: 0
2 Gun Sag Compensation: ENABLE
3 Close Direction(Gun):
PLUS
4 Close Direction(Robot): UT: 1 [+Z]
5 Max Motor Torque(%): 100.0
6 Max Pressure(Kgf):
500.0
7 Tip stick detect delay(ms):
0
8 Weld Timing Torque Rate(%)
0 [ TYPE ] EQUIP GUN END
9 Count register:
<*DETAIL*> Descriptions of counter register
10 count
Spot Max wear down check:
register: Spot count register specifies the index of register that is used as the spot welding
<*DETAIL*>
Default value: 0 counter. The register will indicate how many times a spot welding instruction has
been executed.
Tip dress count register: Tip dress <*DETAIL*>
12 Wear Down Cal: COMP count register specifies the index of register that is used to indicate when
Default value: 0 the tip is to be dressed. The register will indicate how many times spot welding
[ TYPE ] EQUIP GUNhas been performed.
Tip change count Tip change count register specifies the index of register that is used to indicate
register: when the tip is to be replaced. The register will indicate how many times spot
Default value: 0 welding has been performed.
Using servo gun the first time, please refer to “APPENDIX C

RECOMMENDED SETTING”..
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B-80954EN/01 4. MANUAL OPERATIONS
4 MANUAL OPERATIONS
The following manual operations can be done using the teach
pendant.
1. Manual pressurization and manual Pressure Condition

change-over
Pressurization can be performed manually by operating
keys on the teach pendant
2. Manual stroke and manual stroke change-over
The stroke of the servo gun can be changed by operating
keys on the teach pendant.
3. User program-based operation (special operation)
User-created pressurization and stroke programs can be
executed by operating keys on the teach pendant.
4. Manual welding
Welding can be performed manually by operating keys
on the Manual welding screen.
5. Jog operation (group 2 manual operation)
Jogging is possible on the servo gun movable axis in the
same manner as for robot jogging. Usually, the stroke
of the servo gun can be changed manually as described
above. However, jogging can be used on the servo gun
movable axis, for example, for zero-position mastering.
6. Simplified teaching
A teach assistance MACRO program for the servo gun
can be executed by operating keys on the teach pendant.
It can be used, for example, to teach welding points,
which are difficult to check visually.
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4. MANUAL OPERATIONS B-80954EN/01
4.1 MANUAL PRESSURIZATION AND MANUAL PRESSURE

CONDITION CHANGE-OVER
･ On the Manual operation screen, specify the Pressuring

time and whether to open the servo gun. (See [1]
below.)
･ On the Pressure Condition screen (data screen), select

TRUE from “Manual” for a condition used for manual
pressurization.
･ Specify (or confirm) the details of the Pressure Condition.

(See [2] below.)
･ Pressing GUN1 key displays a window including

Pressure Condition numbers. While the window is
displayed, pressing the GUN1 key switches the Pressure
Conditions
When a key other than the GUN1 key is pressed, or if all
keys are kept unused for a while, the window disappears
automatically.
SERVO GUN DATA G1 JOINT 10 %

PRESSURE / EQ:1 Gun:1 1/50
No. Press(Kgf) Manual Comment
1 180.0 TRUE [FRNT PANEL]
2 195.0 TRUE [REAR PANEL]
3 185.0 TRUE [SIDE PANEL ]
4 0.0 FALSE [ ]
: :
50 0.0 FALSE [ ]
[ TYPE ] EQUIP GUN DETAIL COPY >
Gun number
Pressurization
condition number
GN1 No. 1
FRNT PANEL Comment
180.0Kgf
Pressure
GN1 No. 1 GN1 No. 2 GN1 No. 3

GUN 1
FRNT PANEL REAR PANEL SIDE PANEL
180.0Kgf 195.0Kgf 185.0Kgf
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SHIFT ･ Pressing the GUN 1 key while holding down the SHIFT
key triggers pressurization.
GUN 1
Select enable
These positions must be generated. and disable
Current pos Open pos

Pressure Pressure
start pos end pos
Press pos
Movable
side
Panel
Stationary Time
side
･ Once pressurization has been started, you need not keep

pressing the GUN1 key.
･ If you want to discontinue the movement, release the
SHIFT key.
･ If Gun Open Position is enabled, holding down the
SHIFT key causes the gun to be opened when the
specified Pressuring time elapses.
･ The opening amount is determined according to the
Manual stroke condition that is currently active (see the
next item).
･ 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.
･ If you want to dry run the machine (with no workpiece
loaded), set the workpiece thickness to 0 mm.
･ If 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.)
･ If the SHIFT key is released while the gun is opening,
the manual pressure operation will make the gun press
again. If you want to open the gun after the condition,
you should use "manual stroke" for opening the gun.
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【1】Specifying the Pressuring time and whether to open the

gun
1. Display the SERVO GUN SETUP screen.

MENUS key → “6 SETUP” → F1“[Type]”
→ “Spot welding”
2. Select “9 Manual Operation Setup” (by placing the
cursor on <* DETAIL *>, then pressing the ENTER
key). The Manual setting screen appears.
Specify the following items:
Pressuing Pressurization is continued for the specified Pressuring time.

Time:
Gun If you want to open the gun after the specified Pressuring time
Open: elapses, select TRUE. If you do not want to open the gun
after the specified Pressuring time elapses, select FALSE. If
FALSE is selected, it is necessary to open the gun by manual
stroke operation.
SETUP Spot Weld G2 JOINT 10 %

SERVO GUN SETUP 9/9
1 Equip number: 1
2 Gun select: SINGLE
3 Weld completion signal: ENABLE
4 Weld complete delay: 420
5 Detect condition: LEVEL
6 Detect weld done: DISABLE
7 Weld done timeout(ms): 100
8 General Setup: <*DETAIL*>
9 Manual Operation Setup: <*DETAIL*>

MANUAL / EQ:1 Gun:1 2/8
Manual Pressure
1 Pressuring Time(sec): 3.0
2 Gun Open: TRUE
3 Use Pressure Program: FALSE
4 Pressure Program: [ ]
Manual Backup
5 Backup Speed(%): 100
6 Backup stroke: <*DETAIL*>
7 Use Backup Program: FALSE
8 Backup Program: [ ]
[ TYPE ] EQUIP GUN TRUE FALSE
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【2】Specifying Pressure Condition details
1. Display the Pressure Condition screen.

DATA key → F1”[TYPE]” → “Pressure”
2. Pressing F4“DETAIL” displays the servo gun
Pressure Condition detail screen.
Specify part.

1 180.0 TRUE [FRONT PNL ]
2 195.0 TRUE [REAR PNL ]
: : : :
PRESSURE / EQ:1 Gun:1 No:1 1/8 [ TYPE ] EQUIP GUN DETAIL COPY >
1 Comment: [FRONT PNL ]
2 Standard Pressure(Kgf): 180.0 Pressure (Kgf)
3 Part Thickness(mm): 8.0 Part Thickness (mm)
4 Pushing Depth(mm): 5.0 Pushing Depth(mm) : Set the same value used for pressure
5 Gun Sag Comp Value(mm): 0.0 calibration
6 Weld Delay Time(msec) 0
7 Auto Route: <*DETAIL*>
8 Stand Alone/Manual SPOT: <*DETAIL*>
[ TYPE ] EQUIP GUN LIST

AUTO ROUTE / EQ:1 Gun:1 No:1 1/17
(Approach Position)
1 Approach Position: ENABLE
2 Tolerance Gun(mm): 0.0
3 Tolerance Robot(mm): 0.0
(Pressure Start Position)
Tolerance of pressure start pos(mm)
Termination type of pressure start pos
6 Termination Type: CNT 100
7 Acc instruction: ACC100
(Pressure Position) Decelerate Rate ： The decelerate rate of speed
8 Decelerate Rate(%): 100.0 between pressure start pos and pressure pos. If
9 Termination Type: CNT 100 decelerate rate is 100%, the speed is not changed.
Termination type of pressure pos
(Pressure End Position)
11 Tolerance Gun(mm): 0.0 Tolerance of pressure end pos(mm)
Termination type of pressure end pos
(Open Position)
15 Gun Open: DISABLE

STANDALONE / EQ:1 Gun:1 No:1 1/4
1 Speed(%): 100 Speed of gun

4 Use Path: FALSE
-15-
4.2 MANUAL STROKE AND MANUAL STROKE CHANGE-OVER
The stroke of the servo gun can be changed by operating keys

on the teach pendant.
･ On the setting screen, specify the stroke speed. (See [1]

below.)
On the stroke condition screen, specify the opening
amount and select “TRUE” from “Manual” for the
Pressure Condition. (See [2] below.)

BACKUP / EQ:1 Gun:1 1/15
No. Comment Stroke(mm) Manual
1 [OPEN SMALL] 50.000 TRUE
2 [OPEN MIDDL] 80.000 TRUE
3 [OPEN LARGE] 120.000 TRUE
4 [ ] 0.000 FALSE
: :
15 [ ] 0.000 FALSE
[ TYPE ] EQUIP GUN RECORD CLEAR
･ 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 condition
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.
-16-
・ 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.
【1】Specifying the stroke speed
1. Display the SERVO GUN SETUP screen.

MENUS key → “6 SETUP” → F1“[TYPE]”
→ “Spot welding”
2. Select “9 Manual Operation Setup” (by placing the
cursor on <* DETAIL *>, then pressing the ENTER key).
The Manual Operation Setup screen appears.

SERVO GUN SETUP 9/9
1 Equip number: 1
3 Weld completion signal: ENABLE
4 weld complete delay: 420
5 detect condition: LEVEL
7 weld done timeout(ms): 100
[ TYPE ] EQUIP
Specify the following item:
Backup Speed(%): The gun moves along the axis at this speed.

Manual Pressure
2 Gun Open: TRUE
Manual Backup
6 Backup stroke:
<*DETAIL*>
[ TYPE ] EQUIP GUN
-17-
【2】Stroke condition screen
1. On the Manual Operation Setup screen (screen

described above), select “Backup stroke” (by placing the
cursor on <* DETAIL *>, then pressing the ENTER key).
The Backup Stroke screen appears.

1 [SHORT ] 50.000 TRUE
3 [LONG ] 120.000 TRUE
4 [ ] 0.000 FALSE
5 [ ] 0.000 FALSE
6 [ ] 0.000 FALSE
: : : :
2. Specify the following items.
- Comment : Enter the text of a comment.

- Stroke : Specify the amount of stroke using either of the following
two methods:
1) Direct entrly.
2) Hold down the SHIFT key and press F4“RECORD” to
acquire the current opening amount.
- Manual : Select MANUAL if manual stroke operation is to be used.
3. To cancel any setting, place the cursor on the target

number and press F5“CLEAR”. A message will appear
to prompt you to confirm your request. So press
F4“YES”.
-18-
4.3 USER PROGRAM-BASED OPERATION

(SPECIAL OPERATION)
Programs that can be executed this way are limited to those

for operating only the servo gun axis. If the servo gun axis
is in motion group 2, therefore, the motion group of the user-
created program should be set to [*,1,*,*,* ]. (It is invalid
even if the motion group is set to [*,*,*,*,*])
Unlike, ordinary MACRO programs, this function enables

the pressurization program to be executed by key operation,
even if other programs for teaching servo gun movement are
paused.
･ User program-based pressurization (for customizing

manual pressurization)
If Use Pressure Program is set to TRUE, a user-created

program (specified at Pressure Program can be executed
by holding down the SHIFT key and pressing the GUN1
key.

Manual Pressure
2 Gun Open: TRUE
3 Use Pressure Program: TRUE
4 Pressure Program: [MY_PRESS]
Manual Backup
[ TYPE ] EQUIP GUN
-19-
･ User program-based stroke switching (for customizing

manual stroke)
If Use Backup Program is set to TRUE on the Manual

setting screen, a user-created program (specified at
Backup Program) can be executed by holding down the
SHIFT key and pressing the BU (Backup) key.

Manual Pressure
2 Gun Open: TRUE
Manual Backup
7 Use Backup Program: TRUE
8 Backup Program: [MY_STROK]
[ TYPE ] EQUIP GUN
CAUTION
1 If MACRO programs are assigned to SU[1]…[4],
they override the operation of other programs.
2 This function disables Manual Pressure and Manual
Stroke.
-20-
4.4 MANUAL WELDING
Welding can be performed manually by operating keys on the

Manual welding screen.
･ Display the Manual welding screen.

1. Select the MENUS key to bring up the screen menu.
2. Select “3 MANUAL FCTNS”.
4. Select “Spot welding”. The MANUAL FCTN Spot
screen appears.
The currently active welding condition numbers

MANUAL FCTNS Spot G1 JOINT 10 %
are displayed here.
1/8
If a spot welding instruction [P=2, S=4, BU=0] has
1 Equip number: 1
been executed in a program, the following are
displayed: Pressure condition (P)=2, Stroke
GUN 1 (current)
condition (BU)=0, Spot schedule (S)=4.
3 Pressure condition: ( 2) 1
If welding has not been performed, no current
4 Stroke condition: ( 0) 0
values are displayed (*****).
5 Spot schedule: ( 4) 0
GUN 2 (current)
6 Pressure condition: (*****) *****
Pressure and Stroke condition, and Spot weld
7 Stroke condition: (*****) *****
schedule are specified here. Manual welding is
8 Spot schedule: (*****) *****
performed according to the specified conditions/
schedule.
[ TYPE ] EQUIP EXEC
・ Specify Pressure condition, Stroke condition and Spot

weld schedule.
・ Holding down the SHIFT key, then pressing F3“EXEC”
causes pressurization, welding, and opening to be
performed under the specified conditions. 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 movable tip moves, but the
stationary tip does not. Neither tip wear compensation
nor arm deflection compensation is performed on the
stationary tip, but tip wear compensation is performed
on the movable tip.
-21-
4.5 JOG OPERATION (GROUP 2 MANUAL 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 manually. 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.
-22-
4.6 SIMPLIFIED TEACHING
Teach assistance MACRO programs can be executed by

operating the SU[1] to SU[7] keys on the teach pendant.
These MACRO programs can be used to help, for example,
teach welding spots, which are difficult to check visually.
An ordinary MACRO program cannot be started, if another
program has the same motion group and is at a temporary
stop. This restriction does not apply to MACRO programs
assigned using this function, however.
CAUTION
This function cannot be used for pedestal guns.
(1) Install a teach assistance program in the robot.

This MACRO program moves the stationary tip
longitudinally with respect to the gun and stops it the
moment it touches the workpiece, as shown below. The
customer is requested to prepare an external sensor for
detecting when they touch each other. Be sure to remove
the sensor and any related cable before starting welding.
Move the stationary tip longitudinally.
[MACRO program (example)]

1: IF SDI[1]=OFF,JMP LBL[1] [Explanation]
2: OVERRIDE=10% Line 1: Safety signal (SDI[1]). Simplified teaching causes the robot main
3: R[10] body axis to operate. The safety signal is used to prevent
=$SGGUN[1].$SETUP.$TOOL_NUM malfunction. The safety signal should be turned on before
4: UTOOL_NUM=R[10] simplified teaching is started.
5: SKIP CONDITION SDI[2]=ON Line 2: A low override value is specified.
6: LBL[2] Line 3: The tool coordinate system number for which the gun closing
7: PR[9]=LPOS direction for the stationary tip is specified is assigned to R[10].
Line 4: The current tool coordinate system number is changed to the one
specified above.
Line 5: A signal for indicating when the stationary tip touches the
workpiece is set up as a skip condition.
Line 6: If the operation specified on line 8 does not cause the workpiece to
be touched, a jump occurs to this line.
Line 7: The current position is saved to PR[9].
-23-
8: L PR[9] 100mm/sec CNT100 Line 8: The robot is moved from the current position (PR[9]) by an amount
Tool_Offset,PR[10] specified in PR[10] in the gun closing direction, then stopped the
Skip,LBL[2],PR[9]=LPOS moment the workpiece is touched (the touch signal becomes ON).
9: L PR[9] 2000mm/sec FINE At the same time, the current position of the robot is memorized in
10: END PR[9] the moment the touch signal becomes on. If the workpiece
11: LBL[1] is not touched, a jump is made to line 6.
12: UALM[1] Line 9: The robot coasts before it stops. So the robot is moved back to
[END] the position memorized in PR[9].
Line10: Normal end
Line11: A jump occurs to this line, if the safety signal is off.
Line12: A user alarm is taught.
Cautions related to MACRO program creation

1. The numbers specified in SDI[ ], R[ ], and PR[ ] in the
sample program should be replaced with those actually
used by the customer.
2. The method for setting a movement amount in PR[10] in
the sample program varies depending on the gun closing
direction specified for the stationary tip on the General
Setup screen.
･ Use the cartesian representation of Position

Register.
･ Specify 50.0 mm or so as the movement amount.
･ See the following table for what to specify.
General Setup screen:
Close Direction (Robot): UT:1[ +Z ]
Gun closing direction What to specify

+X Set a positive value only in item X.
-X Set a negative value only in item X.
+Y Set a positive value only in item Y.
-Y Set a negative value only in item Y.
+Z Set a positive value only in item Z.
-Z Set a negative value only in item Z.
FIX This function is unusable.
Reset all the other items to 0.
Example) Position Register value if the gun closing

direction is specified as [+Z]
Group 1 (robot axis)
X: 0.0 mm W: 0.0 deg
Y: 0.0 mm P: 0.0 deg
Z: 50.0 mm R: 0.0 deg
Group 2 (Servo Gun axis)

J1 : 0.0 mm
-24-
(2) Assign the MACRO program with any key from SU[1] to
SU[7].
Register a MACRO program created at (1) with any key
from SU[1] to SU[7], using the same method as for
macro setting.
(3) Set up system variables.

Assign a value to the $MACRSPSUMSK system
variable in order to enable the MACRO program
assigned at (2) to be started even if a program that has
the same motion group as that MACRO program is at a
temporary stop. The value to be assigned to the system
variable varies as listed below depending on what SU
number the program is registered with.
SU[1] 1 If more than one MACRO program is assigned, total the values
SU[2] 2 corresponding to the SU[*] for which the MACRO programs are
SU[3] 4 assigned, and assign the sum to the $MACRSPSUMSK system
SU[4] 8 variable.
SU[5] 16 Example) If MACRO programs are assigned to SU[3] and SU[4]:
SU[6] 32 $MACRSPSUMSK = 4 + 8 = 12
SU[7] 64
-25-
5. PROGRAMING B-80954EN/01
5 PROGRAMING
This section describes programing operation related to spot
weld of servo gun.
Please refer to the list of instructions related to servo gun
”APPENDIX D LIST OF SERVO GUN INSTRUCTIONS”.
-26-
B-80954EN/01 5. PROGRAMING
5.1 SPOT WELDING INSTRUCTIONS
Instructions used in a program to specify servo gun operation

are generically called spot welding instructions. Processes
(such as pressurization, welding, and opening) specified
using a spot welding instruction is called a spot welding
sequence.
Spot welding instructions perform tip wear compensation
and arm deflection compensation as well as the following
welding sequences.
･ Approach operation:
The specified approach position is approached according to
the specified tolerance amount.
･ Pressure start operation:

The specified pressure start position is approached according
to the specified tolerance amount. And the pressuring
operation is started.
･ Pressurization:
Pressurization is performed according to the specified
pressure.
･ Welding:
A welding signal is sent to the welding timer when the
pressure reaches the specified value.
･ Opening:
The gun is opened in response to the welding completion
signal.
5.1.1 Instruction Format
Indirect specification type :

This instruction type specifies only a welding condition.
Pressurization and stroke conditions are specified previously
using a servo gun condition instruction.
SPOT [i]
i: Welding condition number (0 to 32767)

This instruction type specifies a welding condition
number to be output to the welding timer. The
specified value is sent to the welding timer via a
condition signal (spot welding output signal).
-27-
If 0 is specified, the SPOT welding instruction is

ignored.
Direct specification type :

This instruction type specifies pressurization (P), welding (S),
stroke (BU) conditions directly.
SPOT [P=n, S=i, BU=m]
n : Pressure Condition number (1 to 99)

When "*" is specified, the pressure condition
specified by a Servo Gun Pressure Condition
instruction (GUN1 P[n]) previously will be used.
i : Welding condition number (0 to 32767)
Note When indirect type of index (R[i] or AR[i]) is
used, the value of register or argument must be
within 0 to 16384
m : Stroke condition number (0 to 30)
When "*" is specified, the stroke condition specified
by Servo Gun Stroke Condition instruction (GUN1
BU[m]) previously will be used.
NOTE
･ When the welding Condition is "S=0", Pressure
motion will not be done in the SPOT instruction.
･ Both types (indirect and direct) can be used in both
motion option and single instructions.The motion
option instructions can control both stationary and
movable tips in the pressurization sequence, while
the single instructions can control only the movable
tip.
Basically, please use direct type instruction.
The usage of the indirect type instruction is
described in the section “servo gun condition
instruction”.
1:L P[1] 2000mm/sec CNT100 SPOT[10]
1:L P[1] 2000mm/sec CNT100
SPOT[P=1,S=10,BU=5]
･ SPOT instruction must be used in motion option.
Single instruction type of SPOT instruction shall not
be used (even though it can be taught).
(Standalone instruction)
1: SPOT[10]
1: SPOT[P=1,S=10,BU=5]
-28-
5.1.2 Pressure Condition Setting
It is necessary for the programing a spot instruction to

specify the pressure condition which determine the weld
pressure and pressure motion.
In a spot welding instruction, pressurization and other

conditions are determined according to the specified Pressure
Condition number. This section described the setup of these
conditions .
1: L P[1] 2000mm/sec CNT100
: SPOT[P=3,S=5,BU=2]
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
| 1 Registers | ]=0 Select “Pressure”.
| 2 Position Reg | ]=0 3. The servo gun Pressure Condition list setting screen
| 3 Pressure | ]=0
appears.
| 4 Backup | ]=0
| +----------
| TYPE | Using the following function keys,
you can set the pressure data.
F4 DETAIL Displays the detail setting of the Pressure
SERVO GUN DATA G2 JOINT 10 % schedule, then you can setup the detail setting.
PRESSURE/EQ:1 Gun:1 1/99
F5 COPY Pressing this key with the cursor put on the
1 50.0 TRUE [ ] condition of a copy source displays a prompt for
2 150.0 TRUE [ ] the condition number for a copy destination.
3 150.0 TRUE [ ] Specifying the copy destination triggers a copy.
: : : :
[ TYPE ] EQUIP GUN DETAIL OPY >
4 Pressing F4“DETAIL”. The servo gun Pressure
Condition detail screen appears. Pressing F4“TRUE”
brings you back to the Pressure Condition list screen.
PRESSURE/EQ:1Gun:1 No:3 1/8
1 Comment: [ ]
2 Standard Pressure(Kgf): 350.0
3 Part Thickness(mm): 0.0
4 PushingDepth(mm): 1.0
5 Gun Sag Comp Value(mm): 0.0
8 Stand Alone/ManualSPOT:<*DETAIL*>
-29-
Descriptions of items to be set up

Comment A comment can be added to each Pressure Condition.
Weld Pressure (Kgf) Weld Pressure specifies the pressure to be applied when a spot welding instruction is
Minimum: 0.0 executed.
Maximum: 9999.9
Pressure Profile Pressure Profile displays the ON/OFF state of pressure profile control, and sets the
pressure profile details.
Put the cursor on the <*DETAIL*> and press the enter key to bring up this screen.
For details, see "14 Pressure Profile Control Function."
Note
The pressure profile control function is an optional function.
Part Thickness (mm) Part Thickness specifies the thickness of the workpiece to be welded.
Minimum: 0.0
Maximum: 1000.0
Pushing Depth (mm) Pushing Depth specifies the push-in amount measured from the upper surface of the
Maximum: 100.0 target workpiece. Set the same value used for pressure calibration.
Push-in amount
Workpiece thickness
Gun Sag Comp Value (mm) Gun Sag Comp Value specifies a compensation amount if “Gun Sag Comp Value” has
Minimum: -1000.0 been specified on the General Setup screen.
Maximum: 1000.0
Weld Instruction Lag Time Weld Instruction Lag Time specifies the lag time from arrival at the target pressure
(msec) specified by the weld instruction timing up to when the weld instruction and weld condition
Minimum: 0 signals are output. This item is used when "weld instruction timing" is specified in the
Maximum: 10000 general setup screen.
Pressure
Specified
pressure
Weld instruction timing (%)
Time
Weld instruction
Weld condition Weld instruction lag time
(msec)
Auto Route Open the auto route setup screen. Auto Route specifies a approach position, pressure
start position, pressure position, pressure end position and open position.
Stand Alone/Manual SPOT Open the standalone/Manual SPOT setup screen. This screen specifies a special setup
only for standalone SPOT instruction and Manual weld operation.
-30-
Auto Roue setup
SERVO GUN DATA G2 JOINT 10 % SERVO GUN DATA G2 JOINT 10 %

PRESSURE / EQ:1 Gun:1 No:6 7/8 AUTO ROUTE / EQ:1 Gun:1 No:6 1/17
1 Comment : [ ] (Approach Position)
2 Standard Pressure(Kgf) : 350.0 1 Approach Position: ENABLE
3 Part Thickness(mm): 0.0 2 Tolerance Gun(mm): 5.0
4 Pushing Depth(mm): 1.0 3 Tolerance Robot(mm): 0.0
5 Gun Sag Comp Value(mm): 0.0 (Pressure Start Position)
6 Weld Delay Time(msec) 0 4 Tolerance Gun(mm): 0.0
7 Auto Route: <*DETAIL*> 5 Tolerance Robot(mm): 0.0
8 Stand Alone/Manual SPOT: <*DETAIL*> 6 Termination Type: FINE***
(Pressure Position)
[ TYPE ] EQUIP GUN LIST 8 Decelerate Rate(%): 10.0
9 Termination Type: FINE***
(Pressure End Position)
(Open Position)
15 Gun Open: DISABLE
The following positions are created with taught position and

the auto route setup in the pressuring motion.
Select enable
These positions must be generated. and disable
Current pos Open pos

Pressure Pressure
start pos end pos
Press pos
Movable
side
Panel
Stationary
side
Time
Select enable and disable
-31-
Description of "Auto Route" Setting Item

(Approach Position Setting) The approach position to the pressuring start position
Approach position Specify whether or not to use the approach ①Approach position
Default: ENABLE position.
- DISABLE = Approach position is not used. Gun
- ENABLE = Approach position is used. 40mm
Set the following when the approach position
1 8mm
is enabled.
Tolerance Gun [mm] Specify the approach position of the movable 5mm
Min.: 0.0 side tip as a distance from the top side of the Robot
Max.: 1000.0 part.
Tolerance Robot [mm] Specify the approach position of the fixed
Min.: 0.0 side tip as a distance from the bottom side of
Max.: 1000.0 the part.
NOTE
About the Approach Position Setting
FANUC recommends using the approach position set to ENABLE.
Note, however, that the approach position should be set to DISABLE in the following
instances. The following describes how to use the approach position when the
approach position is set to DISABLE. Select either of the following methods by
switching the $SGSYSCFG.$NOAPPROACH system variable setting.
• To set the approach position as the teaching position
(default:$SGSYSCFG.$NOAPPROACH = FALSE):
Operation statements with the SPOT instruction operate in the following order:
teaching position -> pressure start position -> pressure position -> pressure end
position -> open position (when set to ENABLE). If the approach position is taken as
the teaching position, movement from the approach position is such that only the
gun axis moves. So, when the approach position is used for this purpose, set the
pressure start position (Tolerance Gun) to "0".
• To teach individual approach positions:
When this method is used, modify the $SGSYSCFG.$NOAPPROACH system
variable as follows:
FALSE → TRUE
Teach individual approach position in front of operation statements with the SPOT
instruction.
Operation statements with the SPOT instruction operate in the following order:
pressure start position → pressure position → pressure end position → open
position (when set to ENABLE). That is, the operation position at the beginning of
operation statements with the SPOT instruction become the pressure start position.
When the operation statement is used in this way, do not set a large pressure start
position tolerance and use the operation statement for the approach position. This is
because it will be disadvantageous in terms of cycle time if the distance from the
pressure start position up to pressure start is longer as torque and deceleration are
carried out at the pressure start position.
Note, however, that this is necessarily not the case if this setting does not adversely
influence the cycle time.
-32-
(Pressuring Start Position Sets the pressure start position by

Setting) specifying the distance from the part.
Tolerance Gun [mm] Specify the pressure start position of the ②Pressuring start
Min.: 0.0 movable side tip as a distance from the top position
Max.: 1000.0 side of the part.
Tolerance Robot [mm] Specify the pressure start position of the fixed 0mm
Min.: 0.0 side tip as a distance from the bottom side of
0mm
Max.: 1000.0 the part.
Termination Type Specify the termination type of the motion to
Default: FINE the pressure position.
-FINE = Operates in the fine mode.
-CNT 0 to 100 = Operates in the continuous
mode at a specified rate.
-NONE = Termination in the operation
statement taught by the SPOT instruction is
used as it is.
ACC Instruction [%] Set the value of the accelerate rate operation
Default: ACC 100 option command for moving to the pressure
start position.
NOTE
About the Pressuring Start Position (tolerance gun)
The servo gun software uses the pressure start position as the boundary for
changing the gun torque and starting pressure control. The gun speed is also
changed to a speed corresponding to the decelerate rate. This is to minimize
pressure overshoot by limiting the speed of contact between the gun and the panel.
(The decelerate rate is automatically set matched to the specified pressure
according to a speed to pressure relationship calculated by pressure calibration.)
This change in speed is carried out during movement to the distance of the movable
side tolerance from the pressure start time. However, if the tolerance is small,
deceleration may be insufficient. If this happens, the panel strongly contacts the gun,
and pressure overshoots.
Adjust as follows if this phenomenon occurs:
1. Try setting a larger tolerance for the movable side of the pressure start position.
2. Try setting a smaller value for the termination type of the pressure start position.
(Reduce the value n of CNT n.)
When set to CNT0 or FINE, the decelerate rate sometimes may not be sufficient.
If overshoot occurs even at the CNT0 or FINE settings, the servo gun may be
contacting the panel before the pressure start point. If this happens, check the part
thickness setting.
3. Try setting a smaller value for the decelerate rate of the pressure position. (e.g. 80.0
→ 60.0)
-33-
(Pressuring Position Setting) Set the operation at arrival to the pressure position.
Decelerate Rate [%] This rate is automatically set according to the ③Pressuring position
Min.: 1.0 pressure setting.
Max.: 100.0 The speed at arrival to the pressure position
is the decelerate rate multiplied by the
teaching speed. Deceleration is not carried 5mm
out if 100% is set.
Termination type Specify the termination type of the motion to
Default: FINE the pressure position.
-NONE = The termination type of the
operation statement taught by the SPOT
instruction is used as it is.
ACC Instruction [%] Set the value of the accelerate rate operation
Default: ACC 100 option command for moving to the pressure
start position.
(Pressuring End Position) The position where the gun opens after pressuring is called the "pressure end
position." Specify this position, the termination type for operation to this position
and the accelerate rate instruction value.
Tolerance Gun [mm] Specify the pressure end position of the ④Pressuring end position
Min.: 0.0 movable side tip as a distance from the top
Max.: 1000.0 side of the part.
Tolerance Robot [mm] Specify the pressure end position of the
Min.: 0.0 movable side tip as a distance from the 3mm
Max.: 1000.0 bottom side of the part. 3mm
Default: CNT 0 the pressure end position.
-NONE = The termination type of the
operation statement taught by the SPOT
instruction is used as it is.
ACC Instruction [%] Specify the value of the accelerate rate
Default: ACC 100 instruction for the motion to the pressure end
position.
-34-
(Open Position Setting) Specify the termination type of the operation to this open position and the value of
the accelerate rate instruction.
Gun open Specify whether or not to generate the gun ⑤Open position
Default: FALSE open position.
Not using the gun open position is
advantageous in terms of cycle time as long 40mm
as operation from the pressure end position
to the next position is not adversely affected.
5mm
-TRUE = Generates the gun open position.
-FALSE = Does not generate the gun open
position.
Default: CNT 0 the open position.
-NONE = Termination in the operation
statement taught by the SPOT instruction is
used as it is.
Accelerate rate instruction [%] Specify the value of the accelerate rate
Default: ACC 100 instruction for the motion to the open
position.
-35-
NOTE
1. About Differences In Open Operation According to Gun Open Setting
• When the gun open position is set to TRUE:
(1) When approach position is set to TRUE:
After the deposition check, the movable side tip opens at the stroke position
specified by the stroke No., and the fixed side tip opens at the gun open position.
Note, however, that both the fixed side and movable side tips open at the approach
position when the stroke No. is "0".
(2). When the gun open position is set to FALSE:
After the deposition check, the movable side tip opens at the stroke position
specified by the stroke No., and the fixed side tip, and the fixed side tip remains as it
is.
Note, however, that both the fixed side and movable side tips open at the teaching
position (position data of line containing the SPOT instruction) when the stroke No. is
"0".
• When gun open is set to FALSE:
Execution of the spot welding instruction ends at the Pressuring end position.
2. With X guns, set only the movable side tolerances on the automatic path, and set the
tolerances on the fixed sides to 0 mm. This is because the fixed side tip also moves
when the movable (gun axis) side is operated. When the fixed side tolerance is set,
the movable side tip may contact the part.
This tip may

be touching
Gun tip the part.
Tolerance
Robot
Robot tip
-36-
Standalone SPOT / Manual SPOT operetion
SERVO GUN DATA G2 JOINT 10 % SERVO GUN DATA G2 JOINT 10 %

PRESSURE / EQ:1 Gun:1 No:6 8/8 STANDALONE / EQ:1 Gun:1 No:6 1/4
1 Comment: [ ]
2 Standard Pressure(Kgf): 350.0 1 Speed(%): 100
3 Part Thickness(mm): 0.0 2 Termination Type: CNT 100
4 PushingDepth(mm): 1.0 3 Acc instruction: ACC100
5 Gun Sag Comp Value(mm): 0.0 4 Use Path: FALSE
8 StandAlone/ManualSPOT:
<*DETAIL*>
[ TYPE ] EQUIP GUN LIST [ TYPE ] EQUIP GUN END
Items to be used only in individual spot welding instructions

Speed (%) Speed specifies the motion speed of the movable tip.
Minimum: 0
Maximum: 100
Termination Type Temination Type specifies a type of positioning for
Default value : CNT moving the movable tip to the Soft Touch and motion
100 positions.
Use Acc Use Acc specifies whether to use the ACC motion
Default value: option instruction in pressurization and opening
DISABLE motions.
DISABLE = no ACC motion option instruction is used.
ENABLE = an ACC motion option instruction is used.
Acc Value Acc Value specifies an acceleration value if “Use Acc”
Minimum : 1 has been enabled.
Maximum : 500
Use Path Use Path specifies whether to use Path motion option
Default value: instruction in pressurization and opening motion.
DISABLE DISABLE = no Path motion option instruction is used.
ENABLE = an Path motion option instruction is used.
CAUTION
The above settings are used also in manual
pressurization and manual welding.
Using sevo gun at the fisrt time, please refer to “APPENDIX

C RECOMMENDATORY SETTING”.
-37-
5.1.3 Welding Sequence
This section describes a welding spot instruction-based

welding sequence.
1: L P[1] 2000mm/sec CNT100

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

pressure is reached.
･ The welding sequence outputs welding condition 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.
Pressure
Specified pressure
Output signals
Pressurization signal
*1
Welding condition (i, j)

Welding strobe *2
Welding command *3
Input signal
Welding completion
Pressurization Welding sequence Opening
SPOT[,S=5,]
5(10)=0 1 0 1(2) :
R-J3 15 Schedule sign #0: SDO [ 0] *****
Welding
16 Schedule sign #1: SDO [ 0] *****
timer
:
SDO[8]=ON
SDO[9]=OFF
SDO[10]=ON
SDO[11]=OFF
*1) When the tip starts to move to the pressure position, the
press signal is output. (The signal becomes ON from
the approach position if the approach position is enabled,
otherwise the signal becomes ON from the pressure
start position.)
-38-
*2) 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 “$20 STOP.G, SG_ER_PRSSRTA Pressure
shortage (%s, %d)” appears, resulting in program
execution being discontinued.
*3) 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
5.1.4 Backup Condition Setting
In a spot welding instruction, the opening amount is

determined according to the specified Backup condition
number.
1: L P[1] 2000mm/sec CNT100

: SPOT[P=3,S=5,BU=
BU=2
BU=2]
1 Press the DATA key to display the DATA screen.

2 Press F1“[TYPE]” to display the pull-up menu.
3 Select “Backup”. The Backup setting screen appears.

__________________ TRUE [ ]
| 1 Registers | FALSE [ ]
Stroke: | 2 Position Reg | FALSE [ ]
The amount of gun opening. | 3 Pressure | FALSE [ ]
| 4 Backup | FALSE [ ]
| +----------
| TYPE | EQUIP GUN DETAIL COPY >

1 [ ] 0.000 TRUE
2 [ ] 5.000 TRUE
3 [ ] 10.000 TRUE
4 [ ] 20.000 TRUE
-39-
4 Specify “Comment”, “Stroke(mm)” and “Manual”.
Comment Enter the text of a comment.

Stroke Specify the amount of stroke using either of the following
two methods:
1) Direct entry. (Default method).
2) Hold down the SHIFT key and press F4“RECORD” to
acquire the absolute value of the current position.
Manual Specify whether to use the specified stroke amount
during manual stroke operation.
To cancel any setting, place the cursor on the target number

and press F5“CLEAR”. A message will appear to prompt
you to confirm your request. Then press F4“YES”.
5.1.5 Teaching Position
･ When a spot welding instruction is taught, the

stationary tip is kept touching a panel.
(2) The movable tip can be in any position. It would be wise to
Movable tip
keep it opened to an appropriate position, though.
Panel
Stationary tip
(1) Jog the stationary tip until it touches the panel.
(3) While holding down the SHIFT key, press F2”SINGLE”.
･ To teach a position, use a new tip.

･ If tip wear compensation is enabled, a wear amount is
deducted from a taught position, when the taught
position is corrected.
Master teaching
New tip
New tip
Touch up
Apparent position teaching with a Position correction with a wear amount deducted, in which case a
worn tip used position that would be taught with a new tip used can be acquired
-40-
･ 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
･ When position compensation, tool compensation, and

incremental instructions are taught for an motion
statement with a spot welding instruction, make the
spot welding instruction the last one in the sequence.
1: L P[1] 2000mm/sec CNT100
: Offset,PR[1] SPOT[P=3,S=10,BU=0]
･ Incremental instruction (INC) must not be used with
SPOT instruction in a motion instruction.
5.1.6 The detail of positions generated by taught position and auto

route setup
Following positions are generated by the SPOT instruction as

follows.
1: L P[1] 2000mm/sec CNT100

: SPOT[P=3,S=5,BU=
BU=2
BU=2]
Approach position Enable/disable Pressure Condition is used to

specify whether to enable
approach position
Movable tip Position Workpiece upper surface -
Ta : Approach tolerance (movable tip) tolerance (Ta) + tip wear amount
(movable tip)
Position Taught position – tolerance (Tb) +
Tb : Approach tolerance (stationary tip) tip wear amount
(stationary tip) Motion type Specified by program(L:linear
Stationary tip
type)
Speed Specified by program(2000mm/sec)
Term tpye Specified by program(CNT100)
Pressure start position Enable/disable Always enabled

Position Workpiece upper surface -
Da: Pressure start
(movable tip) tolerance (Da) + tip wear amount
position tolerance
(movable tip) Position Taught position – tolerance (Db) +
(stationary tip) tip wear amount
Db: Pressure start
position tolerance
Motion type Specified by program(L:linear
(stationary tip) type)
Speed Specified by
program(2000mm/sec)
Term tpye Setting screen
-41-
Pressurization position Enable/disable Always enabled

Position Workpiece upper surface + push-
(movable tip) in amount + tip wear amount
Position Taught position - arm deflection
(stationary tip) compensation amount + tip wear
amount
type)
Speed Speed specified by program x
deceleration ratio
Pressure end position Enable/disable Always enabled

Position Workpiece upper surface -
Oa : Pressure end (movable tip) tolerance (Oa) + tip wear amount
position tolerance Position Taught position – tolerance (Ob) +
(movable tip) (stationary tip) tip wear amount
Ob : Pressure end Motion type Specified by program(L:linear
position tolerance
(stationary tip) type)
Speed Specified by
program(2000mm/sec)
Opening position Enable/disable Pressure Condition is used to

specify whether to enable gun
Ta : Approach tolerance opening
(movable tip) Position If BU = 0:
(movable tip) Workpiece upper surface -
Tb : Approach tolerance tolerance (Ta) + tip wear amount
(stationary tip) (Same position as approach
position)
If BU is nonzero:
Opening amount specified as
stroke condition + tip wear amount
Position If approach position is enabled:
(stationary tip) Taught position – tolerance (Tb) +
tip wear amount
If soft touch is disabled:
Taught position
type)
Speed Specified by
program(2000mm/sec)
Acceleration Setting screen
CAUTION
Please specify 100 to ACC value.
-42-
5.1.7 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, the current pressure is maintained,
and program execution is stopped.
• 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.
5.1.8 E-Stop
• When an emergency stop or power interruption is

carried out during pressure control, the pressure is not
maintained.
• When an emergency stop or power interruption is
carried out, the weld signal and weld condition signal
turn OFF.
• A restart resumes program execution from the spot
sequence.
When an emergency stop or power interruption is
carried out 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 interruption processing must be enabled.
5.1.9 Single-Step Testing
In the single-step operation mode (a program statement on

the current line is executed at a time), a SPOT welding
instruction executes a motion to the approach position at
first, then complete spot welding sequence (pressure start
motion, pressure motion, welding and gun opening) by the
2nd single step execution.
After the first single step execution of a SPOT instruction,
the cursor is still on the instruction. And the spot welding
sequence is completed by the 2nd single step execution, the
cursor moves to the next line.
-43-
5.1.10 Backward Execution (BWD)
･ In backward execution (BWD), single spot welding

instructions are ignored; no spot welding sequence
(pressurization and welding) is executed.
･ In BWD, the single spot welding instruction performs
nothing.
Example:
1:J P[1] 100％ FINE
2:SPOT[P=2,S=10,BU=0]
3:J P[2] 100％ FINE
If BWD is started at the third line, the second line is ignored, and the first line is
executed.
-44-
5.2 OTHER INSTRUCTIONS
This section describes other instructions for servo gun

function except SPOT instruciton.
5.2.1 Servo Gun Condition Instruction
The servo gun condition instruction is used to specify

pressurization and stroke conditions previously, while the
spot welding instruction (SPOT [i]) specifies only a welding
condition or SPOT welding instruction using "*" for the
pressure condition or the stroke condition
(SPOT[P=*,S=i,BU=*]).
Instruction format
GUN1 P[n]
n: Pressure Condition Number (1 to 99）
GUN1 BU[m]
m: Stroke Condition Number（0 to 30）
Teaching method
1. On the editing screen, press F1”[INST]”.
A list of Logic instructions appears.
2. Select “8 ---next page---” to search for
“Servo gun cond.” selection.
3. Select “Servo gun cond”, then a condition to be taught.
Instruction G1 JOINT 10 %
1 Registers 5 JMP/LBL
2 I/O 6 SPOT WELDING
3 IF/SELECT 7 Servo gun cond.
4 WAIT 8 ---next page---
PROGRAM
Servo gun condition G1 JOINT 10 %

1 GUN1 P[...] 5
2 GUN1 BU[...] 6
3 7
4 8
PROGRAM
-45-
･ The servo gun condition instruction specifies only

conditions. Actual operation is triggered using spot
welding instructions.
This instruction is used in pair with the spot welding
instruction (SPOT [i]) that specifies only a welding
condition.
1:GUN1 P[10]
2:GUN1 BU[0]
3:L P[2] 2000mm/sec CNT100
: SPOT[4] P=10, S=4, BU=0
4:L P[3] 2000mm/sec CNT100
: SPOT[5] P=10, S=5, BU=0
5:L P[4] 2000mm/sec CNT100
: SPOT[6] P=10, S=6, BU=0
･ The servo gun condition instruction does not affect the

spot welding instruction (SPOT [P, S, BU]) that specifies
pressurization and stroke conditions.
1:GUN1 P[10]
2:GUN1 BU[0]
3:L P[2] 2000mm/sec CNT100
: SPOT [4] P=10, S=4, BU=0
4:L P[3] 2000mm/sec CNT 100
: SPOT [Ｐ=2,Ｓ=7,BU=1] P=2, S=7, BU=1
5:L P[4] 2000mm/sec CNT 100
: SPOT [6] P=10, S=6, BU=0
5.2.2 Pressurization Instruction
The pressurization instruction is intended to perform

pressurization (up to pressurization in a spot welding
sequence).
The pressurization instruction does not open the gun or
perform welding after pressurization is completed.
Like spot welding instructions, the pressurization
instruction carries out tip wear compensation and arm
deflection compensation.
Instruction format
Press_motion P = [n]
Pressure condition number (1 to 50) gun 1
･ Pressurization is performed according to pressure

condition numbers specified with n and o.
･ The pressurization instruction can be used as both
moton option and single instructions.
－Motion option instruction
The additional-operation instruction controls both
movable and stationary tips during a pressurization
-46-
sequence. It also performs tip wear compensation

and gun deflection compensation.
1: J P[1] 100% FINE

: Press_motion P=[1]
･ The pressurization instruction performs only

pressurization. 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: Pressure Condition
: Press_motion P=[1]
2: WAIT 2.00sec Line 2: Pressuring time
3:L P[2] 100mm/sec FINE Line 3: Gun Opening
5.2.3 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 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 changes the motor

torque limit for the movable tip by calculating it by
multiplying the specified pressure by a conversion factor
(pressure-torque).
It also modifies the excessive-error threshold value in
order to prevent excessive error at pressurization.
-47-
･ 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 lead to an excessive load to be laid 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 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
-48-
5.3 STROKE SWITCHING
This section explains how program-specified stroke switching

is performed.
･ Unlike air guns, the servo gun is not provided with a

dedicated stroke switching instruction. Stroke
switching is implemented using an additional-operation
statement.
･ Use of an motion option instruction for the servo gun

offers the following advantages, which are not available
with air guns.
- The gun opening amount can be specified to any
value.
- The gun opening amount can be changed even in
backward operation (with interference with the
surrounding avoided).
Instruction format (Motion statement format)
Position Data
J P[i] 100% CNTk
Motion Type Motion Speed Termination Type
Motion Type： P(Joint), L(Linear), C(Circular)

Position Data: P[1] to [1500], PR[1] to[10]
The position data of a group specified for the servo gun
specifies the opening amount on the servo gun axis
Motion Speed: Varies value according to the Motion Type.
Termination FINE, CNT0～100
Type：
-49-
6. TIP WEAR DOWN COMPENSATION B-80954EN/01
6 TIP WEAR DOWN COMPENSATION

On the servo gun, wear down on both the fixed side tip and
movable side tip can be compensated.
This chapter describes the following:
1. Flow of tip wear down compensation

Describes the flow of operation when tip wear down is
compensated.
For details, see "6.1 Flow of Tip Wear Compensation."
2. Tip wear detection methods

Describes how to detect tip wear down.
For details, see "6.2 Wear Down Value Detection
Methods."
3. Creation of a wear down value comp. program

Describes various types of wear down value detection
programs.
For details, see "6.3 Creating a Wear Detection Program."
4. Wear down value reset program

Describes the wear down value reset program that is
executed when the tip is changed.
For details, see "6.4 Wear Down Value Reset Program."
5. Abnormal wear down value detection

Describes how to detect abnormal calculated wear down
values.
For details, see "6.5 Detection of Abnormal Wear Down
Value."
6. Checking the reference point and wear down value

Describes how to check the loaded reference point and
calculated wear down values on the teaching panel screen.
For details, see "6.6 Checking the Reference point and
Wear Down Value."
9. Compensation of wear down value for stationary arm

moving with moving gun (X gun)
Describes items needed for compensating wear down
values of X guns.
For details, see "6.7 Tip wear down compensation for
stationary arm moving with movable arm (X gun)."
-50-
B-80954EN/01 6. TIP WEAR DOWN COMPENSATION
6.1 FLOW OF TIP WEAR COMPENSATION
Compensate tip wear down as follows:
Set tip wear down

compensation :Setting/operations unique to tip
wear compensation
Teaching :General operations
Read reference point
Continuous system
operation
Detect wear down

value
Tip wear down value < YES

usable range?
NO
Change tip.
Reset wear down

value
Tip Wear Down Value Carry out the settings in "6-9 Guns on Which the
Compensation Fixed Side Also Moves When the Movable Arm is
Settings Moved" in the case of X guns (fixed side also moves).
Teaching Master teaching using a new tip
Load reference point Execute the load reference point program.
(Switch the SDI to the reference point acquisition
side in the above program.)
Normally, this should be carried out only once.
Continuous system Daily welding operation
operation Determine the wear down value detection cycle in
this operation. (at every 2000 welds, every 8 hours,
visual check, etc.)
Detect wear down Execute the wear down value detection program
value when the wear down value detection cycle is
reached.
(Switch the SDI to the respective wear down value
calculation side in the above program.)
Change tip. Completely stop the robot, and change the worn
down tip with a new tip.
Reset wear down Execute wear down value reset program
value.
-51-
NOTE
･ When loading the reference point, be sure to use the
same tip as when master teaching was carried out.
･ Execute loading of the reference point and
calculation of the wear down values with override set
to 100%. (This is to ensure that loading of reference
the point and calculation of the wear down values
each time are executed at the same speed.)
･ When the tip is changed with a new tip the wear
down value must be reset. However, the reference
point must not be loaded. If the reference point is
loaded after the tip is changed, teaching must be
corrected. The reference point must be the same as
that for a taught tip or equivalent part.
-52-
6.2 WEAR DOWN VALUE DETECTION METHODS
The FANUC Servo Gun function allows you to use one of the
following three methods to detect the wear down value of
each tip.
Select the method suited your particular system
requirements.
･ Incremental operation method (for C gun)

･ Teaching position operation method (for C gun)
･ Register calculation method (for X gun)
C guns and X guns above are defined as follows:
C gun: A gun whose fixed side tip does not operate even
if the movable side tip is moved. (a gun whose
movable side tip only moves)
X gun: A gun whose fixed side tip also operates when
the movable side tip is moved. (a gun whose tips
on both sides move)
Each of these methods calculate the wear down value

according to the following principles:
Incremental operation method:

Incremental operation is used to calculate the wear
down value from the gun and robot positions when the
gun grips the reference panel.
Grip the reference panel by both tips, Grip the reference panel by worn down
and load the reference position. tips, and load the position.
Reference
points a
where,
b is the total wear down value of both tips
a is wear down value on the fixed side
･ Wear down value of gun = a
･ Wear down value of robot = b - a
-53-
Teaching position operation method:

Normal operation is used to calculate the wear down
value of each tip from the difference between the
reference point and the tip end points of the worn down
tip.
Move only the fixed side tip, and load Move only the movable side tip, and
the movable side tip end point. load the fixed side tip end point.
Photoelectric b
switch
where,
the wear down values of each tip when a0, b0 on the
reference tip (new) and a1, b1 on the worn tip
･ Wear down value of gun = a1 - a0
･ Wear down value of robot = b1 - b0
Register calculation method:

Only the fixed side (robot side) is moved to calculate the
wear down value of each tip from the difference between
the reference point and the tip end points of the worn
down tip.
By register calculation, all registers and position
registers are used to calculate all operations without
using the macro programs provided for calculating the
wear down values.
Move only the fixed side tip, and load Move only the fixed side tip (robot
the reference point at the fixed side tip side), and the reference point of
end. movable side tip end is loaded.
World coordinate
system World coordinate
system
where,
the wear down values of each tip when a0, b0 on the
reference tip (new) and a1, b1 on the worn tip
･ Wear down value of gun = a1 - a0

･ Wear down value of robot = b1 - b0
-54-
6.3 CREATING A WEAR DOWN VALUE DETECTION PROGRAM
This section describes how to create wear down value

detection programs for each of the wear detection methods.
6.3.1 Incremental operation method
NOTE
An external sensor is needed for detecting contact of
the movable side tip and fixed side tip with the
reference panel so that the nip position is loaded as
the reference point.
･ Program
NOTE
First, load the tip reference point. Then, calculate the
wear down value at the same operating conditions
(operation speed and teaching position) as when the
reference point was loaded.
Create the following reference point and wear down value

load program. The following macros are used in this
program:
SGGETPOS： Loads the reference point.

SGCALCU： Calculates the wear down value of each tip.
SDI[1]: Sets the signal (or input signal from photoelectric

tube or other external sensor) that turns ON when
the panel contacts the fixed side tip.
SDI[2]: Sets the signal (or input signal from photoelectric
tube or other external sensor) that turns ON when
the panel contacts the movable side tip.
SDI[10]: Signal for switching between reference point
acquisition (ON) and wear down value calculation
(OFF)
-55-
Example Program
[Explanation]
1st line: EQNUM=Equipment No. of gun on which the tip
1: $SGTIPCMP.$EQNUM=1 end position is loaded
2: $SGTIPCMP.$PRINDEX=1 2nd line: PRINDEX=Position register No. that is used for
3: J P[1:ORIGINAL]100% FINE
4: J P[2:APPROACH] 100% FINE loading the tip end position
5: SKIP CONDITION DI[1]=ON 3rd line: Move to origin position.
6: L P[3:STATIONARY] 100mm/sec 4th line: Move to approach position.
FINE
INC SKIP,LBL [1] 5th line: Teach the signal that is input when the panel
7: SKIP CONDITION DI[2]=ON contacts the fixed side tip as the skip condition.
8: L P[4:MOVABLE] 100mm/sec FINE 6th line: Incrementally move the fixed side tip.
INC SKIP,LBL [1]
9: PR[1]=LPOS -Skip conditions are satisfied by contact with the
10: IF DI[10]=ON JMP LBL [10] panel, and program execution moves to the 8th
11: CALL SGCALCU
line.
12: JMP LBL [11]
13: LBL [10] -Jump to the 14th line, and generate the alarm
14: CALL SGGETPOS (user alarm [1]) if the fixed side tip does not
15: LBL [11]
contact the panel.
16: L P[2:APPROACH] 100mm/sec
FINE 7th line: Teach the signal that is input when the panel
17: END contacts the movable side tip as the skip condition.
18: LBL [1]
8th line: Incrementally move the movable side tip.
19: UALM[1]
[END] -Skip conditions are satisfied by contact with the
panel, and program execution moves to the 10th
line.
-Generate user alarm [1] if the movable side tip
does not contact the panel.
9th line: Load the tip end position to PR[1]. Set the position
register No. to the same as PRINDEX (system
variable in 3rd line).
10th to 15th lines: Reference point load and wear down value
calculation macros are switched and called up by
SDI[10].
16th line: Move to approach position.
17th line: Normal end
18th line: Jump here if panel is not contacted.
19th line: User alarm is generated.
NOTE
The above is merely a sample program. Change the
actual speed, termination type, signals and position
register No. to suit the requirements of your system.
Switching of Acquisition of Reference Point and Tip Wear

Down Value Calculation by SDI
SDI is used to switch between reference point acquisition and
tip wear down value calculation as shown in the flow chart.
-56-
1st to 9th lines
NO
SDI=ON?
YES
Acquisition of Calculation of tip wear
reference point down values
16th to 19th lines
6.3.2 Teaching position operation method
NOTE
An external sensor is needed for detecting arrival of
the tip end at the measurement position.
･ Program
NOTE
as when the reference point was loaded.
Create the following reference point and wear down value

load program. The following macros are used in this
program:
SGSTDRBT： Loads the reference point on the gun.

SGSTDGUN： Loads the reference point on the robot.
SGWDNRBT： Loads the tip end position on the gun.
SGWDNGUN： Loads the tip end position on the robot.
SGCALCU2： Calculates the tip wear down values.
SDI[1]: Signal that turns ON when the tip crosses the

photoelectric switch
SDI[10]: Signal for switching between reference point
acquisition (ON) and wear down value calculation
(OFF)
-57-
Example Program
[Explanation]
1st line: EQNUM=Equipment No. of gun on which the tip
1: $SGTIPCMP.$EQNUM=1
2: $SGTIPCMP.$PRINDEX=1 end position is loaded
3: J P[1:ORIGINAL] 100% FINE 2nd line: PRINDEX=Position register No. that is used for
4: J P[2:APPROACH] 100% FINE loading the tip end position
5: SKIP CONDITION DI[1]=ON
6: L P[3:STATIONARY] 100mm/sec 3rd line: Move to origin position.
FINE 4th line: Move to approach position.
: SKIP, LBL [1] 5th line: Teach the signal that is input when the tip crosses
7: PR[1]=LPOS
8: IF DI[10]=ON JMP LBL [10] the photoelectric switch as the skip condition.
9: CALL SGWDNRBT 6th line: Move the robot side, and move the fixed side tip to
10: JMP LBL [11] a position where it completely crosses the
11: LBL [10]
12: CALL SGSTDRBT photoelectric switch.
13: LBL [11] -Jump to the 8th line when the tip crosses the
14: L P[2:APPROACH] 100mm/sec photoelectric switch.
FINE
15: L P[4:MOVABLE] 100mm/sec FINE -Jump to label [1] and generate an alarm if the
: SKIP, LBL [1] photoelectric switch is not crossed even if the tip
16: PR[1]=LPOS moves to position [3].
17: IF DI[10]=ON JMP LBL [20]
18: CALL SGWDNGUN 7th line: Load the current position to PR[1]. Set the position
19: CALL SGCALCU2 register No. to the same as PRINDEX.
20: JMP LBL [21] 8th to 13 lines: Select and call up fixed side reference point
21: LBL[20]
22: CALL SGSTDGUN load macro (SGSTDRBT) and fixed side tip end
23: LBL [21] position load macro (SGWDNRBT) according to the
24: L P[2:APPROACH] 100mm/sec state of SDI.
FINE
25: END 14th line: Evacuate to the approach position.
26: LBL[1] 15th line: Move the gun axis only, and move the movable side
27: UALM[1] tip to a position where it completely crosses the
[END ]
photoelectric switch.
-Jump to the 12th line when the tip crosses the
photoelectric switch.
-Jump to label [1] and generate an alarm if the
photoelectric switch is not crossed even if the tip
moves to position [4].
16th line: Load the current position to PR[1]. Set the position
register No. to the same as PRINDEX.
17th to 23rd lines: Select and call up movable side reference
point load macro (SGSTDGUN) and movable side
tip end position load macro (SGWDNGUN) + both
tip wear down value calculation macros
(SGCALCU2) according to the state of SDI.
24th line: Evacuate to the approach position.

25th line: Normal end
26th line: Jump to here if the skip condition is not satisfied
in the 11th line.
27th line: Generate an alarm if the photoelectric switch is
not crossed.
-58-
NOTE
Switching of Acquisition of Reference Point and Tip Wear

Down Value Calculation by SDI
SDI is used to switch between reference point acquisition and
tip wear down value calculation as shown in the flow chart.
1st to 7th lines
NO
SDI=ON?
YES
SGSTDGUN SGWDNGUN
Acquisition of robot Acquisition of robot tip end
reference point position
14th to 16th lines
NO
SDI=ON?
YES SGWDNGUN
Acquisition of gun tip end
SGSTDGUN position
Acquisition of gun
reference point SGCALCU2
Calculation of tip wear down
values
24th to 27th lines
6.3.3 Register operation method
NOTE
An external sensor is needed for detecting arrival of
the tip end at the measurement position.
･ Program
Create the following two programs:
1) Reference point and wear position load program
2) Compensation amount calculation program
NOTE
as when the reference point was loaded.
-59-
Create the following reference point and wear down

value load program. The positions are loaded to the
following registers in this program:
SDI[1]: Signal that turns ON when the tip crosses the

photoelectric switch
PR [1]: Loads the reference point on the movable side.
PR [3]: Loads the reference point on the fixed side.
PR [2]: Loads the wear down position on the movable
side.
PR [4]: Loads the wear down position on the fixed side.
Example of Position Load Program

1: J P[1:ORIGINAL] 100% FINE [Explanation]
2: J P[2:APPROACH] 100% FINE 1st line: Move to original position.
3: SKIP CONDITION DI[1]=ON 2nd line: Move to approach position.
4: L P[3:STATIONARY] 100mm/sec FINE
SKIP, LBL[1] 3rd line: Teach the signal that is input when the tip
5: IF DI[10]=ON JMP LBL [10] crosses the photoelectric switch as the skip
6: PR[2:WRDWN STATIONARY]=LPOS condition.
7: JMP LBL [11]
8: LBL [10] 4th line: Move the robot side, and move the fixed side
9: PR[1:STNDRD STATIONARY]=LPOS tip to a position where it completely crosses
10: LBL [11] the photoelectric switch.
11: L P[2:APPROACH] 100mm/sec FINE
12: L P[4:STATIONARY] 100mm/sec FINE - Jump to the 8th line when the tip crosses the
SKIP, LBL[1] photoelectric switch.
13: IF DI[10]=ON JMP LBL [20] - Jump to label [1] and generate an alarm if
14: PR[4:WRDWN MOVABLE]=LPOS
15: CALL CALCU the photoelectric switch is not crossed even if
16: JMP LBL [21] the tip moves to position [3].
17: LBL [20] 5th line: Select loading of the current position to PR[1]
18: PR[3:STNDRD MOVABLE]=LPOS
19: LBL [21] and loading to PR[2] according to the state of
20: L P[2:APPROACH] 100mm/sec FINE SDI.
21: END 11th line: Evacuate to the approach position.
22: LBL[1]
23: UALM[1] 12th line: Move the robot side, and move the movable
[END ] side tip to a position where it completely
crosses the photoelectric switch.
- Jump to the 12th line when the tip crosses
the photoelectric switch.
- Jump to label [1] and generate an alarm if
the photoelectric switch is not crossed even if
the tip moves to position [4].
13th to 19th lines: Select loading of the current position
to PR[3] and loading to PR[4] according to the
state of SDI.
20th line: Evacuate to the approach position.
21st line: Normal end
22nd line: Jump to here if the skip condition is not
satisfied in the 11th line.
23rd line: Generate an alarm if the photoelectric switch
is not crossed.
-60-
NOTE
Switching of Acquisition of Reference Point and Tip

Wear Down Value Calculation by SDI
SDI is used to switch between reference point
acquisition and tip wear down value calculation as
shown in the flow chart.
1st to 4th lines
NO
SDI=ON?
YES
Position register[1] Position register[2]
Acquisition of robot Acquisition of robot tip end
reference point position
11th to 12th lines
NO
SDI=ON?
YES Position register[4]

Acquisition of gun tip end
Position register[3] position
Acquisition of gun
reference point SGCALCU2
Calculation of tip wear down
values
20th to 23rd lines
2) Compensation amount calculation program
･ To not detect abnormal wear down values:

The sample program in 1) is for when the robot is moved
in the Z direction in the world coordinate system, and
the position is loaded. That is, the wear down value is
calculated from the difference in the Z component in the
position register that is memorized as the reference
point and wear down position.
Example of Compensation Amount Calculation Program

1: R[5:WRDWN VALUE MOVE] [Explanation]
=PR[GP1:3,3:WRDWN MOVABLE] 1st line: Wear down value calculation of movable side
: －PR[GP1:4,3:STANDARD MOVABLE]
2: R[6:WRDWN VALUE STAT]
tip
=R[GP1:2,3:STNDRD STATIONARY] 2nd line: Wear down value calculation of fixed side tip
: －PR[GP1:1,3:WRDWN STATIONARY] 3rd line: Set wear down value of movable side tip to
3: $SGGUN1.$SETUP.$WRDWN_TIP
=R[5:VALUE MOVE]
system variable.
4: $SGGUN1.$SETUP.$WRDWN_RBT 4th line: Set wear down value of fixed side tip to
=R[6:VALUE STAT] system variable.
[END]
-61-
NOTE
register No. and position register No. to suit the
requirements of your system.
･ To detect abnormal wear down values:

To detect abnormal wear down values, set the maximum
wear down detection in the General Setup screen.
Example of Wear Down Value Calculation Program

[Explanation]
1: R[5:WRDWN VALUE MOVE]
1st line: Wear down value calculation of movable side
=PR[GP1:3,3:WRDWN MOVABLE] tip
: －PR[GP1:4,3:STANDARD MOVABLE] 2nd line: Wear down value calculation of fixed side tip
2: R[6:WRDWN VALUE STAT]
=R[GP1:2,3:STNDRD STATIONARY]
3rd line: Set previous wear down value of movable side
: －PR[GP1:1,3:WRDWN STATIONARY] tip to register.
3: R[8:PREV WRDWN MOVE] 4th line: Set wear down value of movable side tip to
=$SGGUN1.$SETUP.$WRDWN_TIP
4: $SGGUN1.$SETUP.$WRDWN_TIP
system variable.
= R[5:WRDWN VALUE MOVE] 5th line: Set previous wear down value of fixed side tip
5: R[9:PREV WRDWN STAT] to register.
=$SGGUN1.$SETUP.$WRDWN_RBT
6: $SGGUN1.$SETUP.$WRDWN_RBT
6th line: Set wear down value of fixed side tip to
=R[6:WRDWN VALUE STAT] system variable.
7: !Set wear down check setup to register 7th line: Comment (Substitute set value to register.)
8: R[10:MAX WRDWN MOVE]
=$SGGUN1.$SETUP.$MAXWDNTIP
8th line: Set movable side tip maximum wear down
9: R[11:DO MOVE] value to register.
=$SGGUN1.$SETUP.$TIPINFIOIDX 9th line: Set movable side tip error inform signal No. to
10: R[12:INC ERROR MOVE]
=$SGGUN1.$SETUP.$MAXWDNTIPER
register.
11: R[13:MAX WRDWN STAT] 10th line: Set movable side tip increased error to
=$SGGUN1.$SETUP.$MAXWDNRBT register.
12: R[14:DO STAT]
=$SGGUN1.$SETUP.$RBTINFIOIDX
11th line: Set fixed side tip maximum wear down value
13: R[15:INC ERROR STAT] to register.
=$SGGUN1.$SETUP.$MAXWDNRBTER 12th line: Set fixed side tip error inform signal No. to
14: !Check maximum wear down value
of moveable tip
register.
15: IF R[10:MAX WRDWN MOVE]=0 13th line: Set fixed side tip increased error to register.
OR R[11:DO MOVE]=0, 14th line: Comment (Start checking maximum wear
: JMP LBL[1]
16: IF R[5:WRDWN VALUE MOVE]
down on movable side.)
<=R[10:MAX WRDWN MOVE], 15th line: Do not execute the check when movable side
: JMP LBL[2] maximum wear down value or error inform
17: DO[R[11]]=ON
18: JMP LBL[1] signal No. is set to "0".
19: LBL[2] 16th line: Check whether or not detected movable side
20: DO[R[11]]=OFF wear down value exceeds maximum value. If
21: LBL[1]
22: !Check increase error of movable tip it does not, jump to label [2]. If it does, proceed
23: IF R[12:INC ERROR MOVE]=0, JMP LBL[3] to the next line.
24: R[16:INC VALUE MOVE]= 17th line: Turn inform signal ON.
: R[8:PREV WRDWN MOVE]-
R[5:WRDWN MOVE] 18th line: Jump to label [1].
25: IF R[16:INC VALUE MOVE] 19th line: Label [2]
<=R[12:INC ERROR MOVE], 20th line: Turn inform signal OFF.
: JMP LBL[3]
26: UALM[1] 21st line: Label [1]
27: LBL[3] 22nd line: Comment (Start checking the increased error
on the movable side.)
-62-
28: ! Check maximum wear down value 23rd line: Do not execute the check when the movable
of stationary tip side increased error is set to "0".
29: IF R[13:MAX WRDWN STAT]=0
OR R[14:DO STAT]=0,
24th line: Calculate increase from previous and current
: JMP LBL[4] wear down values.
30: IF R[6:WRDWN VALUE STAT] 25th line: Check whether or not the calculated increase
<=R[13:MAX WRDWN STAT],
: JMP LBL[5]
exceeds the increased error. If it does not,
31: DO[R[14]]=ON jump to label [3]. If it does, proceed to the next
32:J MP LBL[4] line.
33: LBL[5]
34: DO[R[14]]=OFF 26th line: Display the user alarm for the increased
35: LBL[4] error.
36: ! Check increase error of movable 27th line: Label [3]
tip
37: IF R[15:INC ERROR STAT]=0, JMP 28th line: Comment (Start checking the maximum wear
LBL[6] down value on the fixed side.)
38: R[17:INC VALUE STAT]= 29th line: Do not execute the check when the fixed side
: R[9:PREV WRDWN STAT]-
R[6:WRDWN VALUE STAT] maximum wear down value is set to "0".
39: IFR[17:INC VALUE STAT] 30th line: Check whether or not the detected wear down
<=R[15: INC ERROR STAT], value on the fixed side exceeds the maximum
: JMP LBL[6]
40: UALM[2] value. If it does not, jump to label [5]. If it does,
41: LBL[6] proceed to the next line.
[END] 31st line: Turn inform signal ON.
32nd line: Jump to label [4].
33rd line: Label [5]
34th line: Turn inform signal OFF.
35th line: Label [4]
36th line: Comment (Start checking increased error on
movable side.)
37th line: Do not execute the check when the fixed side
increased error is set to "0".
38th line: Calculate increase from previous and current
wear down values.
39th line: Check whether or not the calculated increase
exceeds the increased error. If it does not,
jump to label [3]. If it does, proceed to the next
line.
40th line: Display the user alarm for the increased
error.
41st line: Label [6].
NOTE
actual signals, register Nos. and position register
Nos. to suit the requirements of your system.
-63-
6.4 WEAR DOWN VALUE RESET PROGRAM
When a worn down tip is changed with a new tip, the wear
down value so far must be reset, or cleared to "0".
NOTE
Resetting of wear down values is common to all wear
compensation values.
You can call up the following macro programs for resetting

the wear down values:
SGRSET： Resets the wear down values on the gun and robot
simultaneously.
SGRSTGUN： Reset only the wear down value on the gun.
SGRSTRBT： Reset only the wear down value on the robot.
For example, create and execute the following programs to

reset the tip wear down values of both the fixed and movable
sides.
Example Program
1st line: $SGTIPCMP.%EQUM=(equipment No. of gun on
1: $SGTIPCMP.$EQNUM=1 which the reference point is loaded)
2: $SGTIPCMP.$GUNNUM=1 2nd line: $SGTIPCMP.%GUNNUM=(gun No. on which the
3: CALL SGRESE
reference point is loaded)
3rd line: Calls up the wear down value reset program No.
NOTE
actual gun equipment No. and gun No. in the
program to suit the requirements of your system.
-64-
6.5 DETECTION OF ABNORMAL WEAR AMOUNT
･ Detection of maximum wear amount

If a calculated wear amount is larger than a specified
allowable maximum wear amount, the signal SDO[] is issued.
This function can be used to check for a wear amount
detection error and determine when to replace tips.
A calculated wear amount is larger
than an allowable maximum wear SDO[] ON
Reference tip
amount.
･ On the SETUP screen of Sopt Weld, specify an allowable

maximum wear amount and a notification signal for
WEAR DOWN CHECK / EQ:1 Gun:1 1/6 both stationary and movable tips. (->)
･ If 0 mm is specified as an allowable maximum wear
Maximum wear down check (Gun)
1 Max wear down value (mm) : 0.00 amount, no wear amount detection is executed.
2 Increased error (mm) : 0.00 ･ The positive sign corresponds to wear. If 5 mm is
3 Inform signal :
DO[ 0]
specified, the signal is output when wear becomes
Maximum wear down check (Robot) greater than 5 mm; a wear of 5 mm is acceptable.
4 Max wear down value (mm) : 0.00 ･ The notification signal is kept output until wear amount
5 Increased error (mm) : 0.00
6 Inform signal :
detection (SGCALCU or SGCALCU2) is attempted
DO[ 0] again.
･ If SGCALCU or SGCALCU2 detects that the current
[ TYPE ] EQUIP GUN END
wear amount is within the allowable maximum amount,
it turns off the notification signal; also a user program
can be used to turn it off.
･ Detection of tip's apparent extension

A check is made to see if the newly calculated wear amount is
smaller than the previous wear amount (the tip appears as if
it became longer). If wear compensation is carried out after
a tip is ground, this function detects that the current wear
amount is smaller than the previous wear amount (the tip
appears as if it became longer) because of metal chip deposits
on the tip. If the tip's apparent extension amount is larger
than a specified allowable amount, an alarm is issued.
Current wear amount

Previous wear Current wear -）Previous wear amount
Reference tip amount amount Apparent extension amount
> specified value
Excessive apparent extension amount

alarm
-65-
･ On the SETUP screen of Spot Weld, specify allowable

WEAR DOWN CHECK/EQ:1 Gun:1 2/6 maximum apparent extension amounts for the movable
and stationary tip separately.
Maximum wear down check (Gun) ･ If 0 is specified, no detection is attempted.
1 Max wear down value (mm) 0.00
2 Increased error (mm) : 0.00 ･ The positive sign corresponds to the tip's apparent
3 Inform signal : DO[ 0] extension.
Maximum wear down check (Robot)
4 Max wear down value (mm) : 0.00
･ The following alarms are issued:
5 Increased error (mm) : 0.00 SVGN-032 STOP.G “Tip increased error (Gun)”
6 Inform signal : DO[ 0] SVGN-033 STOP.G “Tip increased error (Robot)”
NOTE
If wear compensation is executed after tip replacement, the current wear amount
appears to be smaller than the previous wear amount. To prevent erroneous
detection, it is necessary to reset the wear amount after tip replacement
An increased error will result if a worn down tip is used as it is for compensating wear
down. The tip wear down value must be reset after the tip is changed to prevent
erroneous detection. Note, however, that the excessive error increase alarm occurs
if the installation error between a changed tip and the reference tip exceeds the
increased error amount as shown in the figure below. If this happens, the changed
tip may be installed with excessive play. Check the installation of the tip
Reference tip Changed tip
Mounting error
Current calculated wear down value = mounting error

-） Previous calculated wear down value = 0 (caused by reset)
Mounting error > specified value
Excessive error increase alarm
-66-
･ Setup for maximum wear down check
SETUP Spot Weld G2 JOINT 10 % SETUP Spot Weld G2 JOINT 10 %

GENERAL / EQ:1 Gun : 1 10/12 WEAR DOWN CHECK / EQ:1 Gun:1 1/6
1 Tip Wear Down Comp : ENABLE
2 Gun Sag Compensation : ENABLE Maximum wear down check (Gun)
3 Close Direction (Gun) : PLUS 1 Max wear down value (mm) : 0.00
4 Close Direction (Robot) : UT : 1 [+Z ] 2 Increased error (mm) : 0.00
5 Max Motor Torque (%) : 100.0 3 Inform signal : DO[ 0]
6 Max Pressure (Kgf) : 500.0 Maximum wear down check (Robot)
7 Tip stick detect delay (ms) : 0 4 Max wear down value (mm) : 0.00
8 Weld Timing Torque Rate(%) 0 5 Increased error (mm) : 0.00
9 Count register: <*DETAIL*> 6 Inform signal : DO[ 0]
10 Max wear down check : <*DETAIL*>
11 Pressure Cal : INCOMP <*DETAIL*>
12 Wear Down Cal : COMP <*DETAIL*>
[ TYPE ] EQUIP GUN
Maximum Wear Down Check" items

Movable tip
Max wear down value (mm) Max wear down value (Gun) specifies an allowable maximum wear amount for
Default value: 0.0 the movable tip. If a calculated tip wear amount for the movable tip is higher
than this value, an SDO specified at Inform signal (Gun) will be output. If 0
mm is specified, however, no wear amount check is made. The valid data
range is between 0.0 and 100.0.
Increased error (mm) Increased error (Gun) specifies an allowable error for a tip wear increase. A
Default value: 0.0 calculated tip wear amount may turn out to be lower than the previous tip wear
amount because of cutting chip deposits (the tip appears as if it extended). If
this tip size increment is higher than the specified allowable error, a “Tip
increased error (Gun)” alarm will be issued. If 0 mm is specified, however, no
wear amount check is made. The valid data range is between 0.0 and 100.0.
Inform signal Inform Signal (Gun) specifies an DO. If a calculated tip wear amount for the
Default value: 0.0 movable tip is higher than the value specified at Max wear down value (mm),
the specified DO will be output. If 0 is specified, however, no wear amount
check is made.
Stationary tip
Max wear down value (mm) Max wear down value (Robot) specifies an allowable maximum wear amount
Default value: 0.0 for the stationary tip. If a calculated tip wear amount for the stationary tip is
higher than this value, an SDO specified at Inform signal (Robot) will be output.
If 0 mm is specified, however, no wear amount check is made. The valid data
range is between 0.0 and 100.0.
Increased error (mm) Increased error (Robot) specifies an allowable error for a tip wear increase. A
Default value: 0.0 calculated tip wear amount may turn out to be lower than the previous tip wear
amount because of cutting chip deposits (the tip appears as if it extended). If
this tip size increment is higher than the specified allowable error, a “Tip
increased error (Robot)” alarm will be issued. If 0 mm is specified, however,
no wear amount check is made. The valid data range is between 0.0 and
100.0.
Inform signal Inform signal (Robot) specifies an DO. If a calculated tip wear amount for the
Default value: 0.0 stationary tip is higher than the value specified at Max wear down value(mm),
the specified DO will be output. If 0 is specified, however, no wear amount
check is made.
-67-
6.6 CHECKING THE REFERENCE POINT AND WEAR DOWN

VALUE
You can confirm the reference point and wear down value
loaded by the reference point program in the following
screens.
You can also confirm the calculated wear down value in the
Status (Monitor) screen.
1. Press the SELECT SCREEN key to display the Screen

menu.
2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select 8 Spot welding. The Servo Gun Setup screen is
displayed.
5. Select 8 General Setup.
(Move the cursor to <*DETAIL*> and press the ENT
key.)
6. Select 22 Wear Down Cal.
(Move the cursor to <*DETAIL*> and press the ENT
key.)
The Load Tip Reference Point screen is displayed.

SERVO GUN SETUP 8/9
1 Equip number : 1
:
8 General Setup : <*DETAIL*>
9 Manual Operation Setup : <*DETAIL*>
[ TYPE ] EQUIP

GENERAL / EQ:1 Gun:1 12/12
10 Max wear down check : <*DETAIL*>

11 Pressure Cal : COMP <*DETAIL*>
12 Wear Down Cal : INCOMP <*DETAIL*>
[ TYPE ] EQUIP GUN
When the reference point is loaded, Wear Down Cal in the

general setup screen changes to COMP from INCOMP.
-68-

Tip Wear Down Calibration / 1/5
Equip number:1 Gun:1
･ When the wear down value is calculated, the value is
1 Calibration Status: COMP
2 Wear down value (Gun) (mm) : 0.00 displayed at Wear Down Value. You can confirm the
3 Wear down value (Robot) (mm) :0.00 wear down value in the Status (Monitor) screen.
4 Standard pos (Gun) : ･ You can directly enter the wear down value in this
Group: 2 J1: 0.00
5 Standard pos (Robot) : screen. (This value can be directly overwritten.)
Group: 1 UF:0 UT:0 ･ You can confirm the loaded reference point in this screen
X: 0.00 Y: 0.00 Z: 0.00
(excluding the PR calculation method).
[ TYPE ] END COMP INCOMP
-69-
6.7 TIP WEAR DOWN COMPENSATION FOR STATIONARY

ARM MOVING WITH MOVABLE ARM(X GUN)
In case of guns which have a stationary arm moving with a

movable tip, the stationary tip also move even if only
Move movable tip

Movable tip
Statianay tip also move

Stationary tip
movable tip's wear down is compensated.

If compensate tip wearing of these guns by changing movable
tip position as C gun, panel will be bent to a direction.
If compensate as a C Gun…
Panel will be bent at welding

Compensate (decrease)
Compensate (decrease) the the tolerance of stationary
tolerance of movable tip for tip tip for tip wear amount of
wear amount of movable tip stationary tip.
It is necessary for this type of gun to consider the move

distance of stationary tip at tip wear compensation.
This move distance is changed by tip wear amount and gun
open/close distance.
For the compensation, it is necessary to set data representing
the relation between gun open/close distance with stationary
tip's move distance.
Setting
Set the following system variable.
$SGGUN1.$TW
$METHOD
$SCALE
$OPEN[10]
$CLOS[10]
-70-
Each system variable means as the followings.

$METHOD 1＝ "Push depth adjust": Add total tip wear amount
Default value= 4 to push depth of movable tip.
2＝ "All points offset"： Add compensate distance
at pressure position to all position in SPOT
sequence.
3＝ "3 points offset"： Add compensate distance at
pressure position to pressure start position,
pressure position and pressure end position.
4＝ "All points adjust"： Calculate compensate
distance at each point in SPOT sequence.
（Default）
5＝ "3 points adjust"： Calculate compensate
distance at pressure start position, pressure
position, pressure end position.
$SCALE A number for scaling open/close data of another
Default value=1.0 gun.
This is used when some gun have the same
mechanizm.
$OPEN[1]～[10] Representing the relation between gun open
distance with move distance of stational tip.
$CLOS[1]～[10] Representing the relation between gun close
distance with move distance of stational tip.
$OPEN[1]～[10]and $CLOS[1]～[10]consist of the following

system variables.
$WIDHT Servo gun stroke width where the following $RATIO
Default value =10[mm] and $OFFSET are satisfied.
$RATIO a in the following equation (1)
Default value= 0.0
$OFFSET b in the following equation
Default value= 0.0[mm]
Y = a･X + b ………………………(1) Y (move distance of stationary tip)

Y： move distance of stationary tip $OPEN[i]
X： Gun open/close distance $WIDTH = ΔX
$RATIO = a
$OFFSET = b
(X2,Y2)
(X1,Y1)
Y2 b a
Y1
X1
X2
ΔX (=$WIDTH) X (Gun open distance)
-71-
Therefore, $SCALE, $OPEN[i] and $CLOS[i] mean as the

following.
OPEN[1] OPEN[10] Y
+X
+X In case of $SCALE = 1.0
Changed to $SCALE = 2.0

CLOS[10]
CLOS[1]
Close Open/Close Open

distance = 0
Setting for C Gun

（All of the followings are default value.）
Please set up as the followings for C gun or X gun with
completely stationary arm.
$METHOD = 4
$SCALE = 1.0
Stationary tip will not move by Gun open/ close, therefore all
$OPEN[i], $CLOS[i] will be set as,
$RATIO = 0.0
$OFFSET = 0.0
Compensation amount
= tip wear amount of stationary tip
Y (move distance of stationary tip)

Movable tip
a=0, b=0
Stationary tip
ΔX
Movable tip
Stationary
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B-80954EN/01 7. GUN DEFLECTION COMPENSATION
7 GUN DEFLECTION COMPENSATION

Compensating for gun deflection that may occur at
pressurization will enable a spot welding sequence to always
be performed at an optimum position.
･ Compensation method
Gun deflection is compensated for by setting up a gun
deflection amount previously measured at
pressurization as a Pressure Condition and pushing up
the stationary tip by the deflection amount according to
the Pressure Condition before pressure is applied.
State with no gun deflection compensation State with gun deflection compensation
Gun deflection
compensation amount h ｈ
･ Compensation amount setting method

DATA Registers G2 JOINT 10 % Setup compensation amount by using the following
R[ 1: ]=0 procedures
__________________ ]=0
| 1 Registers | ]=0
| 2 Position Reg | ]=0 1. Press the DATA key to display the DATA screen
| 3 Pressure | ]=0 2. Press F1“[TYPE]” to display the pull-up menu.
| 4 Backup
| +----------
| ]=0
3. Select “Pressure”. The servo gun Pressure Condition
| TYPE | list setting screen appears.
4. Press F4"DETAIL". The servo gun Pressure Condition
detail setting screen appears.
SERVO GUN DATA G2 JOINT 10 % 5. Input the gun deflection amount to the item "5 Gun Sag
No. Press (Kgf) Manual Comment
Compensation（mm）" in the screen.
1 180.0 TRUE [FRONT PNL]
2 195.0 TRUE [REAR PNL ]
3 185.0 TRUE [SIDE PNL ] SERVO GUN DATA G2 JOINT 10 %
4 0.0 FALSE [ ] PRESSURE / EQ:1 Gun:1 No:1 5/8
: : : : 1 Comment: [FRONT PNL ]
2 Standard Pressure (Kgf) : 350.0
[ TYPE ] EQUIP GUN DETAIL COPY > 3 Part Thickness (mm) : 0.0
4 Pushing Depth (mm) : 1.0
5 Gun Sag Comp Value (mm) : 0.0
7 Auto Route : <*DETAIL*>
8 Stand Alone/Manual SPOT :<*DETAIL*>
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8. TIP STICK SIGNAL DETECTION FUNCTION B-80954EN/01
8 TIP STICK SIGNAL DETECTION FUNCTION

The deposition signal detection function checks the state of
the deposition detection signal after the specified time has
elapsed since the reception of the welding completion signal,
and stops the robot if deposition has occurred.
This function is enabled by specifying "SDI[] number used for
the deposition detection signal (deposition detection signal)"
and "delay time between the welding completion signal and
the deposition detection signal (deposition detection delay
time)."
NOTE
The customer is requested to prepare the equipment
for detecting deposition and the deposition detection
signal.
･ Deposition detection signal setting method

I/O Spot Input G1 JOINT 10 %
Display the I/O screen by executing the following
I/O SPOT / EQ:1 1/6 procedure
1 Weld completion : DI [ 1] ***** 1. Press the MENUS key to bring up the screen menu.
2 Weld alarm : DI [ 2] *****
3 Weld comp release : DI [ 3] *****
2. Select “5 I/O”.
4 Tip stick detect : DI [ 4] ***** 3. Press F1“[TYPE]” to display the pull-up menu.
5 Pressure enable : DI [ 5] ***** 4. Select “Spot welding”. The I/O Spot Input/Output
6 Comp confirmation : DI [ 6] *****
screen appears.
[ TYPE ] EQUIP IN/OUT 5. Set up “4 Tip stick detect” on Spot Input screen.
･ Deposition detection delay time setting method

SETUP Spot Weld G2 JOINT 10 % Display the General Setup screen by executing the
1 Tip Wear Down Comp : ENABLE following procedure
2 Gun Sag Compensation : ENABLE 1. Press the MENUS key to bring up the screen menu.
3 Close Direction (Gun) : PLUS 2. Select “6 SETUP”.
4 Close Direction (Robot): UT: 1 [+Z]
5 Max Motor Torque (%) : 100.0 3. Press F1“[TYPE]” to display the pull-up menu.
6 Max Pressure (Kgf) : 500.0 4. Select “Spot welding”. The SETUP SPOT Weld
7 Tip stick detect delay (ms) : 0 screen appears.
8 Weld Timing Torque Rate(%) 0
9 Count register : <*DETAIL*> 5. Select "8 General Setup". (Move the cursor on
10 Max wear down check :<*DETAIL*> <*DETAIL*> and press ENTER key.) General
11 Pressure Cal : INCOMP <*DETAIL*> Setup screen for Servo Gun setup appears.
12 Wear Down Cal : INCOMP <*DETAIL*>
6. Specify "7 Tip stick detect delay(ms)"
･ Deposition detection timing signal setting method
Display the SPOT Welding I/O screen by executing the
following procedure
-74-
B-80954EN/01 8. TIP STICK SIGNAL DETECTION FUNCTION
I/O Spot Output
I/O SPOT / EQ:1
G1 JOINT 10 %
8/23
: 4. Select “Spot welding”. The I/O Spot Input/Output
7 Weld tear off : DO [ 7] ***** screen appears.
8 Tip stick timing : DO [ 8] *****
9 Schedule sign #0 : DO [ 9] *****
5. Set up “8 Tip stick detect timing:"
:
･ Deposition check timing
[ TYPE ] EQUIP IN/OUT
A deposition check is made by detecting a deposition
detection signal from the welding timer when the
deposition detection delay time elapses after the tip has
been retracted to the escape position. If the deposition
detection signal is on, a deposition alarm stops the robot.
Move to pressure end position
Deposition
＜Deposition check?＞
Oa : Pressure end position OK
tolerance (movable tip)
Release pressure Stop on alarm
Ob : Pressure end position
Tolerance
(stationary tip) Open gun
Termination type = CNT100：
Movement to If CNT 100 is specified

the pressure end position
☆
Deposition detection
delay time
This signal is output to adjust the detection timing
Deposition detection between the welding timer and the robot.
timing signal
Termination type = FINE：
Movement to
the pressure end position If FINE is specified
☆
delay time
timing signal
-75-
9. DEPOSITION REMOVAL FUNCTION B-80954EN/01
9 DEPOSITION REMOVAL FUNCTION
NOTE
Using this function requires that a hardware option
unit be installed.
･ Deposition removal function

If deposition occurs between the electrode tip and the
welded workpiece, the worker will perform an operation
called hammering to separate the tip from workpiece
after welding. With the servo gun, it is necessary to open
the movable tip (on the extended axis) manually (gun
axis jogging or manual stroke opening) in addition to
hammering. This manual operation is performed usually
without an external emergency stop. For the deposition
removal function, however, the amplifier power for six
robot axes is turned off to protect the operator. To be
specific, a deposition removal screen is provided. On this
screen, specifying deposition removal enables manual
operation by switching off the amplifier power for six
robot axes but without switching off the power for the
additional axis.
Functions
1. On the deposition removal screen shown below,
enabling “Stick tear off” switches off the servo power
for six robot axes.
2. Under this condition, operation commands issued to
the six robot axes cannot run the robot.
3. Under this condition, only the servo gun movable
axis is active.
4. Enabling deposition removal inhibits the program
from starting.
5. If an output signal is assigned a signal number at “7
Weld tear off” on the spot I/O screen, this signal is
kept on as long as deposition removal is enabled.
Deposition removal setting method

Display the deposition screen by executing the
Stick Tear Off G1 JOINT 10 % following procedure
STICK TEAR OFF / EQ:1 Gun:1 1/1 1. Press the MENUS key to bring up the screen menu.
1 Stick tear off: DISABLE
2. Select “3 MANUAL FCTNS”.
3. Press F1“[TYPE]”.
[ TYPE ] EQUIP ENABLE 4. Select “Tear off”.
-76-
B-80954EN/01 9. DEPOSITION REMOVAL FUNCTION
5. Placing the cursor on line 1, then pressing the

F4“ENABLE” key enables this function. Pressing
the F5“DISABLE” key disables the function. If a
configuration signal has been set up, SDO is turned
on and off if the function is enabled and disabled,
respectively.
･ To use a confirmation signal, it is necessary to set up a

signal number for the confirmation signal in advance. If
0 is specified as the signal number, the confirmation
signal is disabled.
CAUTION
The confirmation signal is switched between ON
and OFF only when the setting of deposition
removal is switched (enabled or disabled). If you set
up the confirmation signal, disable the deposition
removal function, then make the enable/disable
state of deposition removal match the ON/OFF
state of DO.
NOTE
The user must judge whether or not this function
conforms to the user's safety standards.
-77-
10. SERVO GUN MONITORING B-80954EN/01
10 SERVO GUN MONITORING

The state of the spot welding instruction being executed is
displayed on the servo gun monitoring screen at real-time.
-78-
B-80954EN/01 10. SERVO GUN MONITORING
･ Display method
Display the servo gun monitoring screen by executing
the following procedure.
Procedure
2. Select “0 -- NEXT --“ and “4 STATUS”.
4. Select “Spot welding”. The SERVO GUN
Monitoring screen appears.
STATUS Spot Weld G1 JOINT 10 %

SERVO GUN / EQ:1 Gun:1 1/13
1 Gun type : SINGLE
2 Pressure cond numbe r: (stnd 1) 1
3 Current schedule number : 1
4 Backup cond number : (stnd 1) 1
5 Wear down value (Gun) (mm) : 2.00
6 Wear down value (Robot) (mm) : 2.00
7 Pressure value (kgf) : 0.00
8 Current position (Gun) (mm) : 0.00
9 Tip dress counter : 100
10 Tip exchange counter : 200
11 Total spot counts : 3000
12 Spot count register : 1
13 Register value : 2469
[ TYPE ] EQUIP GUN
-79-
10. SERVO GUN MONITORING B-80954EN/01
･ Display items
Gun type Indicates whether a double gun is in use.
Pressure cond number Indicates the servo gun condition data number
and stnd specified for the spot welding instruction being
executed. If no spot welding instruction is being
executed, the Pressure Condition data specified for
the most recently executed spot welding instruction
is indicated. The “stnd” item displays the Pressure
Condition data number specified by the servo gun
Pressure Condition instruction.
Current schedule Indicates the current spot welding condition number.
number
Backup cond number Indicates the stroke condition data number specified
and stnd for the spot welding instruction being executed. If
no spot welding instruction is being executed, the
stroke condition data number specified for the most
recently executed spot welding instruction is
indicated. The “stnd” item displays the stroke
condition data number specified by the servo gun
Pressure Condition instruction.
Wear down value Indicates the wear amount of the movable tip.
(Gun) (mm)
Wear down 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 applied
between the tips.
Current position (Gun) Indicates the current gun position on the gun axis.
(mm)
Tip dress counter Indicates a value in the tip dress counter register
specified on the setting screen. This value is
incremented by one each time spot welding is
performed.
Tip exchange counter Indicates a value in the tip replacement counter
register specified on the setting screen. This value
is incremented by one each time spot welding is
performed.
Total spot counts This value is incremented each time spot welding is
performed.
Spot count register Indicates the number of a register a value in which is
incremented each time spot welding is performed.
Register value Current value in the counter register.
-80-
B-80954EN/01 11. TEST EXECUTION
11 TEST EXECUTION
Test execution (test run) can be carried out to run the robot
on a standalone basis before it is put into automatic
operation on a production line. This section focuses on how
to enable/disable pressurization and welding, which are
related to the spot welding sequence.

TEST CYCLE G1 JOINT 10 % 2. Select "2 TEST CYCLE". TEST CYCLE screen appears.
2/4
3. You can switch Pressurization ENABLE/ DISABLE, Welding
Group number: 1
Robot lock (each group): DISABLE ENABLE/ DISABLE on the screen.
Equip number: 1
Gun close(each equip): ENABLE
Gun welding(each equip): ENABLE
Digital/Analog I/O: DISABLE Gun close (each equip) If “DISABLE” is selected, no spot welding
Default value: ENABLE sequence (pressurization, welding, or
[TYPE] EQUlP ENABLE DISABLE opening) is not performed during the
execution of a spot welding instruction.
Nothing is performed during the execution
of a simple spot welding instruction.
During the execution of an additional-
operation instruction, movement occurs to
a taught point on the gun and robot axes.
Gun welding No welding sequence is performed during

(each equip) the execution of a spot welding instruction.
Default value: ENABLE Neither pressurization nor opening
sequence is executed. No schedule
signal is sent to the welding timer. No
completion signal is awaited. After
pressurization, gun opening is carried out
when the welding time specified at “Spot
welding” has elapsed.
ALARM
HOLD
The ENABLE/DISABLE states
：：
explained above are indicated
GUN ENBL using the status indication LEDs
on the teach pendant.
WELD ENBL
-81-
12. INDEPENDENT MOTION B-80954EN/01
12 INDEPENDENT MOTION
NOTE
Use of this function requires that a hardware option
unit be installed.
Because the servo gun and robot axes are controlled in

separate motion groups, the following items are possible with
the Robot Lock.
• Applying the machine lock to the robot axis enables

manual operation of only the gun axis.
• Applying the machine lock to the gun axis enables
manual operation of only the robot axis.
NOTE
The user must judge whether or not this function
conforms to the user's safety standards.
-82-
B-80954EN/01 13. PRESSURE ENABLE AND COMPLETION CONFIRMATION SIGNALS
13 PRESSURE ENABLE AND COMPLETION

CONFIRMATION SIGNALS
-83-
13. PRESSURE ENABLE AND COMPLETION CONFIRMATION SIGNALS B-80954EN/01
13.1 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
Movement to approach position
OFF/ time-out
Wait for Pressure enable signal
to become ON
ON
Pressurization Time-out alarm
SETTING
I/O Spot Input G1 JOINT 10 % 3. Press F1“[TYPE]” to display the pull-up menu.
I/O SPOT / EQ:1
1 Weld completion :
5/6
DI [ 1] *****
4. Select “Spot welding”. The I/O Spot Input/Output
2 Weld alarm : DI [ 2] ***** screen appears.
3 Weld comp release : DI [ 3] ***** 5. Press F3"IN/OUT" to switch to the input screen.
4 Tip stick detect :
5 Pressure enable :
DI [ 4] *****
DI [ 5] *****
6. Assign DI signal for " Pressure enable". If the index
6 Comp confirmation : DI [ 6] ***** of DI signal is 0, this function is disabled.
･ The time-out value is defaulted to 3 seconds. To change
the value, update the following system variable (msec).
$SPOTEQSETUP[1].$PEN_TMOUT = 5000 (Change to

5sec)
Others
This function does not work with:
･ Pressurization instruction
･ Manual pressurization
･ Manual welding
If a time-out condition occurs, the following alarm

message appears, causing the program to pause.
"SVGN-035 Pressure enable time out”
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B-80954EN/01 13. PRESSURE ENABLE AND COMPLETION CONFIRMATION SIGNALS
13.2 WELD COMPLETION CONFIRMATION SIGNAL
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 Weld completion signal to
become ON
ON
Next instruction Time-out alarm
SETTING
I/O Spot Input G1 JOINT 10 % 2. Select “5 I/O”.
I/O SPOT / EQ:1 6/6 3. Press F1“[TYPE]” to display the pull-up menu.
1 Weld completion : DI [ 1] ***** 4. Select “Spot welding”. The I/O Spot Input/Output
2 Weld alarm : DI [ 2] *****
3 Weld comp release : DI [ 3] ***** screen appears.
4 Tip stick detect : DI [ 4] ***** 5. Press F3"IN/OUT" to switch to the input screen.
5 Pressure enable : DI [ 5] ***** 6. Assign DI signal for " Comp confirmation". If the
6 Comp confirmation : DI [ 6] *****
index of DI signal is 0, this function is disabled.
･ The time-out value is defaulted to 3 seconds. To change
the value, update the following system variable (msec).
$SPOTEQSETUP[1].$NSE_TMOUT
$SPOTEQSETUP[1].$NSE_TMOUT = 5000 (Change to

5sec)
Others
This function does not work with:
･ Pressurization instruction
･ Manual pressurization
･ 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-
14. PRESSURE PROFILE CONTROL FUNCTION B-80954EN/01
14 PRESSURE PROFILE CONTROL FUNCTION
-86-
B-80954EN/01 14. PRESSURE PROFILE CONTROL FUNCTION
14.1 OVERVIEW
It is possible to control pressure value with multi-step in

servo gun spot welding. This function can increase a welding
quality. This function is an optional.
･ Maximum 3 steps pressure can be specified for each step
(Before welding, In welding, After welding).
･ 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
-87-
14.2 PROFILE DATA
14.2.1 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*>
2. Move cursor to "3 Pressure Profile", and push ENTER

key.
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.
[ TYPE ] EQUIP GUN ENABLE
Please refer to the next page for the meaning of each

items.
-88-
B-80954EN/01 14. PRESSURE PROFILE CONTROL FUNCTION
14.2.2 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
2 Standard Pressure (Kgf) : Pbase Standard pressure value
3 Init Press: Pf0 [Kgf] (PRf0[%]) This is standard value is for the following pressure
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.
[ TYPE ] EQUIP GUN ENABLE
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)
-89-
($SGPPDCFG.$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.
14.3 LIMITATIONS
Please do not shorten a specified time in a profile data too

much. (10Kgf/msec is a standard)
-90-
15 GUN CHANGE FUNCTION
15. GUN CHANGE FUNCTION B-80954EN/01
15.1 OUTLINE
15.1.1 Feature of function
･ It is possible to switch more than two servo guns without

power off.
･ Even the servo gun which does not have backup battery
of pulse coder can uses this function.
NOTE
This document calls the servo gun without backup
battery “batteryless type”.
･ In the case of batteryless type, the automatic calibration

can be done in a short period.
15.1.2 Basic specification
The total number of 10 guns per system, 6 guns per equipment

changable gun The each equipment can control only one gun at the
same time.
The period of gun 0.4 sec（Battery type）/ 0.4 sec(Battery less type) *1)
detach
The period of gun ４ sec(Battery type)/6 sec(Batteryless type) *1)
attach
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.
15.1.3 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.
･ Do not stop the gun during the calibration motion.
･ The line tracking can not used with gun change function.
--92
B-80954EN/01 15. GUN CHANGE FUNCTION
15.1.4 System Configuration
Servo gun change system is constructed as follows.
Gun k
Detach/Attach
Gun 1 Gun 2 Gun 3 Gun 8
Robot = Motion group 1 ...
J1 J2 J1 J6
i (10 - i) （Max６）
EQ1 EQ2
= Motion group m = Motion group n
R-J3
Controller
You 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)
-93-
15.1.5 Outline of installation
□ Select “Servo gun” to the euipment SETUP SERVO GUN

Initial setup
type.
□ Enable the gun change. 1 Equip number : 1
□ Set gun number configuration. 2 Equip type : [SERVO GUN]
Controlled
3 Motion Group (Gun) : 2
start
4 Motion Group (Robot) : 1
5 Gun Change : ENABLE
[ TYPE ] EQUIP GUN_CFG
□ Set On to the battery type.
Provisional attach □ Execute gun attach
instruction.
SETUP GUN CHANGE G1 JOINT 10 %
□ Perform zero position
Gun Change / EQ:1 GUN:1 9/9
mastering
1 Comment : [ ]
□ Perform calibration.
2 Attach signal : SDI[ 1]
3 Indntify signal : SDI[ 2]
Gun change setup □ Select correct battery type. 4 Battery : OFF
□ Select correct calibrate motion 5 Calibration motion type : [TYPE 3]
type. Calibration motion
6 Calibration Speed (%) : 100
7 Acc value : 100
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
--94
15.2 INITIAL SETUP
The following initial setup is needed to install the servo gun

change system.
･ Motion parameter setup(NOBOT 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”.
-95-
15.3 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
AXS Comment BatteryType
3. Press F1[TYPE].
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
3 GUN [ 1: Part C ] ON[------]
F3:DETAIL. The detail screen is displayed.
[ TYPE ] EQUIP DETAIL

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 6, to suit the
user's particular system requirements.
(See Table 3.1 and Fig. 3.1.)
--96
Calibration motion type Selection Criteria

･ 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.
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
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
position (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."

position (near the 0 position) where the
-97-
distance to the open limit is two or more turns

of the motor.
position (near the open limit) where the distance to
the open limit is two or less turns of the motor.
･ 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."

position (near the 0 position) where the
distance to the position where the detect signal
turns ON is two or more turns of the motor in
the open direction.
position (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.
Table 3.1 Calibration Motion Type

Type Calibration Motion Set Position of
Reference position
Type 1 The servo gun is opened by two turns of the Position when gun
motor, and then calibrated at the position is detached
where it is closed by two turns. NOTE 1 Reference position
Set setting item (1) on the next page. is not required.
NOTE 2
Type 2 The servo gun is closed by two turns of the Position when gun
motor, and then calibrated at the position is detached
where it is opened by two turns. Reference position
Set setting item (1) on the next page. NOTE is not required.
1 NOTE 2
Type 3 The servo gun is opened to its open limit, Open limit position
and then calibrated. Arrival at the open limit
is detected by motor torque.
Set setting items (1), (2) and (3) on the next
page.
--98
Type 4 The servo gun is closed by two turns of the Open limit position
motor, opened to its open limit, and then
calibrated. Arrival at the open limit is
detected by motor torque.
page.
Type 5 The servo gun is opened until the detection Position where
signal turns ON, and then calibrated. detection signal
Set setting items (1), (2) and (4) on the next turns ON
page.
Type 6 The servo gun is closed by two turns of the Position where
motor, opened until the detection signal detection signal
turns ON, and then calibrated. turns ON
page.
NOTE
1 Gun master data is lost if 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 0 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.
-99-
Fig. 15.3 Calibration Motion Type

Type 1 Type 2
When the gun is detached near 0 position When the gun is detached near the open limit
2 turns
2 turns of motor 2 turns 2 turns of motor
(open direction) (close direction)
Position when Position when
gun is detached gun is detached
Type 3 Type 4
Torqu Torqu
e
2 turns of motor
Detection (close direction) Detection
Reference position setting Reference position

position during quick setting position during
mastering quick mastering
Type 5 Type 6
Input Input
signal signal
ON ON
OFF 2 turns of motor OFF

Detection (close direction) Detection
Reference position
Reference position setting setting position
position during quick during quick
mastering mastering
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
--100
Screen for Calibration Types 3, 4 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]
[ TYPE ] LIST [ TYPE ] LIST
(1) Open limit operation setting (Set on all calibration

types.)
Calibration speed Specify the calibration motion operation speed
Accelerate rate Specify the calibration motion accelerate rate
Default is 100(%).
(2) Position register No. setting (Set as follows when types 3

to 6 are set in the Calibration Setup.)
Position register Position register for holding the momentary position
No where 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.)
(3) Open limit detection torque setting (Set as follows when

types 3 or 4 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%.
(4) 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.
-101-
15.4 SETTING THE REFERENCE POSITION
15.4.1 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
2 Gun Sag Compensation: DISABLE
3 Close Direcrion(Gun): PLUS
4 Close Direction(Robot): UT:1 [+Z ]
6 Max Pressure(Kgf): 500.0
7 Tip stick detect delay(ms): 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."
--102
15.4.2 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
-103-
15.5 GUN CHANGE INSTRUCTION
15.5.1 GUN DETACH instruction
This instruction can detach the servo gun without power off.
：
Format：
･ GUN DETACH[i]
i： Gun number（1～10）
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]]
15.5.2 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（1～10）
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
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z ]
--104
15.5.3 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
15.5.4 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
-105-
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.
In the case of GUN DETACH instruction, both robot and servo gun do not move at all.
15.5.5 Backward execution
Both GUN ATTACH and GUN DETACH instruction can not

be execute by backward execution.
--106
15.6 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

Attach
+5V Detach
Pulse coder line

0V Attach
Detach
Detach/Attach status Gun1 Attach Non gun Non gun Gun2 attach
Gun1 Gun2
Detaching Attaching
-107-
15.7 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 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
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.
--108
15.8 SERVO GUN SETUP
On gun change systems, the following settings must be

carried out each time that the gun is changed.
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

1 Tip Wear Down Comp: DISABLE
4 Close Direction(Robot): UT: 1 [+Z ]
8 Weld Timing Torque Rate(%) 0
9 Counter register: <*DETAIL*>
10 Max wear down check <*DETAIL*>
12 Wear Down Cal: INCOMP <*DETAIL*>
Key for switching gun No
-109-
15.9 TEACHING
In the gun change system, the normal spot instruction can be

used. But, in the gun change system, please note the
folloiwng points.
15.9.1 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
--110
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.
15.9.2 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
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
：
99: END 99:Normal end
NOTE
This is sample program. Create the program related
to your system.
-111-
16. SAVING THE SERVO GUN SETTINGS B-80954EN/01
16 SAVING THE SERVO GUN SETTINGS

All the servo gun settings specified on the following screens
are saved to SYSSPOT.SV.
This is done by selecting “All of above” or “Application” in
“[BACKUP]” on the FILE screen.
Initial, general, Pressure Condition, and stroke condition

setting screens
-112-
B-80954EN/01 17. ALARM CODE TABLE
17 ALARM CODE TABLE

SVGN-001 STOP.G “Serious Internal error”
[Cause] Error in the system software
[Remedy] Inform your FANUC service representative
of what the error is like.
SVGN-002 STOP.G “No sysvar pointer”

SVGN-003 STOP.G “No global variables”

SVGN-004 STOP.G “Unable to Allocate Memory”

[Cause] Memory is in short supply.
[Remedy] Take note of what the error is like. Switch
on the power and check the remaining
memory capacity with the memory state list
screen, then call your FANUC service
representative.
SVGN-005 STOP.G “Wrong TPP inst. format”

[Cause] The internal format of a spot welding
instruction is incorrect.
[Remedy] Teach the spot welding instruction once
more.
SVGN-006 STOP.G “Another TASK used this equip.”

[Cause] The target welding machine is already being
used by another program.
[Remedy] Forcibly terminate the auxiliary screen.
SVGN-007 STOP.G “Pre execution failed”

-113-
17. ALARM CODE TABLE B-80954EN/01
SVGN-008 STOP.G “Syntax error”

[Cause] An instruction for air guns was executed.
[Remedy] Teach the correct instruction once more by
referring the applicable operator's manual.
SVGN-009 STOP.G “Motion Group config. mismatch”

[Cause] An motion group held by the program does
not match that specified for the stationary
tip.
[Remedy] Make an motion group held by the program
match that specified for the stationary tip.
To be specific, change the welding machine
equipment number specified on the program
detail screen or the motion group of the
servo gun controlled using the equipment
number so that the equipment number and
motion group match the motion group
specified on the program detail screen.
SVGN-010 STOP.G “Invalid SG group config.”

[Cause] The motion group number for the movable
tip is invalid.
[Remedy] Check the motion group number specified
for the movable tip with the initial setting
screen.
SVGN-012 STOP.G “Invalid value for index”

[Cause] The register number is invalid, or the
content of the register is invalid.
[Remedy] Check the register number, or the register
content.
SVGN-013 STOP.G “Pressure exceeds limit”

[Cause] The specified pressure is higher than the
allowable maximum pressure.
[Remedy] Specify a lower pressure, or increase the
allowable maximum pressure.
SVGN-014 STOP.G “Associate TID not found”

SVGN-015 STOP.G “Setup Configuration error”

-114-
SVGN-016 STOP.G “Specified pressure too low”

[Cause] The specified pressure is too low.
[Remedy] Specify a higher pressure, or re-adjust the
pressurization coefficient and decrease
coefficient B.
SVGN-017 STOP.G “Invalid pressure coefficient”

[Cause] The value of pressurization coefficient A is
incorrect.
[Remedy] Keep the value of pressurization coefficient
A between 0.1 and 100.
SVGN-018 STOP.G “Illegal torque limit value”

[Cause] The specified torque limit is invalid.
[Remedy] 1. Check the allowable maximum torque
which must be between 1 and 100.
2. Check the relationship between the
specified pressure and the pressure
coefficients. If this error occurs during
pressure adjustment, check the specified
torque which must be between 1 and 100.
SVGN-019 WARN “Pressure shortage (%s, %d)”

[Cause] The actual pressure does not reach the
specified pressure.
[Remedy] Make sure that each tip touches the
workpiece securely.
SVGN-020 STOP.G “Pressure shortage (%s, %d)”

[Cause] The actual pressure does not reach the
specified pressure.
[Remedy] 1. Make sure that each tip touches the work
piece securely.
2. Check that the tip wear compensation
amount is correct.
3. If the push-in amount is small, increase it.
4. Make sure that servo parameters [7] and
[112] satisfy the following relationship:
Servo parameters [7] [112] = 2097512/servo parameters [7]

[47]
Setup Procedure
1. Press the SELECT SCREEN key to
display the Screen menu.
2. Press 0 NEXT and 6 SYSTEM.
3. Press F1 TYPE to display the Screen
Selection menu.
4. Select Variables.
-115-
5. Set $SVPRM_ENB to "1".

6. Press F1 TYPE to display the Screen
Selection menu.
7. Select Servo Param. The Servo Parameter
screen is displayed.
8. Press F2 AXIS, enter "7" and press the
ENT key.
9. Note down the values of system parameters
[7] and [47].
10.Set the calculated values to system
parameters [7] and [112] with numbers
past the decimal point rounded.
11 Press F5 DONE.
SVGN-21 STOP.G “Uninitialized BU condition”

[Cause] If gun opening is enabled, the probable cause
is that a stroke condition instruction for
specifying an opening amount has not been
executed.
[Remedy] 1. If gun opening is enabled, specify a stroke
opening amount using a stroke condition
instruction. If the stroke condition
number is specified as 0, the gun is
opened to the opening position defined as
an opening position for pressurization
start.
Example: 1: L P[1] 2000mm/sec CNT100
: SPOT[10]
2. If gun opening is not to be performed,
disable it in the Pressure Condition data.
SVGN-22 STOP.G “Uninitialized Pres. condition”

[Cause] No Pressure Condition instruction has been
executed. The Pressure Condition number
specified in a Pressure Condition instruction
is invalid.
[Remedy] Specify a Pressure Condition number in a
Pressure Condition instruction for a servo
gun instruction, then execute a spot welding
instruction.
SVGN-23 STOP.G “Incomplete Pressure calibration”

[Cause] No pressure adjustment has been performed.
[Remedy] Perform pressure adjustment.
SVGN-24 STOP.G “Incomplete Wear Down calibration”

[Cause] No tip reference position has been acquired.
[Remedy] Acquire a tip reference position.
-116-
SVGN-25 STOP.G “Illegal BU condition number”

[Cause] A value specified as a stroke condition
number is invalid.
[Remedy] Check the value specified as the stroke
condition number.
SVGN-26 STOP.G “Illegal P condition number”

[Cause] A value specified as a Pressure Condition
number is invalid.
[Remedy] Check the value specified as the Pressure
Condition number.
SVGN-27 STOP.G “Untaught element encountered”

[Cause] Some statements in the program have not
been taught.
[Remedy] Teach them.
SVGN-28 STOP.G “Pos. type is JOINT”

[Cause] The position data is an axis type.
[Remedy] Change the type of the position data to an
orthogonal type.
SVGN-29 STOP.G “Over max motor torque value”

[Cause] A motor torque converted from the specified
pressure is higher than the allowable
maximum motor torque.
[Remedy] Specify a lower pressure. Also check that
allowable maximum motor torque is correct.
SVGN-30 STOP.G “Tip Stick detection”

[Cause] The deposition detection signal is on.
[Remedy] Remove deposition.
SVGN-31 STOP.G “Tear Off is executing”

[Cause] No program can be started during deposition
removal.
[Remedy] Try to start the program after deposition
removal is completed.
SVGN-32 STOP.G “Tip increased error (Gun)”

[Cause] The wear amount of the movable tip has
exceeded the tip's apparent extension
amount.
[Remedy] It is likely that metal chip deposits are on
the movable tip. Check the state of the tip.
SVGN-33 STOP.G “Tip increased error (Robot)”

[Cause] The wear amount of the stationary tip has
exceeded the tip's apparent extension
amount.
-117-
[Remedy] It is likely that metal chip deposits are on

the stationary tip. Check the state of the
tip.
SVGN-34 STOP.G “Pressure value over (%s, %d)”
[Cause] The actual pressure is higher than the
specified pressure.
[Remedy] Make sure that each tip touches the
workpiece securely.
SVGN-35 STOP.G “Pressure enable time out”

[Cause] The pressurization enable signal failed to
become on within the specified time.
[Remedy] Remove any cause that prevents the
pressurization enable signal from being
turned on.
The time-out value can be adjusted by
updating the following system variable:
$SPOTEQSETUP[1].$PEN_TMOUT
SVGN-36 STOP.G “Comp confirmation time out”

[Cause] The completion confirmation signal failed to
become on within the specified time.
[Remedy] Remove any cause that prevents the
completion confirmation signal from being
turned on.
The time-out value can be adjusted by
updating the following system variable:
$SPOTEQSETUP[1].$NSE_TMOUT
SVGN-37 STOP.G “Illegal pressure enable signal”

[Cause] An attempt was made to assign a
nonexisting signal as the pressurization
enable signal.
[Remedy] Check the setting of the pressurization
enable signal.
I/O screen → F1“[TYPE]” → “Spot
welding” → input signal
SVGN-38 STOP.G “Illegal comp confirmation signal”

[Cause] An attempt was made to assign a
nonexisting signal as the completion
confirmation signal.
[Remedy] Check the setting of the pressurization
enable signal.
I/O screen → F1“[TYPE]” → “Spot
welding” → input signal
SVGN-039 STOP.G "Incomplete Servo/param tuning"

[Cause] The servo for using high-precision pressure
control is not adjusted.
-118-
[Remedy] Adjust the servo for high-precision pressure

control according to the Servo Gun Function
Setup Manual.
SVGN-51 WARN “Backup stroke is not selected.”

[Cause] No stroke number has been selected in
manual operation.
[Remedy] On the stroke setting screen, specify a stroke
value, and enable manual-operation items,
then press the BU (Buckup) key to select the
desired stroke.
SVGN-52 WARN “Motion group mismatch.”

[Cause] The group number for a manual
pressurization program or manual stroke
program is different from the group number
of the servo gun.
[Remedy] Change the program group number so that
they become the same.
SVGN-53 WARN “Backup stroke is not set.”

[Cause] No stroke amount has been set up for a
specified stroke number.
[Remedy] Specify a stroke amount for the specified
stroke number.
SVGN-54 STOP.G “$EQNUM is invalid number”

[Cause] A value assigned to $EQNUM is invalid.
[Remedy] Assign a system-registered equipment
number to $EQNUM.
SVGN-55 STOP.G “$EQNUM is not Servo Gun.”

[Cause] An equipment number specified in
$EQNUM has not been set up for the servo
gun.
[Remedy] Assign the equipment number of the servo
gun to $EQNUM.
SVGN-56 STOP.G “$GUNNUN is invalid number.”

[Cause] A value assigned to $GUNNUM is invalid.
[Remedy] Only 1 (for GUN1) and 2 (for GUN2) can be
assigned to $GUNNUM.
SVGN-57 STOP.G “Tip Wear Down Cal. Is IMCOMP.”

[Cause] A tip wear amount cannot be calculated,
because no tip reference position has been
acquired.
[Remedy] Acquire a tip reference position.
-119-
SVGN-58 STOP.G “UT or UF is different.”

[Cause] The current tool coordinate system number
or user coordinate system number is
different from one where the reference
position has been acquired.
[Remedy] Make them match.
SVGN-59 STOP.G “Cannot read specified PR [].”

[Cause] An attempt to call a position register
specified in $PRINDEX failed.
[Remedy] Check the value of $PRINDEX.
SVGN-60 WARN “Pressure program is not set.”

[Cause] No pressurization program has been set up.
[Remedy] Specify a pressurization program on the
manual setting screen.
SVGN-61 WARN “Backup program is not set.”

[Cause] No manual stroke program has been set up.
[Remedy] Specify a manual stroke program on the
manual setting screen.
SVGN-62 WARN “Pressure data is not selected.”

[Cause] A pressurization data number to be used for
manual pressurization has not been
selected.
[Remedy] On the pressurization data screen, specify
pressurization data, and select ENABLE for
manual-operation items, then press the
GUN key to select the desired Pressure
Condition.
SVGN-63 WARN “Pressure data is not set.”

[Cause] The specified pressurization data is
incorrect.
[Remedy] Assign correct pressurization data to the
specified pressurization data number.
The following describes alarms exclusive to gun changing.
SVGN-70 PAUSE.L Disable Gun Change.

[Cause] The gun change instruction (attach/detach)
was instructed with the air gun set in the
Gun Change Initial Setup screen, or when
gun change was set to ENABLE.
[Remedy] Start control to open the Gun Change Initial
Setup screen, set the equipment type to
Servo Gun and set gun change to ENABLE.
-120-
SVGN-71 PAUSE.L Machine lock is ENABLE

[Cause] 1) The robot axis machine lock was set to
ENABLE when the gun attach or detach
instruction was executed.
2) The servo gun axis machine lock was set to
ENABLE when the detach instruction was
executed.
[Remedy] Cancel, the robot axis or servo gun axis

machine lock.
SVGN-72 PAUSE.L Illegal assignment of gun axis

[Cause] The gun No. and axis No. assignments are
incorrect.
[Remedy] Check the gun No. and axis No.
assignments.
SVGN-73 PAUSE.L Gun not detached (AXISORDER)

[Cause] An attempt was made to execute the gun
attach instruction with the servo gun not
detached.
System variable $AXIS ORDER should be
changed to "0".
[Remedy] The gun attach instruction cannot be
executed with the gun detached.
SVGN-74 PAUSE.L Gun not detached

attach instruction with none of the servo
guns detached.
The servo gun attach confirmation signal is
OFF.
[Remedy] The gun attach instruction cannot be
executed unless the gun is detached.
SVGN-75 PAUSE.L Gun not attached

detach instruction with none of the servo
guns attached.
The servo gun attach confirmation signal is
OFF.
[Remedy] The gun detach instruction cannot be
executed unless the gun is attached.
SVGN-76 PAUSE.L Another process is executing

[Cause] Another program is executing the gun attach
or detach instruction.
[Remedy] Re-execute the instruction the other
program has finished executing the gun
attach or detach instruction.
-121-
SVGN-77 PAUSE.L Gun identify signal is OFF

[Cause] The servo gun identify signal is OFF.
[Remedy] Make sure that the gun No. taught to the
instruction is the same as the actual gun.
Make sure that the servo gun identify signal
is correctly set.
SVGN-78 PAUSE.L Gun set signal is OFF

[Cause] The servo gun set signal is OFF.
[Remedy] Check to see if the gun is correctly set or not.
Make sure that the gun set signal is
correctly set.
SVGN-79 PAUSE.L Gun change canceled

[Cause] Processing of the gun attach or detach
instruction was canceled.
[Remedy] Restart the system.
SVGN-80 PAUSE.L Gun change timeout

[Cause] Processing of the gun attach or detach
instruction ended in a timeout.
[Remedy] Check the signal settings and re-execute.
If this error occurred as a result of the gun
detach instruction, check the MCC in the
gun change unit to see if it has blown.
SVGN-81 SYSTEM Gun mastering data is lost

[Cause] Gun master data was lost due to an
unexpected stop during servo gun
mastering.
[Remedy] Refer to "G.2 The robot stopped during
calibration."
SVGN-82 WARM Gun mastering is failed

[Cause] Gun mastering failed due to an unexpected
stop during servo gun mastering.
[Remedy] Execute the instruction again to re-execute
mastering.
SVGN-83 PAUSE.L GUN ATTACH is failed

[Cause] Failed to execute the gun attach instruction.
Refer to the CAUSE code for details of the
cause.
[Remedy] Remedy according to the CAUSE code.
SVGN-84 PAUSE.L GUN DETACH is failed

[Cause] Failed to detach the gun. Refer to the
CAUSE code for details of the cause.
[Remedy] Remedy according to the CAUSE code.
-122-
SVGN-85 PAUSE.L Robot not mastered(Gun axis)

[Cause] The servo gun axis is not mastered.
[Remedy] Master the servo gun axis.
SVGN-86 PAUSE.L Robot not calibrated(Gun axis)

[Cause] The servo gun axis is not calibrated.
[Remedy] Calibrate the servo gun axis.
SVGN-87 PAUSE.L Ref pos not set(Gun axis)

[Cause] The reference position needed for quick
mastering has not been set.
[Remedy] Set the reference position again.
SVGN-88 PAUSE.L Another gun is attached

[Cause] A gun different from the gun No. specified in
the gun attach instruction.
[Remedy] Check the gun No. specified in the gun
attach instruction.
SVGN-89 PAUSE.L Calibrate motion is failed

[Cause] The detection conditions (touch torque or
detection signal) were not satisfied during
calibration.
[Remedy] Check the detection conditions in the Gun
Change Setup screen.
Refer to "G.3 Calibration motion failed."
SVGN-90 PAUSE.L PR[] index is not set

[Cause] The position register No. is not set for
calibration motion types 3 to 6.
[Remedy] Set the position register No. in the Gun
Change Setup screen.
SVGN-91 PAUSE.L "Touch torque is not set."

[Cause] The touch torque is not set at Alignment
motion type 3,4.
[Remedy] Set the touch torque in the gun change setup
menu.
SVGN-92 PAUSE.L "Detect signal is not set."

[Cause] The detect signal is not set at Alignment
motion type 5,6.
[Remedy] Set the detect signal in the gun change setup
menu.
-123-
APPENDIX
B-80954EN/01 APPENDIX
Appendix A Construction of Servo gun screen

･ INITIAL SETUP SCREEN （This screen can be displayed at CONTROL START
Menu.））
4. SETUP SERVOGUN Servo gun initial setup screen
MENUS
･ SETUP SCREEN
MENUS 6. SETUP F1[TYPE] 2. Spot welding
Equipment 1
Equipment 2
Spot sequence setup screen
…<*DETAIL*> Prev
(Gun number 2)
（Gun number1）
General setup screen
…<*DETAIL*> Prev (Provided Same

F3:GUN screen fo Gun1）
Counter register setup
Max tip wear down check
Pressure calibration
Tip wear down calibration
Manual setup screen
･ I/O SETUP SCREEN
5. I/O 3. Spot welding

MENUS F1[TYPE]
Equipment 1
SPOT I/O setup screen Equipment 2
Input signal setup 装置

Output signal setup 1
F3「IN/OUT」
Servo gun input signal Servo gun output signal
-127-
APPENDIX B-80954EN/01
･ STATUS SCREEN
MENUS 4. STATUS F1[TYPE] 3. Spot welding
Equipment 1
Equipment 2
Status screen
F3:GUN
Gun1 status screen Gun2 status screen
･ DATA SCREEN
3. Pressure
4. Backup
DATA F1[TYPE]
Equipment 1
DATA screen Equipment 2
Pressure setup screen Backup setup screen
Pressure condition 1 Backup condition 1
F4:DETAIL F4:LIST
Backup condition 2
Pressure condition 1 detail
Pressure condition 99 Backup condition 30
-128-
Appendix B Construction of Servo gun gun

change screen
・INITIAL SETUP SCREEN（
（This screen can be displayed at CONTROL START
）
Menu.）
Equipment 1
Equipment 2
4. SETUP SERVOGUN
MENUS Servo gun initial setup screen F2:EQUIP
F3:GUN_CFG F2:END
Servo gun configuration screen
･ SETUP SCREEN
Gun Change
MENUS 6. SETUP F1[TYPE]
（Gun number1） (Gun number 2) Equipment 1

Equipment 2
Gun Change list screen Gun Change list screen F2:EQUIP

F3:GUN
F3:DETAIL F3:LIST F3:DETAIL F3:LIST
Gun change setup detail Gun change setup detail
･ STATUS SCREEN
Gun Change
MENUS 4. STATUS F1[TYPE]
Equipment 1
Equipment 2
F3:GUN
Gun change status screen Gun change status screen F2:EQUIP
-129-
Appendix C Recommendatory Setting

First-time users of Servo Gun should refer to the following
values.
General Setup
Spot Welding
Welder Number of currently selected welder is displayed
Gun Select SINGLE
Weld completion DISABLE
signal
Weld complete 500 (Pressuring time when welding is DISABLE in Test
delay [msec] Cycle screen)
Detect condition Level
Detect weld done DISABLE
Weld done (default as is)
timeout [msec]
Servo Gun
Tip Wear DISABLE (Set to ENABLE when the environment (program)
Down Comp for executing tip wear down compensation is available.)
Gun Sag DISABLE (Set to ENABLE if actual sag of gun is a cause for
Vompensation concern.)
Close Refer to separate "Servo Gun Supplementary Manual
Direction (Gun) (B-80954EN-1)."
Close Direction Refer to separate "Servo Gun Supplementary Manual
(Robot) (B-80954EN-1)."
Max Motor 100.0
Torque [%]
Max Pressure Set this matched to the max. allowable Pressure of the gun
[Kgf] in use. Input range: 1.0 to 9999.9
Tip stick detect 0
delay [msec]
Count Register
Count register 0
Tip dress count 0
register
Tip change count 0
register
Maximum Wear Down Value Detection

Max wear down
0.0
value (Gun) [mm]
Increased error
0.0
(Gun) [mm]
Inform signal (Gun) 0
Max wear down
0.0
value (Robot) [mm]
Increased error
0.0
(Robot) [mm]
Inform signal (Robot) 0
-130-
Example) Program
1: PL[1]2000mm/sec CNT 100
: SPOT[P=3, S=10, BU=0]
Pressuring Conditions
Pressuring Conditions[3]
Comment An appropriate comment can be set.
Standard Pressure 200.0 : Specify the Pressure during actual execution
[Kgf] of the spot weld instruction.
Part Thickness [mm] 1.8 : Specify the thickness of the actual part to be
welded.
Pushing Depth [mm] 5 : Match to the pushing depth during pressure
calibration.
Gun Sag Comp Value 0.0
[mm]
Auto Route (Set the recommended value at the shaded

section in the Auto Route Setup screen.)
(1) Approach position Item Conditions/Value Item to See
Position ON/OFF ENABLE Pressuring condition
Gun Position (Gun) 40 mm Pressuring condition
Position (Robot) 5 mm Pressuring condition
40mm
Part thickness 1.8 mm Pressuring condition
1.8mm Speed 2000 mm/sec Program value
5mm Termination CNT 100 Program value
Robut Position ON/OFF ON (generated at all -

times)
(2) Pressuring start position Position (Gun) 0 mm Pressure Start Position/Setup
screen
Position (Robot) 0 mm Pressure Start Position/Setup
screen
0mm
Speed 2000 mm/sec Program value
0mm Termination CNT 20 Pressure Start Position/Setup
screen
Position ON/OFF ON (generated at all -

(3) Pressuring position times)
Position (Gun) 5 mm Pushing Depth/Pressuring
conditions
Position (Robot) Teaching point (robot Program value
5mm
TCP of P[1])
Speed (Decelerate 2000 mm/sec Program value x Decelerate
rate) (Decelerate rate is set rate (Pressuring conditions)
automatically according
to Pressure.)
Termination CNT 0 Pressure Start Position/Setup
screen
(4) Pressuring end position Position ON/OFF ON (generated at all

times)
Position (Gun) 3 mm Pressuring end
position/Setup screen
3mm Position (Robot) 3 mm Pressuring end
3mm position/Setup screen
Termination CNT 100 Pressuring end
position/Setup screen
-131-
(5) Open position Item Conditions/Value Item to See

Position ON/OFF FALSE (Generated Pressuring conditions
only when gun open is
40mm set to TRUE.)
Position (Gun) Same position as BU=0: Pressuring condition
approach position (as
Teaching
approach position is
ENABLED and BU is 0)
Position (Robot) Same position as BU=0: Pressuring condition
approach position (as
approach position is
ENABLED and BU is 0)
Termination CNT 100 Open Position/Setup screen
NOTE
1 The system automatically sets the decelerate rate at
the pressure position according to the preset
pressure.
2 When the CNT value for positioning at the pressure
end position is large, the panel may be momentarily
pressed when the gun is opened. If this happens,
either reduce the CNT value, or increase the
tolerance.
3 Not using the open position reduces the cycle time as
long as the operation from the pressure end position
to the next position is not adversely influenced.
4 Set the accelerate rate at all positions to 100.
Single Spot Weld Instruction/Manual Spot Weld

Speed [%] 100 (= max. speed)
Termination Type CNT 100
Acc instruction [%] ACC 100
Use Path FALSE
-132-
Appendix D List of servo gun instructions

There are five typical servo gun instruction types.
･ Spot welding instructions (see 5.1)

These instructions execute a sequence of pressurization,
welding, and opening.
(Example)
SPOT This instruction type specifies a Pressure Condition (P),
[P=3, S=10, BU=0] welding condition (S), and stroke condition (BU) directly.
SPOT [10] Specifies only a welding condition. Pressurization and
stroke conditions are specified previously using the servo
gun condition instruction (see below).
･ Servo gun condition instructions (see 5.2.1)

These instructions are used to specify pressurization and
stroke conditions previously if the spot welding instruction
specifies only a welding condition.
(Example)
GUN1 P[3] Specifies a Pressure Condition previously.
GUN1 BU[0] Specifies a stroke condition previously.
･ Pressurization instructions (see 5.2.2)

These instructions perform only pressurization.
(Example)
press_motion P=[3] Performs pressurization according to the specified
Pressure Condition (P).
･ Pressure instructions (see5.2.3)

Pressure instructions are used to regulate pressure if you want to
perform pressurization using an ordinary operation statement
rather than spot welding and pressurization instructions.
Use of the pressure instructions can reduce the load on the
workpiece and gun even if only ordinary operation
statements are used, for example, to grasp the workpiece.
(Example)
Pressure [500]kgf After this pressure instruction is executed, the maximum
output torque of the servo gun motor is limited to within
the value corresponding to the specified pressure. It
can be used to limit the pressure applied in grasping the
workpiece.
Pressure level Cancels the maximum output torque of the servo gun
Gun1 motor specified using the above instruction.
･ Gun change instructions (see 15.5)

These instructions perform detachment and attachment of
servo gun
(Example)
GUN DETACH[1] Detach servo gun which gun number is 1.
GUN ATTACH[2] Attach servo gun which gun number is 2.
-133-
Appendix E Gun Change Reference Position Setup

Method (battery-less type)
E.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
･ 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.
-134-
*1) Touch torque

Increase the value from about ±2, and calculate the
1 Comment [ ] value at which erroneous detection of contact
2 Attach signal: DI[ 1] occurs.
3 Identify signal DI[ 2]
4 Battery: OFF
The sign of touch torque is the sign that is currently
5 Calibration motion type: [TYPE 3] displayed at Touch torque at the Calibration Setup
Calibration Motion Setup screen on the right.
6 Calibration Speed(%) 100
7 Acc Value: ACC100
8 Position register index PR[ 1]
9 Touch torque(%): ( + ) 5.000
[ TYPE ] LIST
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.
*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 E.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.
-135-
1. Press the SELECT SCREEN key to display the

Screen menu.
2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
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:

1 Comment [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
5 Calibration motion type: [TYPE 3]
6 Calibration Speed(%) 1
7 Acc Value: ACC100
8 Position register index PR[ 1]
9 Touch torque(%): ( + ) 2.000
[ TYPE ] LIST
E.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,*,*,*].
-136-
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
3:J P[2:SWITCH POS] 1% signal turns ON. (Jump to label[1] if the
*2) FINE ACC100 *3)SKIP, detection 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.
･ 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.
*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 E.2 Quick Mastering Reference
Position Setup with the servo gun contacting the open
limit.
-137-
♦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.
3. Press F1 TYPE to display the Screen Selection
menu.
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:

1 Comment: [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
5 Calibration motion type: [TYPE 5]
6 Calibration Speed(%): 1
7 Acc Value: ACC100
8 Position register index: PR[ 1]
9 Detect signal: DI[ 0]
[ TYPE ] LIST
-138-
E.2 Quick Mastering Reference Position Setup
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
Be sure to set the group of
cold start state.
Servo gun axis
Follow the procedure below to set the reference points:
1. Press the AUX key to select 3 CHANGE GROUP.

SYSTEM Master Cal G2 OINT 10 % Change the operation group to the desired servo gun
TORQUE = [ON ] group (e.g. 2nd group).
1 FIXTURE POITION MASTER 2. Press the SELECT SCREEN key to display the Screen
2 ZERO POSITION MASTER
3 QUICK MASTER menu.
4 SINGLE AXIS MASTER 3. Press 0 NEXT and 6 SYSTEM.
5 SET QUICK MASTER REF 4. Press F1 TYPE to display the Screen Selection menu.
6 CALIBRATE
5. If CALIBRATE is not displayed in the menu, select
Press 'ENTER' or number key to select. Variables to display the System Variables screen. Set
the $MASTER_ENB system variable to "1".
[ TYPE ] LOAD RES_PCA DONE
6. Select CALIBRATE at 4. to display the Calibration
screen.
7. Select 5 SET QUICK MASTER REFERENCE and F4
YES.
8. The message "Quick master reference point is set." is
displayed. This indicates that setting of the reference
point is completed.
-139-
Appendix F Troubleshooting
F.1 Insufficient pressure
<The "SVGN-020 Pressure shortage" alarm has occurred.> → Go to Recovery Procedure 1.

↓ No Yes
<Pressure gage indicates insufficient pressure.> → Go to Recovery Procedure 2.

Yes
Recovery Procedure 1
1. Make sure that Part Thickness is set to the correct value
in the pressure conditions data.
Otherwise, change the setting to the actual work
thickness.
Procedure
Open the Pressure Data screen.
DATA → F1:[TYPE] → 3 PRESSURE → (Move the
cursor to the pressure data of P = value.) → F4: LIST

PRESSURE / EQ:1 Gun:1 No:6 7/8
1 Comment: [Front Panel ]
2 Standard Pressure(Kgf): 180.0 Check this value.
4 Pushing Depth(mm): 5.0
:
2. Sufficient pressure is sometimes not output if Pushing

Depth in the pressure conditions data is not set to a
sufficient value. If the Pushing Depth setting is
insufficient, increase the setting.
Procedure
cursor to the pressure data of P=value.) → F4: LIST

2 Standard Pressure(Kgf): 180.0 1 Increase this
3 Part Thickness(mm): 2.0 value.
:
-140-
3. Check the wear down value when tip wear has been
compensated.
Step 1
Check the tip wear in the Spot Weld Status screen.
SELECT SCREEN → 0--NEXT-- → 4 STATUS →
F1:[TYPE] → 2 Spot welding
STATUS Spot Weld G1 JOINT 10 %

SERVO GUN / EQ:1 Gun:1 1/13
1 Gun type: SINGLE
2 Pressure cond number: (stnd 1) 1
3 Current schedule number: 1
4 Backup cond number: (stnd 1) 1
5 Wear down value(Gun)(mm): 2.00
6 Wear down value(Robot)(mm): 2.00 2 Check this
7 Pressure value(kgf): 0.00
value.
8 Current position(Gun)(mm): 0.00
:
:
Step 2
Compare the total wear down value of the movable and
fixed sides against the results of the "Checking the 0
Position" to see if the wear down value is appropriate.
For details on the "Checking the 0 Position", refer to

the materials supplied.
1. Make sure that Standard Pressure is set to the correct
value in the pressure conditions data. (Note that you
cannot set a value greater than the maximum pressure
set in the General Setup screen.)
Procedure
cursor to the pressure data of P=value.) → F4: LIST
SERVO GUN DATA G2 JOINT 10

2 Standard Pressure(Kgf): 180.0 1 Check this value.
:
-141-
2. Pressure may not have been adjusted correctly. Adjust

the pressure again.
In this adjustment, try to specify a torque value (%) at
which the actually used pressure is generated.
Also, specify an acceleration speed (normally, 100%) that
is actually used.
For details of this adjustment procedure, see "1.7
Calibrating the Pressure" in the Supplementary Manual
(B-80954EN-1).
F.2 Pressure is too high, or fluctuates.
Probable causes are that the pressure has not been correctly
adjusted, or that the performance of the servo gun itself has
dropped due to prolonged use.
Recovery Procedure
1. Pushing depth too large
Pressure overshooting can be restricted by adjusting the
pushing depth.
The pushing depth can be adjusted for each pressure
setting in the pressure conditions data.
2. Adjust the pressure.

In this adjustment, try to specify a torque value (%) at
which the actually used pressure is generated.
Also, specify an acceleration speed (normally, 100%) that
is actually used.
For details of this adjustment procedure, see "1.7
Calibrating the Pressure" in the Supplementary Manual
(B-80954EN-1).
F.3 The wear down value cannot be detected correctly.
<Is the Close Direction set correctly?> → Go to Recovery Procedure 1.

No
↓ Yes
<Is the tool coordinate system for loading the reference
point and detecting the wear down value correct?> → Go to Recovery Procedure 2.
No
↓ Yes
<Are reference point loading and wear down
value detection operations correct?> → Go to Recovery Procedure 3.
No
↓ Yes
<Has the detection reference point
(position of photoelectric tube) changed?> → Go to Recovery Procedure 4.
No
-142-
NOTE
This procedure is carried out when the system is
started up. Do not apply this procedure to a system
that is currently running.
Procedure
Open the General Setup screen.
SELECT SCREEN → 6 SETUP → F1:[TYPE] → 2 Spot
welding → 8 General Setup <*DETAIL*>
Follow the procedure below to check the tool coordinate

system No., Close Direction (Gun) and Close Direction
(Robot). Change these values if they are wrong. (Note:
Pressure motion during execution of the SPOT instruction
changes when these values are changed.)
(General Setup screen)
SETUP Spot Weld G1 JOINT10%

1 Tip Wear Down Comp: DISABLE
4 Close Direction(Robot): UT: 1 [+Z] 1 Check these items by
5 Max Motor Torque(%): 100.0 the following methods.
:
･ Check the close direction (gun)

Jog feed the movable side tip, view which key (+ or - key)
closes the gun, and make sure that this key is the same
as the setting in the General Setup screen.
･ Check the close direction (robot)

Match the currently selected tool coordinate system to
the tool coordinate system No. set in the above screen.
Press the coordinate switch key with the Shift key held
down.
The following menu appears. Enter the value of the
robot operation group No. at GROUP and the value of
the tool coordinate system No. in the above General
Setup screen at TOOL.
Make sure that the movable side tip operates in the gun
close direction when the tool is jogged in the axial
direction (in the above example, the +Z direction) set for
the gun close direction.
-143-
SETUP Spot Weld G1 JOINT 10%

3 |TOOL 1|
2 Shift
＋ Manual |JOG 0|
feed |USER 0|
|GROUP 1|
+------------+
NOTE
This procedure is carried out when the system is
started up. Do not apply this procedure to a system
that is currently running.
Check the tool coordinate system No. in the program position

data and the tool coordinate system No. in the General Setup
screen.
Step 1 Open the respective position data in the reference

point load program and wear down value detection
program.
Make sure that the position data UT:* value is the
same as the tool coordinate system No. currently set
in the General Setup screen (refer to Recovery
Procedure 1). If the value is different, proceed to
Step 2.
Step 2 Follow the procedure below to match the tool

coordinate system No. in the program position data
to the tool coordinate system No. in the General
Setup screen.
･ Execute the program one step at a time to move the
robot to the position where the UT values are
different. Make sure that the tool coordinate
system selected for the robot matches position data
UT:*.
･ Press the coordinate system selection key with the
Shift key held down. The same menu as in
Recovery Procedure 1 appears. Enter the value of
the tool coordinate system No. in the Setup screen
to TOOL in the menu.
･ Press F5: CORRECT POSITION to correct the
program position. The prompt below is displayed.
Enter the tool coordinate system No. currently set
to the General Setup screen.
Enter utool no.(GP:1 $UT:2) Enter the value here.
-144-
Remarks:
There is also another recovery procedure in
addition to the above. Re-teach each of these
values from the beginning with tool change shift
and the robot's currently selected tool coordinate
system changed to the tool coordinate system No.
currently set in the General Setup screen.
Step 3 Load the reference point and detect the wear down
value again,
(For details on how to load the reference point, refer
to "The reference point for tip wear compensation
can no longer be found.")
･ Make sure that the same operations (same teaching
positions and operation speeds) are used in both the
reference point load program and wear down value
detection program.
･ Compare the teaching positions and operations speeds in
each of these programs. If they differ, match the settings
in the wear down value detection program with the
values of the reference point load program.
･ Execute the program with override set to 100%.
Load the reference point and detect the wear down value
again.
(For details on how to load the reference point, refer to "The
reference point for tip wear compensation can no longer be
found.")
F.4 Pressure cannot be output manually.
<The "SVGN-063 Pressure data is not set" alarm

has occurred.> → Go to Recovery Procedure 1
Yes
↓ No
< The "SVGN-020 Pressure shortage" alarm has
occurred. > → Go to Recovery Procedure 2
Yes
↓ No
<The "SVGN-053 Backup stroke is not set" alarm
has occurred.> → Go to Recovery Procedure 3
Yes
↓ No
<Gun does not open after pressure is applied.> → Go to Recovery Procedure 4
Yes
-145-
Set MANUAL to TRUE under the conditions used for
manually applying pressure in the pressure conditions data
(Data screen) by referring to "Manual Pressure and
Switching Manual Pressure Conditions" in the Instruction
Manual. Then, press only the GUN SELECT key to select the
pressure conditions to be used and then manually apply
pressure by pressing the Shift and the GUN SELECT keys.
Step
Open the Pressuring Condition Data screen.
DATA → F1:[TYPE] → 3 PRESSURE

1 180.0 TRUE [FRONT PANEL]
2 195.0 FALSE [REAR PANEL ]
3 185.0 FALSE [SIDE PANEL]
4 0.0 FALSE [ ] 1 Set this value to TRUE.
: : : :
Check operation by referring to Recovery Procedure 1 of
"Insufficient pressure."
Gun open operation after pressuring is enabled. If so, set the
stroke to be opened to in the stroke conditions data (Data
screen) and set MANUAL to TRUE by referring to "Manual
Stroke and Switching the Manual Stroke" in the Instruction
Manual. Then, press only the STROKE key to select the
stroke conditions to be used and then manually apply
pressure by pressing the Shift and the GUN SELECT keys.
Step
DATA → F1:[TYPE] → 3 Stroke

1 Set this value to TRUE.
2 [SHORT ] 80.000 FALSE
3 [LONG ] 120.000 FALSE
4 [ ] 0.000 FALSE
: : : :
: : : :
-146-
Make sure that the gun open operation is set to TRUE .
Enable this operation if it is not enabled.
Step
Open the Manual Setup screen.
SELECT SCREEN → 6 SETUP → F1:[TYPE] → Spot
welding → 9 MANUAL SETUP <*DETAIL*>

Manual Pressure
2 Gun Open: TRUE 2 Set this value to TRUE.
:
:
F.5 The end signal is ignored and welding is ended.
Recovery Procedure
Make sure that the weld completion signal in the General
Setup screen is enabled. Enable the signal if it is not enabled.
Step
Open the Setup screen.
SELECT SCREEN → 6 SETUP → F1:[TYPE] → 2 Spot
welding

SERVO GUN SETUP 3/9
1 Equip number: 1
3 Weld completion signal: ENABLE 1 Set this value to ENABLE.
4 weld complete delay: 420
5 detect condition: LEVEL
7 weld done timeout(ms): 100
[ TYPE ] EQUIP ENABLE DISABLE
-147-
F.6 The next line is executed without Pressuring carried out.
Recovery Procedure
Make sure that Gun close (each equip) in the Test Cycle
screen is enabled. Enable the signal if it is not enabled.
Step
Open the Test Cycle screen.
SELECT SCREEN → 3 TEST CYCLE → F1:[TYPE] → 1 Spot
welding
TEST CYCLE G1 JOINT 10 %
Group number: 1
Robot lock (each group) DISABLE
Equip number: 1
Gun close (each equip) ENABLE
1 Set this value to ENABLE.
Gun welding(each equip) ENABLE
Digital/Analog I/O: ENABLE
NOTE
The LED on the teaching panel goes out if the Gun
close (each equip) is set to DISABLE.
F.7 The next line is executed without welding carried out.
Recovery Procedure
Make sure that Gun welding (each equip) in the Test Cycle
screen is enabled. Enable the signal if it is not enabled.
Step
Open the Test Cycle screen.
SELECT SCREEN → 3 TEST CYCLE → F1:[TYPE] → 1 Spot
welding
TEST CYCLE G1 JOINT 10 %
Group number: 1
Robot lock (each group) DISABLE
Equip number: 1
Gun close (each equip) ENABLE
1 Set this value to ENABLE.
Gun welding(each equip) ENABLE
Digital/Analog I/O: ENABLE
NOTE
The LED on the teaching panel goes out if the Gun
welding (each equip) is set to DISABLE.
-148-
F.8 The reference point for tip wear compensation can no longer be
found.
Loading of the reference point was carried out by mistake on

a worn down tip.
The reference part and photoelectric tube are out of
alignment.
Preparations
Follow the procedure below to teach the reference point with
the tips used for master teaching attached to the gun. This is
simulate the relationship between the tip and the robot that
was used for teaching.
Step 1 Determine a reference point where the absolute

position with the robot will not change.
Step 2 Create a reference point program, and bring the
fixed side tip into contact with the reference point as
shown below to teach the position to the robot. This
teaching point is used as the position data for each
axis type. The SPOT instruction need not be
executed for teaching.
1 Reference point
2 Fixed jig
3 Movable side tip
Recovery Procedure
The reference point must be reloaded if this phenomenon
occurs according to the procedure below.
Step 1 Attach new tips on both the movable and fixed sides.
Step 2 Set the wear down value for tip wear down
compensation to "0" on both the movable and fixed
sides.
Set this in the Tip Reference Position screen.
SELECT SCREEN → 6 SETUP → F1:[TYPE] → 2
Spot welding 8 General Setup <*DETAIL*> → 22
Wear Down Cal <*DETAIL*>
-149-


3 Wear down value(Robot)(mm): 0.00 1 Set this value
4 Standard pos(Gun):
Group: 2 J1: 20.00 to 0.
5 Standard pos(Robot):
Group: 1 UF:1 UT:1
X:-1500.00 Y: 500.00 Z: 900.00
Step 3 Fine-adjust the tool coordinate system so that the

tool end point contacts the new fixed side tip. Use
TOOL COORDINATE SYSTEM NO. in the General
Setup screen as the tool coordinate system. (Refer to
Recovery Procedure 1 of "F-3 The wear down value
cannot be detected correctly."
Play back the reference point that you taught in
"Preparations" above. Measure the difference
between the fixed side tip end and the reference
point.
2㎜
2 Fixed side tip
In the above figure, let's assume that the fixed side

tip end is 2 mm away from the reference point. This
2 mm becomes the difference with the tip that was
used for teaching. As the newly attached tip is used
as the reference tip, change the tool coordinate
system so that the fixed side tip contacts the panel.
Open the General Setup screen, and check the Close
Direction (Robot) and tool coordinate system No. of
the fixed side tip. (Refer to Recovery Procedure 1 of
"F-3 The wear down value cannot be detected
correctly."
Let's assume that the Close Direction (Robot) is +Z,
and the tool coordinate system No. is 1.
Open the Coordinate System Setup screen, and view
the detailed data of tool coordinate system No.1. To
move the tool 2 mm closer in the gun close direction
as shown in the figure, subtract 2 mm from the close
-150-
direction coordinate axis (Z) value. (Or, add 2 mm if

the gun close direction is the -Z axis.)
SELECT SCREEN → 6 SETUP → F1:[TYPE] → 4

COORDINATE STSTEM → F2:DETAIL
SETUP Frames G1 JOINT 10%

Tool Frame Setup / Direct Entry 1/7
Frame Number:1
1 Comment: *******************
2 X: 900.000
3 Y: 0.000
4 Z: 800.000 1 Set this value to
5 W: -90.000
800-2=798.
6P 0.000
7R -90.000
Configuration Ｎ, 0, 0, 0
After you have changed the tool coordinate system,

play back the reference point again to make sure
that the fixed side tip contacts the panel.
Step 4 Carry out 0 position mastering of the movable side

tip. Jog feed the movable side tip, and take the
position where the reference point contacts the
movable tip end as the master 0 position.
Step 5 Load the tip reference point.
F.9 The gun has bent.
<Misalignment in only the gun open/close

directions> → Go to Recovery Procedure 1.
↓ No Yes
<Gun is greatly misaligned from its originally

taught position.> → Go to Recovery Procedure 2.
Yes
Preparations
Carry out the preparations described in "F.8 The reference
point for tip wear compensation can no longer be found," and
teach the reference point The reference point need not be
taught if it has already been taught.
-151-
When tip wear down compensation is enabled, misalignment
in the gun open/close directions ca be compensated as tip
wear down. Execute the tip wear down detection program to
load the wear down values. (This assumes that the reference
point has already been loaded by the tip that was used
during teaching.)
When you execute this program, even tips that have
extended in length as a result of repair are detected as a
minus wear down amount and can be correctly compensated.
Step 1 Repair the gun and install new tips on both the
movable and fixed sides.
Step 2 Set the wear down amount for tip wear down
compensation to "0" on both the movable and fixed
sides in the Tip Reference Point screen.
SELECT SCREEN → 6 SETUP → F1:[TYPE] 2 Spot
welding → 8 General Setup <*DETAIL*> → 22
Wear Down Cal <*DETAIL*>


3 Wear down value(Robot)(mm): 0.00 1 Set this value
4 Standard pos(Gun):
to 0.
Group: 2 J1: 20.00
5 Standard pos(Robot):
Group: 1 UF:0 UT:0
X:-1500.00 Y: 500.00 Z: 900.00
Step 3 Set the tool coordinate system by one of the

following two methods:
1. Set the tool coordinate system again so that the
tool end point contacts the new fixed side tip.
Set the tool coordinate system following the
same method used when the system was started
up. (This is to set the tool coordinate system as
close as possible to the original tool coordinate
system.)
Next, play back the reference position that you
taught in Preparations. Make sure that the tool
end point of the movable side tip comes to the
correct reference point.
-152-
If the reference point is played back incorrectly,

either set the tool coordinate system again, or
fine-adjust in the next item.
2. Measure the difference between the tool end

point of the movable side tip and the reference
point, and directly modify the values of the tool
coordinate system so that the movable side tip
comes to the correct reference point. (Refer to
Step 3 of "F-8 The reference point for tip wear
compensation can no longer be found.")
Step 4 Carry out 0 position mastering of the movable side

tip. Jog feed the movable side tip, and take the
position where the reference point contacts the
movable tip end as the master 0 position.
Step 5 Play back the entire program one step at a time, and
check for any interference and that pressure is
applied at the correct positions.
Step 6 When tip wear down is to be compensated, load the
reference point after carrying out steps 4 and 5.
･ To correct teaching
[Master Teaching]
"Master teaching" refers to teaching positions using a
new tip on a panel or master body that is used as the
reference for creating programs.
Teach a position where the movable side tip is contacting
the [Teaching Position] panel.
Movable side tip
Gun wait type:

Bring the fixed side tip close to the panel, and teach at the touch
Panel
position.
Fixed side tip Fixed gun:
Bring the panel close to the fixed side tip, and teach at the touch
position.
[Teaching Method]
(1) Jog feed the robot to the position where the panel
contacts the fixed side tip.
(2) The movable side tip may be at any appropriately open
position.
NOTE
The position of the movable side tip during operation
relies on the preset tolerance. For details, refer to the
Instruction Manual.
-153-
(3) Press F2 SINGLE with the Shift key held down.

(4) The current position is taught by executing the SPOT
instruction. Specify pressure conditions (P), welding
conditions (S) and open conditions (BU) for the SPOT
instruction.
(Press only the F2 SINGLE key, and STANDARD that is
displayed. You can now edit the standard operation
statement. From here on, the position is taught at the
newly changed format by the Shift and SINGLE keys.)
[Correcting the Position]

To correct the reference position in a program you have
created a program, teach a position where the movable side
tip is contacting the [Teaching Position] panel.
[Teaching Method]
(1) Compensate for tip wear if it is worn down.
(2) Jog feed the robot to the position where the panel
contacts the fixed side tip.
(3) The movable side tip may be at any appropriately open
position.
(4) Press F5 POSITION CORRECTION with the Shift key
held down.
If tip wear down compensation is enabled, the taught
position obtained by subtracting the tip wear down will
be displayed.
Visually observed teaching point The position corrected by a new tip is

using a worn down tip loaded according to the corrected
position obtained by subtracting the
wear down value.
For details, refer to the Instruction Manual.
･ "Checking the 0 Position"

Calculate the total wear down of the fixed side and
movable side tips from the position where the movable
side tip is contacting the fixed side tip.
Step 1 Jog feed the movable side tip to a position where it

contacts the end of the fixed side tip.
To jog feed the movable side tip, press AUX and then
3 CHANGE GROUP. Make sure that G1 on the 2nd
line of the screen has changed to G2, and then press
the JOG key.
Step 2 View the position data of the movable side tip when
it touches the fixed side tip.
-154-
Step 3 Compare the total wear down calculated by detection

of the wear down with the absolute value of the
movable side tip position data, and judge whether or
not the wear down calculated by detection is
reasonable or not.
Provide the following appropriate criteria for judging
this:
･ (position data of movable side tip) > (total wear down

value)
The detected wear down value is small. (Actually, the tip
is worn more than the detected wear down value.)
･ (position data of movable side tip) < (total wear down

value)
The detected wear down value is large. (Actually, the tip
is worn less than the detected wear down value.)
-155-
Appendix G Troubleshooting (Gun Change)

G.1 The attach instruction is executed when the gun is not
attached.
･Phenomenon
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.
･Remedy 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)

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.
-156-
･Remedy 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.
G.2 The robot stopped during calibration.
･Phenomenon
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
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.
G.3 Calibration motion failed.
•Phenomenon
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.
-157-
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.
･Remedy 1
Carry out steps 6 to 9 of G-1 Remedy 1.
･Remedy 2
Same as Remedy 2 of G-1.
G.4 A different gun from that specified by the attach instruction is

attached.
･Phenomenon
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.
･Remedy
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.
-158-
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.
G.5 The attached gun has been detached by mistake (without using
the detach instruction).
･Phenomenon
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.
･Remedy 1
Same as Remedy 1 of G-1
･Remedy 2
Same as Remedy 2 of G-1
G.6 The gun axis of a detached gun has moved.
･Phenomenon
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.
･Remedy
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.
-159-
G.7 The battery voltage has fallen.
･Phenomenon
The "SRVO-065 BLAL" alarm has occurred with the gun in
an attached state.
･Remedy
1. Change the battery with the gun attached.
2. The gun can be used as it is.
G.8 The battery ran low while the gun was detached.
･Phenomenon
The "SRVO-062 BZAL" and "SRVO-075 Pulse not
established" alarms occurred when the gun was attached.
･Remedy
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
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
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.
-160-
*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.
-161-
B-80954EN/01
INDEX
Gun change reference position setup method (battery-
less type) , 134
A
Gun change sequence, 107
A different gun from that specified by the attach
instruction is attached., 158 Gun change setup, 96
Alarm code table, 113 Gun change status, 108

Gun deflection compensation, 73
B GUN DETACH instruction, 104
Backup condition setting, 39

H
Backward execution, 106
Backward execution (BWD), 44 Hold, 43
Basic specification, 2, 92
I
Battery-less type guns, 102
Battery-mounted type guns, 103 Incremental operation method, 55
Independent motion, 82
C Initial setting, 5
Calibration motion failed., 157 Initial setup, 95
Checking the reference point and wear down value, 68 Instruction format, 27
Construction of servo gun gun change screen, 129 Insufficient pressure, 140
Construction of servo gun screen, 127

J
Control method (Multi-group), 4
Creating a wear down value detection program, 55 Jog operation (group 2 manual operation), 22
D L
Deposition removal function, 76 Limitations, 90
Detection of abnormal wear amount, 65 List of servo gun instructions, 133
E M
E-stop, 43 Manual operations, 11
Manual pressurization and manual pressure condition
change-over, 12
F
Manual stroke and manual stroke change-over, 16
Feature of function, 92
Manual welding, 21
Features of fanuc servo gun, 2
Meaning of each items, 89
Flow of tip wear compensation, 51
Foward execution, 105 N
Names of major servo gun components, 3
G
Notice for teaching, 110
GUN ATTACH instruction, 104
Gun change function , 91
i-1
INDEX B-80954EN/01
Spot welding instructions, 27

O
Spot welding sequence setup screen, 7
Operation, 88
Spot welding setting, 6
Other instructions, 45
Stroke switching, 49
Outline of installation , 94
System configuration, 93
P
T
Pressure cannot be output manually., 145
Teaching, 110
Pressure condition setting, 29
Teaching position, 40
Pressure enable and completion confirmation signals,
83 Teaching position operation method, 57
Pressure enable signal, 84 Test execution, 81
Pressure instruction, 47 The attach instruction is executed when the gun is not
attached., 156
"Pressure is too high, or fluctuates", 142
The attached gun has been detached by mistake
Pressure profile control function, 86 (without using the detach instruction), 159
Pressurization instruction, 46 The battery ran low while the gun was detached, 160
Profile data, 88 The battery voltage has fallen, 160
Programing, 26 The detail of positions generated by taught position and
auto route setup, 41
Q The end signal is ignored and welding is ended, 147
Quick mastering reference position setup, 139 The gun axis of a detached gun has moved, 159
The gun has bent., 151
R The next line is executed without Pressuring carried
out., 148
Recommendatory setting, 130
The next line is executed without welding carried out,
Reference position setup for calibration types 3 and 4, 148
134
The reference point for tip wear compensation can no
Reference position setup for calibration types 5 and 6, longer be found, 149
136
The robot stopped during calibration., 157
Register operation method, 59
The wear down value cannot be detected correctly, 142
Restrictions, 92
Tip stick signal detection function, 74
Tip wear down compensation, 50
S
Tip wear down compensation for stationary arm
Sample program, 105, 111 moving with movable arm (X gun), 70
Saving the servo gun settings, 112 Troubleshooting, 140
Servo gun condition instruction, 45 Troubleshooting (gun change), 156
Servo gun monitoring, 78
Servo gun setup, 8, 109 U
Setting the reference position, 102 User program-based operation (special operation), 19
Simplified teaching, 23
Single-step testing, 43
i-2
B-80954EN/01 INDEX
W
Wear down value detection methods, 53
Wear down value reset program, 64
Weld completion confirmation signal, 85
Welding sequence, 38
i-3

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B-80954EN/01 Table of Contents

2. INITIAL SETTING ......................................................................................................................... 5

3. SPOT WELDING SETTING .................................................................................................... 6

4. MANUAL OPERATIONS ........................................................................................................ 11

6.3.1 Incremental operation method......................................................................................................55

7. GUN DEFLECTION COMPENSATION......................................................................... 73

8. TIP STICK SIGNAL DETECTION FUNCTION ......................................................... 74

9. DEPOSITION REMOVAL FUNCTION ........................................................................... 76

10. SERVO GUN MONITORING................................................................................................ 78

11. TEST EXECUTION..................................................................................................................... 81

12. INDEPENDENT MOTION ...................................................................................................... 82

13. PRESSURE ENABLE AND COMPLETION CONFIRMATION

14. PRESSURE PROFILE CONTROL FUNCTION ....................................................... 86

15. GUN CHANGE FUNCTION ................................................................................................. 91

15.3 GUN CHANGE SETUP ......................................................................................................................96

16. SAVING THE SERVO GUN SETTINGS ..................................................................... 112

17. ALARM CODE TABLE .......................................................................................................... 113

A. Construction of Servo gun screen ............................................................................. 127

B. Construction of Servo gun gun change screen ............................................... 129

C. Recommendatory Setting ................................................................................................. 130

D. List of servo gun instructions ....................................................................................... 133

E. Gun Change Reference Position Setup Method

F.3 The wear down value cannot be detected correctly .......................................................................142

G. Troubleshooting (Gun Change).................................................................................... 156

1.1 FEATURES OF FANUC SERVO GUN

･ Many dedicated servo gun functions (such as manual

1.2 BASIC SPECIFICATION

Pressure setting range 0.1-9999.9[Kgf](in 0.1-kgf steps) (*1)

1.3 NAMES OF MAJOR SERVO GUN COMPONENTS

Servo gun motor

1.4 CONTROL METHOD (MULTI-GROUP)

Control method in the new servo gun system

Motion group 1 Motion group 2

Six robot axes Servo gun axis

Control method in the old servo gun system

Extended axis control

Six robot axes Servo gun axis

1. Servo gun motor initialization

3 SPOT WELDING SETTING

･ Spot I/O setting (I/O menu → “Spot welding”)

･ Spot weld sequence Setup (SETTING menu → “Spot welding”)

･ Servo gun Setup(SETTING menu → “Spot welding”)

･ Pressure Condition setting (DATA screen → “Pressure”)

･ Stroke condition setting (DATA screen → “Backup”)

3.1 SPOT WELDING SEQUENCE SETUP SCREEN

Specify details of settings related to servo gun-based spot

Descriptions of items for spot weld sequence setup

3.2 SERVO GUN SETUP

Specify details of settings related to servo gun by referring to

SETUP Spot Weld G2 JOINT 10 % SETUP Spot Weld G2 JOINT 10 %

Descriptions of items for servo gun setup

Counter register setup

SETUP Spot Weld G2 JOINT SETUP Spot Weld G2 JOINT 10 %

Using servo gun the first time, please refer to “APPENDIX C

1. Manual pressurization and manual Pressure Condition

4.1 MANUAL PRESSURIZATION AND MANUAL PRESSURE

･ On the Manual operation screen, specify the Pressuring

･ On the Pressure Condition screen (data screen), select

･ Specify (or confirm) the details of the Pressure Condition.

･ Pressing GUN1 key displays a window including

SERVO GUN DATA G1 JOINT 10 %

[ TYPE ] EQUIP GUN DETAIL COPY >

GN1 No. 1 GN1 No. 2 GN1 No. 3