Global 2 Servogun Setup Users Manual For 7.5 Rev 1.0

Automation
Specification OVRS
Global 2 Servo Gun Setup Manual Fanuc
SpotTool+ 7.50 with OVRS4 Customization
Version 1.0
February 2018
Opel Automobile GmbH
OV ME Strategy
Author(s):
Andreas Gilles — Opel Automobile GmbH Automobile GmbH /
ME PPA Automatino
Fernando de Pablo — Opel Automobile GmbH Automobile GmbH /
ME PPA Automatino
Forward questions and comments to:

Opel Automobile GmbH Automobile GmbH
Bahnhofsplatz I
Mail Code IPC 42-74
D-65423 Ruesselsheim am Main
Andreas Gilles
Document revisions:
Date Revision By Revision history
2018-02 1.0 Marcin Rydzek Initial
February 2018 Specification OVRS 1 of 111

Version 1.0 Global 2 Servo Gun Setup Manual Global 2 Servogun Setup Users
Manual for 7.5 Rev 1.0.docx
OV ME Strategy
Table of Contents
1 GLOBAL 2 SERVO GUN SETUP MANUAL ............................................................................ 6

1.1 Scope ............................................................................................................................................................................... 6
1.2 Purpose ........................................................................................................................................................................... 6
1.3 Intended audience ....................................................................................................................................................... 6
1.4 Background .................................................................................................................................................................... 6
1.5 Setup Flow ...................................................................................................................................................................... 7
2 GUN INSTALLATION .............................................................................................................. 8

2.1 Gun Mounting................................................................................................................................................................. 8
3 WIZARD SETUP ....................................................................................................................... 9

3.1 Getting Started ............................................................................................................................................................. 9
3.2 Helps and Hints.............................................................................................................................................................. 9
3.2.1 Re-Running the wizard to correct for an incorrect response during initial setup .................................... 9
3.2.2 Re-Running the wizard to add a feature ................................................................................................... 9
4 ESTABLISHING PULSE ON SERVO GUN MOTORS ........................................................... 11

4.1 Resetting BZAL (Battery Zero Alarm) .................................................................................................................... 11
4.2 Establishing Pulse ....................................................................................................................................................... 11
4.2.1 GSWA and SW-Series Motors.................................................................................................................... 11
4.2.2 HT-Series Motor ........................................................................................................................................ 11
5 MASTERING THE GUN ......................................................................................................... 12

5.1 Setting Gun Close Direction...................................................................................................................................... 12
5.2 Mastering the Gun and Setting Axis Limits ........................................................................................................... 13
5.2.1 Single Gun per Equipment........................................................................................................................ 13
5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal) ............................................... 15
5.3 Autotuning ................................................................................................................................................................... 17
5.3.1 Default Autotune Running........................................................................................................................ 17
5.3.2 Advanced Autotune Setup before Tuning............................................................................................... 19
5.3.3 Auto Tune Results ..................................................................................................................................... 20
5.4 Help and Hints ............................................................................................................................................................. 21
5.4.1 Collision detection alarm ......................................................................................................................... 21
5.4.2 Stop Excess Error ...................................................................................................................................... 21
5.4.3 Autotune cannot start .............................................................................................................................. 21
5.4.4 Pressure Shortage .................................................................................................................................... 21
6 PRESSURE CALIBRATION ....................................................................................................22

6.1 Equipment ....................................................................................................................................................................22
6.2 Performing Calibration..............................................................................................................................................22
6.3 Help and Hints .............................................................................................................................................................26
7 OVERTORQUE PROTECTION .............................................................................................28
8 SERVO GUN DIAGNOSIS .....................................................................................................30

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9 THICKNESS CHECK CALIBRATION ....................................................................................32
10 TIP WEAR COMPENSATION ............................................................................................34

10.1 Setup .............................................................................................................................................................................34
10.1.1 Enabling Tip Wear Compensation ....................................................................................................... 34
10.1.2 Running Tip Wear Compensation Setup Program(s) .......................................................................... 36
10.1.3 Wear Ratios .......................................................................................................................................... 36
10.2 Viewing Tip Wear values ...........................................................................................................................................37
10.3 Tip Wear Updating .....................................................................................................................................................38
10.3.1 Tip Wear Routines ................................................................................................................................ 38
11 SET GUN CLOSE DIRECTION ...........................................................................................39

11.1 Carried +Z ....................................................................................................................................................................39
11.1.1 Single Gun ............................................................................................................................................. 39
11.1.2 Dual Gun Single Equipment.................................................................................................................. 40
11.2 Pedestal +Z .................................................................................................................................................................. 41
11.2.1 Single Gun ............................................................................................................................................. 41
11.2.2 Dual Gun Single Equipment.................................................................................................................. 42
12 PRESSURE SCHEDULES ....................................................................................................43

12.1 Background ..................................................................................................................................................................43
12.2 Elements .......................................................................................................................................................................43
12.2.1 Weld Force ............................................................................................................................................ 44
12.2.2 Part Thickness....................................................................................................................................... 44
12.2.3 Gun Sag................................................................................................................................................. 45
12.2.4 Pushing Depth ...................................................................................................................................... 47
12.2.5 Contact Speed...................................................................................................................................... 48
13 BACKUP SCHEDULES .......................................................................................................49
14 DISTANCE SCHEDULES ....................................................................................................50
15 PROGRAM LISTINGS ........................................................................................................ 51

15.1 Style templates ........................................................................................................................................................... 51
15.1.1 Carried Servo Gun ................................................................................................................................ 51
15.1.2 Single Pedestal Servo Gun ................................................................................................................... 52
15.1.3 Dual Pedestal Servo Gun ...................................................................................................................... 53
15.2 Miscellaneous Servo Gun Macros ........................................................................................................................... 54
15.2.1 Stepper Check ...................................................................................................................................... 54
15.2.2 CAP_WEAR............................................................................................................................................ 55
15.2.3 Number of Guns .................................................................................................................................... 55
15.2.4 TW_GUNS ............................................................................................................................................. 56
15.2.5 WR_UPDAT ........................................................................................................................................... 59
15.2.6 Tip Reset ............................................................................................................................................... 61
15.2.7 Cap Select ............................................................................................................................................ 63
16 RECOVERY .........................................................................................................................64
16.1 Recovery from Loss of Mastering........................................................................................................................... 64
16.1.1 Mastering the Gun from the Master/Calibrate screen ........................................................................ 64

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16.2 Cap configuration change ........................................................................................................................................65

16.2.1 Re-Run the wizard ................................................................................................................................ 65
16.2.2 Mastering the Gun and Setting Axis Limits.......................................................................................... 65
16.2.3 Running Tip Wear Setup....................................................................................................................... 65
16.2.4 Completing Pressure Calibration......................................................................................................... 65
16.2.5 Path Touch up....................................................................................................................................... 65
16.3 Motor Replacement ...................................................................................................................................................66
17 SERVO GUN TOOL CHANGE OPTION ............................................................................67

17.1 Purpose .........................................................................................................................................................................67
17.2 Hardware/Software Requirements, Limitations and Recommendations.......................................................67
17.3 Hardware Setup Procedure for Carried Servo Weld Gun(s) ............................................................................ 68
17.4 Running SRVO_TC.PC................................................................................................................................................. 71
17.4.1 SRVO_TC.PC File Execution Procedure ............................................................................................... 72
17.5 Programming and Setup Completion .....................................................................................................................72
17.5.1 GUN ATTACH[x].................................................................................................................................... 72
17.5.2 GUN DETACH[x].................................................................................................................................... 73
17.5.3 Emergency Detach (EMGDTCH.TP) ..................................................................................................... 73
17.5.4 Verification of Gun(s) connections ...................................................................................................... 73
17.5.5 Auto Tune and Pressure Calibration of Guns....................................................................................... 73
18 TOOL CHANGE PROGRAMS SPECIFIC FOR SERVO GUN TOOL CHANGE

APPLICATIONS. ...........................................................................................................................74
18.1 Style template (Servo tool-changer) Single Carried Gun ................................................................................. 74
18.2 Style template (Servo tool-changer) 2 Carried Guns within 1 style .................................................................75
18.3 Style template (Servo tool-changer) 1carried gun and 1 MH end effector ...................................................76
18.4 CAP_WEAR (Servo TC Version ONLY) ....................................................................................................................77
18.5 TCCKTOOL ...................................................................................................................................................................78
18.6 TCGETNUM ...................................................................................................................................................................79
18.7 TCINNEST..................................................................................................................................................................... 80
18.8 TCEMPTY ..................................................................................................................................................................... 82
18.9 TCCLSLID ......................................................................................................................................................................85
18.10 TCOPNLID .................................................................................................................................................................... 86
18.11 TCLTCHTL .................................................................................................................................................................... 88
18.12 TCUNLTCH ................................................................................................................................................................... 89
18.13 TCPICKH1 ......................................................................................................................................................................90
18.14 TCDROPH1 ....................................................................................................................................................................92
18.15 Style 26..........................................................................................................................................................................93
18.16 TCTEACH.......................................................................................................................................................................95
18.17 Servo Gun Tool Change Tip wear specific programs ..........................................................................................95
18.17.1 TW_GUNS (SG tool change specific) ................................................................................................... 95
18.17.2 TW_MEM (SG tool change specific) ..................................................................................................... 97
18.17.3 TW_VER (SG tool change specific) ...................................................................................................... 98
18.18 Servo Gun Tool Changing specific Tip Dress Programs ......................................................................................99
18.18.1 Style 29 TIP DRESS (SG tool change specific) ...................................................................................... 99
18.18.2 TD_PROCx (SG tool change specific) .................................................................................................101
18.18.3 TCDRESCP (SG tool change specific) ..................................................................................................102
18.18.4 TCPSTDRS (SG tool change specific) ..................................................................................................104
19 TROUBLESHOOTING SERVO GUN TOOL CHANGE ................................................... 105

19.1 The attach instruction is executed when the gun is not attached.................................................................105

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19.2 A different gun from that specified by the attach instruction is attached..................................................105
19.3 The attached gun has been detached by mistake (without using the detach instruction) .....................106
19.4 The battery voltage has fallen ..............................................................................................................................106
19.5 The battery ran low while the gun was ................................................................................................................106
20 VARIABLE LISTING (CONDENSED) .............................................................................. 108

20.1 $SGSYSCFG ................................................................................................................................................................108
20.1.1 $pst_ertype: Pressure Shortage Error type........................................................................................108
20.1.2 $allow_stdsp: Display Standalone Spot instruction...........................................................................108
20.1.3 $rel_press: Release pressure at program pause................................................................................108
20.1.4 $prs_units: Pressure units ...................................................................................................................108
20.2 Common Errors on Servo Gun Errors .....................................................................................................................108
20.2.1 SRVO-023: SERVO Stop error excess (G:%d A:%d) ............................................................................108
20.2.2 SRVO-024: SERVO Move error excess (G:%d A:%d) ...........................................................................109
20.2.3 SRVO-069: SERVO CRCERR alarm (Grp:%d Ax:%d)............................................................................109
20.2.4 SRVO-062: SERVO BZAL alarm (Group:%d Axis:%d) .........................................................................109
20.2.5 SRVO-068: SERVO DTERR alarm (Grp:%d Ax:%d) ..............................................................................109
20.2.6 SVGN-023: Incomplete Pressure calibration ......................................................................................109
20.2.7 SVGN-024: Incomplete Wear Down calibration .................................................................................109
20.2.8 SVGN-032: Tip increased error............................................................................................................110
20.2.9 SVGN-118: Max wear exceeded .........................................................................................................110
20.2.10 SVGN-020: Pressure shortage .............................................................................................................110
20.3 How to check gun impedance: ............................................................................................................................... 111
20.4 Servo Gun Amp Settings with Gun(s) & Hardware Mismatches....................................................................... 111

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1 Global 2 Servo Gun Setup Manual

1.1 Scope
The following documentation is intended to be a reference document to aid in the setup and installa-
tion of the robotic servo weld guns for all projects using servo guns and Fanuc SpotTool+ 7.50 with the
OVRS4 Customization. This documentation is intended to detail the steps necessary to install a Tolo-
matic servo weld gun on to a Fanuc R-30iA robot. The steps outlined in this manual will allow the in-
tended audience to install the weld gun, calibrate, tune, and program/touchup weld paths.
1.2 Purpose
The steps outlined in this manual will help to ensure that all servo weld guns are integrated and setup
in the same fashion so that the system is easily maintained and is fully functional to all RS specifications
as well as OVCS-2, and OVCH-1. This document is not intended to replace servo gun manuals from Fa-
nuc, but to simply document specific setup criteria specific to Opel Automobile GmbH applications, us-
ing Fanuc SpotTool+ 7.50 with the OVRS4 Customization.
1.3 Intended audience

The intended audience for this document includes robot programmers, engineers, and skilled trades
responsible for setting up the servo gun robots at integration, and maintaining the equipment once it
is installed into the production environment.
1.4 Background
The servo guns that are being referenced use a Tolomatic/Aro3G motor that incorporates a
Fanuc encoder, and connectors that allow it to be controlled by the Fanuc robot. There are 7 different
motor sizes.
1. Tol SW44.
2. Tol HT23.
3. GSWA 201-202-ARO3G. REQUIRES WATER for Operation.
4. GSWA 101-Tol.
5. GSWA 102/103/202/IMA44-Tol.
6. GSWA 201/301/302/IMA33-Tol.
7. FANUC ACa8/4000is-40A/80A

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All motors are driven by the same 40 amp auxiliary amplifier in the robot, as an integrated robot axis.
The basic setup has the robot arm as motion group 1, and the servo guns as group 2, and group 3 if
necessary. The control of the servo gun is integrated into the robot system, such that I/O is not neces-
sary to control the gun functionality, such as backup or equalization. All configured spotwelding guns
in the OV OVRS4 customization will require water flow for STROKE operation.
1.5 Setup Flow

The following flow chart is a process of the steps necessary to setup a servo gun robot
Confirm
Mount & Connect Section
connectors
Gun 2
are clear
Setup Run Controlled Section

Application Wizard Start 3
Perform Cold Start
GSWA -101 Reset Section

GSWA -102 Pulse code 4
GSWA -103 Faults
Master & Set Section

New caps 5
Menu Utilities Limits
Auto Tune Done in Test
Cell Prior to
Integration if
Section
Perform T1 Possible
6
Pressure Calibration 100 %
Review Overtorque Section

Protection 7
Section
Perform 8
Thickness Calibration
Section
Run Tip Wear Setup 9
New Caps
Setup Macro Tip Wear
Section
Gun - Moveable Set Carried : +Z
10
Robot - Stationary Pedestal : + Z
Gun Close Direction
Section
Setup
11
Pressure Schedules
Section
Enable / Disable 12
Desired Setup
Schedules within Back up Schedules
Gun Range Section
Touch 13
Teach-Touch up
to
Path Metal
Tip Dress
Setup

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2 Gun Installation
2.1 Gun Mounting
When mounting the gun to the robot faceplate, care should be given to the way the connectors for the
motor will route. There are 2 connectors that are used to control the Tolomatic motor from the robot.
The first is the power cable and the second is the encoder cable. These should be positioned such that
the cables and connectors are in the safest location relative to projected path. If there‟s interference
it is possible to rotate the motor end cap +- 90° . See motor documentation on rotating the connectors
on the end cap.

Version 1.0 Gun Installation Global 2 Servogun Setup Users
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3 Wizard Setup
The wizard allows the robot software to be configured for the specific application. The programmer
needs only answer a few questions and the software configures itself based on the answers chosen by
the programmer. This functionality has been further enhanced to include setting up of the servo gun
applications, including group and axis data that previously needed to be done manually before running
the wizard. This presented some complexity issues and has been remedied by adding the necessary
functionality to the wizard. If the application is SERVO TOOL CHANGER please refer to Section 15
and 16.
3.1 Getting Started

Before running the wizard, some information regarding the robot and application need to be gathered.
They are as follows:
1. Robot software version.
· Must be 7.50Pxx with OVRS4 Customization dated 05/26/2009 or later. · An update will be nec-
essary if the software is not up to this level.
2. Information about the application that the robot performs
· Carried or Pedestal Process
3. Information about the servo guns
· Motor Type
· Maximum Force for the gun (NOT the maximum motor force)
· Net Gear Ratio (NOT the motor ratio)
· Maximum gun opening (NOT the maximum motor stroke)
· Gun type: Pinch/X-style or C-style
· Auxiliary Amplifier that the servo motor is attached to
4. Information on how the guns are going to be used (If multiple guns exist)
Dual gun single equipment
Dual gun Dual equipment, 1 or 2 weld controllers
· Affects tip wear compensation and pressure schedule approach.
If the appropriate groups are not present when the wizard is run, the wizard will automatically add the
Servo Gun group and then boot back to controlled start. It is important that a full load memory card
with the AP1 directory be plugged into the controller when servo gun groups are added. Once the robot
has returned to Controlled start it will be necessary to re-run the wizard to configure the robot applica-
tion. To see an example of running the servo gun setup wizard please refer to the 7.50P-xx Wizard man-
ual-OV Customization document.
3.2 Helps and Hints

3.2.1 Re-Running the wizard to correct for an incorrect response during initial setup
If a mistake was made in the initial setup of the wizard, the easiest way to recover is to re-run the wizard.
This will allow the robot to automatically reconfigure for the change. There is no need to reboot back
to controlled start if you are currently at controlled start. Simply rerun the wizard, making sure to take
your time. It is necessary to set Cell I/O every time the wizard is run as the robot resets the cell interface
to default when the wizard is launched.
3.2.2 Re-Running the wizard to add a feature
If it is necessary to add a feature such as a tip dresser or Transformer Over Temp switch, it is not neces-
sary to re-run the wizard completely. It is necessary, however, to Boot to Controlled start and launch

Version 1.0 Wizard Setup Global 2 Servogun Setup Users
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the Wizard. Select Item #3 „Add to Configuration‟. This will allow the user to add the necessary items,
without having to run through the entire wizard. Prior to adding a feature, it is best to back up the
robot, in the event an error occurs. A backup all is sufficient
1. Perform a Backup All of the controller
2. Perform a Controlled Start
3. Start the wizard
· Select Option #3 „Add to Configuration‟
· Follow the prompts as necessary
4. Perform a cold boot
5. Query any new DeviceNet nodes as necessary.

Version 1.0 Wizard Setup Global 2 Servogun Setup Users
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4 Establishing Pulse on Servo Gun Motors

Once the groups and axis are configured and the wizard run, it is necessary to master the guns. This
procedure is critical and must be followed as outlined below for each configured servo gun.
4.1 Resetting BZAL (Battery Zero Alarm)

As is the case any time a motor is installed on the robot it will be necessary to clear the BZAL alarm that
indicates that the system has lost communication with the encoder.
The steps necessary for clearing the BZAL alarm:
1. Press [MENUS] -> [NEXT] -> [SYSTEM] -> [Master/Cal]
2. Press [FCTN] ->[3: CHANGE GROUP] (Select the Servo Gun group, either 2 or 3)
3. Press [F3: RES PCA]
4. Select [F4: YES] when prompted to „Reset pulse coder alarm?
5. Repeat steps 2 and 3 for all servo gun groups.
6. Cycle the power on the robot controller.
7. SRVO-075 Pulse not established will be displayed in the fault log upon power up.
4.2 Establishing Pulse
Before the Gun can be mastered it is necessary to establish pulse with the Fanuc Encoder that is
mounted in the Tolomatic motor.
4.2.1 GSWA and SW-Series Motors
The method used to establish pulse on the SW series motor is identical to the method used to master a
standard Fanuc motor.
1. Select Group 2 for equipment 1, Group 3 for equipment 2
· Press [FCTN] then Item [3: Change Group]
2. Jog Servo Gun axis until pulse is established. (The robot may indicate on the teach pendent
that 'Pulse has been Established')
· Jog the axis in both the +X and -X direction until 'Pulse is established'
· For a second gun on that equipment jog the second axis in the +Y and -Y direction until 'Pulse
is established'.
4.2.2 HT-Series Motor
For the HT-series motors, because they are 4-pole rather than an 8-pole require an additional step to
establish pulse with the encoder. It is not possible to immediately jog the axis without manually rotat-
ing the motor by hand.
To establish pulse on the HT-Series motors it is necessary to perform the following for each gun:
1. Locate the manual override key/gear on the servogun actuator.
2. Loosen the cover and slide out of the way. (Do not remove completely)
3. Using a screwdriver carefully rotate gear one complete revolution.
4. Attempt to jog the gun.
· If successful, the gun will move, and the gun can then be mastered
· If unsuccessful, the robot will still indicate a pulse not established alarm. Repeat step 3 and 4
until successful.
5. Replace cover on manual override access.

Version 1.0 Establishing Pulse on Servo Gun Motors Global 2 Servogun Setup Users
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5 Mastering the Gun

This is the recommended method to master the weld gun, because it calibrates the axis automatically
and sets the servo gun limits to the limit defined in the Wizard setup at controlled start. This method
also verifies that the gun close direction is correct such that there is commonality among all guns and
for the capability to download simulations.
To access the Gun Setup and Autotuning screen:
Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]
The follow-
ing steps
must be
completed
in order.
5.1 Setting Gun Close Direction

The first step in calibrating the gun is to set the gun close direction. This is to set the robot up such that
+X on the teach pendent closes the gun. Follow the directions and then proceed to the next step.
1. Select [Set Gun Motion Sign], and follow instructions
Note:For all OV servo guns we want +X to close the gun tips and -X to open the gun (+Y/-Y for the second
gun on the same Group Axis). If this is not the case, as with reverse parallel guns, it will be necessary to
go into controlled start and to change the motion sign under the axis configuration from False to True.
This should only be the case on reverse parallel guns.

Version 1.0 Mastering the Gun Global 2 Servogun Setup Users
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5.2 Mastering the Gun and Setting Axis Limits

5.2.1 Single Gun per Equipment
1. Select [Set Gun specs, master gun]
2. Answer [YES] When prompted if you know the gun‟s tip displacement of the gun (Gear Ratio
from the gun tag)
3. Answer [YES] When prompted if you know the gun‟s stroke limits (Max Open Distance from the
gun tag )
4. Follow the directions to master the gun and set limits
5. Close the Gun until the caps are touching and Press [F4:Closed]
6. Enter the Tip Displacement (This is the Value that was entered in the Wizard at controlled start)

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This will actually

master and cali-
brate the gun at
once, allowing
you to jog the
gun open to the
axis limit that
was set off the
gun tag at con-
trolled start.
7. Enter the Open and Closed limits for the weld gun.
· The open limit is the value that was entered at controlled start. The closed limit is 20mm for all
guns
8. Press [F3:COMP] when complete

9. It is now necessary to Autotune the motor.

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5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal)
Because of the way Fanuc handles Dual guns on „1‟ equipment, it is necessary to master both guns to-
gether even though they each have their own Servo Gun Tune screen. The following will outline the steps
necessary to Setup dual guns as a single equipment.
1. Select [Set Gun Specs, Master Gun] for Gun 1
The EQUIP The INDEX

button is used to button is used to
switch between switch between
guns on different guns on the
equipment same equipment
2. Answer [YES] When prompted if you know the gun‟s tip displacement of the gun (Gear Ratio
from the gun tag)

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3. Answer [YES] When prompted if you know the gun‟s stroke limits (Max Open Distance from the
gun tag ) .
4. Follow the directions to master the gun and set limits with the following changes
· Both guns associated with the active equipment must be mastered together
· Jog both guns closed before selecting F4 at step 1.
· Enter the Tip Displacement and Limits
Jog both guns

associated with the
active Equipment to
the closed position.
Then F4 is pressed it
will master and
calibrate both guns
associated with the
Equipment, not just
the active gun
5. Repeat steps 1 - 3 for the other gun on the active equipment.

· Use the Index button to switch between guns on the same equipment
· This is necessary to get the gun 2 screen to indicate that everything is set.
· This is easily accomplished by using the backup keys and closing the backups to 0mm before
mastering for gun 2.

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6. Once both guns are mastered, proceed to autotuning.

5.3 Autotuning
The purpose of Autotuning is to have the robot calculate certain properties of the weld gun that are
necessary for proper operation. This operation must be completed prior to pressure calibration, tip
wear setup, or any of the following sections. Autotune must be run for each servo gun separately. It will
be necessary to cycle power after running Autotune before the next gun can be tuned. All guns should
be mastered prior to Autotuning any gun.
5.3.1 Default Autotune Running
1. Select [3: Auto Tune] and Press [Shift] & [F3:EXEC]
· Put robot in T2 mode 100% override

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2. Select [YES] to Begin
3. Select [OK] and continue to hold [Shift] and the Deadman
4. After Auto Tuning completes, it will be necessary to cycle power for the new parameters to take
effect.
5. Repeat above steps for all configured servo guns

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5.3.2 Advanced Autotune Setup before Tuning

For the IMA33 motor please set the following additional Autotune Setup parameters, this is done by
pressing ENTER on Item #3 Autotune from /MENUS/Utilities/Gun Setup. Verify or set system parameters
for the IMA33 motor.
***ONLY Set these Parameters for the IMA33 motor**
Reload = DISABLE
$SGGUNX.$ATUN.$ACC_MODE =2
$SGGUNX.$ATUN.$INIT_FILTER =0
$SGGUNX.$ATUN.$ACCEL_TIME1 = 64
$SGGUNX.$ATUN.$ACC_GRP_MIN = 64
$SGGUNX.$ATUN.$TUN_METHOD =0
***Parameters for ALL NON-IMA33 motors**

Reload = DISABLE
$SGGUNX.$ATUN.$ACC_MODE =4
$SGGUNX.$ATUN.$INIT_FILTER = 30
$SGGUNX.$ATUN.$ACCEL_TIME1 = 100
$SGGUNX.$ATUN.$ACC_GRP_MIN = 100
$SGGUNX.$ATUN.$TUN_METHOD =1

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5.3.3 Auto Tune Results

Close Threshold 123 Improvements dampens the effects of the servo gun experiencing friction due to
mechanical issues. Autotuning a gun provides a summary of guns tuning results on the user screen and
instructions on how to proceed. Each gun will post results after tuning.
USER
Servo Gun Tuning Results EQ:1,GUN:1

Summarizes
Overtorque SOT 1084 (ct) Standard over-
TH1,TH2, -542, -503 (ct) torque and close
TH3 -382 (ct) threshold values.
Minimum Calibration Force 1600 (nwt)
Execution Date 07-MAY-10 09:54
EQ:1, GUN:1 Process Results OK
Gives indication if gun tuned ok. If the gun did not tune ok this means the gun tuned with an SOT >1400(ct).
Please check the gun mechanism for following:
· C-guns need the gun slide/carriage bearings aligned.
· X-guns for binding in the gun pivot bearings.
· If the gun is new, stroke the gun several cycles and retune
Notify the project weld gun engineer, if you determine any of these issues.
1. There is binding on the moveable tip of the slide.
2. There are mechanical restriction or gun chassis alignment problems.
TUNEDIAG.PC creates an Autotune timestamp of up to 10 records. To view these records select TUNE-
DIAG.PC, then press DATA/KAREL VARS/ TUNEDATE. This can be useful in logging the history of how
often the gun has been retuned. Note deselect TUNEDIAG.PC by selecting another program, so future
auto tunings can be recorded. Backup TUNEDIAG.VA from MD device to view the results offline on a
PC.
SVGN-044 AutoTune Successfully Complete

TUNEDIAG LINE 0 AUTO ABORTED S2 G3 JOINT100 %
DATA\KAREL\Vars
TUNEDATE 1/20
1 [1,1] '07-MAY-10 09:54'
2 [1,2] '1'
3 [2,1] '10-MAY-10 11:31 '
4 [2,2] '1'
5 [3,1] '10-MAY-10 11:39 '
6 [3,2] '2'
7 [4,1] '10-MAY-10 11:42 '
8 [4,2] '3'
9 [5,1] '10-MAY-10 11:49 '
10 [5,2] '1'
11 [6,1] '10-MAY-10 11:53 '
[ TYPE ]
TUNEDATE: Is based on the date and time on the controller. Ensure that the robot controller is setup
with the correct date and time.

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5.4 Help and Hints

If autotuning fails there are a number of possible reasons. The following are a list of the faults that can
occur as well as some possible remedies to these faults.
Note that tuning can pass successfully regardless of the results of step 5.3.2
5.4.1 Collision detection alarm
· The axis limits may be swapped.
· The axis limits are not set correctly.
· The gun may not be mastered correctly.
· Perhaps Detailed Autotune is required and value specification is need for load ration and accel
time.
5.4.2 Stop Excess Error
· The axis limits may be swapped.
· Gun close direction may be incorrect. Should be Plus.
· +X should close the gun, if it opens the gun then the motion sign under NoBot setup at Con-
trolled start needs to be changed.
· The gun may not me mastered correctly.
5.4.3 Autotune cannot start
· Verify that the robot is in T2 mode with 100% override active.
5.4.4 Pressure Shortage
· Verify Mastering o Make sure tips are toucing
· Verify Servo Gun setup at controlled start under Maintenance.

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6 Pressure calibration
Once the servo weld gun has been mastered and Auto Tuned, it is necessary to perform a pressure cal-
ibration on the system such that the robot can determine the relationship of motor torque to tip force.
Pressure calibration will need to be carried out for each servo gun.
6.1 Equipment
To perform pressure calibration you will need the following items.
1. Calibrated Pressure Gauge set to tracking force rather than Peak especially for C-guns.
2. Force gauge holder assembly
· This allows for one person pressure calibration by fixing the force gauge to the stationary gun
arm so that the operator has both hands free to run the pressure calibration from the teach
pendent.
· It is not recommended to run pressure calibration without this assembly because it is too cum-
bersome to hold the force gauge and execute the pressure commands from the teach pen-
dent.
NOTE:Because the weld gun is an additional axis to the robot, this task must be performed with servo
power available to all robot axes.
6.2 Performing Calibration
Pressure calibration is to be performed in T1 mode at 100% override. This is possible because the force
calibration takes place at 50mm/s, which is less than 250mm/s.
The following are the steps necessary to calibrate the weld pressures on a servo gun:
1. Press [MENUS] -> [Setup] -> [Servo Gun]
2. Select <*DETAIL*> under General Setup
3. Select <*DETAIL*> under Pressure Cal: (Should show INCOMP)

Version 1.0 Pressure calibration Global 2 Servogun Setup Users
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4. Select [F4:Yes] when prompted to start pressure calibration

5. Select [F4:OK] to acknowledge the torque limit note
6. Verify the following settings
· [Pressuring Time (sec)] = 2.0
These settings are for the standard
· [Thickness of Gauge (mm)] = 13.0
Sensor Development Force Gauge
· [Pushing Depth (mm)] = 8.0
· [Gun Open Value (mm)] = 20.0
Verify

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7. Verify or Add the following Pressure Targets
Verify or add the fol-

lowing pressure tar-
gets:
Set the Lowest pres-

sure equal to the tip
dress cutter force
Ensure the last pres-

sure table entry is
equal to the max
force rating of the
gun
For Guns with a

max force < or
equal to 3600.0 nwt
the Pressure calibra-
tion points
on the left will be
populated up to the
max force of the gun.
This ensures the pres-

sure calibration table
utilizes the max num-
ber of standard weld
pressure points.
8. Set the force gauge for Tracking Mode, especially when pressure checking C-Type guns lowest
pressure. This should reduce erratic measurements due to the kinematics of the gun.
9. Attach the force gauge to the stationary arm of the weld gun such that the gauge face is rest-
ing on the stationary tip.
10. Enter initial torque % for first pressure calibration test. 5% is a good starting point.
Enter Torque per-

centage here
Start off at a low

torque to get an
idea of how the gun
will perform ~5%
starting torque
Verify

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11. Verify that the speed is 50mm/s

12. With the robot servos reset press SHIFT-[F3: Pressure] to have the robot close the gun at what-
ever torque was specified. (Cursor must be on the line for the requested torque)
13. Step A. Adjust Torque (%) up or down until the desired force is achieved. When pressure cali-
brating some C-Type guns, lowest pressure may require torque percentage to be as low as or even
lower than 1%. This may result in unreliable pressure readings. Again, make sure the force gauge is
set for Tracking Mode. Contact the OV robotics lead engineer if Torque Percentages are less than
1%.
14. Step B. Switch the force guage to Peak Mode and with the robot servos reset press SHIFT-[F3:
Pressure] to have the robot close the gun. Record the peak pressure. If the peak pressure is greater
than the targeted pressure, this gun is experiencing significant amount of friction. Peak values above
2000kN are abnormal and could cause damage to the Tipdresser. Contact the weld gun engineer to
service gun before proceding with the gun setup. Note some guns may need to exercised to break
them in. After the gun has been serviced or broke in, rerun Autotune and begin pressure calibration
at step 1 again.
Torque can be
adjusted in 0.1%
increments
15. Repeat steps 9 – 13a for each of the pressures in the table up to the maximum rated force of the
gun. Make sure not to exceed the rated force for the gun. The motors are stronger than the guns.
· If the necessary torque required to reach a required force exceeds the allowed torque (Max
Gun Toque (%)), it will be necessary to exit pressure calibration by setting pressure calibration
complete, and accepting/updating the torque limits when prompted. This will update the
over-torque limits. To complete pressure calibration simply restart pressure calibration and
the limits will have been increased, allowing for the completion of pressure calibration.
16. When torque values have been entered for all valid pressures in the table, change the Calibra-
tion Status to complete.

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Cursor up to INCOMP
when complete with
pressure calibration
Press F4:COMP to complete

pressure calibration
17. Select [F4:COMP] to enable new parameters
18. Select [F2:END] to complete Pressure Calibration

6.3 Help and Hints
The majority of the issues that will occur during pressure calibration are errors that have to do with the
pressure calibration settings.
1. Move Error Excess
· Make sure pushing depth is set less than the gauge thickness
2. Stop Excess Error
· Verify gauge thickness
§ When error occurs, select [POSN] if faulted position is -13.01 to -13.99, change thickness to
14 mm.
3. Collision guard alarm
· Make sure that the gauge thickness is set correctly
4. Pressure gauge shows radically different pressures
· Increase Pressuring time

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5. Gun cannot achieve the lowest requested pressure in the calibration table.. This could be indi-
cation that the gun is experiencing higher than normal friction. Accept the lowest attainable pres-
sure with the guage in tracking mode. Complete the remaining pressure calibration targets ,then re-
view the details of servo gun overtorque protection menu(Section 7.0). If the Standard overtorque
value exceeds 1400 torque counts the gun mechanism is experiencing higher than normal resistance
during and must be checked for the following:
· C-guns need the gun slide/carriage bearings aligned.
· X-guns could binding in the gun pivot bearings.
· A failing servo actuator.
Notify the project weld gun engineer, if you determine any of these issues.
6. Requested Torque % exceeds limit and Pressure calibration cannot be performed
· This occurs when attempting to calibrate a torque that is greater than that specified under
Max Gun Toque (%). This can occur because the values that Fanuc defaults to are conservative
and assume full mechanical advantage.
· To allow calibration to use torques greater than max torque it is necessary to exit pressure
calibration by setting pressure calibration complete and accepting/updating the torque limits
when prompted. This will update the over-torque limits.
· Restart Pressure calibration and the limits will have been increased, allowing for the comple-
tion of pressure calibration.

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7 Overtorque Protection
Servo Gun OverTorque protection is part of the Enhanced Servo Gun Software Option. OverTorque Pro-
tection is designed to reduce the damage to servo guns and servo gun actuators cause by excessive tip
force. OverTorque protection monitors the motor current on the servo gun axis to determine if an un-
expected disturbance is present. It then removes servo power from the motor and post a “Collision
Detect Alarm” when a potential over torque condition is captured.
OverTorque Protection is enabled by default with a sensitivity of 100%. To optimize OverTorque Pro-
tection the sensitivity can be increased to a max of 200% or decreased to 1. Note that the sensitivity
can only be decreased to the max force of the gun. Sensitivity can only be modified after the servo gun
has completed the Autotune process.
It is important to view the Standard Overtorque value after Autotune and Pressure calibrating a servo
gun. This value is an indirect measure of the friction in a gun as measured during Autotune. The peak
value is captured during the Autotune process. Guns that exhibit high Standard OverTorques are sub-
ject to momentarily achieving higher than desired tip forces. This is a result of the gun needed a mini-
mal amount of force to move, and in some cases this force due to friction can be larger than a desired
welding or tip dress force. If this value is twice as large as the lowest pressure in the pressure calibration
table; (1000N/1600N tip dress force) this condition exists. It is normal for new guns to experience a
break in period and they should be re-Autotuned and repressure calibrated after being broke in. Guns
with Standard Overtorques above 1400 torque counts should be evaluated for mechanical issues.
To view the Overtorque Protection Menus and the Standard Overtorque value use the following pro-
cedure:

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3. Select <*DETAIL*> under Overtorque protection
4. Select <*DETAIL*> under Parameter Summary and press Enter
5. Ensure Standard Overtorque doesn‟t exceed 1400 torque counts

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8 Servo Gun Diagnosis

As servo gun friction changes from its pressure calibrated state, tip forces can be affected. This servo
gun software option is used to detect changes in servo gun friction and inform the user and cell control-
ler via an in the cell interface.
As part of the Global 2 (2012-2014) contract extension, this option is part of the base software bundle
for robots purchased under the new agreement. For Global 2 robots purchased under the (2009-2012)
agreement, it will need to purchased and manually installed.
Recommended SG Diagnosis Setup:
1. Set System Variable $SGDIAGCFG.$AUTORESET = 2. This resets the baseline record each time
SG diag is ran after the gun is Autotuned.

3. Select <*DETAIL*> under General Setup.

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4. Select <*DETAIL*> under Servogun diagnosis
5. Set up screen as follows:
Enable
0.8% is a % of am-
plifier torque in-
crease where tip
forces may begin
to deviate by 10%
Program called each

cycle during capwear.
Set to create SG Diag record daily, the

next time capwear calls TWZRCLB2 after
9:00 per the robots system clock.
Diag should be scheduled after the gun
is in normal operation(cycled).
SGTorqAlert bit mapped to cell interface

to alert system of that the torque has in-
creased and the gun should be pressure
checked! Output stays on until manually
shutoff by user on DO screen to confirm
alert has been acknowledged!!

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9 Thickness check calibration

Once Pressure calibration is complete it is necessary to go back to gun setup and perform the “Thick-
ness Check Calibration”. This allows for the gun to more accurately calculate part thickness with the
gun at force.
1. Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]
2. Cursor down to item 4 „Thickness Check Calibration‟ and press [Shift F3:EXEC] with the dead
man in and robot reset (T2 100% Override)
3. Select [YES] when prompted “Are you sure you want to do this:

Version 1.0 Thickness check calibration Global 2 Servogun Setup Users
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4. Select [OK] when prompted
5. When calibration is complete, the teach pendent will indicate Complete
6. Perform steps 1-5 for all configured servo guns.

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10 Tip Wear Compensation

Because the OV Global weld guns do not include equalizers, it is necessary to program the stationary
tip touching the metal. As the stationary tip wears through welding and tip dress, it is necessary to
determine the amount of tip wear present on each tip, and to offset the robot path to keep the station-
ary tip in contact with the part throughout the life of the cap. To enable this, the robot has certain
macros that setup the tip wear compensation, and other macros that will calculate the wear throughout
the life of the cap.
There are a few things that must be remembered when running with tip wear compensation enabled.
First is that after changing the caps on the robot, it is necessary to update the tip wear, telling the robot
that it has new tips. If this is not done, the robot may bend the flange with the stationary tip, causing
damage to the part, gun, or causing collision alarms.
10.1 Setup
To setup Tip Wear Compensation it is necessary to enable compensation under Servo Gun Setup, and
to run the respective setup program for the configured servo guns. For dual guns on a single equipment
tip wear compensation is enabled or disabled for both guns
10.1.1 Enabling Tip Wear Compensation
To enable Tip Wear compensation, navigate to the Servo Gun Setup Menu for the respective gun and
enable Tip Wear Compensation.

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3. [Enable] Tip Wear Down Comp
ENABLE
Tip Wear Standard

will show COMP
when setup program
is run
Note: For dual guns Tip Wear compensation is Enabled/Disabled for both guns.
For 2 guns on 1
Equipment, Tip Wear
Comp, Gun Sag and
robot close direction
are under Dual Gun
Common
ENABLE

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10.1.2 Running Tip Wear Compensation Setup Program(s)

To run the tip wear setup program, simply select the appropriate setup program and run the program
from the teach pendent. Be sure that new caps are firmly seated on the gun before running the tip wear
setup routine. TW_SETGx will take the gun stroke limits from the gun setup utility to reference cap
wear. If TW_SETGx is run any other time, verify that the servo setup gun stroke limits match the gun
stroke utility setup screen. If they don‟t match, manually enter the proper stroke limits on the stroke
limit screen under MENUS/SETUP/SERVO GUN/GUN STROKE LIMIT. Note: If the robot is a Tool Changer
TW_SETGx is replaced with TWSTGXTC
The setup programs (macros) are as follows:
TW_SETG1.TP for Gun 1
The tip wear setup program for Tool Changers is as follows:

TWSTGXTC.TP for R[13:Current Head]
10.1.3 Wear Ratios
The wear ratio is the ratio of wear between the stationary tip and moveable tip. It is set relative to the
stationary tip. Therefore a wear ratio of .4 is 40% of total wear is relative to the stationary tip and 60%
to the moveable tip. Each gun has its own wear ratio, and they are set via registers for ease of use. By
default all ratios are set to .5, or equal wear for each tip. Based on metal stack-up and coating they can
be adjusted to better reflect the actual wear ratio.
The tip wear registers are as follows:
R[5: TW Ratio fix G1]=.5 for Gun 1


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10.2 Viewing Tip Wear values

To view the tip wear values:
3. Select <*DETAIL*> under Tip Wear Standrd
Shows complete
when tip wear
setup has been
complete
The actual measured tip

wear will show up here.It
will show 0.00 immedi-
ately after tipwear setup
is complete. After a wear
update, or a cap change
this value may be non
zero. All measurements
are based relative to the
setup. The values may
not be zero after a cap
change, as all caps are
slightly different in
length

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10.3 Tip Wear Updating

Once tip wear setup has been completed, the robot will periodically update the tip wear value by run-
ning a tip wear routine that will close the gun and determine the total amount of wear. It will then apply
the tip wear ratio in splitting the wear between the moveable and stationary tips. The standard
software is configured to update one gun every cycle. For a single gun case, it will update every cycle,
and for a four gun case it will update each gun every 4 cycles. There is a register in the robot that keeps
track of the last gun updated and indexes to the next gun automatically.
10.3.1 Tip Wear Routines
There are 4 different programs that are run to perform the necessary tip wear functionality. For the
most part the operator will need to do nothing with these routines as they are nested into the code, but
are listed here for completeness. A fifth routine has been added for the Spottool7.50PXX software to
provide enhanced tip information.
10.3.1.1 TW_GUNS
This program is run whenever the steppers are reset, or whenever new cap are placed on the robot. This
routine calls TW_UPDCC(x) for every configured servo gun.
10.3.1.2 CAP_WEAR
This program is run every cycle to update the tip wear on one of the servo guns. This routine is typically
run on the way home after entering segment 63 (clear of transfer) or during a drop-off for a pedestal
application. This routine will only update a single gun every cycle because of the time involved ~ 4
seconds. With that said, each gun will update every 4th cycle worst case.
10.3.1.3 TW_UPDT(x) x= gun number

This is the routine that Cap Wear calls to update the wear on a specific gun. This routine is also called
outright to update a specific gun by the tip dress routines. When this routine is run, it will close the
selected gun and measure the tip wear from the original position that was recorded when Tip Wear
Setup was done. This routine expects that each successive measurement will show increased wear. This
routine will allow the caps to grow by a small amount (configurable) in case of a 'Cling-On' during a tip
dress.
10.3.1.4 TW_UPDCC(x) x= gun number

This is the routine that TW_GUNS calls to update the wear on each gun. When this routine is run it will
close the selected gun and measure the tip wear from the original position that was recorded when Tip
Wear Setup was done. This routine expects the caps to grow, as expected with new caps.
10.3.1.5 TW_REG(x) x=gun number

This routine was added for the Spottool7.50Pxx to provide enhanced servo gun tip wear information.
It updates the amount of wear during the tip dress and posts the servo gun tip approaching max wear
warning bit.
10.3.1.6 WR_UPDAT(x)(y) x=gun number y= new tips flag

This routine was invisible in Spottool7.50P07 and lower. This routine updates or resets the tipwear val-
ues.

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11 Set Gun Close Direction

The gun close direction defines direction the tips move to close and weld. For the moveable tip which
the Fanuc software refers to as Gun, should be set to PLUS, indicating that the positive displacement of
the moveable tip closes the gun. For the Stationary tip, which the Fanuc software refers to as Robot,
needs to be set to indicate the direction that the TCP must move to bring the stationary tip to the work
piece. This setting is critical, because it determines the direction the robot will move to place work
piece on the stationary tip as it goes through the motions that encompass a weld with a servo gun.
11.1 Carried +Z
For Carried spot welding applications, the gun Close direction (Robot) shall be relative to the Utool of
the gun and shall be +Z, for the tool as defined in RS-3.
11.1.1 Single Gun
UT: UTOOL
Should be set to
UT for Carried
Applications
1 (UTOOL #)
This is the Utool to use
for Close Gun Direction
(Robot)
+Z
The direction the robot
moves relative to the
UTOOL to bring the sta-
tionary tip to the metal

Version 1.0 Set Gun Close Direction Global 2 Servogun Setup Users
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11.1.2 Dual Gun Single Equipment
Select [Detail]
to look at Dual
Gun Common
Items
UT: UTOOL
Should be set to
UT for Carried
Applications
+Z
The direction
the robot
moves relative
to the UTOOL
to bring the
stationary tip
to the metal
1 (UTOOL #)
This is the Utool
to use for Close
Gun Direction
(Robot)

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11.2 Pedestal +Z
For Pedestal spot welding applications, the gun Close direction (Robot) shall be relative to the UFrame
of the gun and shall be -Z, for the tool as defined in RS-3.
11.2.1 Single Gun
UF: FRAME(RTCP)
Should be set to UT for
Carried Applications
1 (UFRAME #)
This is the UFrame to use
for Close Gun Direction
(Robot)
+Z
UFRAME to bring the sta-
tionary tip to the metal

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11.2.2 Dual Gun Single Equipment
Select [Detail] to look at

Dual Gun Common Items
UF: FRAME(RTCP) Should

be set to UT for Carried
Applications
+Z
UFRAME to bring the
stationary tip to the
metal
1 (UFRAME #)
This is the UFrame to
use for Close Gun Di-
rection (Robot)

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12 Pressure schedules
Opel Automobile GmbH has standardized on the Pressure Schedules that are to be used for all servo
welding applications. They include 2 schedules for each of the approved weld forces, with the only dif-
ference being the part thickness set under pressure schedule detail. These 16 pressure schedules are
not to be modified, because they include the best compromise between speed, performance and com-
plexity. If a need arises that requires a unique pressure schedule, it will be necessary to add a schedule.
However, this will require buy-in from the lead robot and welding engineers due to the fact that it af-
fects the weld spot verification process, and leads to uniqueness, and added complexity.
12.1 Background
The pressure schedules in the robot controls more than just the weld pressures, it also controls the way
the robot approaches a weld and departs after a successful weld. There are 99 pressure schedules
available for each gun. The elements listed below are available for each of the 99 schedules.
To access the pressure schedules in the robot:
1. Press [Data]
2. Press [F1: Type] -> [Pressure]
1. Setting
Manual=True will
cause the specified
Verify schedule to appear
These are the in the select list
default pressure when the [Gun] U1
schedules for all key is pressed by
robots. Only the the user
forces up to the
max rated force 2. Pressing [Gun]
of the gun will (non-shifted) U1
be present will
select the next
Pressure Schedule
in the list that is set
TRUE
3. Pressing [Shift] -
[Gun] U1 will cause
the weld gun to
move to close at
the defined pres-
sure
Note: When validating pressure schedules, it is important to do so with tryout mode DISABLED
12.2 Elements
There are 5 elements to each pressure schedule that need to be set correctly for the servo guns to op-
erate in an efficient and effective manner.
1. Weld Force
· The amount of force the gun will apply before welding.
2. Part Thickness

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· The expected thickness of the part (stack up) that is to be welded.

3. Gun Sag
· The amount of deflection (flex) on the stationary tip that is caused by closing the gun to the
prescribed pressure.
4. Pushing Depth
· The maximum distance that the robot will push to build pressure.
5. Contact Speed
· The speed at which the welding electrodes will contact the work piece.
12.2.1 Weld Force
The weld pressure is the tip force (weld pressure) the robot will apply before initiating the weld control-
ler.
To access a pressure schedule in the robot:
1. Press [Data] hard key
2. Press [F1: Type] - > [5: Pressure]
3. Cursor to select desired schedule
4. 4Select [F4: Detail]
5. Cursor to Weld Pressure to modify
NOTE: Because the robot does not initiate the weld before the gun is at pressure minimal squeeze time
is necessary in the welder control.
12.2.2 Part Thickness
The part thickness must be set in order for the robot to quickly perform the weld, and can also be used
to detect that the correct / all parts to be welded are present. The part thickness needs to be set rea-
sonably close to the actual thickness of the part(s) to be welded because the robot uses this thickness
to determine when to switch from positional to torque mode. If this value is too large the robot will
switch to torque mode to early, and will have to search (at a slower speed) until it detects the part. If
this value is too small it is possible that the tips could touch the part while still in positional rather than
torque mode. This could lead to collision alarms, and some part deformation.

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4. Select [F4: Detail]
5. Cursor to Part Thickness to modify
Part Thickness of
3.3mm for pressure
schedule # 1
12.2.3 Gun Sag

The servo gun has the ability to compensate for gun deflection as the weld force increases, allowing the
stationary tip to remain in the same position as the force increases. This is especially important on C-
Guns where the stationary/fixed gun arm wants to deflect under load. By setting up gun sag, the robot
can move the stationary/fixed tip in the opposite direction of deflection, allowing for a consistent weld
location without the use of an equalizer. This is especially important because the C-Guns do not incor-
porate pneumatic or spring equalization, with the exception of dual guns and hard automatic fixture
guns.
12.2.3.1 Enabling
The Gun Sag Compensation must be enabled for the robot to compensate for gun deflection.

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3. Select Enable under [Gun Sag Compensation]
Select:
Enable
12.2.3.2 Setup
1. Make sure that Gun Sag Compensation is enabled
2. Verify that the gun sag values are not 0.0mm in the pressure schedule detail page. [Gun Sag
Comp Value (mm)] will be calculated automatically from data taken during Autotuning, and will be
automatically filled into the pressure schedules once pressure calibration is complete.

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This value is calculated auto-

matically after Auto Tuning
and Pressure Calibration are
completed
12.2.4 Pushing Depth

The pushing depth indicates how far the robot will move past where it expects to build pressure, before
it faults with a pressure shortage. If the part thickness is set to 3mm, the robot expects to build force
when the tips are 3mm apart. The pushing depth feature allows the robot to search past this point to
build pressure so that minor variations in part thickness to not cause nuisance faults. This is also useful
in that we want to have a single pressure schedule for a given force, and to have the part thickness set
to the thickest of the stack-ups that are going to use that force. Given this plan, the default pushing
depth for all pressure schedules is 6mm.
5. Cursor to pushing depth to modify
Pushing depth
is 6mm for
schedules 1-16
Part thickness
will vary by
schedule

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12.2.5 Contact Speed

Contact speed indicates the speed at which the welding electrodes will contact the work piece. This
value by default is the speed that was used during the pressure calibration of the servo gun. This value
should not be adjusted except for certain applications such as tip dress that a higher or lower contact
speed is desired for the process.
Note: Increasing the contact speed higher than that used for calibration can lead to a higher force de-
viation from that calibrated.
5. Cursor to Contact Speed percentage to modify
Calibrated speed
for all schedules by
default is 50mm/s

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13 Backup schedules
The robot has the ability to program backup positions that specify how much the gun is to open when
the specified Backup schedule is called. This offers a simplified method of programming gun open
positions, without requiring the user to jog the weld gun axis. The backup command can be added to
the standard SPOT instruction, or executed as a manual function using the Backup Key.
There are 30 backup schedules that can be programmed for each gun.
To locate the Backup Data:
1. [DATA] -> [F1:TYPE] -> [6:Backup]
1. Setting Manual=True will

cause the specified gun
open distance to appear in
the select list when the
[BACKUP] U2 key is
pressed by the user
2.Pressing [BACKUP] (non-

shifted) U2 will select the
next Backup position in the
list
3.Pressing [Shift] -
[BACKUP] U2 will cause
the weld gun to move to
the currently selected
Backup position
The Backup Schedules are pre-defined in 10mm increments. This will allow for easy assignment of
Backup Schedules without referring to the backup data. I.e. Backup No. 1 is 10mm, BU #2 is 20mm, BU
#15 is 150mm and so on. This table can be adjusted as necessary for specific applications, but should
be fine as is, with the operator setting Manual = True for those positions that they want to access from
the Backup Key.

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14 Distance Schedules
The robot has the ability to program distance schedules that specify how close the gun is to be to the
work piece as it approaches a weld. The associated parameters are for Gun (Moveable) Robot (Sta-
tionary) tips. These distance schedules are used in the SPOT instruction to determine the position the
robot moves the caps to prior to and after a weld. All values are in addition to the part thickness. So if
you are calling a SPOT instruction with a pressure schedule that is 3mm, and you use SD (Start Distance)
=4, the tips are 11mm apart. 4mm above the part and 4mm below the part. The same applies for ED
(End Distance), which is where the robot will move the gun to after the weld.
L P[2] 1500mm/sec CNT100

SPOT[SD=4,P=1,S=1,ED=4] ;
There are 99 distance schedules that can be programmed for each gun.
To locate the Distance Data:

1. [DATA] -> [F1:TYPE] -> [Distance]
The Distance Schedules are pre-defined in 1mm increments for distances 1 thru 20 this will allow for
easy assignment of Distance Schedules without referring to the distance data. I.e. Distance #1 is 1mm,
Distance #10 is 10mm and so on. Distance Schedules 21-34 range from 40mm-320mm, this allows for
multiple open distances for the moveable tip.

Version 1.0 Distance Schedules Global 2 Servogun Setup Users
OV ME Strategy
15 Program listings
15.1 Style templates
The following templates are unique to servo gun applications and are listed here so that the differences
can be explained and documented.
15.1.1 Carried Servo Gun
/PROG STYLE01
…
1: !************************* ;
2: !STYLE 01 CARRIED WELDER ;
3: !Servo Gun TEMPLATE ;
4: !************************* ;
5: ;
6: ! Line-XX Platform-XX ;
7: ! Station XXX - Robot X ;
8: ;
9: !ECHO STYLE AND OPTION ;
10: GO[1:ManualStyle]=... ;
11: ECHO OPTION ;
12: MAINT_PROG[1]=MOV_REPR ;
13: ;
14: CALL S01POUNC ;
15: ;
16: CALL STPR_CHK ;
17: ;
18: CALL S01PROC1 ;
19: ;
20: RUN CAP_WEAR ;
21: ;
22: MOVE TO HOME ;
23: ;
24: WAIT (F[1:Capwear Complete]) ;
/POS
/END
WAIT (F[1]
This wait allows for the tip wear
update to complete prior to the
style aborting

Version 1.0 Program listings Global 2 Servogun Setup Users
OV ME Strategy
15.1.2 Single Pedestal Servo Gun

/PROG STYLE01
…
1: !************************* ;
2: !STYLE XX MH ped spot ;
3: ! Servo gun TEMPLATE ;
4: !************************* ;
5: ;
8: ;
11: ECHO OPTION ;
12: ;
13: !FFR HANDLER ;
14: IF DO[43:FFRActive]=ON,JMP LBL[10] ;
15: ;
16: CALL POUNCE ;
17: ;
18: CALL STPR_CHK ;
19: ;
20: CALL SxxPICK1 ;
21: ;
22: LBL[10] ;
23: MAINT_PROG[1]=FFRPROC1 ;
24: ;
25: !************************************ ;
26: !IF NO TIP DRESSERS ; Remove this section if no tip-
27: !CONFIGURED REMOVE THIS ; dressers are configured.
28: !SECTION ;
29: CALL TDDMPCHK(1) ;
30: !************************************ ;
31: ;
32: CALL SxxPROC1 ;
33: ;
34: !FFR HANDLER FOR PROCESS 1 ;
36: ;
37: !****************************** ;
38: !IF NO TIP DRESSERS ;
39: !CONFIGURED REPLACE ;
40: !CALL TD_PD_CK WITH ;
41: !RUN CAP_WEAR ; Replace CALL TD_PD_CK with
42: CALL TD_PD_CK ; RUN CAP_WEAR if no tipdressers
43: !****************************** ; are configured.
44: ;
45: CALL SxxDROP1 ;
46: ;
47: MOVE TO HOME ;
48: ;
50: LBL[99] ;
/POS
/END

OV ME Strategy
15.1.3 Dual Pedestal Servo Gun

/PROG style01
…
1: !************************* ;
2: !STYLE 09 MH 2ped spot ;
3: ! Servo gun TEMPLATE ;
4: !************************* ;
5: ;
8: ;
9: ;
11: GO[1:ManualStyle]=1 ;
12: ECHO OPTION ;
13: ;
14: !FFR HANDLER ;
15: IF DO[43:FFRActive]=ON,JMP LBL[R[160]] ;
16: ;
17: CALL POUNCE ;
18: ;
19: CALL STPR_CHK ;
20: ;
21: CALL S01PICK1 ;
22: ;
23: LBL[10] ;
24: R[160:FFR Process LBL]=10 ;
26: ;
27: !********************* ;
28: !IF NO TIP DRESSERS ; Remove this section if no
29: !CONFIGURED REMOVE THIS ; tipdressers are configured.
30: !SECTION ;
32: !********************* ;
33: ;
34: CALL S01PROC1 ;
35: ;
38: ;
39: LBL[20] ;
40: R[160:FFR Process LBL]=20 ;
42: ;
43: !********************* ;
44: !IF NO TIP DRESSERS ; Remove this section if no
45: !CONFIGURED REMOVE THIS ; tipdressers are configured.
46: !SECTION ;
48: !********************* ;
49: ;
50: CALL S01PROC2 ;
51: ;
54: ;
55: !********************* ;
56: !IF NO TIP DRESSERS ;
57: !CONFIGURED REPLACE ;
Replace CALL TD_PD_CK with
58: !CALL TD_PD_CK WITH ; RUN CAP_WEAR if no tip-
59: !RUN CAP_WEAR ; dressers are configured
60: CALL TD_PD_CK ;
61: !********************* ;
62: ;
63: CALL SxxDROP1 ;

OV ME Strategy
64: ;
65: MOVE TO HOME ;
67: LBL[99] ;
/POS
/END
15.2 Miscellaneous Servo Gun Macros

15.2.1 Stepper Check
This routine is called at pounce by all servo gun applications. It checks if the Steppers are reset, and if
so performs a tip wear update automatically. This is critical if the steppers were reset from the DEP, or
through some means that did not do a tip wear update. This routine does not check if an update was
done, but simply performs an update on all configured Servo Guns. This routine will also check that all
configured steppers are reset and prompt the user to reset all or abort if it detects only one of two step-
pers reset. The reason for this check, is that it is critical for dual guns on one equipment that they are
capped out together, because of the tip wear compensation and the lack of equalizers.
/PROG STPR_CHK Macro

1: !******************************** ;
2: !THIS MACRO RUNS TIP WEAR UPDATE ;
3: !IF IT DETECTS THAT STEPPERS ARE ;
4: !RESET ;
5: !IT CHECKS FOR ALL CONFIGURED SCR ;
6: !******************************** ;
7: ;
8: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[10] ;
9: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[10] ;
10: JMP LBL[20] ;
11: ;
12: LBL[10] ;
13: IF DI[397:diSW1StepReset]=ON,JMP LBL[40] ;
14: JMP LBL[99] ;
15: ;
16: LBL[20] ;
17: IF DI[397:diSW1StepReset]=ON AND DI[413]=ON,JMP LBL[40] ;
18: IF DI[397:diSW1StepReset]=ON AND DI[413]=OFF,JMP LBL[30] ;
19: IF DI[397:diSW1StepReset]=OFF AND DI[413]=ON,JMP LBL[30] ;
20: JMP LBL[99] ;
21: ;
22: LBL[30] ;
23: !******************************** ;
24: !PROMT USER FOR DIRECTION ;
25: !IF ALL CONFIGURED STEPPERS ARE ; BOTH STEPPERS ARE NOT RESET
26: !NOT RESET ; VERIFTY THAT ALL CAPS CHANGED
27: !******************************** ; SELECT:
29: DO[48:Process1Fault]=ON ; (YES) TO RESET ALL STEPPERS
30: CALL PROMPTYN(3,40) ;
31: ; (NO) TO ABORT STYLE
32: DO[48:Process1Fault]=OFF ;
33: IF R[40:Prompt Y/N]=1,CALL TIP_RST ;
34: IF R[40:Prompt Y/N]=0,CALL ABORTIT ;
35: JMP LBL[99] ;
37: LBL[40] ;
38: !If Air gun skip tip wear update ;
39: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ;
40: !Wear Skip From Predress ;
41: IF R[221:Last TD Sched]=60 OR R[221:Last TD Sched]=247 OR R[221:Last TD Sched]=249 OR R[221:Last TD
Sched]=251 OR R[221:Last TD Sched]=253,JMP LBL[99] ;
42: CALL TW_GUNS ;
43: LBL[99] ;

OV ME Strategy
15.2.2 CAP_WEAR
This routine is called either by the style program or by the tip dress check program for pedestal tip
dressing robots. For carried guns this routine should be called after the robot is clear of transfer (Seg-
ment 63) and on the way home. For pedestal applications this routine should be called before the drop
off routine, so that the robot can update a gun while dropping the part off. This routine calls
NUM_GUNS which determines the number of servo guns on the robot. It then increments a R15 by 1 and
does a wear update on that gun. Once the number of guns limit is reached it sets R15 to 0 and the
updating starts back at gun 1. The semaphore allows this task to compete prior to aborting the style
program. See style templates for examples
/PROG CAP_WEAR Macro

…
1: F[1:Capwear Complete]=(OFF) ;
2: IF ($SPOTCONFIG.$STROKE_ENBL=0 OR DO[43:FFRActive]=ON),JMP LBL[99] ;
3: CALL CHK_TIPS ;
4: IF R[218:CapWear Skip]=1,JMP LBL[99] ;
5: CALL NUM_GUNS ;
6: R[15:SERVO WEAR UPDT]=R[15:SERVO WEAR UPDT]+1 ;
7: IF R[15:SERVO WEAR UPDT]>R[16:NUM SERVO GUNS],JMP LBL[10] ;
8: ;
9: CALL TW_UPD(R[15:SERVO WEAR UPDT]) ;
10: CALL TW_REG(R[15:SERVO WEAR UPDT]) ;
11: JMP LBL[20] ;
12: ;
13: LBL[10] ;
14: R[15:SERVO WEAR UPDT]=0 ;
15: ;
16: LBL[20] ;
17: IF R[15:SERVO WEAR UPDT]=R[16:NUM SERVO GUNS],JMP LBL[10] ;
18: ;
19: LBL[99] ;
20: F[1:Capwear Complete]=(ON) ;
/POS
/END
15.2.3 Number of Guns

This routine is called by CAP_WEAR and simply determines the number of servo guns active on the ro-
bot. It puts this value in R16
/PROG NUM_GUNS Macro

…
1: ;
2: !GUN 1 IS EQ1 GUN 1 ;
3: R[16:NUM SERVO GUNS]=1 ;
4: IF $spoteqsetup[1].$num_guns=1,JMP LBL[10] ;
7: LBL[10:END EQ1 CHECK] ;
8: ;
9: IF $SPOTNUMEQ=1,JMP LBL[99] ;
11: ;
15: JMP LBL[30] ;
16: ;
17: LBL[20: RESET GUN 3] ;
20: ;

OV ME Strategy

25: ;
26: LBL[99] ;
/POS
/END
15.2.4 TW_GUNS
This routine is called by TIP_RST, after a cap change to run a tip wear update on all configured servo
gun. TW_UPDCC(X) is the tip wear program for new caps (Tip Wear Update Caps Changed), where X
is the gun number. This routine also makes sure that stroke is enabled, so the robot does not try to
update in no stroke.
/PROG TW_GUNS Macro

…
1: LBL[1] ;
3: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ;
7: CALL TW_UPDCC(1) ;
8: ;
9: !VERIFY NEW/CORRECT CAP ;
10: R[20:SERVO GUN WORK]=($SGGUN1.$SETUP.$WRDWN_TIP) ;
11: R[21:SERVO GUN WORK]=($SGGUN1.$SETUP.$WRDWN_RBT) ;
12: R[28:SERVO GUN WORK]=($SGGUN1.$SGTWD.$GNWR_AT_CHG) ;
13: R[29:SERVO GUN WORK]=($SGGUN1.$SGTWD.$RBWR_AT_CHG) ;
14: ;
15: !Set Cap Wear Tip Tolerance Check ;
16: !Compare new tips to Large/Small ;
17: !tolerance based on last tip wear ;
18: CALL SETWRTOL(1) ;
19: ;
20: !Ensure New Cap is within Toleran ;
21: IF R[20:SERVO GUN WORK]>R[219:NwCapsWearUprLmt] OR R[20:SERVO GUN
WORK]<R[220:NwCapsWearLwrLmt] OR R[21:SERVO GUN WORK]>R[219:NwCapsWearUprLmt]
OR R[21:SERVO GUN WORK]<R[220:NwCapsWearLwrLmt],JMP LBL[15] ;
22: ;
23: IF (R[20:SERVO GUN WORK]-R[28:SERVO GUN WORK]<>0),JMP LBL[45] ;
25: CALL TW_REG(1) ;
26: ;
29: WAIT .30(sec) ;
31: ;
37: ;
42: ;

OV ME Strategy

45: ;
49: ;
50: LBL[10:END EQ1 CHECK] ;
51: ;
52: IF $SPOTNUMEQ=1,JMP LBL[99] ;
53: ;
59: WAIT .30(sec) ;
61: ;
67: ;
72: ;
WORK]<R[220:NwCapsWearLwrLmt] OR R[21:SERVO GUN WORK]>R[219:NwCapsWearUprLmt] OR R[21:SERVO
GUN WORK]<R[220:NwCapsWearLwrLmt],JMP LBL[15] ;
75: ;
79: ;
80: JMP LBL[30] ;
81: ;
84: WAIT .30(sec) ;
86: ;
92: ;
97: ;
WORK]<R[220:NwCapsWearLwrLmt] OR R[21:SERVO GUN WORK]>R[219:NwCapsWearUprLmt] OR R[21:SERVO
GUN WORK]<R[220:NwCapsWearLwrLmt],JMP LBL[15] ;
100: ;
104: ;

OV ME Strategy
107: !GUN 4 IS EQ2 GUN 2 ;

108: WAIT .30(sec) ;
110: ;
116: ;
121: ;
124: ;
128: ;
129: JMP LBL[99] ;
130: ;
131: LBL[15] ;
132: !Ensure Water is OFF ;
133: CALL WTR_OFF(1) ;
137: LBL[25] ;
138: IF (R[219:NwCapsWearUprLmt]<>R[235:SmallCapWrUprLmt] AND
R[220:NwCapsWearLwrLmt]<>R[236:SmallCapWrLwrLmt]),JMP LBL[35] ;
139: ;
140: CALL CAPLOSS ;
141: IF R[40:Prompt Y/N]=1,JMP LBL[99] ;
142: ;
143: CALL USERCLR ;
144: CALL USERPAGE ;
145: MESSAGE[CAP CHANGE OUT OF TOLERANCE] ;
146: MESSAGE[...] ;
147: MESSAGE[STEPPERS HAVE BEEN RESET!] ;
148: MESSAGE[CONFIRM NEW CAPS AT] ;
149: MESSAGE[NEW TIPS ERROR PROMPT] ;
150: MESSAGE[TO CONTINUE!] ;
151: DO[48:Process1Fault]=ON ;
152: UALM[49] ;
154: JMP LBL[15] ;
155: ;
156: LBL[35] ;
157: CALL USERCLR ;
159: ;
160: MESSAGE[CAP CHANGE OUT OF TOLERANCE] ;
161: MESSAGE[...] ;
162: MESSAGE[ CAP CHANGE VERIFICATION] ;
163: MESSAGE[ FAILED TIP WEAR CHECK ] ;
164: MESSAGE[CHECK GUN FOR:] ;
165: MESSAGE[1. CORRECT CAP TYPE ] ;
166: MESSAGE[2. NEW CAPS] ;
167: MESSAGE[3. SERVO GUN MASTERING] ;
168: MESSAGE[!WEAR WITH NEW CAPS NOT <2mm] ;
170: UALM[49] ;

OV ME Strategy
172: JMP LBL[1] ;
173: ;
174: LBL[45] ;
175: CALL USERCLR ;
177: ;
178: MESSAGE[...] ;
179: MESSAGE[...] ;
180: MESSAGE[ WEAR AFTER CAPCHANGE] ;
181: MESSAGE[ IS NOT ZERO] ;
182: MESSAGE[...] ;
183: MESSAGE[...] ;
184: MESSAGE[ REPLACE CAPS] ;
185: MESSAGE[...] ;
186: MESSAGE[...] ;
188: UALM[49] ;
190: JMP LBL[1] ;
191: ;
192: LBL[99] ;
192: !Reset Wtroff TP Flag so WS resets;
154: F[10:WTROFF TP CONT]=(OFF) ;
193: !Ensure Water Reset ;
194: CALL RST_WTR ;
197: ;
/POS
/END
15.2.5 WR_UPDAT
This routine is called to execute tipwear update or reset the wear values. Gun number and a new tips
flag is passed to this program depending on the robot program execution. In some cases the tipwear
is updated, in other cases it is reset with new weld caps.
/PROG WR_UPDAT Macro

2: !Program description ;
3: ! Update fixtureless wear measmt ;
4: ! Version:6.40 ;
5: ;
6: !Input parameters ;
7: ! AR[1]: Gun number ;
8: ! AR[2]: New tip ( reset wr ) ;
9: ;
10: !Data registers R[] used ;
11: ! R[10]: Work register ;
12: ! R[11]: Work register ;
13: ;
14: !Position registers used ;
15: ! PR[20]: Position at wr start ;
16: ! PR[21]: Work position register ; 17: ;
18: !Update grp mask for motn prog ;
19: ! Parm1: gun number ;
20: ! Parm2: program name ;
21: CALL TWKGPMSK(AR[1],'TW_MVGUN') ;
22: ;
23: !Write present position to PR ;
24: ! Parm1: Gun ;
25: ! Parm2: Position register index ;
26: ! Parm3: Typ(1=opndist,2=curpos) ;
27: CALL TWKWRTPR(AR[1],20,2) ;
28: ;
29: !Write open distance to PR ;

OV ME Strategy
30: ! Parm1: Gun ;

32: ! Parm3: Typ(1=opndist,2=curpos) ; 33: ! Parm4: Magnitude of open dist ;
34: CALL TWKWRTPR(AR[1],21,1,25) ;
35: ;
36: !Move gun to PR ;
37: ! Parm1: Velocity label ;
39: CALL TW_MVGUN(1,21) ;
40: WAIT 0.00(sec) ;
41: ;
42: !Calibrate 0 with worn tips ;
43: ! parm1: gun number ;
44: ! parm2: data register1 ;
45: ! parm3: position register ;
46: ! parm4: data register2 ;
47: CALL TWKZRCLB(AR[1],10,21) ;
48: WAIT 0.00(sec) ;
49: ;
50: !Reset ref to 0 before checking ;
51: !for wear error, if new tip ;
52: R[10:SERVO GUN WORK]=AR[2] ;
53: IF R[10:SERVO GUN WORK]<>1,JMP LBL[1] ;
54: CALL TWKRSWDN ;
55: LBL[1] ;
56: ;
57: !Update wear amounts ;
58: !Parm1: 0<=Robot wear ratio<=1.0 ;
59: !RbtTipWear = ( rbtwr_ratio * ;
60: ! total wear ) ;
61: !Parm2: New tip installed ;
62: IF AR[1]=1,JMP LBL[11] ;
63: IF AR[1]=2,JMP LBL[12] ;
64: IF AR[1]=3,JMP LBL[13] ;
65: IF AR[1]=4,JMP LBL[14] ;
66: ;
67: LBL[99] ;
68: !Move gun to PR ;
69: ! Parm1: Velocity label ;
71: CALL TW_MVGUN(1,20) ;
72: IF AR[1]=1 AND $SPOTCONFIG.$NUM_WD_CTLS=1 AND $SPOTNUMEQ=2,JMP
LBL[98] ;
73: IF AR[1]=1 AND $SPOTEQSETUP[1].$NUM_GUNS=2,JMP LBL[98] ;
74: IF AR[1]=1 AND $SPOTCONFIG.$NUM_WD_CTLS=2 AND
$SPOTEQSETUP[1].$NUM_GUNS=1 AND DO[60:Proc2TipMaintReq]=ON,JMP LBL[98] ;
75: IF AR[1]=3 AND $SPOTEQSETUP[2].$NUM_GUNS=2,JMP LBL[98] ;
77: LBL[98] ;
78: END ;
79: ;
80: LBL[11] ;
81: CALL TWKCALC2(R[5:TW Ratio fix G1],AR[2]) ;
82: JMP LBL[99] ;
83: LBL[12] ;
85: JMP LBL[99] ;
86: LBL[13] ;
88: JMP LBL[99] ;
89: LBL[14] ;
91: JMP LBL[99] ;
/POS
/END

OV ME Strategy
15.2.6 Tip Reset

This routine gets called to all reset steppers. This can occur either at a 'Request Continue' with a deci-
sion code 14, or as a style 27 'Cap Change'. For pneumatic gun applications this routine checks that the
watersavers have detected a 'Cap Loss' or are bypassed before allowing the steppers to be reset. If it
detects that the configured watersavers are not tripped, or bypassed it will prompt the user to 1. Reset
anyway or 2. Skip Reset. If the watersavers were tripped, or the operator selected reset anyway, the
robot will then reset all configured steppers and watersavers. Servo Gun applications will alway reset
all configured steppers and perform a TW_GUNS which will error proof that the caps were changed and
update the wear.
/PROG TIP_RST Macro

1: !******************************** ;
2: !TIP RESET WELD CNTRLS ;
3: !THIS MACRO RESETS STEPPERS ;
4: !FOR ALL CONFIGURED SCRS ;
5: !IF CAP LOSS OR BYPASS DETECTED ;
6: !******************************** ;
7: ;
8: IF $SPOTCONFIG.$NUM_WD_CTLS=1 OR $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[10] ;
9: IF DI[453:diG1WS_CapLoss]=ON AND DI[461]=ON,JMP LBL[20] ;
10: IF DI[451:diG1WS_Bypassed]=ON AND DI[459]=ON,JMP LBL[20] ;
11: IF DI[453:diG1WS_CapLoss]=ON AND DI[459]=ON,JMP LBL[20] ;
12: IF DI[451:diG1WS_Bypassed]=ON AND DI[461]=ON,JMP LBL[20] ;
13: JMP LBL[30] ;
14: ;
15: LBL[10] ;
16: IF DI[453:diG1WS_CapLoss]=ON OR DI[451:diG1WS_Bypassed]=ON,JMP LBL[20] ;
17: !Determine if Tool Changer ;
18: CALL CKDNETND(54,38) ;
19: !IF SERVO GUN and not TC SKIP CAP ;
20: IF ($sgcfg[1].$EQUIP_TYPE=2 AND R[38:DNetNode Present]=0),JMP LBL[20] ;
21: IF R[38:DNetNode Present]=0,JMP LBL[30] ;
22: IF ($sgcfg[1].$EQUIP_TYPE=2 OR DI[129:di_TCCapsCC_Mode]=ON),JMP LBL[20] ;
23: ;
24: JMP LBL[30] ;
25: ;
26: LBL[20] ;
27: !RESET STEPPER AND WATER SAVER ;
28: !FOR WELD CONTROLLER 1 ;
29: ;
30: CALL RST_STP(1) ;
31: CALL RST_WTR ;
32: ;
35: !RESET STEPPER AND WATER SAVER ;
36: !FOR WELD CONTROLLER 2 ;
37: ;
38: CALL RST_STP(2) ;
39: CALL RST_WTR ;
40: ;
41: JMP LBL[40] ;
42: ;
43: LBL[30] ;
45: ;
46: !******************************** ;
47: !PROMT USER TO RESET ANYWAY IF ;
48: !WATERSAVERS DID NOT TRIP ;
49: !OR WERE NOT BYPASSED ;
50: !******************************** ;
51: ;

OV ME Strategy
52: !******************************** ;
53: !IF BUSY ON CALL CAPLOSS, ;
54: !GO TO MENUS 9 USER SCREEN ;
55: !******************************** ;
57: CALL CAPLOSS ;
58: !******************************** ;
61: !******************************** ;
62: ;
65: ;
66: LBL[40] ;
67: !Reset Wear Since Cap Change ;
68: R[54:TD1 CntSinceCC]=0 ;
72: ;
74: CALL SG_LOADD(17) ;
75: IF R[17:SG OPTION LOADED]=0,JMP LBL[99] ;
77: ;
78: !Determine Fanuc Servo ;
79: !S/W Option J665 ;
80: !If option exists T/C device ;
81: !is present, if not manual ;
82: !modification is required ;
83: CALL SGTCLOAD ;
84: IF R[163]=0,JMP LBL[50] ;
85: ;
89: !Latched and Rbt Holding Gun ;
90: CALL TCGETNUM ;
91: !TW Only on Servo Spot ;
92: IF GI[17:giTCAppType]<2 OR GI[17:giTCAppType]>3,JMP LBL[99] ;
93: LBL[50] ;
94: CALL TW_GUNS ;
95: IF (R[226:DNETCFG 64/256]<>1),DO[132:SGApprTipReplace]=OFF ;
96: LBL[99] ;
/POS
/END

OV ME Strategy
15.2.7 Cap Select

This routine is called at FFR to allow the user to select that the caps were changed, so that the robot can
reset the steppers and perform a tip wear update before returning to the style to re-weld the part.
/PROG CAP_SELC Macro

…
1: !******************************** ;
2: !THIS MACRO ALLOWS THE USER TO ;
3: !SELECT IF THE CAPS WERE CHANGED ;
4: !AT FFR ;
5: !STEPPERS ARE RESET IF USER ;
6: !ANSWERS YES TO THE PROMPT ;
7: !******************************** ;
8: ;
9: !******************************** ; CAPLOSS replaced PROMPTYN(4,40) in
10: !PROMT USER FOR DIRECTION ; SPOTTOOL 7.20 P40 to improve recovery
11: !IF CAPS CHANGES AT FFR ; with user interactions.
12: !******************************** ;
13: ;
14: !******************************** ;
17: !******************************** ;
18: CALL CAPLOSS ;
19: !******************************** ;
22: !******************************** ;
23: ;
24: IF R[40:Prompt Y/N]=1,CALL TIP_RST ;
25: ;
26: LBL[99] ;
27: CALL USERCLR ;
28: CALL USERPAGE ;

OV ME Strategy
16 Recovery
The following are the recommended recovery procedures necessary to recover from the most common
and foreseeable errors that will occur once the servo guns are in production. It is anticipated that this
section will grow as we garner more information and additional lessons learned.
16.1 Recovery from Loss of Mastering

The steps outlined below are necessary to recover from a loss of mastering, after the robot has been
setup and programmed. It is recommended that the caps not be changed before the following proce-
dure, as the wear in the caps are accounted for in the recalibrate routine.
16.1.1 Mastering the Gun from the Master/Calibrate screen
This method is to be used to recover from a loss of mastering after initial setup of the servo gun has
been performed.
1. Do not replace the electrodes
· The robot will use the existing cap wear to calculate correct position and update the tip wear
automatically
2. Press [MENUS] -> [NEXT PAGE] -> [SYSTEM] -> [Gun Master]
3. Select [Select F3:BZAL] to reset the battery zero alarm and cycle power
4. Re-Establish pulse with the encoder

5. Select [NEXT]
6. Jog the welding electrodes (tips) together until they just touch
7. Select [F4:RECALB]
· This will master and calibrate the gun, and update the tip wear compensation master position

Version 1.0 Recovery Global 2 Servogun Setup Users
OV ME Strategy
8. The axis is now mastered

9. Verify the weld path, and touch up if necessary
16.2 Cap configuration change
The steps outlined below are necessary to change from one cap configuration to another due to prod-
uct or process changes. This includes the change of cap size, say from a #2 short to a #2 long, or change
from one shank style to another. It is not recommended to single axis master and update limits on this
axis, as this tends not to work, and can cause issues with tip wear.
16.2.1 Re-Run the wizard
To ensure that the transition from the original cap configuration to the new configuration is successful
and straight forward, it is necessary to delete the gun axis in question from the group, and to re-enter
the axis with the new information, paying close attention to the axis limits. The easiest way to accom-
plish this is to re-run the wizard and to select YES when prompted to setup the servo gun axis.
16.2.2 Mastering the Gun and Setting Axis Limits
Because the axis information has been updated it is necessary to re-run the gun mastering and axis
setup.
See section Mastering the Gun to re-master the gun
16.2.3 Running Tip Wear Setup
Because the mastering information has changed, particularly the master counts with the new caps, it
will be necessary to re-run tip wear setup.
See section Tip Wear Compensation to setup tip wear compensation. It may also be necessary to up-
date the wear ratio when changing cap configurations.
16.2.4 Completing Pressure Calibration
Because the gun setup has changed pressure calibration has changed and should be verified. Most
likely the torque to force curve has not changed due to a simple cap change, but should be verified.
The values that were recorded during the initial setup of the pressure table are still in the robot, and all
that should be necessary is to select complete on pressure schedule setup. There is no need to go and
setup the pressure schedules again, only to verify the calibration.
See section Pressure calibration for information concerning pressure calibration.
16.2.5 Path Touch up
Because the tip configuration has been changed it will be necessary to touch up the path.

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16.3 Motor Replacement

The steps necessary to recover from a motor replacement are nearly identical to those outlined in Re-
covery from Loss of Mastering, with the added steps that Autotune needs to be run as outlined in Au-
totuning, and pressure calibration needs to be re-run as outlined in Pressure calibration. It should not
be necessary to run Autotuning again
Steps to recover from motor replacement:
1. Replace Motor
2. Re-master the gun
3. Re-run Autotune for the specific gun
4. Re-Run Pressure Calibration
Note: This assumes that the replacement motor type is the same make and model.

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17 SERVO GUN TOOL CHANGE OPTION

17.1 Purpose
The steps outlined in this section of the manual will help the user to add servo gun axis to the robot for
tool changing applications. The robot personality on the SpotTool+ 7.50 w/OVRS4 Customization will
have the option +SGChanger. This option on the personality will be used by the user to add servo gun
axis to group 2 or group 3 depending on configuration.
17.2 Hardware/Software Requirements, Limitations and Recommendations

For a robot that has tool changing for carried servo weld guns enabled, the robot is configured for a
single weld gun, one weld controller and one water saver. To be able to tool change multiple carried
servo weld guns, you will need the following on the robot controller:
1. Robot controller hardware (Fanuc part # A05B-2507-C400) to support this option. Specify this
part with “kit” in syntax when ordering to receive all the parts like connectors etc.
2. All Tool changing robots will need to be upgraded to Spottool v7.50Pxx.
3. J665 Fanuc Servo Gun Change software option loaded on the robot
4. Battery packs for the Tol-O-Matic motor (1 pack per gun Tol-O-Matic part # 27509039). The
battery packs are to be purchased from Tol-O-Matic, by the gun supplier or by the line builder.
5. Maximum of 4 servo weld guns on tool changers are currently supported by OV.
6. Guns cannot be shared between robots. For example, Robot R1‟s guns cannot be used on
Robot R3 and vice versa.
7. Guns will be dropped off in their respective nests with tips opened.
8. We recommend that you teach the pick and drop paths for the weld guns in TOOL # 5 or a tool
number that is not being used. If maximum number of guns is 2, you could teach these paths in tool
number 3.
9. To avoid confusion, reserve TOOL # 1- Tool # 4 for weld gun Utool‟s since by default the gun at-
tach routine will set the utool to the gun # it is picking and the gun equalization is based on the utool
information which will also normally default to gun number.
10. Set the dip switches representing gun number on the tool side (Node 55) of the tool changers,
prior to commencing programming.
11. Air guns and servo guns cannot be mixed on the same robot.
12. Carried weld guns and ped weld guns cannot be combined on robots with gun tool changers
13. Gen. 6 weld timer is required for multi gun tool changing
14. An Ethernet cell interface is required and the expanded I/O map required. Custom mapping will
be required on Global 1 robots.
15. Air guns use integrated dense packs, shoulder mounted valves and/or hip mounts are not sup-
ported.
16. Whenever any gun requests / requires cap change, all caps will be changed on all guns
17. Tip dress before cap change is only required on the gun that is held at the time of cap change,
not all 4 guns. The tip dresser only needs to run once to verify cutter functionality.
18. If multiple tip dressers are required to accommodate different cap / cutter combinations, addi-
tional steps will be required to dress before cap change.
19. One gun is held during cap change process.

Version 1.0 SERVO GUN TOOL CHANGE OPTION Global 2 Servogun Setup Users
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20. Water saver can only verify the caps are changed on the gun that is held. Cannot error proof
that caps have been removed from all guns.
21. All guns are dressed after cap change before next job is processed.
22. All guns are stored in the, at home, open position when on the stands.
23. Cap change must be planned activity with time allotted for it.
24. Tip dressing occurs after the current job is processed and before the next job starts. If two guns
are used on a single job and one needs to tip dress, gun that requires it is picked up and dressed at
the end of the job before next job is started.
25. If multiple tip dressers are required to accommodate different cap / cutter combinations, addi-
tional steps will be required to dress before cap change.
26. All guns are stored in the, at home, open position when on the stands.
27. Water saver can only verify the caps are changed on the gun that is held. Cannot error proof
that caps have been removed from all guns.
28. If the PLC or Robot or WC losses memory or is reloaded, all caps must be changed and all guns
are dressed before next job. Manual intervention required
29. The robot and the PLC must track which gun is held.
30. FFR does not swap guns; FFR only applies to the gun that is held. FFR does not support tool
change for hot backup.
31. Robots will be processed to hold the high runner tool at home under normal conditions. After
cap change or tip dress the robot may have to pick up the high runner tool on the next cycle.
17.3 Hardware Setup Procedure for Carried Servo Weld Gun(s)
The procedure described here is strictly for carried servo guns on tool changers for changing 2 guns. If
adding more than 2 guns, this procedure has to be repeated for guns 3 and 4. It is recommended to
discuss special cases with Robot Software Standards Team (MAAC N/A) since every possible combina-
tion cannot be comprehended in this manual.
1. Run the Setup Wizard for GUN #1 as described in Section 3. Run the wizard as a single carried
gun. In servo gun tool changing applications all the guns that are on tool changers belong to the
same group but with multiple axis. Typically in strict carried servo gun tool change application, the
servo guns will belong to group 2 with 2 axis, one for each gun.
2. Control Start the robot again.
3. Press [MENUS, MAINTENANCE], then press [ENTER]. The screen will indicate GROUP 1 the robot
arm and GROUP 2 servo axis. GROUP 2 will require modification; this GROUP can contain up to 3 more
servo axis for a total of 4 servo guns.

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4. Cursor down to Servo Gun Axis and Press F4 [MANUAL].

5. Servo gun axis for servo guns on tool changers are added to the servo gun changing group. In
this case of 2 carried guns on tool changers, axis will be added to group 2. By running the wizard, we
have already added axis 1 to group 2 and now we need to add an additional axis to this group.
Total Servo Gun Axes:

This value will be equal to
total number of guns. Each
time an axis is added this
value will increment.
6. Press [#2 Add Servo Gun Axis].
Partial: Allows user a specific MOTOR

code, with known parameters. Allows the
use of codes for amp number, and brake
number. Partial is used because addi-
tional motor information will be entered
via gun setup utility.
Complete: User must specify all Servo

Gun motor parameters. You will have to
enter all the motor parameters manually.

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MOTOR CODE:
Enter motor code from table
below here. Contact MAAC
N/A if the motor code is not
listed.
7. Press [#1 Partial (Minimal setup questions)]. Enter the motor code from the table below for the
correct motor type on gun 2 etc.
Motor Code Motor Description OVRS-4 Servo Motor

41653 Tolomatic HT12 40A types and MOTOR code.
41909 Tolomatic HT23 40A
42421 Tolomatic SW44 40A
42423 Tolomatic SW44 80A
42677 Tolomatic SWGA C-Type 40A
42679 Tolomatic SWGA C-Type 80A
42933 Tolomatic SWGA X/P 40A
42935 Tolomatic SWGA X/P 80A
43301 ARO 3G, 8-pole (40A aux)
43303 ARO 3G, 8-pole (80A aux)
43701 Tolomatic IMA33 40A
8. Partial Question Set only requires a FANUC specific 5 digit number. Please refer to the table
above for your specific motor. OV Global robots typically have 40A amplifiers. Please check controller
to verify amplifier size. If motor is not listed in the table, [#2 Complete (All setup questions)] must be
selected.

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9. Press [ENTER] to acknowledge amplifier number, amp 2.

Note: The servo amplifier will typically match the GROUP number. If the servo axis is added to GROUP
3, then the amplifier number will be 3. This would be the case if there is a servo gun permanently at-
tached to the robot as a pedestal welder.
10. Press [ENTER] to acknowledge brake number, brake number 0.

11. Repeat steps 5 thru 10 for the remaining number of guns
12. Press [MENUS, NEXT, SETUP SERVO GUN], and cursor to Gun Change and [ENABLE] the feature.
13. Press [Function, Cold Start].
17.4 Running SRVO_TC.PC
To assist with set up of Servo Gun Tool Change for the Additional AXES added the PC file SRVO_TC.PC
has been created. This setup file must be run outside of the customization wizard after the hardware
was configured in Section 15.3. Run the file SRVO_TC.PC at a normal Start and it will load the OV Stand-
ard Pressure Calibration data setup, Pressure table setup, Distance schedule setup, additional nest I/O.

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17.4.1 SRVO_TC.PC File Execution Procedure

1. Press [Select], and select the program SRVO_TC.PC from the listing.
2. Press [ENTER] on the program and ENABLE the teach pendant and hit [SHIFT FWD] to run the
program.
3. User will be prompted for total number of guns, and total number of tipdressers. Answer all
questions then cycle power on robot controller or use the teach pendant to cycle power.
17.5 Programming and Setup Completion
The gun setup and pressure calibration now needs to be completed for each gun. The pick and drop
paths must be taught and GUN ATTACH macro executed prior to finishing setup. Refer to Section 16 of
this manual for path file naming conventions. We recommend that you program the pick and drop
paths with a UTOOL number greater than the maximum number of guns. That is if we are tool changing
2 weld guns, then program the pick path and drop paths with UTOOL number greater than or equal to
3. Since servo gun robots uses UTOOL orientation to determine its equalization direction and the
UTOOL is set via the GUN ATTACH macro, UTOOL 1 for gun 1 and UTOOL 2 should be used for gun 2.
When performing auto tune etc., if the robot is not holding a gun, you will see the following screen.
17.5.1 GUN ATTACH[x]

This macro with the argument value is used to let the system know the gun number the robot is picking
up. It should preferably be called after the gun is latched to the robot side of the changer and it at-
taches servo gun to the robot without the need for cycling power.
Example: GUN ATTACH [1] or GUN ATTACH [R[X]] or GUN ATTACH [AR[1]]. After servo gun is attached,
the UTOOL number is changed to the argument number (hence the need to have utool number match
the gun number) which is specified as a gun close direction of fixed side in the servo gun setup screen.

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17.5.2 GUN DETACH[x]

This macro is used to detach a servo gun without powering off. By default, the calibration motion type
is set to “Type 7”. This can be changed on the servo gun setup page by changing the Battery to “OFF”.
By setting the calibration motion type to “Type 7” prior to detaching the servo gun, the servo gun is
closed automatically, and the gun close position is set as the reference position. Refer to E-Doc for fur-
ther clarification on other calibration types. OV direction is to use batteries on servo guns, so other
types of calibration types should not be use.
Example: GUN DETACH [1] or GUN DETACH [R[X]] or GUN DETACH [AR[1]]
GUN ATTACH AND GUN DETACH WILL NOT execute by backward execution (SHFT BWD).
17.5.3 Emergency Detach (EMGDTCH.TP)
This macro is used to disable the communications to servo gun axes when there is damage to the com-
munication of the servo gun. This macro can be executed ONLY in teach mode, followed by a power
cycle from the teach pendant to reset all servo gun attach[x] variables. After execution of this macro
the user can now manually decouple the gun and fix the communications issues with the servo gun.
17.5.4 Verification of Gun(s) connections
Once a gun is picked up and the GUN ATTACH macro has been executed, verify that the attached gun
is correct by visiting the Gun Change Status screen.
1. Press [MENUS].
2. Select [#0 NEXT PAGE], [#4 STATUS].
3. Press F1 [TYPE].
4. Select “Gun change”.
17.5.5 Auto Tune and Pressure Calibration of Guns

Remove all Pressure points in the Pressure Calibration Table above the max gun pressure.
Pickup each gun and finish setup of the gun as described in Section 4 -10 of this manual

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18 Tool Change programs specific for Servo Gun Tool Change

Applications.
18.1 Style template (Servo tool-changer) Single Carried Gun
/PROG Template 21
1: !************************* ;
2: !STYLE XX CARRIED WELDER ;
3: !WITH Tool CHANGE TEMPLATE ;
4: !************************* ;
5: ;
8: ;
10: GO[1:ManualStyle]=... ; TCCKTOOL(X)
11: ECHO OPTION ; This routine performs a check to make
12: MAINT_PROG[1]=MOV_REPR ; sure that the gun used for the style is
13: ; correct. The user must attach the gun
14: CALL POUNCE ;
15: ; number to be used for the style. If the
16: !TCCKTOOL(X) represents ; style is triggered with the wrong gun,
17: ! the tool needed for ; the robot will exchange guns for the
18: ! the process program ; proper gun.
19: CALL TCCKTOOL(1) ;
20: IF $sgcfg[1].$EQUIP_TYPE<>2,JMP LBL[1] ;
21: R[237:SkipCapWrMem]=0 ;
22: IF $MCR_GRP[2].$MACHINELOCK=0,JMP LBL[1] ;
23: !SGATTACH(X) represents ;
24: ! the tool needed for ;
25: ! the process program ;
26: CALL SGATTACH(1) ;
27: LBL[1] ;
28: CALL STPR_CHK ;
29: ;
30: CALL SXXPROC1 ;
31: ;
32: RUN CAP_WEAR ;
33: ;
34: MOVE TO HOME ;
/POS
/END

Version 1.0 Tool Change programs specific for Servo Gun Tool Global 2 Servogun Setup Users
Change Applications.
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18.2 Style template (Servo tool-changer) 2 Carried Guns within 1 style

/PROG Template 23
1: !************************* ;
2: !STYLE XX CARRIED WELDER ;
3: !TOOL CHANGE TEMPLATE FOR ;
4: !MULTI-GUNS WITHIN ONE STYLE ;
5: !************************* ;
6: ;
9: ;
10: !Disable Error Recovery ;
11: $SVPRG_ENB=0 ;
12: ;
15: ECHO OPTION ;
17: ;
18: CALL POUNCE ;
19: ;
20: ;
21: LBL[10] ;
22: !TCCKTOOL(X) represents ;
24: ! process 1 program ;
33: LBL[1] ;
34: CALL STPR_CHK ;
35: ;
36: CALL SxxPROC1 ;
37: ;
38: CALL CAP_WEAR ;
39: ;
40: REQUEST CONTINUE ;
41: SET SEGMENT(7) ;
42: ;
43: LBL[20] ;
54: LBL[2] ;
55: CALL STPR_CHK ;
56: ;
57: CALL SxxPROC2 ;
58: ;
59: RUN CAP_WEAR ;
60: ;
61: LBL[99] ;
62: MOVE TO HOME ;
64: !Enable Error Recovery ;

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65: $SVPRG_ENB=1 ;
/POS
/END
18.3 Style template (Servo tool-changer) 1carried gun and 1 MH end effector
/PROG Template 24
1: !************************* ;
2: !STYLE XX Carried SG EOAT ;
3: !and Carried MH EOAT ;
4: !WITH Tool CHANGE TEMPLATE ;
5: !************************* ;
6: ;
9: ;
12: ECHO OPTION ;
14: ;
15: CALL POUNCE ;
16: ;
28: LBL[1] ;
29: CALL STPR_CHK ;
30: ;
31: CALL SxxPROC1 ;
32: ;
34: ;
35: CALL CAP_WEAR ;
36: ;
37: REQUEST CONTINUE ;
39: ;
41: !the tool needed for MH ;
43: ;
44: CALL SxxPICK1 ;
45: ;
46: CALL SxxDROP1 ;
47: ;
48: LBL[99] ;
49: MOVE TO HOME ;
/POS
/END

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18.4 CAP_WEAR (Servo TC Version ONLY)

/PROG CAP_WEAR
2: !CAP WEAR FOR SERVO GUNS ON ;
3: !TOOL CHANGER ;
4: LBL[1] ;
5: ;
6: !Determine TC/Application ;
7: !TW Only on Servo Spot ;
9: ;
10: !Determine if Servo Spot ;
11: !Latched and Rbt Holding Gun ;
12: CALL TCGETNUM ;
13: ;
14: IF ($SPOTCONFIG.$STROKE_ENBL=0 OR DO[43:FFRActive]=ON),JMP LBL[99] ;
15: CALL CHK_TIPS ;
16: IF R[218:CapWear Skip]=1,JMP LBL[99] ;
17: IF $SCR.$NUM_GROUP=2 AND $SHC_GRP[2].$SHC_ENB=0,JMP LBL[10] ;
18: IF $SCR.$NUM_GROUP>2 AND $SHC_GRP[3].$SHC_ENB=0,JMP LBL[10] ;
19: IF DI[697:diToolLatched]=ON AND DI[698:diToolUnlatched]=OFF AND R[154:Head Detect]=1 AND GI[15:giTool-
Number]=R[113:Current Head],JMP LBL[20] ;
20: ;
21: MESSAGE[TOOL CHANGER FAULT] ;
22: MESSAGE[DI697 SHOULD BE ON] ;
23: MESSAGE[DI698 SHOULD BE OFF ] ;
24: MESSAGE[R[154] SHOULD BE 1] ;
25: MESSAGE[AND GI[15]=R[113]] ;
26: MESSAGE[RUN TCLTCHTL,THEN] ; CAP_WEAR
27: MESSAGE[RESUME CAP_WEAR] ; This routine performs a wear measurement check on
28: DO[45:MHFault]=ON ; the gun(s). The program has been modified to make
29: UALM[3] ;
30: DO[45:MHFault]=OFF ; sure that wear is measure for the attached gun that
31: JMP LBL[1] ; is read from
32: ; the tool changer. A variable check for Fanuc Tool
33: LBL[20] ; change option is also done, along with a GI[15] tool
34: CALL TW_UPD(R[113:Current Head]) ;
35: CALL TW_REG(R[113:Current Head]) ; reading and GI[17] app. reading.
36: IF R[237:SkipCapWearMem]=1,JMP LBL[99] ;
37: CALL TW_MEM(R[113:Current Head]) ;
38: JMP LBL[99] ;
39: ;
40: !CAP WEAR FOR REGULAR SERVO GUNS ;
41: LBL[10] ;
42: CALL NUM_GUNS ;
43: R[15:SERVO WEAR UPDT]=R[15:SERVO WEAR UPDT]+1 ;
44: IF R[15:SERVO WEAR UPDT]>R[16:NUM SERVO GUNS],JMP LBL[30] ;
45: CALL TW_UPD(R[15:SERVO WEAR UPDT]) ;
46: CALL TW_REG(R[15:SERVO WEAR UPDT]) ;
47: JMP LBL[40] ;
48: ;
49: LBL[30] ;
50: R[15:SERVO WEAR UPDT]=0 ;
51: LBL[40] ;
52: IF R[15:SERVO WEAR UPDT]=R[16:NUM SERVO GUNS],JMP LBL[30] ;
53: ;
54: LBL[99] ;
/POS

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18.5 TCCKTOOL
This routine is used to perform attached gun verification and gun swap with the required gun.
If the attached gun on the robot is not the one that the passed argument calls for, the robot will perform
a gun change with the correct gun (passed argument). You may choose to modify the path calls, if the
path naming for pick and drop is different than the one used in here. For example; if the path name in
your particular application is “S10PICK1”, than change TCPICKH1 to “S10PICK1” etc.
/PROG TCCKTOOL Macro

1: R[155:Head Selection]=AR[1] ;
2: ;
3: CALL TCGETNUM ;
4: ;
5: IF GI[15:giToolNumber]>0 AND GI[15:giToolNumber]<5 AND R[113:Current Head]>0 AND R[113:Current
Head]<5,JMP LBL[20] ;
6: JMP LBL[30] ;
7: ;
8: !DROP OFF THE HEAD ;
9: LBL[20] ;
10: IF R[113:Current Head]=R[155:Head Selection],JMP LBL[250] ;
11: SELECT R[113:Current Head]=1,JMP LBL[110] ;
12: =2,JMP LBL[120] ;
13: =3,JMP LBL[130] ;
14: =4,JMP LBL[140] ;
15: ELSE,JMP LBL[30] ;
16: ;
17: !PICK UP HEAD ;
18: LBL[30] ;
19: SELECT R[155:Head Selection]=1,JMP LBL[210] ;
20: =2,JMP LBL[220] ;
21: =3,JMP LBL[230] ;
22: =4,JMP LBL[240] ;
23: =5,JMP LBL[250] ;
25: ;
26: LBL[110] ;
27: CALL TCDROPH1 ;
28: JMP LBL[30] ;
29: ;
30: LBL[120] ;
31: CALL TCDROPH2 ; This section will drop off the gun.
32: JMP LBL[30] ; Macro supports up to 4 total guns.
33: ;
34: LBL[130] ;
35: CALL TCDROPH3 ;
36: JMP LBL[30] ;
37: ;
38: LBL[140] ;
39: CALL TCDROPH4 ;
40: JMP LBL[30] ;
41: ;
42: LBL[210] ;
43: CALL TCPICKH1 ;
44: JMP LBL[99] ;
45: ; This section will pick up the gun.
46: LBL[220] ; Macro supports up to 4 total guns.
47: CALL TCPICKH2 ;
48: JMP LBL[99] ;
49: ;
50: LBL[230] ;
51: CALL TCPICKH3 ;
52: JMP LBL[99] ;
53: ;
54: LBL[240] ;

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55: CALL TCPICKH4 ;

56: JMP LBL[99] ;
57: ;
58: LBL[250] ;
59: !Current Head = Head Selected ;
60: !If Tool APP = Spot, Check Water ;
61: IF ((GI[17:giTCAppType]=2 OR GI[17:giTCAppType]=3) AND $SPOTCONFIG.$STROKE_ENBL=1),CALL RST_WTR
;
62: !IF not in Tool change, skip Move ;
63: IF GO[1:ManualStyle]<>26,JMP LBL[99] ;
64: MOVE TO HOME ;
65: ;
66: LBL[99:PROGRAM END] ;
18.6 TCGETNUM
This routine performs tool attached check and returns the gun number attached to the robot based on
GI[15] which is loaded in R[113] for use by other routines.
/PROG TCGETNUM Macro

DV_STCHK(2,55,112)
1: !******************************** ; AR[1]: Device Net Board
2: !CHECK CURRENT TOOL'S ID ; AR[2]: Node number
3: !******************************** ; AR[3]: Status and R[X] to return.
4: ;
5: LBL[1] ;
6: ; This KAREL call will ensure that the robot side of the
7: CALL DV_STCHK(2,55,112) ; tool changer Device Net is operational and ONLINE.
8: !Not online & Latched ;
9: IF R[112:DNET Node Status]<2 AND DI[697:diToolLatched]=ON AND DI[698:diToolUnlatched]=OFF,JMP LBL[5] ;
10: ;
11: !Not online & not Latched ;
12: IF R[112:DNET Node Status]<2 AND DI[697:diToolLatched]=OFF AND DI[698:diToolUnlatched]=ON,JMP LBL[99] ;
13: ;
14: !Online & not Latched ;
15: IF R[112:DNET Node Status]=2 AND DI[697:diToolLatched]=OFF AND DI[698:diToolUnlatched]=ON,JMP LBL[15] ;
16: ;
17: !Check for Valid Tool# ;
18: R[113:Current Head]=GI[15:giToolNumber] ;
19: IF (R[113:Current Head]<1 OR R[113:Current Head]>4),JMP LBL[25] ;
20: ;
22: END ;
23: ;
24: ;
25: !******FAULTS******** ;
26: LBL[5:TOOL CHANGER FAU] ;
27: MESSAGE[...] ;
28: MESSAGE[TOOL CHANGER FAULT.] ;
29: MESSAGE[ TOOL SIDE OF TOOL] ;
30: MESSAGE[ CHANGER, DEVICENET] ;
31: MESSAGE[ NODE 55, IS NOT] ;
32: MESSAGE[ ONLINE. NODE 55 MUST] ;
33: MESSAGE[ BE ONLINE TO CONTINUE.] ;
34: DO[45:MHFault]=ON ;
35: UALM[1] ;
36: DO[45:MHFault]=OFF ;
37: JMP LBL[1] ;
38: ;
39: LBL[15:TOOL Latch FAU] ;
40: MESSAGE[...] ;
41: MESSAGE[TOOL LATCH FAULT.] ;
42: MESSAGE[TOOL NOT LATCHED] ;
43: MESSAGE[ Check inputs for] ;
44: MESSAGE[DI697 diToolLatched=On] ;
45: MESSAGE[DI698 diToolUnlatch=Off] ;

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47: UALM[1] ;
49: JMP LBL[1] ;
50: ;
51: LBL[25:ATTACHED TOOL # ] ;
52: MESSAGE[...] ;
54: MESSAGE[ ATTACHED TOOL] ;
55: MESSAGE[ NUMBER OUT OF RANGE.] ;
56: MESSAGE[ GUN NUMBER SHOULD BE] ;
57: MESSAGE[ 1,2,3, OR 4 ONLY.] ;
59: UALM[1] ;
61: JMP LBL[1] ;
/POS
/END
18.7 TCINNEST
This routine will perform a tool input check to determine if a gun is in the nest. This macro essentially
will perform a “part check” for a servo gun in the nest. Reference only for robot controlled tool nests.
/PROG TCINNEST Macro

1: !******************************** ;
2: !HEAD IN NEST MACRO ;
3: !******************************** ;
4: LBL[1:MAIN LOOP] ;
5: R[162:TC PlaceHolder]=AR[1] ;
6: LBL[10:RETRY LOOP] ;
7: SELECT R[162:TC PlaceHolder]=1,JMP LBL[20] ;
8: =2,JMP LBL[40] ;
8: =3,JMP LBL[70] ;
8: =4,JMP LBL[80] ;
10: ;
1: !***Nest 1 Check** ;
22: LBL[20:HEAD IN NEST1] ;
1: !Check if it has a slide ;
23: IF DI[723:diGun1InNest]=ON AND DI[725:diSlide@Robot]=ON,JMP LBL[99] ;
20: JMP LBL[15] ;
46: ;
32: LBL[30] ;
23: IF DI[723:diGun1InNest]=ON,JMP LBL[99] ;
45: JMP LBL[25] ;
46: ;
46: ;
1: !***Nest 2 Check** ;
32: LBL[40:HEAD IN NEST2] ;
1: !Check # of slides ;
22: IF R[27]=1,JMP LBL[60] ;
20: JMP LBL[35] ;
32: LBL[60] ;
20: JMP LBL[45] ;
46: ;
32: LBL[50] ;
33: IF DI[731:diGun2InNest]=ON ,JMP LBL[99] ;
45: JMP LBL[55] ;
46: ;
46: ;
1: !***Nest 3 Check** ;

OV ME Strategy
22: LBL[70:NEST 3 EMPTY CHK] ;

45: JMP LBL[65] ;
31: ;
1: !***Nest 4 Check** ;
45: JMP LBL[75] ;
46: ;
46: ;
48: R[162:TC PlaceHolder]=0 ;
46: END ;
46: ;
46: ;
1: !******FAULTS******** ;
11: LBL[5:Invalid Nest Num] ;
12: MESSAGE[...] ;
14: MESSAGE[ INVALID LID SELECTED.] ;
15: MESSAGE[ LID SELECTION MUST] ;
16: MESSAGE[ BE 1 OR 2.] ;
18: UALM[3] ;
20: JMP LBL[1] ;
21: ;
22: LBL[15] ;
24: MESSAGE[...] ;
25: MESSAGE[HEAD IN NEST 1 FAULT.] ;
26: MESSAGE[HEAD IN NEST 1 INPUT] ;
27: MESSAGE[AND NEST IN POSITION] ;
28: MESSAGE[SHOULD BE ON. NEED ] ;
29: MESSAGE[DI[723] AND DI[725] ON] ;
43: UALM[3] ;
45: JMP LBL[10] ;
31: ;
22: LBL[25] ;
24: MESSAGE[...] ;
29: MESSAGE[DI[723] ON] ;
43: UALM[3] ;
45: JMP LBL[10] ;
31: ;
22: LBL[35] ;
34: MESSAGE[...] ;
43: UALM[3] ;
45: JMP LBL[10] ;
31: ;
22: LBL[45] ;
34: MESSAGE[...] ;

OV ME Strategy

43: UALM[3] ;
45: JMP LBL[10] ;
31: ;
22: LBL[55] ;
34: MESSAGE[...] ;
39: MESSAGE[DI[731] ON] ;
43: UALM[3] ;
45: JMP LBL[10] ;
21: ;
11: LBL[65] ;
34: MESSAGE[...] ;
38: MESSAGE[NEED DI[739]ON] ;
43: UALM[3] ;
45: JMP LBL[10] ;
21: ;
11: LBL[75] ;
34: MESSAGE[...] ;
38: MESSAGE[NEED DI[747]ON] ;
43: UALM[3] ;
45: JMP LBL[10] ;
/END
18.8 TCEMPTY
This routine will perform a tool input check to determine if a gun nest is empty. This macro essentially
will perform a “NO part check” for a servo gun. Reference only for robot controlled tool nests.
/PROG TCEMPTY Macro

1: !******************************** ;
2: !NEST EMPTY MACRO ;
3: !******************************** ;
8: =2,JMP LBL[40] ;
9: =3,JMP LBL[70] ;
10: =4,JMP LBL[80] ;
12: ;
13: !***Nest 1 Check** ;
17: IF DI[723:diHead1InNest]=OFF AND DI[725:diNest1InPos]=ON,JMP LBL[99] ;
18: JMP LBL[15] ;
19: ;
20: LBL[30] ;
21: IF DI[723:diHead1InNest]=OFF,JMP LBL[99] ;

OV ME Strategy
22: JMP LBL[25] ;

23: ;
24: ;
25: !***Nest 2 Check** ;
29: !Check
: of slides ;
30: IF R[27:Num of TC Slides]=1,JMP LBL[60] ;
31: IF DI[731:diHead2InNest]=OFF AND DI[733:diNest2InPos]=ON,JMP LBL[99] ;
32: JMP LBL[35] ;
33: LBL[60] ;
34: IF DI[727]=OFF AND DI[725:diNest1InPos]=ON,JMP LBL[99] ;
35: JMP LBL[45] ;
36: ;
37: LBL[50] ;
39: JMP LBL[55] ;
40: ;
41: ;
42: !***Nest 3 Check** ;
45: JMP LBL[65] ;
46: ;
47: !***Nest 4 Check** ;
50: JMP LBL[75] ;
51: ;
52: ;
55: END ;
56: ;
57: ;
58: !******FAULTS************ ;
60: MESSAGE[...] ;
66: UALM[3] ;
68: JMP LBL[1] ;
69: ;
70: LBL[15] ;
71: MESSAGE[...] ;
75: MESSAGE[NEED DI[723]OFF ] ;
76: MESSAGE[ AND DI[725] ON] ;
78: UALM[3] ;
80: JMP LBL[10] ;
81: ;
82: LBL[25] ;
83: MESSAGE[...] ;
86: MESSAGE[NEED DI[723]OFF ] ;

OV ME Strategy
88: UALM[3] ;
90: JMP LBL[10] ;
91: ;
92: LBL[35] ;
93: MESSAGE[...] ;
97: MESSAGE[NEED DI[731]OFF] ;
100: UALM[3] ;
102: JMP LBL[10] ;
103: ;
104: LBL[45] ;
105: MESSAGE[...] ;
112: UALM[3] ;
114: JMP LBL[10] ;
115: ;
116: LBL[55] ;
117: MESSAGE[...] ;
122: UALM[3] ;
124: JMP LBL[10] ;
125: ;
126: LBL[65] ;
127: MESSAGE[...] ;
132: UALM[3] ;
134: JMP LBL[10] ;
135: ;
136: LBL[75] ;
137: MESSAGE[...] ;
142: UALM[3] ;
144: JMP LBL[10] ;

OV ME Strategy
18.9 TCCLSLID
This macro will close the tool change nest cover lid, if one exists. Reference only for robot controlled tool
nests.
/PROG TCCLSLID Macro

1: !******************************** ;
2: !CLOSE LID MACRO ;
3: !******************************** ;
5: $WAITTMOUT=500 ;
9: =2,JMP LBL[30] ;
10: =3,JMP LBL[40] ;
11: =4,JMP LBL[50] ;
13: ;
14: LBL[20:CLOSE LID 1] ;
15: IF R[27:Num of TC Slides]=1 AND R[154:Head Detect]=0 AND R[155:Head Selection]>0 AND R[155:Head Selec-
tion]<5,JMP LBL[99] ;
16: DO[722:doOpenNest1]=OFF ;
17: DO[721:doCloseNest1]=ON ;
18: WAIT DI[721:diNest1Closed]=ON AND DI[722:diNest1Open]=OFF TIMEOUT,LBL[15] ;
19: JMP LBL[99] ;
20: ;
23: DO[730]=OFF ;
24: DO[729]=ON ;
26: JMP LBL[99] ;
27: ;
32: JMP LBL[99] ;
33: ;
38: ;
41: END ;
42: ;
43: ;
44: !******FAULTS********* ;
46: MESSAGE[...] ;
52: UALM[3] ;
54: JMP LBL[1] ;
55: ;
56: LBL[15:CLOSE LID 1 FAUL] ;
57: MESSAGE[...] ;
59: MESSAGE[ LID 1 CLOSE INPUTS] ;

OV ME Strategy
60: MESSAGE[ NOT MADE. NEED] ;

61: MESSAGE[ DI[721] ON AND] ;
62: MESSAGE[ DI[722] OFF.] ;
64: UALM[3] ;
66: JMP LBL[10] ;
67: ;
69: MESSAGE[...] ;
76: UALM[3] ;
78: JMP LBL[10] ;
79: ;
81: MESSAGE[...] ;
88: UALM[3] ;
90: JMP LBL[10] ;
91: ;
93: MESSAGE[...] ;
100: UALM[3] ;
102: JMP LBL[10] ;
/END
18.10 TCOPNLID
This macro will open the tool change nest cover lid, if one exists. Reference only for robot controlled tool
nests.
/PROG TCOPNLID Macro

1: !******************************** ;
2: !OPEN LID MACRO ;
3: !******************************** ;
5: $WAITTMOUT=500 ;
9: =2,JMP LBL[30] ;
10: =3,JMP LBL[40] ;
11: =4,JMP LBL[50] ;
13: ;
14: LBL[20:OPEN LID 1] ;
15: DO[721:doCloseNest1]=OFF ;

OV ME Strategy
16: DO[722:doOpenNest1]=ON ;
17: WAIT DI[722:diNest1Open]=ON AND DI[721:diNest1Closed]=OFF TIMEOUT,LBL[15] ;
18: JMP LBL[99] ;
19: ;
22: DO[729]=OFF ;
23: DO[730]=ON ;
25: JMP LBL[99] ;
26: ;
31: JMP LBL[99] ;
32: ;
37: ;
40: END ;
41: ;
42: ;
43: !******FAULTS********* ;
45: MESSAGE[...] ;
51: UALM[3] ;
53: JMP LBL[1] ;
54: ;
55: LBL[15:OPEN LID 1 FAULT] ;
56: MESSAGE[...] ;
58: MESSAGE[ LID 1 OPEN INPUTS] ;
63: UALM[3] ;
65: JMP LBL[10] ;
66: ;
68: MESSAGE[...] ;
75: UALM[3] ;
77: JMP LBL[10] ;
78: ;
80: MESSAGE[...] ;

OV ME Strategy

87: UALM[3] ;
89: JMP LBL[10] ;
90: ;
92: MESSAGE[...] ;
99: UALM[3] ;
101: JMP LBL[10] ;
/POS
/END
18.11 TCLTCHTL
This macro is used to latch the robot side of the tool changer to the tool side of the tool changer.
/PROG TCLTCHTL Macro
1: !******************************** ;
2: !LATCH TOOL CHANGER HEAD ;
3: !******************************** ;
4: ;
6: IF DI[700:diAuxPowerOKT1Ch]=OFF,JMP LBL[5] ;
7: DO[698:doUnlatchTool]=OFF ;
8: DO[697:doLatchTool]=ON ;
9: WAIT DI[697:diToolLatched]=ON TIMEOUT,LBL[15] ;
10: ;
11: LBL[99:PROGRAM END] ; DV_AROFF(2,55)
12: CALL DV_AROFF(2,55) ; AR[1] = Device Net Board
13: R[113:Current Head]=GI[15:giToolNumber] ; AR[2] = Node number
14: R[154:Head Detect]=1 ;
15: R[158:Tool Connecting]=1 ;
16: END ; This KAREL program call will enable the Device
17: ; Net error checking for node 55 (Tool Side of
18: ; tool changer)
19: !******FAULTS******** ;
20: LBL[5] ;
21: MESSAGE[...] ;
22: MESSAGE[AUX POWER FAULT.] ;
23: MESSAGE[ NO AUX POWER AT ROBOT ] ;
24: MESSAGE[ SIDE OF TOOL CHANGER.] ;
25: MESSAGE[ NEED DI[700] ON.] ;
27: UALM[3] ;
29: JMP LBL[1] ;
30: ;
31: LBL[15] ;
32: !Double Check before FLT ;
33: IF DI[697:diToolLatched]=ON AND DI[698:diToolUnlatched]=OFF,JMP LBL[99] ;
34: MESSAGE[...] ;
36: MESSAGE[ TOOL CHANGER FAILED TO] ;
37: MESSAGE[ COUPLE. NEED DI[697]] ;
38: MESSAGE[ ON AND DI[698] OFF.] ;

OV ME Strategy
40: UALM[3] ;
42: JMP LBL[1] ;
/POS
/END
18.12 TCUNLTCH
This macro is used to unlatch the robot side of the tool changer to the tool side of the tool changer.
1: !******************************** ;
2: !UNLATCH TOOL CHANGER HEAD ;
3: !******************************** ;
4: ; DV_AROFF(2,55)
5: LBL[10:MAIN LOOP] ; AR[1] = Device Net Board
6: IF DI[700:diAuxPowerOKT1Ch]=OFF,JMP LBL[5] ; AR[2] = Node number
7: CALL DV_ARON(2,55) ;
8: DO[697:doLatchTool]=OFF ;
9: DO[698:doUnlatchTool]=ON ; This KAREL program call will disable the Device
10: WAIT DI[698:diToolUnlatched]=ON TIMEOUT,LBL[15] ; Net error checking for node 55 (Tool Side of tool
11: ; changer). The node is not monitored if it is not
12: LBL[99:PROGRAM END] ; connected to the robot.
13: R[113:Current Head]=0 ;
14: R[154:Head Detect]=0 ;
15: R[158:Tool Connecting]=0 ;
16: !Reset Tipdress request ;
17: !for carried spotwelders ;
18: IF (GI[17:giTCAppType]=2 OR GI[17:giTCAppType]=3),DO[53:Proc1TipMaintReq]=OFF ;
19: IF (GI[17:giTCAppType]=2 OR GI[17:giTCAppType]=3),DO[60:Proc2TipMaintReq]=OFF ;
20: END ;
21: ;
22: ;
23: !*******FAULTS******* ;
24: LBL[5] ;
25: MESSAGE[...] ;
26: MESSAGE[AUX POWER FAULT.] ;
27: MESSAGE[ NO AUX POWER AT ROBOT ] ;
28: MESSAGE[ SIDE OF TOOL CHANGER.] ;
29: MESSAGE[ NEED DI[700] ON.] ;
30: LBL[54:MH FAULT LOGIC] ;
32: UALM[3] ;
34: JMP LBL[10] ;
35: ;
36: LBL[15] ;
37: IF DI[697:diToolLatched]=OFF AND DI[698:diToolUnlatched]=ON,JMP LBL[99] ;
38: IF DI[699:diUnlatchEnrgzed]=ON,JMP LBL[16] ;
39: MESSAGE[...] ;
41: MESSAGE[ ANTI-DROP SWITCH NOT] ;
42: MESSAGE[ MADE. DI[699] MUST BE] ;
43: MESSAGE[ ON IN ORDER TO] ;
44: MESSAGE[ UNLATCH HEAD. CHECK] ;
45: MESSAGE[ FOR SWITCH MADE, WHEN] ;
46: MESSAGE[ TOOL IS IN THE NEST.] ;
48: UALM[3] ;
50: JMP LBL[10] ;
51: ;
52: LBL[16:TOOL CHNG FAULT] ;
53: MESSAGE[...] ;
55: MESSAGE[ TOOL CHANGER FAILED TO] ;

OV ME Strategy
56: MESSAGE[ UNLATCH. NEED DI[698]] ;

57: MESSAGE[ ON AND DI[697] LOW.] ;
59: UALM[3] ;
61: JMP LBL[10] ;
/POS
/END
18.13 TCPICKH1
This routine is used to pickup gun number 1. The name of the routine can be modified to reflect your
particular naming convention. If you choose to modify the program name, make the corresponding
change to TCCKTOOL routine. There are 3 user modification areas within this routine.
/PROG TCPICKH1
1: !BEGIN PICK HEAD PROGRAM ;

2: !FOR TOOL (1) ;
3: ;
4: !CHECK FOR NEST EMPTY ; User Modification Area 1:
5: ! NOTE: REMOVE NEST EMPTY MACRO ; If Tool Nests are controlled by PLC,
6: ! IF NEST IS CONTROLLED BY ; modify per application the path
7: ! THE PLC. SEG. REQ FOR PLC NEST ; segments required from the PLC here.
8: ;
9: CALL TCINNEST(1) ;
10: ; If Tool Nests are controlled by PLC,
11: !OPEN TOOL CHANGER NEST LID ; REMOVE TCINNEST macro call.
12: !NOTE: REMOVE OPEN LID MACRO ;
13: !IF LID IS CONTROLLED BY ;
14: !THE PLC. ;
15: CALL TCOPNLID(1) ;
16: ; User Modification Area 2:
17: !MOVES TO NEST 1 FROM COMMON PT ; If Tool Nests are controlled by PLC,
18: !Modify UTOOL if required ; REMOVE TCOPNLID macro call.
19: UTOOL_NUM=1 ;
20: ;
21:J P[1] 35% CNT100 ; UTOOL_NUM
22:J P[2] 35% CNT100 ; Note: Utool number is associated
23:L P[3] 600mm/sec FINE ; with the GUN ATTACH instruction,
24:L P[4] 100mm/sec FINE ;
25: CALL TCLTCHTL ;
tool changing via points should ref-
26: ; erence tool changer pin for UTOOL.
27: !ADD DEVICE ONLINE CALLS ;
28: !WITHOUT STATUS CHECK ARG ;
29: !FOR ALL EOAT DEVICES ;
30: !CALL DV_ONLN(2,x,0) ;
31: !x = EOAT DNET Node # ;
32: ;
33: !IF TOOL CHANGE APP NOT WELDING ;
34: !SKIP WATER RESET ;
36: !RESET WATER EARLY ;
37: DO[450:doG1Wateroff]=ON ;
38: DO[449:doRstG1WaterSvr]=PULSE,1.0sec ;
39: !IF AIR GUN SKIP SG ATTACH ;
42: ;
43: LBL[10:Air Gun Setup It] ;
45: !User must set these per AG confi ;
46: !if guns differ in nodes & config ;
47: !Set to 1 if gun has bkup open de ;
48: !$SPOTEQSETUP[1].$DET_BU_OPEN[1]= ;

OV ME Strategy
49: !Set to 1 if has gun stroke only ;

50: !and open gun switch ;
51: !$SPOTEQSETUP[1].$DET_BU_CL[1]=0 ;
52: LBL[20] ;
53: !MOVES TO CHECK POSITION ;
54: !NOTE: REMOVE NEST EMPTY MACRO ;
55: !IF NEST IS CONTROLLED BY ;
56: !THE PLC. ;
57: !Modify UTOOL if required ;
58: UTOOL_NUM=1 ;
59: ;
62: ;
63: CALL TCEMPTY(1) ;
64: ;
66: !SKIP WATER RESET and CAP WEAR ;
68: CALL RST_WTR ;
69: !IF AIR GUN SKIP WEAR ;
72: RUN CAP_WEAR ;
73: LBL[30] ;
74: ;
75: !CLOSE TOOL CHANGER NEST LID ;
76: !NOTE: REMOVE CLOSE LID MACRO ;
77: !IF LID IS CONTROLLED BY ;
78: !THE PLC. ;
79: CALL TCCLSLID(1) ; User Modification Area 3:
80: ;
81: !MOVES TO COMMON PT FROM NEST 1 ; If Tool Nests are controlled by PLC,
82: !Modify UTOOL if required ; REMOVE TCCLSLID macro call.
83: UTOOL_NUM=1 ;
84: ;
85:L P[7] 350mm/sec CNT100 ;
86:J P[8] 50% CNT100 ;
87:J P[9] 50% CNT100 ;
88: ;
89: !ADD DEVICE ONLINE CALLS ;
90: !WITH STATUS CHECK ;
91: !FOR ALL EOAT DEVICES ;
92: !FOLLOWED BY THE ;
93: !DEVICE AUTO RECONNECT ;
94: !OFF CALLS ;
95: !CALL DV_ONLN(2,x,1) ;
96: !CALL DV_AROFF(2,x) ;
98: ;
99: !IF TOOL CHANGE APP NOT SG WELDIN ;
100: !SKIP WEAR VERIFICATION ;
101: IF (GI[17:giTCAppType]<2 OR GI[17:giTCAppType]>3),JMP LBL[99] ;
104: CALL TW_VER(1) ;
105: LBL[99]

OV ME Strategy
18.14 TCDROPH1
This routine is used to drop gun number 1. The name of the routine can be modified to reflect your par-
ticular naming convention. If you choose to modify the program name, make the
corresponding change to TCCHKGUN routine. There are 3 user modification areas within this routine.
/PROG TCDROPH1
1: !BEGIN DROP HEAD PROGRAM ;
2: !FOR TOOL (1) ;
3: ;
4: !CHECK FOR NEST EMPTY ; User Modification Area 1:
5: ! NOTE: REMOVE NEST EMPTY MACRO ; If Tool Nests are controlled byPLC,
6: ! IF NEST IS CONTROLLED BY ; modify per application the path
7: ! THE PLC. SEG. REQ FOR PLC NEST ;
8: CALL TCEMPTY(1) ;
segments required from the PLC here.
9: ;
10: !OPEN TOOL CHANGER NEST LID ; If Tool Nests are controlled by PLC,
11: ! NOTE: REMOVE OPEN LID MACRO ; REMOVE TCEMPTY macro call.
12: ! IF LID IS CONTROLLED BY ;
13: ! THE PLC. ;
14: CALL TCOPNLID(1) ;
15: ;
17: !SKIP WATER OFF ;
19: !IF AIR GUN SKIP CAP_WEAR ;
21: !IF CAPWEAR FLAG NOT SET ;
22: !CALL CAPWEAR BEFORE DROPING GUN ; User Modification Area 2:
23: IF (!F[1:Capwear Complete]),CALL CAP_WEAR ; If Tool Nests are controlled by PLC,
24: LBL[1] ; REMOVE TCOPNLID macro call.
26: LBL[10] ;
27: ; UTOOL_NUM
28: !MOVES TO NEST 1 FROM POUNCE ; Note: Utool number is associated
29: !Modify UTOOL if required ; with the GUN ATTACH instruction,
30: UTOOL_NUM=1 ;
31: ; tool changing via points should ref-
32:J P[1] 50% CNT100 ; erence tool changer pin for UTOOL.
33:J P[2] 50% CNT100 ;
34:L P[3] 500mm/sec CNT100 ;
37: ;
39: !SKIP OPENGUNS BEFORE DROPOFF ;
41: CALL OPENGUNS ;
42: !IF AIR GUN SKIP SG DETACH ;
44: CALL SGDETACH(1) ;
45: LBL[20] ;
46: ;
47: !User must add custom open/close ;
48: !commands to as required for ;
49: !for nested equipment ex. ;
50: !If Macro Open Gripper(1,2) ;
51: !If outputs ;
52: !DO[Open]=ON ;
53: !DO[Close]=OFF ;
54: ;
55: !ADD DISCONNECT COMMANDS ;
56: !ADD ALL EOAT DEVICES ;
57: !CALL DV_ARON(2,x) ;

OV ME Strategy
59: ;
60: CALL TCUNLTCH ; 1
61: ;
62: !MOVES TO CHECK POSITION ;
63: ! NOTE: REMOVE HEAD IN NEST MACRO ;
64: ! IF NEST IS CONTROLLED BY ;
65: ! THE PLC. ;
67: UTOOL_NUM=1 ;
68: ;
70: ;
71: CALL TCINNEST(1) ;
72: ;
73: ;
74: !CLOSE TOOL CHANGER NEST LID ;
75: ! NOTE: REMOVE CLOSE LID MACRO ;
76: ! IF LID IS CONTROLLED BY ;
77: ! THE PLC. ;
78: CALL TCCLSLID(1) ; User Modification Area 3:
79: ;
80: !MOVES TO POUNCE FROM NEST 1 ; If Tool Nests are controlled by PLC,
REMOVE TCCLSLID macro call.
82: UTOOL_NUM=1 ;
83: ;
84:J P[7] 35% CNT100 ;
85:J P[8] 50% CNT100 ;
86:J P[9] 75% CNT100 ;
18.15 Style 26
Tool change style used to swap tools.
1: !******************************** ;
2: !STYLE 26 PLC CHANGE TOOL(S) ;
3: !******************************** ;
4: !DCD 0 Swap with backup ;
5: !DCD 1 Pick Tool/Gun 1 ;
9: !DCD 5 Drop TL/Gun return Home ;
10: ;
12: ;
13: CALL POUNCE ;
15: ;
16: !Allow Teach Exchange ;
17: IF SO[7:TP enabled]=ON,CALL TCTEACH ;
18: ;
19: IF GI[15:giToolNumber]=0,JMP LBL[1] ;
22: CALL TCGETNUM ;
23: R[162:TC PlaceHolder]=R[113:Current Head] ;
24: !Check that Held Gun ;
25: !Is Not Machine Locked ;
26: !For Servo Gun Only ;
29: =2,JMP LBL[20] ;
30: =3,JMP LBL[30] ;
31: =4,JMP LBL[40] ;
32: LBL[10:ENABLE G1] ;

OV ME Strategy
34: JMP LBL[1] ;

37: JMP LBL[1] ;
40: JMP LBL[1] ;
43: ;
44: LBL[1] ;
45: !Capture DCD Code from PLC ;
46: R[151:$SHELLWRK$CURDCD]=$SHELL_WRK.$CUR_DECSN ;
47: IF R[151:$SHELLWRK$CURDCD]=0,JMP LBL[50] ;
48: !Determined Tool/Gun Action ;
49: CALL TCCKTOOL(R[151:$SHELLWRK$CURDCD]) ;
50: JMP LBL[99] ;
51: ;
52: !******************************** ;
53: !DCD 0 will Swap Tool/Gun ;
54: !with backup. Backup MUST BE ;
55: !AN IDENTICAL Tool/Gun ! ;
56: !User must enter value of ;
57: ;
58: LBL[50:SWAP Bkup] ;
59: !Determine Tool/Gun on Robot ;
60: CALL TCGETNUM ;
61: ;
62: IF R[113:Current Head]=0,JMP LBL[15] ;
63: !User must set BACKUP GUN Numbers ;
65: =2,JMP LBL[70] ;
66: =3,JMP LBL[80] ;
67: =4,JMP LBL[90] ;
69: ;
70: LBL[60:TLGN1 Bkup] ;
71: !Set Backup gun using TCCKTOOL() ;
72: !CALL TCCKTOOL(BKUP Tool/GUN) ;
73: JMP LBL[99] ;
74: ;
78: JMP LBL[99] ;
79: ;
83: JMP LBL[99] ;
84: ;
88: ;
89: LBL[99:END] ;
90: MOVE TO HOME ;
91: END ;
92: ;
93: ;
94: !*****FAULTS******** ;
95: LBL[5:Invalid Gun Num] ;
96: MESSAGE[...] ;
98: MESSAGE[ INVALID GUN NUMBER] ;
99: MESSAGE[ R[113] AND GI[15] MUST] ;
100: MESSAGE[ BE 1, 2, 3 OR 4] ;

OV ME Strategy
102: UALM[3] ;
104: JMP LBL[1] ;
105: ;
106: LBL[15:CANNOT SWAP] ;
107: MESSAGE[...] ;
108: MESSAGE[ NOTHING IS ATTACHED] ;
109: MESSAGE[ TO ROBOT. DO NOT KNOW] ;
110: MESSAGE[ WHAT TO SWAP WITH.] ;
112: UALM[3] ;
114: JMP LBL[99] ;
/POS
/END
18.16 TCTEACH
Used to manually swap guns. If in teach, this Karel driven menu is called to allow the user to determine
toolchange options instead of the PLC.
STYLE26 - Tool/Gun Exchange when run from the pendant in teach:
18.17 Servo Gun Tool Change Tip wear specific programs

There are 3 Servo gun Tool change specific programs relating to tip wear that perform specific wear
tracking functions.
18.17.1 TW_GUNS (SG tool change specific)
This macro performs tip wear reset for servo gun tool change applications. It only adjusts the wear val-
ues for the gun that the robot is holding.
1: !FOR SG GUN WITH TOOLCHANGE ONLY ;

2: LBL[1] ;
4: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ;
7: ;
8: CALL TW_UPDCC(R[113:Current Head]) ;
9: CALL TW_REG(R[113:Current Head]) ;

OV ME Strategy
10: CALL TW_MEM(R[113:Current Head]) ;

11: ;
13: =2,JMP LBL[20] ;
14: =3,JMP LBL[30] ;
15: =4,JMP LBL[40] ;
17: ;
24: IF R[20:SERVO GUN WORK]>R[219:NwCapsWearUppLMT] OR
R[20:SERVO GUN WORK]<R[220:NwCapsWearLwrLMT] OR
R[21:SERVOWORK]>R[219:NwCapsWearUppLMT] OR
R[21:SERVO GUN WORK]<R[220:NwCapsWearLwrLMT],JMP LBL[15] ;
25: ;
28: JMP LBL[99] ;
29: ;
R[21:SERVO GUN WORK]>R[219:NwCapsWearUppLMT] OR
37: ;
40: JMP LBL[99] ;
41: ;
49: ;
52: JMP LBL[99] ;
53: ;
62: ;

OV ME Strategy
65: JMP LBL[99] ;

66: ;
67: LBL[15] ;
68: MESSAGE[ CAP CHANGE OUT ] ;
69: MESSAGE[ TOLERANCE] ;
70: MESSAGE[...] ;
71: MESSAGE[ LIMITS STORED IN] ;
72: MESSAGE[ REGISTERS[219,220] ;
73: MESSAGE[...] ;
74: MESSAGE[ CHECK ROBOT FOR] ;
75: MESSAGE[ CORRECT CAPS] ;
77: UALM[49] ;
79: JMP LBL[1] ;
80: ;
81: LBL[25] ;
82: CALL USERCLR ;
83: CALL USERPAGE ;
84: ;
85: MESSAGE[ WEAR AFTER CAPCHANGE] ;
86: MESSAGE[ IS NOT ZERO] ;
87: MESSAGE[...] ;
88: MESSAGE[...] ;
89: MESSAGE[ REPLACE CAPS] ;
91: UALM[49] ;
93: JMP LBL[1] ;
94: ;
95: LBL[35] ;
96: MESSAGE[ INVALID ARGUMENT] ;
97: UALM[1] ;
98: JMP LBL[1] ;
99: ;
100: LBL[99] ;
102: ;
18.17.2 TW_MEM (SG tool change specific)

This macro records the current tip wear at tool changing nest(s) for tip wear verification. Guns are
dropped off to the nests open and this will verify an unexpected cap change activity.
1: !This macro sets the ;

2: !cap wear memory registers ;
3: !for the servo gun tool ;
4: !change application ;
5: !for error proofing ;
6: ;
7: LBL[1:BEGIN] ;
8: R[151:$SHELLWRK$CURDCD]=AR[1] ;
9: ;
10: SELECT R[151:$SHELLWRK$CURDCD]=1,JMP LBL[10] ;
11: =2,JMP LBL[20] ;
12: =3,JMP LBL[30] ;
13: =4,JMP LBL[40] ;
15: END ;
16: ;
17: LBL[10] ;
18: R[227:G1GN Wr At Nest]=R[201:G1GN Wear Snc CC] ;
19: R[228:G1RB Wr At Nest]=R[202:G1RB Wear Snc CC] ;
20: ;
21: JMP LBL[99] ;
22: ;

OV ME Strategy
23: LBL[20] ;
24: ;
27: ;
28: JMP LBL[99] ;
29: ;
30: LBL[30] ;
33: ;
34: JMP LBL[99] ;
35: ;
36: LBL[40] ;
39: ;
40: JMP LBL[99] ;
41: ;
42: LBL[15:INVALID ARGUMENT] ;
43: UALM[1] ;
44: JMP LBL[1] ;
45: ;
46: LBL[99] ;
18.17.3 TW_VER (SG tool change specific)

This macro is used to compare the tip wear after picking up a gun compared to the tip wear when it was
set down. This will verify that an unexpected cap change didn‟t occur.
1: !This macro compares the ;

2: !cap wear memory registers ;
3: !for the servo gun tool ;
4: !change application ;
5: !for error proofing ;
6: ;
7: LBL[1:BEGIN] ;
10: ;
11: SELECT R[151:$SHELLWRK$CURDCD]=1,JMP LBL[10] ;
12: =2,JMP LBL[20] ;
13: =3,JMP LBL[30] ;
14: =4,JMP LBL[40] ;
16: END ;
17: ;
18: LBL[10] ;
19: R[20:SERVO GUN WORK]=R[201:G1GN Wear Snc CC]-R[227:G1GN Wr At Nest] ;
20: R[21:SERVO GUN WORK]=R[202:G1RB Wear Snc CC]-R[228:G1RB Wr At Nest] ;
21: IF R[20:SERVO GUN WORK]>R[235:PkDpCapWrUprLmt] OR
R[20:SERVO GUN WORK]<R[236:PkDpCapWrLwrLmt] OR
R[21:SERVO GUN WORK]>R[235:PkDpCapWrUprLmt] OR
R[21:SERVO GUN WORK]<R[236:PkDpCapWrLwrLmt],JMP LBL[15] ;
22: ;
23: JMP LBL[99] ;
24: ;
25: LBL[20] ;
26: ;
30: ;

OV ME Strategy
31: JMP LBL[99] ;

32: ;
33: LBL[30] ;
37: ;
38: JMP LBL[99] ;
39: ;
40: LBL[40] ;
44: ;
45: JMP LBL[99] ;
46: ;
47: LBL[15] ;
48: CALL USERCLR ;
49: CALL USERPAGE ;
50: MESSAGE[UNEXPECTED CAPWEAR] ;
51: MESSAGE[CAP CHANGE NOT DETECT] ;
52: MESSAGE[BY ROBOT] ;
53: MESSAGE[...........] ;
54: MESSAGE[EVALUATE CAPWEAR] ;
55: MESSAGE[LIMITS R[235,236] ;
56: MESSAGE[...........] ;
57: MESSAGE[ROBOT WILL REQ] ;
58: MESSAGE[CAP CHANGE ON ALL GUNS] ;
59: ;
61: IF (R[226:DNETCFG 64/256]<>1),DO[130:SGProc1TipChgReq]=ON ;
62: UALM[49] ;
64: ;
65: LBL[99] ;
18.18 Servo Gun Tool Changing specific Tip Dress Programs

Several Tip dress macros have a modified version for the Servo Gun tool change applications.
18.18.1 Style 29 TIP DRESS (SG tool change specific)
The carried tip style for the SG tool changing application is modified to dress the currently held gun with
the TDPROCx path.
1: !TipDress Style 29 ;
2: !carried with toolchanging ;
3: MESSAGE[TIP DRESS CARRIED] ;
4: ;
6: ;
8: ;
9: ECHO OPTION ;
10: ;
12: ;
13: LBL[1] ;
14: !Determine Gun on Robot ;
15: CALL TCGETNUM ;

OV ME Strategy
16: ;
18: !No TD if MH Tool/Stud ;
20: ;
22: ;
23: !Check that Held Gun ;
24: !Is Not Machine Locked ;
25: !For Servo Gun Only ;
28: =2,JMP LBL[20] ;
29: =3,JMP LBL[30] ;
30: =4,JMP LBL[40] ;
34: JMP LBL[50] ;
37: JMP LBL[50] ;
40: JMP LBL[50] ;
43: ;
44: LBL[50:SelectTpDresPath] ;
45: ;
47: =2,JMP LBL[70] ;
48: =3,JMP LBL[80] ;
49: =4,JMP LBL[90] ;
51: ;
52: LBL[60] ;
53: CALL TD_PROC1 ;
54: JMP LBL[99] ;
55: LBL[70] ;
56: CALL TD_PROC2 ;
57: JMP LBL[99] ;
58: LBL[80] ;
59: CALL TD_PROC3 ;
60: JMP LBL[99] ;
61: LBL[90] ;
62: CALL TD_PROC4 ;
63: ;
64: LBL[99] ;
65: MOVE TO HOME ;
66: END ;
67: ;
68: !****FAULTS****** ;
69: LBL[5:Invalid Gun Num] ;
70: MESSAGE[...] ;
72: MESSAGE[ INVALID GUN NUMBER] ;
73: MESSAGE[ R[113] AND GI[15] MUST] ;
74: MESSAGE[ BE 1, 2, 3 OR 4] ;
76: UALM[3] ;
78: JMP LBL[1] ;

OV ME Strategy
18.18.2 TD_PROCx (SG tool change specific)

The carried tip dress process x macros, where x equals the gun # 1-4. No two guns should have the same
tip dress path even if they are identical type guns. Note that the arguments attached to the CUTRLMT
and TCDRESCP calls are equal to the tip dress motor being used, therefore, the user may have to modify.
1: !TIPDRESS PROCESS 1 ;
2: MESSAGE[TIP DRESS GUN1] ;
3: ;
4: !Note: CUTRLMT and DRESCAPS ;
5: !need identical arguments ;
6: !which should be in respect ;
7: !to the tipdress motor used ;
8: CALL CUTRLMT(1) ;
9: ;
10: LBL[1] ;
11: !SGTC GUN CHECK ;
12: IF SO[7:TP enabled]=OFF,JMP LBL[10] ;
18: CALL TCGETNUM ;
19: IF R[113:Current Head]=0 AND R[113:Current Head]>4,JMP LBL[5] ;
20: ;
21: LBL[10] ;
22: ;
23: UTOOL_NUM=1 ;
24: ;
25: !PROGRAM PATH TO POINT ;
26: !Teach G2 Staging Pt @50mm ;
27: !Opening for Servo Guns ;
28: ;
29: !Teach G2 Aiming Pt @50mm ;
30: !Opening for Servo Guns ;
31: ;
32: !Teach Firing Pt. ;
33: ;
34: CALL TCDRESCP(1) ;
35: ;
36: !PROGRAM RETURN PATH ;
37: ;
39: CALL TCPSTDRS ;
40: ;
42: END ;
43: ;
44: LBL[5:FAULTS] ;
45: MESSAGE[...] ;
46: MESSAGE[NO GUN ] ;
47: MESSAGE[OR INVALID TOOL TYPE] ;
48: MESSAGE[ ATTACH GUN ] ;
49: MESSAGE[BEFORE ATTEMPTING] ;
50: MESSAGE[A TIP DRESS] ;
51: MESSAGE[... ] ;
53: UALM[1] ;
55: JMP LBL[1] ;

OV ME Strategy
18.18.3 TCDRESCP (SG tool change specific)

This is the carried servo gun tool change macro listing that dresses the caps for the gun number equal
to argument X. Note that for carried servo gun tool changing the following weld schedules are used for
tipdressing:
Gun # Predress Tipdress
1 247 248
2 249 250
3 251 252
4 253 254
1: !UPDATES TIPDRESS POSITION ;
2: !toolchanging specific ;
3: LBL[1] ;
4: PR[8:TipDress Pos]=LPOS ;
5: LBL[10] ;
6: CALL RST_WTR ;
8: ;
9: SELECT R[151:$SHELLWRK$CURDCD]=1,CALL TD_1_ON ;
10: =2,CALL TD_2_ON ;
11: =3,CALL TD_3_ON ;
12: =4,CALL TD_4_ON ;
14: ;
16: =2,JMP LBL[50] ;
17: =3,JMP LBL[80] ;
18: =4,JMP LBL[110] ;
20: ;
21: !*****Dress Gun1******** ;
22: LBL[20] ;
24: ;
25: !TIP DRESS SCHEDULE ;
26:L PR[8:TipDress Pos] 1500mm/sec CNT100
: SPOT[SD=1,P=97,S=248,ED=20] ;
27: JMP LBL[40] ;
28: ;
29: LBL[30] ;
30: !PRE-DRESS SCHEDULE ;
: SPOT[SD=1,P=96,S=247,ED=20] ;
32: ;
33: LBL[40] ;
34: CALL TD_CHK(AR[1]) ;
35: IF AR[1]=1 AND R[90:TD1 RETRY]=1,JMP LBL[10] ;
39: CALL TD_OFF ;
40: ;
41: END ;
42: ;
43: !*****Dress Gun2******** ;
44: LBL[50] ;
46: ;
: SPOT[SD=1,P=97,S=250,ED=20] ;
49: JMP LBL[70] ;
50: ;

OV ME Strategy
51: LBL[60] ;
: SPOT[SD=1,P=96,S=249,ED=20] ;
54: ;
55: LBL[70] ;
61: CALL TD_OFF ;
62: END ;
63: ;
64: !*****Dress Gun3******** ;
65: LBL[80] ;
66: ;
68: ;
: SPOT[SD=1,P=97,S=252,ED=20] ;
71: JMP LBL[100] ;
72: ;
73: LBL[90] ;
: SPOT[SD=1,P=96,S=251,ED=20] ;
76: ;
77: LBL[100] ;
83: CALL TD_OFF ;
84: ;
85: END ;
86: ;
87: !*****Dress Gun4******** ;
88: LBL[110] ;
89: ;
91: ;
: SPOT[SD=1,P=97,S=254,ED=20] ;
94: JMP LBL[130] ;
95: ;
96: LBL[120] ;
: SPOT[SD=1,P=96,S=253,ED=20] ;
99: ;
100: LBL[130] ;
106: CALL TD_OFF ;
107: ;
108: END ;
109: !************ FAULTS ************ ;
111: UALM[1] ;
112: JMP LBL[1] ;

OV ME Strategy
18.18.4 TCPSTDRS (SG tool change specific)

This macro updates the cap wear after the caps have been dress for gun X. It differ from regular servo
gun post dress in that calls TW_MEM for tip wear error proofing with multi guns.
1: !TC POST DRESS GUN(X) ;

2: ;
3: LBL[1] ;
4: !Determine Gun on Robot ;
5: CALL TCGETNUM ;
6: ;
8: =2,JMP LBL[20] ;
9: =3,JMP LBL[30] ;
10: =4,JMP LBL[40] ;
12: END ;
13: ;
14: LBL[10:Gun1] ;
16: R[22:SERVO GUN WORK]=R[201:G1GN Wear Snc CC] ;
17: R[23:SERVO GUN WORK]=R[202:G1RB Wear Snc CC] ;
18: CALL TW_UPD(1) ;
20: CALL TW_MEM(1) ;
21: JMP LBL[50] ;
22: ;
23: LBL[20:Gun2] ;
30: JMP LBL[50] ;
31: ;
32: LBL[30:Gun3] ;
39: JMP LBL[50] ;
40: ;
41: LBL[40:Gun4] ;
48: JMP LBL[50] ;
49: ;
50: ;
52: UALM[1] ;
53: JMP LBL[1] ;
54: ;
55: LBL[50] ;
56: DO[53:Proc1TipMaintReq]=OFF ;
57: LBL[99] ;

OV ME Strategy
19 Troubleshooting Servo Gun Tool Change

19.1 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 :
Turn the machine lock ON in the servo gun operation group (normally, group 2) in the Test Cycle screen.
Move the robot by manual feed so that the robot and gun are physically attached.
1. Turn the controller OFF then ON again.
2. 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.
3. Then, carry out gun 0 position mastering and calibration manually.
4. The gun pulse values and mastering data are lost. So, move the gun by manual feed to cancel
the "SRVO-075 Pulse not established" alarm.
5. . Carry out gun 0 position mastering and calibration manually. The gun 0 position may be an
approximate position.
6. 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.
7. Execute the attach instruction again to attach the gun. Calibration this time is carried out at
the reference position to restore the position.
8. Battery mounted gun. The gun is attached and positioned, so it can be used as it is.
Remedy 2 :
1. Directly change the system variable to detach the gun. To do this, set the following system vari-
able 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 physi-
cally 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.
19.2 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.
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.

Version 1.0 Troubleshooting Servo Gun Tool Change Global 2 Servogun Setup Users
OV ME Strategy
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 dif-
ferent to when it was detached. So, gun 2 may be calibrated to the wrong position by the attach in-
struction executed in step 4 above, resulting is misalignment between its actual and desired posi-
tions. In this case, carry out gun 0 position mastering and calibration manually.
When gun 2 is other than the above:
Gun 2 can be used as it is.
5. Gun 1 can be used as it is by executing the attach instruction to attach the gun.
19.3 The attached gun has been detached by mistake (without using the detach in-
struction)
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 C-1
Remedy 2:
Same as Remedy 2 of C-1
19.4 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.
19.5 The battery ran low while the gun was
Phenomenon:
The "SRVO-062 BZAL" and "SRVO-075 Pulse not established" alarms occurred when the gun was at-
tached.
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 Pulse not established" alarm.
4. Carry out gun 0 position mastering and calibration manually. When the reference position has
been set:
5. Press F3:RESET_PULSE in the Calibration screen, and select YES.
7. Move the gun by manual feed to cancel the "SRVO-075 Pulse not established" alarm.

OV ME Strategy
8. Move the gun by manual feed to the reference position marked by a line marking or alignment
mark.
9. Execute 3 QUICK MASTERING in the Calibration screen.
Touch torque
Increase the value from about ±2, and calculate the value at which erroneous detection of contact oc-
curs. 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.

OV ME Strategy
20 Variable Listing (Condensed)

The following are variables that relate to servo guns.
20.1 $SGSYSCFG
20.1.1 $pst_ertype: Pressure Shortage Error type
0 = The pressure shortage error is posted as a warning (programs do not pause )
1 = The pressure shortage error is posted as a pause error.
20.1.2 $allow_stdsp: Display Standalone Spot instruction
FALSE = Editor does not display standalone spot instruction
TRUE = Editor will display standalone spot instruction
20.1.3 $rel_press: Release pressure at program pause
0: Keep pressure at paused
1: Release pressure at paused
20.1.4 $prs_units: Pressure units
This variable indicates how pressure data is displayed (and entered). The internal representation and
stored values are in kgf.
1= lbf
2= Newton
0,other kgf ( default )
20.2 Common Errors on Servo Gun Errors

20.2.1 SRVO-023: SERVO Stop error excess (G:%d A:%d)
Cause:
When the servo stopped, the position error was abnormally large.
Remedy:
1. Check the ARM1 cable for connectivity, and that no bent pins exist.
2. Check voltage on ARM1 cable (approx100-300Vac when commanded to move).
3. Check that gear ratio is set correctly and matches gun tag. Press Menu‟s then Type select Auto-
tune the value will under Tip Displacement.
4. If a disconnection is not found, replace the servo amplifier or the servo motor.
Cause:
Robot encounter SERVO Move error excess during the pressurization of a weld. This could indicate that
the robot would have to exceed the gun close limit to achieve the desired pressure.
Remedy:
Increase the gun closed limit in small increments. Standard limit is 20mm do not increase beyond 25mm.
(Contact Lead Robotics Engineer if problem persists)
*BEWARE: GUN DAMAGE CAN OCCUR BY BLINDLY INCREASING THIS LIMIT*

Version 1.0 Variable Listing (Condensed) Global 2 Servogun Setup Users
OV ME Strategy
20.2.2 SRVO-024: SERVO Move error excess (G:%d A:%d)

Remedy:
Take the same action as for SRVO–023
20.2.3 SRVO-069: SERVO CRCERR alarm (Grp:%d Ax:%d)
Cause:
The serial data has been disturbed during communication.
Remedy:
1. Check for loose connection on the ARP1 cable. Then reboot robot.
2. Check cable routing (isolate cable from 480v cables and RM1 robot cable) to reduce interfer-
ence.
3. Check for water intrusion in ARP1 connector at servo motor and inside servo gun end cap. Com-
mon for vertical mounted ped guns where bushing is facing upward.
4. Replace servo gun motor.
20.2.4 SRVO-062: SERVO BZAL alarm (Group:%d Axis:%d)
Cause:
This alarm is issued when the battery for backing up the absolute position data of the pulse coder is not
connected. The battery cable inside the robot might have become disconnected.
Remedy:
Correct the cause of the alarm, by pressing MENU‟S then SYSTEM select GUN MASTER press F3 and re-
boot robot. Mastering will need to be performed at this point.
20.2.5 SRVO-068: SERVO DTERR alarm (Grp:%d Ax:%d)
Cause:
The serial pulse coder did not return serial data in response to a request signal.
Remedy:
1. Make sure that the ARP1 connector on the servo gun is securely connected and check for bent
pins.
2. Check that the shielding of the robot interconnection cable (for the pulse coder) and check that
cable is not run with 480v cables.
3. Replace the robot ARP1 cable (for the pulse coder).
4. Replace the pulse coder.
20.2.6 SVGN-023: Incomplete Pressure calibration
Cause:
Incomplete pressure calibration.
Remedy:
1. Go to the Servo Gun Setup: General Setup Page.
2. Select Pressure Cal. and complete the Pressure Calibration process.
20.2.7 SVGN-024: Incomplete Wear Down calibration
Cause:
Incomplete Wear Down calibration.

OV ME Strategy
Remedy:
1. Change Caps with New Caps.
2. Check Zero Position of the Servo Gun and Master if necessary.
3. Run TW_SETG1
20.2.8 SVGN-032: Tip increased error
Cause:
The tip wear down value exceeds the increased error.
Remedy:
1. Check to ensure the CORRECT Weld Tips are on the Weld Gun.
2. If the Weld Tips are not correct, change them, and run Cap_chng/Reset Steppers.
3. If the Weld Tips are correct, run Capwear and verify the gun is closing completely during the
Capwear routine.
4. If the Servo Gun Does not close completely while running Capwear, apply lubricant to the shaft,
exercise the Servo Gun and retry Step 3.
5. If the Servo Gun still does not close the gun may need to be recalibrated (Auto Tuned/Pressure
Cal). Pay close attention to the Gun Impedance Value before and after Auto Tuning. If the Gun Im-
pedance Value increased significantly, the Servo Gun may have a bind or the Servo Motor may need
to be replaced.
6. If a bind is suspected on a C-Type Weld Gun, check the Guide Rod (Slide on Global) on the Mov-
able Side for straightness, wear and heat. Repair/Replace Guide Rod and re-run Step 5.
7. If the Servo Motor seems excessively noisy or the shaft of the motor is excessively warm/hot,
remove the Servo Motor. If the Servo Motor is Noisy, replace the Motor. Inspect the Bushing (Slide on
Global) for weld debris, which may cause the increased Gun Impedance.
20.2.9 SVGN-118: Max wear exceeded
Cause:
The maximum tip wear amount has been exceeded.
Remedy:
1. Inspect weld tips for excessive heat and abnormal wear, and inspect weld gun arms for cracks.
2. If Weld Tips appear normal replace and run Cap_Chng/reset steppers.
3. If there appears to be excessive heat on the weld tips, check for adequate water flow and
check the water tube inside the weld shank.
4. If there appears to be abnormal wear, check the tip dress path, weld pressure at tip dress, and
the tip dress cutter.
5. If weld gun arm is cracked, replace gun arm, check servo gun mastering, and verify all pro-
cess/tipdress paths.
20.2.10 SVGN-020: Pressure shortage
Cause:
Actual pressure is less than the requested pressure.
Remedy:
1. Check mastering of tips.

OV ME Strategy
2. Check tip wear if questionable install new caps and run TW_SETG1 (Always verify stoke limits
before using TW_SETG(X).
3. If problem still exist check part thickness and pushing depth settings in the pressure schedule.
4. If this fault only occurs during CAPWEAR then the gun impedance has changed therefore auto
tuning and pressure calibration are required. The gun needs to be inspected to find the cause of the
impedance change, common issues are weld slag buildup in bushing, improperly installed bushing,
and bent guide rod, (c-gun slide in global applications) If any of the above issues are present-correct
the issue and perform auto-tune and pressure calibration before resuming use of the gun.
5. Record all values associated with Standard Over Torque (Section 7).
Note: Autotune and Pressure calibration is required if any gun mechanical parts are modified or re-
worked.
Always verify the Standard Over Torque (Section 7) before after any mechanical maintenance is per-
formed on the servo gun to see how it affected the characteristics of the gun. Compare old Standard
Over Torque values with the new parameters from a re-worked gun
20.3 How to check gun impedance:

1. Press Menus key
2. Select Setup then hit ENTER
3. Press Type[F1]
4. Select Servo gun
5. Cursor down to 2nd line (General Setup) then hit ENTER
6. Cursor down to Overtorque Protection then hit ENTER
7. Press OK
8. Select Parameter Summary then ENTER
9. Verify item 1 (Display Units) is in TorqCt if not Select F4 to change
10. Gun Impedance is displayed in the row stating “Std. Overtorque Value”.
20.4 Servo Gun Amp Settings with Gun(s) & Hardware Mismatches
When a controller is equipped with additional amp channels than the amount being used by the appli-
cation, the additional amp channels have to be mapped to eliminate hardware mismatches. For ex-
ample, if a robot controller has a single amp as amp 1 and dual amp as amp 2 but is only configured for
1 gun on each amp, the additional amp channel must be configured by setting the following system
variables:
$SCR.$ATR[9]=9
$SCR.$ATRATTRIB[9]=0


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February 2018 Specification OVRS 1 of 111

1 GLOBAL 2 SERVO GUN SETUP MANUAL ............................................................................ 6

2 GUN INSTALLATION .............................................................................................................. 8

3 WIZARD SETUP ....................................................................................................................... 9

4 ESTABLISHING PULSE ON SERVO GUN MOTORS ........................................................... 11

5 MASTERING THE GUN ......................................................................................................... 12

6 PRESSURE CALIBRATION ....................................................................................................22

7 OVERTORQUE PROTECTION .............................................................................................28

8 SERVO GUN DIAGNOSIS .....................................................................................................30

February 2018 Specification OVRS 2 of 111

9 THICKNESS CHECK CALIBRATION ....................................................................................32

10 TIP WEAR COMPENSATION ............................................................................................34

11 SET GUN CLOSE DIRECTION ...........................................................................................39

12 PRESSURE SCHEDULES ....................................................................................................43

13 BACKUP SCHEDULES .......................................................................................................49

14 DISTANCE SCHEDULES ....................................................................................................50

15 PROGRAM LISTINGS ........................................................................................................ 51

February 2018 Specification OVRS 3 of 111

16.2 Cap configuration change ........................................................................................................................................65

17 SERVO GUN TOOL CHANGE OPTION ............................................................................67

18 TOOL CHANGE PROGRAMS SPECIFIC FOR SERVO GUN TOOL CHANGE

19 TROUBLESHOOTING SERVO GUN TOOL CHANGE ................................................... 105

February 2018 Specification OVRS 4 of 111

20 VARIABLE LISTING (CONDENSED) .............................................................................. 108

February 2018 Specification OVRS 5 of 111

1 Global 2 Servo Gun Setup Manual

1.3 Intended audience

February 2018 Specification OVRS 6 of 111

1.5 Setup Flow

Setup Run Controlled Section

Perform Cold Start

GSWA -101 Reset Section

Master & Set Section

Review Overtorque Section

February 2018 Specification OVRS 7 of 111

February 2018 Specification OVRS 8 of 111

3.1 Getting Started

3.2 Helps and Hints

February 2018 Specification OVRS 9 of 111

February 2018 Specification OVRS 10 of 111

4 Establishing Pulse on Servo Gun Motors

4.1 Resetting BZAL (Battery Zero Alarm)

February 2018 Specification OVRS 11 of 111

5 Mastering the Gun

5.1 Setting Gun Close Direction

February 2018 Specification OVRS 12 of 111

5.2 Mastering the Gun and Setting Axis Limits

February 2018 Specification OVRS 13 of 111

This will actually

8. Press [F3:COMP] when complete

February 2018 Specification OVRS 14 of 111

The EQUIP The INDEX

February 2018 Specification OVRS 15 of 111

Jog both guns

5. Repeat steps 1 - 3 for the other gun on the active equipment.

February 2018 Specification OVRS 16 of 111

6. Once both guns are mastered, proceed to autotuning.

*Parameters for ALL NON-IMA33 motors

3. Select <DETAIL> under Pressure Cal: (Should show INCOMP)

3. Select <DETAIL> under Overtorque protection

4. Select <DETAIL> under Parameter Summary and press Enter

4. Select <DETAIL> under Servogun diagnosis

3. Select <DETAIL> under Tip Wear Standrd