Setting Up Arctool

Chapter 5
SETTING UP ARCTOOL
Contents
Chapter 5 SETTING UP ARCTOOL ......................................................................... 5–1

5.1 OVERVIEW ................................................................................................ 5–4
5.2 WELD EQUIPMENT SELECTION ............................................................... 5–4
5.3 WELD SYSTEM SETUP ............................................................................. 5–6
5.3.1 Overview ................................................................................................... 5–6
5.3.2 Monitoring Functions ................................................................................ 5–8
5.3.3 Weld Restart Function .............................................................................. 5–9
5.3.4 Scratch Start Function ............................................................................. 5–11
5.3.5 Repeat Touch Retry Function .................................................................... 5–13
5.3.6 Weld Speed Function ............................................................................... 5–14
5.3.7 Other Functions ....................................................................................... 5–14
5.4 WELD EQUIPMENT SETUP ...................................................................... 5–17
5.5 WELD I/O ................................................................................................. 5–21
5.5.1 Overview .................................................................................................. 5–21
5.5.2 I/O Configuration ..................................................................................... 5–23
5.5.3 Weld I/O Timing Charts ............................................................................ 5–24
5.5.4 Welding Input Signals .............................................................................. 5–25
5.5.5 Welding Output Signals ........................................................................... 5–28
5.5.6 Setting Up Arc Welding I/O ...................................................................... 5–30
5.5.7 Remote Arc Enable .................................................................................. 5–36
5.5.8 Direct Wire Feed Control .......................................................................... 5–37
5.5.9 Remote Wire Inch Control ........................................................................ 5–40
5.5.10 Weld External Output Function .................................................................. 5–42
5.6 WELD PROCEDURES ................................................................................ 5–44
5.6.1 Weld Procedures Data Menu...................................................................... 5–45
5.6.2 The VIEW Function Key ............................................................................. 5–48
5.6.3 The CMND Function Key ............................................................................ 5–49
5.6.4 Weld Start and Weld End Programming..................................................... 5–50
5.6.5 Using Arc Ramping with Weld Procedures ................................................ 5–53
5–1
5. SETTING UP ARCTOOL MAROBAR8203131E REV C
5.6.6 Using HeatWave with Weld Procedures ..................................................... 5–55

5.6.7 Configuring the Weld Procedures Option .................................................. 5–56
5.7 WELD SCHEDULE DATA without WELD PROCEDURES ........................... 5–58
5.8 WELD PROCESS DATA without WELD PROCEDURES ............................ 5–62
5.9 ARCTOOL RAMPING WITH WELD PROCEDURES ..................................... 5–65
5.9.1 Overview .................................................................................................... 5–65
5.9.2 Weld Parameter Ramping .......................................................................... 5–65
5.9.3 Speed Rampint .......................................................................................... 5–71
5.9.4 Weave Ramping ......................................................................................... 5–72
5.9.5 When to Ramp ......................................................................................... 5–73
5.9.6 Resuming after a Fault ............................................................................. 5–74
5.9.7 On-the-Fly ................................................................................................ 5–77
5.9.8 Thru-Arc Seam Tracking .......................................................................... 5–77
5.10 ARCTOOL RAMPING WITHOUT WELD PROCEDURES ............................. 5–77
5.10.1 Overview .................................................................................................. 5–77
5.10.2 Programming Ramping ............................................................................ 5–81
5.10.3 When to Ramp ......................................................................................... 5–83
5.10.4 Resuming after a Fault ............................................................................. 5–84
5.10.5 On-the-Fly ................................................................................................ 5–87
5.10.6 Thru-Arc Seam Tracking .......................................................................... 5–87
5.11 WEAVING ................................................................................................. 5–87
5.11.1 Overview .................................................................................................. 5–87
5.11.2 Weave Setup ............................................................................................ 5–88
5.11.3 Wrist Axis Weaving (option) .................................................................... 5–94
5.11.4 Weave Schedules ..................................................................................... 5–95
5.11.5 Multi-Group Weave ................................................................................ 5–100
5.12 CUSTOMIZED WEAVING ........................................................................ 5–101
5.12.1 Overview ................................................................................................ 5–101
5.12.2 Customized Weaving Instruction ........................................................... 5–101
5.12.3 Weaving Pattern Setting ........................................................................ 5–103
5.12.4 Weaving Pattern Setup .......................................................................... 5–108
5.12.5 Weaving Pattern Setting by KAREL ....................................................... 5–113
5.13 EXTENDED WEAVING ............................................................................ 5–118
5.13.1 Weave Schedule .................................................................................... 5–118
5.13.2 Extended Weaving Schedule ................................................................. 5–118
5.14 WELD CONTROLLER PROGRAM SELECTION ...................................... 5–120
5.14.1 Overview ................................................................................................ 5–120
5.14.2 Enabling Weld Controller Program Selection ......................................... 5–120
5.14.3 Assigning Weld Controller Program Selection Outputs ......................... 5–121
5.14.4 Selecting Weld Controller Programs ...................................................... 5–124
5.14.5 Specifying a Weld Controller Program in a Weld Schedule ................... 5–126
5.15 LINCOLN ELECTRIC POWER WAVE SERIES WELDING
EQUIPMENT ............................................................................................ 5–127
5.15.1 Introduction ........................................................................................... 5–127
5.15.2 Installation Overview ............................................................................. 5–129
5.15.3 Hardware Requirements ........................................................................ 5–129
5.15.4 Software Requirements ......................................................................... 5–129
5.15.5 Equipment Installation ........................................................................... 5–130
5.15.6 Setting Up the Power Wave (all models) ................................................ 5–133
5.15.7 Wire Feeder Selection ............................................................................ 5–134
5.15.8 Strike Wire Feed Speed .......................................................................... 5–135
5.15.9 Power Wave ArcLink Status ................................................................... 5–136
5–2
MAROBAR8203131E REV C 5. SETTING UP ARCTOOL
5.15.10 Selecting Multiple Weld Processes ........................................................ 5–136

5.15.11 Variables that Affect the Operation of the Power Wave .......................... 5–141
5.15.12 Considerations for Touch Sensing ........................................................ 5–141
5.15.13 Considerations for Through Arc Seam Tracking (TAST) ........................ 5–142
5.15.14 Multi-Equipment Setup with the Power Wave ........................................ 5–143
5.15.15 Changing Equipment ............................................................................... 5–146
5.15.16 Error Codes Relevant to the Power Wave Interface ............................... 5–151
5.15.17 Troubleshooting ..................................................................................... 5–152
5.15.18 Hardware Reference Information (for ArcLink® (CAN Bus
Connection)) ........................................................................................... 5–152
5.15.19 ArcLink Interface Overview (ArcLink® (CAN Bus Connection)) ............. 5–153
5.15.20 Molex(SST-DN3-104, SST-DN4-104) Hardware Information .................... 5–153
5.15.21 Woodhead (SST-DN3-104-2, SST-DN4-104-2) Hardware
Information ............................................................................................. 5–155
5.15.22 Standard I/O Configuration for the Power Wave .................................... 5–157
5.15.23 Default Weld System Setup Information ................................................ 5–158
5.16 ................................................................................................... 5–159
FAStart
5.17 WELD ID .................................................................................................. 5–161
5–3
5.1 OVERVIEW
Note Consult your weld equipment vendor concerning the wiring details of the weld controller,
welder cabling, and any special programming setup on the weld equipment. Pay particular attention to
the mode selections on the weld equipment for proper robotic application.
Beginning with the R30iB Controller, Weld Procedures has been adopted as the standard interface.
5.2 WELD EQUIPMENT SELECTION

ArcTool supports welding with many kinds of weld equipment. Specific weld equipment manufacturer
configurations can be selected, and there is a general purpose MIG and TIG welding selection that can
be applied to most welding equipment.
You must specify the weld equipment you are using during Application Setup. After you select the
weld equipment, the setup and I/O items will change to reflect the items necessary for that particular
kind of weld equipment.
In general, weld equipment setup is performed during software installation where you are prompted to
select the type of equipment you intend to use. If you want to change the weld equipment setup after
software installation, use Procedure 5-1 to change the weld equipment setup.
Use Procedure 5-1 to select weld equipment at a Controlled start during Application Setup.
Procedure 5-1 Selecting Weld Equipment at Controlled Start during Application Setup
Steps
1. Perform a Controlled start.

a. If the controller is on , turn it off.
b. On the teach pendant, press and hold the PREV and NEXT keys.
c. While still pressing PREV and NEXT on the teach pendant, turn the power disconnect
circuit breaker to ON. You will see a screen similar to the following.
---------- CONFIGURATION MENU ----------

1 Hot start
2 Cold start
3 Controlled start
4 Maintenance
Select >
5–4
d. After the configuration menu appears on the screen, release the PREV and NEXT keys.
e. Select 3, Controlled start.
Figure 5–1.
ARCTOOL SETUP CONTROLLED START MENUS

1 F number: F00000
2 Welding setup: USA

3 Wire speed units: IPM
4 Weld speed units: IPM
5 Weld speed: 40
6 Manufacturer: Lincoln Electric

7 Model: PowerWave+ArcLnk
Press FCTN then START (COLD) when done
8 Multi-process: ENABLED
9 Number of weld schedules: 32
10 Number of weld equipment: 2
2. If you select 1, F Number, you can enter the F number of your robot. If you select 6,
manufacturer, a [CHOICE] soft key will appear, and you can select from a list of manufacturers
that are loaded on your system. If you select 7 after choosing the manufacturer, you are
presented with options that depend on the equipment Manufacturer. If Lincoln Electric is the
equipment manufacturer, you can select either PowerWave+ENET, STT, or PowerWave 450 as
the controller model. Refer to Section 5.15 for information about Lincoln PowerWave welding
power supplies. If General Purpose is the equipment manufacturer, you can select either MIG
(Volts, WFS), MIG (Volts, Amps), TIG (Amps), or TIG (Amps, WFS) as the controller model.
If you have ordered the Miller Electric Weld Equipment option, you will be able to choose
power supplies from their product line.
See the following screen for an example of selecting General Purpose.
General Purpose weld controller models:

1 MIG (Volts, WFS)
2 MIG (Volts, Amps)
3 TIG (Amps)
4 TIG (Amps, WFS)
Select model (0 to Exit):
See the following screen for an example of selecting Lincoln Electric.
5–5
Lincoln Electric controller models:

1 PowerWave+ArcLnk
2 PowerWave+ENet
3 PowerWave 450
4 STT
See the following screen for an example of selecting Miller Electric (only available if you
have ordered the Miller Equipment Option).
Miller Electric controller models:

1 Deltaweld 452
2 Auto-Invision
2 Auto_Axcess DNET
3. When you are finished setting equipment information, press FCTN.

4. Select START (COLD). The controller will perform a Cold start. When it is finished, the
UTILITIES Hints screen is displayed.
5.3 WELD SYSTEM SETUP
5.3.1 Overview
The SETUP Weld System screen allows you to enable and disable features that control the overall
operation of your weld system. It includes
• Monitoring functions - Section 5.3.2

• Weld restart function - Section 5.3.3
• Scratch start function - Section 5.3.4
• Weld speed function - Section 5.3.6
• Other functions - Section 5.3.7
Use Procedure 5-2 to display the SETUP Weld System screen. The information in the sections that
follow details each of the items in this setup screen.
5–6
Procedure 5-2 Setting up the Weld System
Steps
1. Press MENU.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Weld System. See the following screen as an example.
SETUP Weld System
NAME VALUE UNITS

Monitoring Functions
1 Arc loss: ENABLED
2 Gas shortage: DISABLED
3 Wire shortage: DISABLED
4 Wire stick: ENABLED
5 Power supply failure: ENABLED
6 Coolant shortage: DISABLED
Weld Restart Function
7 Return to path: ENABLED
8 Overlap distance: 0 mm
9 Return to path speed: 200 mm/s
Scratch Start Function
10 Scratch start: ENABLED
11 Distance: 5 mm
12 Return to start speed: 12 mm/s
13 Retry Count: 1
Repeat Touch Retry Function
14 Repeat Touch Retry: ENABLED
15 Retry Count: 2
Weld Speed Function
16 Default speed: 40 IPM
Other Functions
17 On-The-Fly: ENABLED
18 Weld from teach pendant: ENABLED
19 Remote gas purge: DISABLED
20 Remote wire inch: DISABLED
21 Gas Purge Key: Enabled
22 Gas Purge time 5 sec
5. Move the cursor to the item that you want to change and enter the new value.
5–7
5.3.2 Monitoring Functions
ArcTool is capable of monitoring several input signals from the welding equipment. If any of these
signals indicates a problem, welding and program execution are stopped and an error message is
displayed on the teach pendant screen. Refer to Table 5–1 for a listing and description of ArcTool
monitoring functions.
Table 5–1. Monitoring Functions
ITEM DESCRIPTION
Arc loss This item allows you to enable or disable monitoring of the arc detect input. If enabled, and
the arc detect input is OFF for the amount of time set by the value of arc loss error time, the
following error message is display: ARC-018 Lost arc detect. This arc loss time is set on the
SETUP Weld Equip screen. A time duration is used instead of an ON or OFF transition
because the arc detect signal sometimes exhibits noise.
Noise
Arc detect
signal WI[2]
Arc loss time
Weld start Welding
signal WO[1] stopped
Gas shortage This item allows you to enable or disable monitoring of the shielding gas flow during welding.
If enabled, the controller monitors the Gas fault input WI[3]. If this turns ON during welding,
the following error message is displayed: ARC-005 Gas fault.
Wire shortage This item is an input to the robot controller from the weld equipment. This input is connected
to a customer-supplied switch. You can enable or disable whether wire shortage will be
monitored. If wire shortage is enabled, the controller monitors the wire fault input. If this input
turns ON during welding, the following error message is displayed: ARC-006 Wire fault.
5–8
Table 5–1. Monitoring Functions (Cont’d)
Wire stick This item allows you to enable or disable this feature, which determines if the wire is fused to
the weld. Wire stick detection is performed when a program executes an Arc End instruction
or when an error causes welding to be stopped. If a wire stick is detected on an Arc End or
error shutdown, the wire stick reset feature attempts to break the wire stick by applying one or
more (up to three) short, timed bursts of voltage to the wire. After each attempt, wire stick
detection is performed. If the wire is still stuck after the third attempt, an "ARC-010 Wire stick
detected" error message is displayed and the wire stick alarm output is set to ON. If one of the
attempts is successful, normal program execution continues. Enabling the wire stick only
allows the system to check if a wire stick has occurred. You must enable the wire stick reset
function if you want the controller to automatically try to break the wire stick automatically.
If you are using welding equipment that does not provide a wire stick detection circuit, the
welding equipment hardware must contain a blocking diode to perform wirestick checking.
Otherwise, the wire stick output will interpret the transformer windings as a stuck welding wire.
NOTE A circuit on the weld process I/O board is designed to detect a wire stick. It checks for
this condition by applying a small voltage and checking the resistance.
Power supply failure This item allows you to enable or disable monitoring the power supply status. If enabled, the
controller monitors the Power fault input. If this turns ON during welding, the following error
message is displayed: ARC-008 Power supply fault.
Coolant shortage This item allows you to enable or disable the monitoring of coolant flow to the torch. If
enabled, the controller monitors the Water fault input. If this turns ON during welding, the
following error message is displayed: ARC-007 Water fault.
5.3.3 Weld Restart Function
When a fault occurs, the weld restart function will allow the arc to be re-established after the fault has
been cleared. Refer to Table 5–2 for a listing and description of weld restart function items.
5–9
Table 5–2. Weld Restart Function Items
ITEM DESCRIPTION
Return to Path This item allows you to return to the stop position after a fault has occurred.
Caution
The paused program must remain at the same line number as when
the error occurred; otherwise, the weld restart function cannot be
used to resume the program and weld.
If a fault occurs during a weld, the system remembers the currently commanded
welding values and the robot position. As long as the paused program remains at
the same line number, you can jog the robot to correct a problem and still be able
to resume the program and the weld.
If the program is resumed, the robot will automatically move to the position at
which the fault occurred and a weld restart will occur. If the weld restart is
successful, the program and weld will continue normally.
If enabled, the arc welding system will attempt to resume the weld using the
overlap distance and return to path speed.
Note The Return to Path feature can be used when resuming a stopped motion in a paused
program. This feature allows the robot to remember the stop position and return to that
position upon resuming, before continuing along the taught path.
The motion to the stop position is LINEAR, by default. The default speed of
this move is 200 mm/sec. The speed can be changed in the SETUP Weld
System screen. The termination type is FINE, by default. You cannot change the
termination type.
If the robot was welding when the motion stopped and the program paused,
welding will be resumed at the stop position. An overlap distance can be set to
offset the stop position to better tie in the weld.
You restart the weld by resuming the program. No special menu entries are
required. The Return to Path feature is effective from all execution sources
including the teach pendant, SOP, and UOP.
Note Through arc seam tracking (TAST) requires that the Return to Path parameter is
enabled.
Overlap distance This item indicates the distance between the point at which the weld stopped and
units: millimeters (mm) the starting point where the weld is resumed.
Return to path speed This item indicates the speed that the robot will use to move to the weld restart
units: millimeters per position.
second (mm/sec)
5–10
5.3.4 Scratch Start Function
Scratch start is an automatic recovery feature used if an Arc Start fails to strike the arc. Slag
or oxidation on the part or the welding wire can prevent good electrical conduction. Physically
scratching the wire on the part can penetrate the barrier, or moving the wire to a different position on
the part can provide better contact. This is accomplished by feeding the wire and moving the robot.
Refer to Table 5–3 for a listing and description of scratch start function items.
Table 5–3. Scratch Start Function Items
ITEM DESCRIPTION
Scratch start This item allows you to enable or disable the scratch start automatic recovery
function. If enabled, the arc welding system will physically scratch the wire on the
part to penetrate a barrier caused by slag, and also re-position the wire for better
contact. This is done by feeding the wire and moving the robot.
Scratch start begins if the arc welding system does not detect a stable arc detect
input signal.
Distance This item indicates the longest motion the robot will use during a scratch start. If
the distance is longer than the planning weld distance, the robot goes back to start
position when the robot has arrived at arc welding end position.
Return to start speed This item indicates the speed at which the robot will move back to the arc start
position during scratch start. The forward scratch move occurs at the programmed
weld speed.
Retry Maximum retry count of scratch start process.
Successful Scratch Start
If the arc detect signal fails to stabilize, the robot moves forward along the programmed weld a short
distance. If at any time during the forward move the arc is detected, the robot immediately moves
back to the Arc Start position and begins the welding move. The forward scratch move is made at the
programmed speed. The scratch start distance and return to start speed are specified in the SETUP
Weld System screen.
See Figure 5–2 .
5–11
Figure 5–2. Successful Scratch Start
Scratch Distance
P[2] P[3]
P[1]
Arc Start
XArc Detected
Forward Scratch Move
Backward Scratch Move
Welding Move
Unsuccessful Scratch Start
An error will occur if the robot moves the specified scratch distance without achieving a successful
arc start. In this case the robot returns to the arc start position and the program is paused.
See Figure 5–3 .
Figure 5–3. Unsuccessful Scratch Start
Scratch Distance
P[1] P[2] P[3]
Arc Start
Forward scratch move
Backward scratch move
Error Occurs
Scratch Start During Resume of the Weld
If a program is paused during a weld, the weld restart feature can be used to resume the program. If
the arc does not strike, the scratch start feature begins. If the scratch start feature is unsuccessful, the
robot returns to the error position and an error occurs.
See Figure 5–4 .
Figure 5–4. Scratch Start During Resume of the Weld
Scratch Distance
P[1] P[2] P[3]
X X
Arc Forward
Start Error scratch move
position Backward
scratch move
Welding
move
5–12
Scratch Distance and Closely Taught Positions
If the specified scratch distance exceeds the distance to the next taught position, the robot will only
move the distance to the next taught position.
See Figure 5–5 .
Figure 5–5. Scratch Distance and Closely Taught Positions
Scratch Distance
P[1] P[2] P[3]
Arc Start Forward

scratch move
Backward
Length scratch move
of robot
motion
Note Pausing the execution of a forward scratch move will cause the robot to restart the move at that
point and move the original scratch distance.
• When scratch start function is used with thin material, penetration may occur at the start point,
since the heat input becomes too large. In the situation like this, please set “Distance” to 2mm
and “Return to start speed” to 100mm/sec.
• Scratch start function doesn’t work if COORD instruction isn’t applied to the motion instruction
that approach to arc start position at coordinated weld system.
• Scratch start function can work with circular or A motion, HOWEVER the return motion to arc
start position is linear. Since, it is possible that the torch may interfere with the work piece during
the scratch start process, please do not set long scratch distance.
5.3.5 Repeat Touch Retry Function
Repeat touch retry function is another arc recovery function. This function tries to restart the arc at the
same position as the arc welding start position. Once the Arc has been established the robot starts
welding. This function is executed before scratch start function.
5–13
Table 5–4. Retry touch retry function
Item Description
Arc Retry Set enabled/disabled repeat touch retry function
Retry Maximum retry count of repeat touch retry function
5.3.6 Weld Speed Function
Motion instructions used during welding can specify the use of the WELD_SPEED parameter.
WELD_SPEED is defined in the weld schedule specified by an Arc Start instruction. Refer to Table
5–5 for a listing and description of weld speed function items.
Table 5–5. Weld Speed Function Items
ITEM DESCRIPTION
Default speed This item defines the speed the robot will move during welding if the Arc Start
instruction is not executed before the WELD_SPEED motion instruction.
5.3.7 Other Functions
You can also set up other functions on the SETUP Weld System screen. Refer to Table 5–6 for a
listing and description of these functions.
Table 5–6. Other Functions
On-the-fly This item enables or disables the ability to change welding conditions
(voltage, current, wire feed speed, and weaving parameters)
dynamically while welding.
Weld from teach pendant This item enables or disables the ability to arc weld when running a
program from the teach pendant.
5–14
Table 5–6. Other Functions (Cont’d)
Runin This item enables or disables the runin function. This function allows
a different set of welding parameters to be used to establish an arc at
the start of the weld. NOTE: This setting only appears if your system
is using Arc_Start/Arc_End. Weld Procedures (Weld_Start/Weld_End)
allows you to enable/disable RUNIN within the specified weld procedure.
The runin weld condition can be used on an Arc Start to establish
the weld puddle before beginning the weld motion. The runin weld
parameters are used to establish the arc and are held until the specified
runin time elapses. Then, the weld schedule specified in the Arc Start
instruction is used for the weld.
The runin conditions are set up on the DATA Weld Process screen.
Wire burnback/retract This item enables or disables the wire burnback/retract function. NOTE:
This setting only appears if your system is using Arc_Start/Arc_End.
Weld_Procedures allows you to enable/disable burnback within the
specified weld procedure.
During MIG welding, this function maintains the voltage after the wire
feed command is stopped to burn back the wire. Burnback helps to
prevent wire stick.
During TIG welding, this function can retract the wire from the weld.
You can specify the burnback parameters on the DATA Weld Process
screen.
Remote gas purge This item enables the assignment of a digital input for connection of a
remote gas purge switch.
5–15
Table 5–6. Other Functions (Cont’d)
Remote wire inch This item enables the ability to inch the welding wire forward and
backward using digital input signals. When this item is enabled, the
Weld Input screen has two additional entries to define signals for this
purpose.
12 [Remote inch fwd ] DI[ 1] U OFF

13 [Remote inch bwd ] DI[ 2] U OFF
The Weld Equipment Setup screen also has an additional entry for
setting the remote wire inch speed. This speed is different than the
WIRE+ WIRE- speed used for inching wire with the teach pendant keys.
Gas Purge Key Specifies whether to enable/disable the gas purge key function. When
this function is enabled, gas output signal becomes ON by pressing
both Shift key and STATUS key. However, this function can not be used
if you already use the STATUS key with MACRO instruction.
Gas Purge time When you set the gas output signal ON by using gas purge function, gas
flow automatically stops after this time passes. Gas flow immediately
stops by pressing both Shift key and STATUS key again regardless
if this time passes.
Note Refer to Section 5.5.9 for more information on configuring Remote Wire Inch.
5–16
Note With Weld Procedures Runin and burnback can be set per procedure. Without Weld Procedures
Runin and Burnback are global parameters that will affect all arc starts and arc ends. If you are using
a Lincoln Electric PowerWave weld power supply and have enabled the Multi-Process feature, you
will have a set of Runin, Burnback, Wire Stick, and On-the-Fly schedules available for each of the 8
process selections available with this equipment.
5.4 WELD EQUIPMENT SETUP
Weld equipment setup allows you to define how the weld equipment functions. If you are using
welding equipment from Lincoln Electric, the weld equipment setup menu is also where you
configure the weld process mode.
Table 5–7 lists and describes each weld equipment setup item. Use Procedure 5-3 to set up weld
equipment. Use Procedure 5-1 to change the process control.
Table 5–7. Weld Equipment Setup Items
ITEM DESCRIPTION
Process This item defines the kind of welding the equipment performs. MIG or TIG processes are
(Lincoln Electric valid. If you are using Lincoln Electric PowerWave x55 welding equipment, the Process
Equipment) only: selection defines the output characteristics of the welding power supply. In this case
Wire Diameter: you will see additional fields for wire diameter, gas mixture, and a description. . For
Gas Mixture example, you can select GMAW pulsed, Synergic CV, or STT process modes from this
Description: menu. The Wire Diameter, Gas Mixture, and Description fields will indicate the process
characteristics that match the selected PowerWave process mode.
SEARCH for This item is one of three search parameters that can be used to limit the choices when
Process (only for you press the SEARCH (F3) soft key to search the Lincoln Electric PowerWave weld
Lincoln Electric tables. When you place the cursor on this field and press F4, Choice, you can choose
equipment (Old a process from GMAW, GTAW, FCAW, PAW. The field to the right of this entry allows
method before you to specify YES or NO to specify whether this item will be used in limiting the search
Weld Procedures) results. (Old method before Weld Procedures)
SEARCH for This item is the second of three search parameters that can be used to limit the choices
pulse (only for when you search the Lincoln Electric PowerWave weld tables. When you place the
Lincoln Electric cursor on this field the F4 key is used to specify YES and the F5 key specifies NO. The
equipment) field to the right of this entry allows you to specify YES or NO to specify whether this item
will be used in limiting the search results. (Old method before Weld Procedures)
5–17
Table 5–7. Weld Equipment Setup Items (Cont’d)
SEARCH for wire This item is the third of three search parameters that can be used to limit the choices
(only for Lincoln when you search the Lincoln Electric PowerWave weld tables. When you place the
Electric equipment cursor on this field and press F4, Choice, you can select a wire material from None, Steel,
Stainless, Aluminum, or Other. The field to the right of this entry allows you to specify
YES or NO to specify whether this item will be used in limiting the search results. (Old
method before Weld Procedures)
Process control This item defines the weld parameters the welding equipment will use.
(Only present for The choices for MIG welding are VLT + AMPS, and VLT + WFS.
General Purpose The choices for TIG welding are AMPS and AMPS + WFS.
Weld Equipment)
Feeder
WIRE+ WIRE- This item allows you to set how fast the wire will feed when the WIRE+ or WIRE- teach
speed pendant keys are used. Wire speed can be set in mm/sec (millimeters per second),
cm/min (centimeters per minute), or IPM (inches per minute).
Remote Wire Inch This item allows you to set how fast the wire will feed when the remote forward and
Speed remote backward digital input signals are used. This item only appears in this menu if
the remote wire inch function is enabled in the Weld System Setup menu. Wire speed
can be set in mm/sec (millimeters per second), cm/min (centimeters per minute), or
IPM (inches per minute).
Feed This item allows you to enable and disable the setting of the feed forward and feed
forward/backward backward digital output signals.
When set to ENABLED, the feed forward and feed backward digital output signals are set
on and off during welding to feed the welding wire.
When set to DISABLED, the feed forward and feed backward digital output signals are
not set.
Note If you are using Lincoln Electric PowerWave x55/R equipment connected via ArcLink, the
Feed forward/backward setting should be ENABLED.
Wire stick reset This item allows you to enable or disable the automatic wire stick reset function. The
wire stick reset function attempts to burn off wire that can remain attached to the weld
at arc end. This item works together with the Wire Stick Enable/Disable setting on the
Weld System Setup Menu.
5–18
Wire stick reset This item allows you to set the number of times the arc welding system will attempt to
tries burn off a wire that might remain attached to the weld at arc end.
< > Wire Stick Time

WO1 WELD START
WIRE STICK $wstk_ena_dly > <

> < $wstk_dis_dly
ENABLE
(INTERNAL > <
OUTPUT) $wstk_mon_dly
> < $wstk_mon_tim
WIRE STICK
(INTERNAL INPUT)
Caution
The wirestick system variables in $AWEUPR should not be changed unless

absolutely necessary. If the delays are too short, equipment damage might
result.
Timing
Arc start error time This item is the maximum amount of time the arc welding system permits for establishing
an arc during an arc start. If the arc is not established within this time, a scratch start
is begun (if enabled) or an error occurs.
Arc detect time This item is the amount of time after a successful arc start that the arc welding system
requires the arc detect signal to be ON before releasing robot motion. For Lincoln Electric
PowerWave x55/R equipment, this value can be 0 seconds because arc detection is
de-bounced in the welding power supply.
Arc loss error time This item is the maximum amount of time the arc welding system allows to elapse without
detecting an arc before an alarm occurs. This condition is only valid if Arc Loss has been
enabled on the SETUP Weld System screen.
WO1 WELD < > Arc Start Error Time

START > <
Arc Loss Time
WI2 ARC
DETECT < > Arc Detect Time
MOTION
Gas detect time This item defines a time delay, after the gas start output signal is turned ON or OFF, that
the gas fault signal is checked to determine if gas flow is detected or not. This condition
is valid only if the Gas Shortage has been enabled on the SETUP Weld System screen.
Gas purge time This item defines the amount of time gas is allowed to flow through the gas line prior to
striking the arc before the robot reaches the arc start position.
5–19
Gas preflow time This item defines the amount of time the arc welding system allows gas to flow through
the gas line prior to striking the arc after reaching the arc start position.
Note Preflow and postflow will affect cycle time.
Gas postflow time This item defines the amount of time the arc welding system allows the gas to flow after
the arc has been turned off.
Note Preflow and postflow will affect cycle time.
Note The gas output signal remains ON after postflow until wirestick checking is complete if
wirestick check and wirestick reset are enabled.
Strike Wire Feed This item sets the wire approach speed for striking the arc in GMA welding. This only
Speed (Lincoln appears in the menu if you have selected Lincoln Electric PowerWave x55/R equipment.
Electric equipment
only)
Note Refer to Section 5.5.9 for more information on configuring Remote Wire Inch.
Procedure 5-3 Setting Up Weld Equipment
Steps
1. Press MENU.
2. Select SETUP.
4. Select Weld Equip. You will see the SETUP Weld Equip screen. See the following screen
for an example.
Note The screen you see will vary depending on the kind of weld equipment you are using. If
you are using General Purpose TIG without wire feed, items 1 through 4 are not displayed.
5–20
SETUP Weld Equip

Welder: General Purpose MIG (Volts, WFS)
Process: MIG
Process control: VLT+WFS
Feeder: General Purpose
1 WIRE+ WIRE- speed: 50 IPM
2 Feed forward/backward: DISABLED
3 Wire stick reset: ENABLED
4 Wire stick reset tries: 1
Timing
5 Arc start error time: 2.00 sec

6 Arc detect time: 0.06 sec
7 Arc loss error time: 0.25 sec
8 Gas detect time: 0.05 sec
9 Gas purge time: 0.30 sec
10 Gas preflow time: 0.00 sec
11 Gas postflow time: 0.00 sec
12 Strike wire feed speed 80 IPM
5. Move the cursor to the selection you want to change and type the new value.
5.5 WELD I/O
5.5.1 Overview
ArcTool supports several different types of connections to the welding equipment and the choice is
governed by the specific equipment chosen for your application. The welding equipment can be
connected to the robot controller with analog and digital I/O, DeviceNet,, Ethernet I/P or ArcLink.
Each of these interface methods is detailed in the following sections.
5–21
Figure 5–6. Process I/O Weld Cable Pinout
FROM TO
Process I/O CRW1 Weld Equipment Interface
1 DACH 1 < > A Weld Volt Analog Cmd.

2 COMDA 1 < > B Analog Common
3 DACH 2 < > E Weld Wire Feed Analog Cmd.
4 COMDA 2 < > F Analog Common
5 WDI 1 < > c Spare 24V input
6 WDI 2 < > d Arc detect input
7 WDI 3 < > e Gas Shortage input
8 WDI 4 < > f Wire Shortage input
9 WDI 5 < > g Water Shortage input
10 WDI 6 < > h Pwr Supply Fail input
11 WDI 7 < > j Spare 24V input
12 WDI 8 < > k Spare 24V input
13 ADCH 1 < > J Weld Volt Analog Feedback
14 COMAD 1 < > K Feedback Common
15 ADCH 2 < > L Weld Amp Analog Feedback
16 COMAD 2 < > M Feedback Common
17 not used
18 not used
19 OV < > a O VDC signal common
20 OV < > b O VDC signal common
21 OV < > m O VDC signal common
22 OV < > n O VDC signal common
23 WDO 1 < > R Weld Cycle Start output
24 WDO 2 < > S Gas Valve On output
25 WDO 3 < > T Spare 24V output
Standard Direct Wire Feed Lincoln NA-5R Burnback
26 WDO 4 < > U Feed forward Inch forward Feed forward
27 WDO 5 < > V Feed backward Inch backward Feed backward
28 WDO 6 < > W Wirestick alarm Wirestick alarm Wirestick alarm
29 WDO 7 < > X Spare output Feed forward Burnback
30 WDO 8 < > Z Spare output Feed backward Weld output [8]
31 WDI + < > N + Wire Stick Ckt

32 WDI < > P Wire Stick Ckt
33 +24 V < > r + 24 VDC for I/ O
34 +24 V < + 24 VDC for I/ O
Honda MR34
Male < > Amphenol MS 31088-28 21P
> C Unused pin
> D Unused pin
> G Unused pin
> H Unused pin
> P Unused pin
=> s Cable Shield Ground
connect to earth ground
If your system requires more I/O, additional process I/O boards can be added or Modular I/O is
available. Refer to Chapter 8 INPUT/OUTPUT (I/O) SETUP for more information about process
and modular I/O.
Note For weld equipment connected with analog and digital I/O, ICOM3 on the process I/O board
must be set to the B position. Otherwise, the Arc Detect input will not be received by the ArcTool
5–22
software and the Arc Start Fail error will occur. Refer to the Controller Maintenance Manual for the
location of ICOM3 jumper on the process I/O board.
Caution
You must set the ICOM3 jumper with the controller power OFF. Otherwise, you
will cause an inconsistent signal polarity.
The I/O Weld monitor screen displays the items in Table 5–8 .
Table 5–8. I/O Weld Screen Items
ITEM DESCRIPTION
WELD SIGNAL This item displays the different kinds of weld signals.
TYPE This item displays the port type.
# This item displays the port number.
SIM This item displays whether the I/O weld signal is simulated or unsimulated.
STATUS This item displays the kind of status of the I/O weld signal.
You can use the I/O Weld Config screen to configure weld input and output signals.
Table 5–9. I/O Weld Config Screen Items
ITEM DESCRIPTION
Selected Weld Input or This item is an analog or digital input or output signal from the controller to the
Output Signal weld equipment.
5.5.2 I/O Configuration
The ArcTool software automatically configures all I/O information: numbering, rack locations, and
slot locations. Process I/O boards are always assigned a rack location of 0. DeviceNet I/O is assigned
to rack location 81, 82, 83, or 84 depending on how may DeviceNet channels are installed in your
system. ArcLink I/O is assigned to rack location 90, 91, 92, or 93 depending on how many ArcLink
channels are installed in your system. For a description of rack and slot, refer to Section 8.2 .
• If your system contains multiple process I/O boards, the process I/O board closest to the MAIN
CPU is considered slot 1 and its I/O is numbered first.
5–23
• If your system contains both process I/O boards and modular I/O, all process I/O boards are
numbered starting at slot 1.
• If your system contains only modular I/O, the rack closest to the Main CPU board is the first
rack. Slots are numbered from left to right.
• If your system contains both process I/O and ArcLink or DeviceNet I/O, the I/O is numbered
starting with the lowest rack number.
For example, if your ArcTool system contained one process I/O board with 40 digital inputs and a one
digital input modular I/O unit with 40 digital inputs, the process I/O board digital inputs would be
numbered 1-40 and the modular I/O digital inputs would be numbered 41-80.
Another example is a system configured with one process I/O board and one ArcLink I/O channel. In
this case the weld I/O is assigned above the Process I/O because the ArcLink Rack number is higher
than Process I/O (Process I/O rack 0, ArcLink I/O rack 90.)
5.5.3 Weld I/O Timing Charts
Figure 5–7 shows the arc welding timing sequence for MIG welding. Refer to Section 5.4 for
information on setup that affects the timing sequence.
Figure 5–7. MIG Welding Timing Chart
ARC START
ARC END
< > Purge
WO2 GAS START Postflow< >
> < > < Detect
Gas detect
WI3 GAS FAULT Gas detect
< >
Craterfill
AO1 VOLTAGE Burnback < >
Preflow
< >
AO2 WIRE FEED
WO1 WELD START < > Runin
WI2 ARC DETECT
MOTION
5–24
Figure 5–8. TIG Welding Timing Chart
ARC START
ARC END
< > Purge

GAS START Gas detect Gas detect
WO[2] < > Preflow
< Postflow >
GAS FAULT
WI[3] Craterfill < >
CURRENT
AO[1] < >Retract
WIRE FEED
AO[2]
WELD START
WO[1]
FEED FORWARD
WO[4]
FEED BACKWARD
WO[5]
< >Runin
ARC DETECT
WI[2]
MOTION
5.5.4 Welding Input Signals
You can use the I/O Weld In screen to
• View the status of the input signals

• Simulate input signals
5–25
• Force input signals only if the input signal is first simulated.

• Add a description or name to an unused input signal
• Change the pre-assigned port number or port type
Arc welding input signals are pre-assigned when you select the welding equipment during installation.
If you are using a Lincoln Electric PowerWave x55/R series power supply connected via ArcLink,
you can re-assign the Gas Fault, Wire Fault, and Water Fault inputs. See Chapter 8 INPUT/OUTPUT
(I/O) SETUP for more details on re-assigning this I/O.
Note The analog (AI[] and digital (DI[]) inputs displayed on the weld input screen are also displayed
on the analog and digital I/O screens.
Table 5–10 lists and describes each arc welding input signal.
Use Procedure 5-4 to set up arc welding I/O. Refer to Appendix A and refer to Section 5.3 for more
information.
Table 5–10. Arc Welding Input Signals
input signal description
Voltage This item is an analog signal feedback to the controller that

Not available for Lincoln STT welding equipment causes the display of the actual voltage the weld interface
and power supply are using to weld.
Current This item is an analog signal feedback to the controller that

Not available for Lincoln STT welding equipment causes the display of the actual current the weld interface
and power supply are using to weld.
Wire feed speed This item is an analog signal to the controller that causes the
display of the actual wire feed speed the weld interface and
power supply are using to weld.
Arc detect This item is an input from the weld equipment to the controller.
It indicates that the arc has been detected and welding is in
process. This signal is monitored at an Arc Start.
The Arc Detect signal must be ON before the weld will
continue. . If it is not ON at the start of the weld, the error
message "ARC-013 Arc start failed" could appear.
The Arc Detect input signal is also monitored during welding
if the arc loss function is set to enabled on the SETUP Weld
System screen. If the Arc Detect signal turns OFF, the arc
has been lost. This is reported as an error, the robot is
stopped, and the program is paused. The error message is
"ARC-018 Lost arc detect during welding."
5–26
Table 5–10. Arc Welding Input Signals (Cont’d)
Gas fault This item is a fault input from the weld equipment to the
controller. It indicates a lack of shielding gas.
The Gas Fault signal is usually connected to a pressure or
flow switch. This signal is monitored if the gas shortage
function is set to enabled on the SETUP Weld System screen.
The error message, "ARC-005 Gas fault" could appear.
Wire fault This item is a fault input from the weld equipment to the
controller. It indicates either a problem in feeding the wire or
the lack of wire on the spool. You must set up a switch to
monitor the wire.
The Wire Fault signal is monitored during welding if the wire
shortage function is set to enabled on the SETUP Weld
System screen. If a wire fault occurs, it must be corrected
before program execution can continue. The error message,
"ARC-006 Wire fault" could appear.
Water fault This item is a fault input from the weld equipment or torch
cooler equipment to the controller. It indicates a problem
with the water cooler or hoses. It is typically connected to
a customer-supplied flow switch. This signal is monitored
during welding if coolant shortage is set to enabled on the
setup weld screen. The error message, "ARC-007 Water
fault" could appear. Refer to the Error Code Manual for more
information.
Power fault This item is a fault input from the weld equipment to the
controller. It indicates a power supply failure or loss of power.
This is monitored during welding if the power supply failure
function is set to enabled on the setup weld screen. The error
message, "ARC-008 Power supply fault" could appear. Refer
to the Error Code Manual for more information.
Wire Stick This item is an input to the controller that indicates that
the weld wire is fused to the work piece after the arc is
extinguished.
Arc enable This item is an input to the controller used to enable or

disable welding. It is active only during remote operations
(REMOTE is ON). This signal is typically connected to a
remote keyswitch or CMND ENBL on a remote operator
panel. By default, this input is not assigned. It can be
assigned to a digital input using the I/O Weld In screen.
5–27
Table 5–10. Arc Welding Input Signals (Cont’d)
Remote inch fwd This item is an input to the controller used to inch the wire
forward.
Remote inch bwd This item is an input to the controller used to inch the wire
backward.
Note Gas, wire, water, and power might be external inputs requiring customer-supplied switches.
FANUC America Corporation does not supply these switches as standard items.
5.5.5 Welding Output Signals
You can use the I/O Weld Out screen to
• View the status of the output signals

• Simulate output signals
• Force output signals. You can force an output signal that is either simulated or not simulated. If
the output signal is simulated, forcing the output has no affect on weld equipment. If the output
signal is not simulated, the weld equipment turns on and off when forced.
• Add a description or name to an unused input signal
• Change the pre-assigned port number or port type
Arc welding output signals are pre-assigned when you select the welding equipment during
installation. . If you are using a Lincoln Electric PowerWave x55/R series power supply connected
via ArcLink, you can only re-assign the Gas Start output.
Note The analog (AO[] and digital (DO[]) outputs displayed on the weld output screen are also
displayed on the analog and digital I/O screens.
Note During testing, you can use the TEST CYCLE screen to enable or disable arc welding signals.
If you enable these signals, and then later disable them, you must unsimulate the signals using the I/O
Weld Out screen or the UNSIM ALL I/O item on the FCTN menu.
The output signals will vary depending on the kind of weld equipment you are using. Table 5–11 lists
and describes each arc welding output signal.
Use Section 5.5.6 to set up arc welding I/O. Refer to Section 5.4 . Also refer to Section 5.5.8 and
Section 5.14 for more information.
5–28
Table 5–11. Arc Welding Output Signals
Analog Output Signal Description
Voltage (only present if you have selected General This item is an analog output from the controller to the
MIG (Volts & Wire Feed Speed) welding equipment or weld equipment that controls the welding voltage. It is
you are using a Lincoln Electric PowerWave x55/R scaled to the range of the power supply.
power source with a CV (Constant Voltage) process
mode.)
Current (Only present if you have selected General This item is an analog output from the controller to the
MIG (Amps & Volts) welding equipment or TIG weld equipment that controls the welding current. It is
equipment.) scaled to the range of the power supply.
Wire Feed (This item will appear with General MIG This item is an analog output from the controller to the
equipment (Volts & Wire Feed Speed) or CV process weld equipment that controls the speed of the wire
modes. In some Lincoln Electric process modes this feeder. It is scaled to the range of the power supply.
is known as “Workpoint”.)
Trim (Present for Pulsed GMAW welding power This item is an analog output from the controller to the
supplies) weld equipment that controls the welding trim. (Trim is
generally a reference parameter for arc length.) It is
scaled to the range of the power supply.
Peak Current This item is an analog output from the controller to

the weld equipment that controls the welding peak
current. It is scaled to the range of the power supply.
Back Current This item is an analog output from the controller to the
weld equipment that controls the welding background
current. It is scaled to the range of the power supply.
Tailout (Only present for Lincoln Electric STT II This item is a reference parameter controlling the time
process) to decay from peak pulse to background pulse current.
Hot Start (Only present for Lincoln Electric STT II This item is a reference parameter that controls the
process) STT process mode re-strike current.
Digital Output Signal Description
Weld start This item is an output from the controller to the weld
equipment to start welding.
Gas start This item is an output from the controller to the weld
equipment to cause a gas valve to open and gas flow
to begin.
Inch forward This item is an output from the controller to the weld
equipment to advance the wire when you press the
WIRE+ key on the teach pendant.
Inch backward This item is an output from the controller to the weld
equipment to retract the wire when you press the
WIRE- key on the teach pendant.
5–29
Table 5–11. Arc Welding Output Signals (Cont’d)
Wire stick alarm This item is an output from the controller to the weld
equipment to indicate a wire stick is detected.
Feed Forward This item is an output from the controller to the weld
equipment to advance the wire during welding .
Feed Backward This item is an output from the controller to the weld
equipment to retract the wire during welding .
Program Select 1 These items define three outputs that determine which
Program Select 2 weld controller program is selected.
Program Select 3
5.5.6 Setting Up Arc Welding I/O
Use the following procedures to set up arc welding I/O:
• Procedure 5-4 Setting Up Arc Welding I/O

• Procedure 5-5 Configuring Analog Input and Output Signals (AI/AO)
• Procedure 5-6 Reconfiguring Weld Input and Output Signals (WI/WO)
• Procedure 5-8 Using Spare Weld Signals (WI/WO) and Adding Comments
Procedure 5-4 Setting Up Arc Welding I/O
Steps
1. Press MENU.
2. Select I/O.
3. If the I/O Weld screen is not displayed, press F1, [TYPE].
4. Select Weld. You will see either the weld input or output screen. See the following screens for
example.
Note The signal names, port types, and port numbers you see will vary depending on the kind
of weld equipment you are using.
Note The port types and port numbers shown in this screen represent a MIG welding application
that uses a process I/O board.
5–30
I/O Weld In
WELD SIGNAL TYPE # SIM STATUS
1 [Voltage ] AI[ 1] U 0.0
2 [Current ] AI[ 2] U 0.0
3 [ ] WI[ 1] U OFF
4 [Arc detect ] WI[ 2] U ON
5 [Gas fault ] WI[ 3] U OFF
6 [Wire fault ] WI[ 4] U OFF
7 [Water fault ] WI[ 5] U OFF
8 [Power fault ] WI[ 6] U OFF
To change between the display of the input and output screens, press F3, IN/OUT. See the
following screen for an example.
I/O Weld Out

1 [Voltage ] AO[ 1] U 0.0
2 [Wire feed ] AO[ 2] U 0.0
3 [Weld start ] WO[ 1] U OFF
4 [Gas start ] WO[ 2] U ON
5 [ ] WO[ 3] U OFF
6 [Inch forward ] WO[ 4] U OFF
7 [Inch backward ] WO[ 5] U OFF
8 [Wire stick alarm] WO[ 6] U OFF
Note The port types and port numbers shown in this screen represent a Pulsed GMAW process
mode when using a Lincoln Electric PowerWave x55/R weld power supply.
I/O Weld In
1 [Arc Voltage ] AI[ 1] U 0.0
2 [Arc Current ] AI[ 2] U 0.0
3 [Wire Feed ] AI[ 3] U 0.0
4 [Arc detect ] DI[25] U OFF
5 [Gas fault ] DI[27] U OFF
6 [Wire fault ] DI[28] U OFF
7 [Water fault ] DI[29] U OFF
8 [Power fault ] DI[30] U OFF
9 [Wirestick ] DI[31] U OFF
10 [Arc Enable ] [**] * ***
To change between the display of the input and output screens, press F3, IN/OUT. See the
following screen for an example.
5–31
I/O Weld Out

1 [WFS ] AO[ 1] U 0.0
2 [Trim ] AO[ 2] U 0.0
3 [Arc Control ] AO[ 3] U 0.0
4 [Weld start ] DO[25] U OFF
5 [Gas start ] DO[26] U OFF
6 [Inch forward ] DO[28] U OFF
7 [Inch backward ] DO[29] U OFF
8 [Feed forward ] DO[30] U OFF
9 [Feed backward ] DO[31] U OFF
10 [Wire stick alarm] [**] * ***
11 [Proc select 1 ] [**] * ***
11 [Proc select 2 ] [**] * ***
11 [Proc select 3 ] [**] * ***
5. To simulate or not simulate I/O , move the cursor to the SIM column next to the I/O that
you want to affect:
• Press F4, SIMULATE to simulate I/O.

• Press F5, UNSIM to not simulate I/O.
Warning
Any arc welding output that is forced and is not simulated

actually turns equipment on or off. Make sure all personnel
and unnecessary equipment are out of the workcell and that all
safeguards are in place; otherwise, you could injure personnel
or damage equipment.
6. To force a digital output , move the cursor to the STATUS column next to the output that
you want to affect:
• To force ON , press F4, ON.

• To force OFF , press F5, OFF.
Procedure 5-5 Configuring Analog Input and Output Signals (AI/AO)
Steps
Note Do NOT use the following procedure for any Lincoln Electric PowerWave x55/R welding
power supply. The Lincoln Equipment connected with ArcLink is automatically configured and
scaled properly based on the process mode selection in the Weld Equipment Setup menu.
1. Display the I/O Weld Out screen. ( Procedure 5-4 , Step 1 through Step 4 )
5–32
2. Move the cursor to the analog signal you want to configure.

3. Press NEXT, >, and then press F3, CONFIG. See the following screen for an example.
I/O Weld Out

1 AO[ 1 ] ^
(Volts) |
|
2 10.000 +----------------*
| |
| |
3 0.000 | |
+* |
|+---------------+
4 0.000 50.000
Voltage (Volts)
4. Move the cursor to the item you want to adjust, type the new value, and press ENTER. You can
adjust the following items:
• Analog port number

• Analog signal range - maximum
• Analog signal range - minimum
• Welding range - minimum
• Welding range - maximum
5. To determine if the assignment is valid, press F3, VERIFY.
• If the assignment is valid, the message, "Port assignment is valid," is displayed.

• If the assignment is not valid, the message, "Port assignment is invalid," is displayed.
6. To return to the I/O Weld screen, press F2, MONITOR, or press PREV.
5–33
Figure 5–9. Analog Signal Scaling Example
Robot Controller
Weld Equipment
Process I/O
board AI[1..n]
Command Signal Actual Welding
Range Range
Weld Cable
Analog max: 10 Welding max: 50
CRW1 AO[1..n] Analog min: 0 Welding min: 0
connector
Reconfiguring Weld Input and Output Signals (WI/WO)
If you are not using process I/O or are not able to use the standard I/O definition assigned by ArcTool,
you can reconfigure the port type and port number of each digital weld signal. Use Procedure 5-6
to reconfigure weld input and output signals.
Note If you are using Lincoln Electric PowerWave x55/R welding equipment, you can only re-assign
the port type and I/O number to specific welding inputs and outputs. See Procedure 5-7 for more
details.
Procedure 5-6 Reconfiguring Weld Input and Output Signals (WI/WO)
Steps
1. Display the I/O Weld In or I/O Weld Out screen. ( Procedure 5-4 , Step 1 through Step 4 )
2. Move the cursor to the WI or WO signal you want to re-configure.
I/O Weld Out

WELD SIGNAL TYPE #
1 [Weld start ] WO[ 3]
4. To change the port type,

a. Move the cursor to the port type (WO, for example).
b. Press F4, [CHOICE].
5–34
c. Select the signal type you want and press ENTER.

5. To define the port number, move the cursor to the port number, type the number you want,
and press ENTER.

Note Setting an input or output port number to zero is a useful means of de-assigning I/O. For
example, if you need to de-activate the Remote Arc Enable feature, you set the port number
to zero and cycle power.
Procedure 5-7 Reconfiguring Weld Input and Output Signals for Lincoln Electric PowerWave
x55/R Equipment
Reconfiguring the weld input and output signals with Lincoln Electric PowerWave x55/R series weld
equipment connected with ArcLink is restricted to the Gas, Wire, and Water inputs and the Gas Start
output. Use the following procedure to reconfigure these inputs and outputs.
Steps
1. Press the MENU hardkey followed by Next, and System.

2. Press Type and select item 2, Variables.
3. Move the cursor to $AWELEWC and press Enter
4. Move the cursor to $USR_DEF_DO and enter 2 to re-assign the Gas Start Output signal.
5. Move the cursor to $USR_DEF_DI and enter one of the following numbers:
• Gas Fault = 2
• Wire Fault = 4
• Water Fault = 8
To enable reconfiguration of more than one of these inputs, add the number together. For
example, to override the ArcLink assignment of the gas fault and water fault inputs, enter 10 (2
+ 8) in the $USR_DEF_DI field.
6. Cycle power on the controller for this change to take effect.
Using Spare Weld Signals (WI/WO) and Adding Comments
5–35
You can use the weld inputs and outputs (WI/WO) located on the process I/O board not used by
ArcTool in your application programs. You can also add comments or names to the signals. Use
Procedure 5-8 to use spare weld signals (WI/WO) and add comments.
Procedure 5-8 Using Spare Weld Signals (WI/WO) and Adding Comments
Steps
1. Display the I/O Weld In or I/O Weld Out screen. ( Procedure 5-4 , Step 1 through Step 4 )
2. Move the cursor the spare signal you want to use.
I/O Weld Out

WELD SIGNAL TYPE #
1 [Weld start ] WO[ 3]
4. To add a weld signal comment , press ENTER and use the appropriate teach pendant keys
to type the comment. When you are finished, press ENTER.
5.5.7 Remote Arc Enable
Arc enable is an input to the controller to enable or disable welding. It is active only during remote
operations (when REMOTE is ON). The arc enable input is unassigned by default. You can assign
an input to enable or disable welding during remote operations. Use Procedure 5-9 to configure
the arc enable input.
Procedure 5-9 Configuring the Arc Enable Input
Steps
1. Press MENU.
2. Select I/O.
4. If the I/O Weld screen is not displayed, press F1, [TYPE], and select Weld.
5. Press F3, IN/OUT, until the I/O Weld In screen is displayed.
6. Move the cursor the Arc enable input.
5–36
I/O Weld In
WELD SIGNAL TYPE #
1 [Arc enable ] DI[ 8]

a. Move the cursor to the port type (DI, for example).
and press ENTER.

12. To unassign remote arc enable, set the port number to zero.
13. If you have made any changes to the configuration of the arc enable input, you must turn off
the controller and then turn it on for the changes to take effect.
5.5.8 Direct Wire Feed Control
Direct wire feed control provides two weld outputs to control the wire feed motor and direction
during welding: feed forward and feed backward.
Note If you are using Lincoln PowerWave equipment connected with ArcLink, direct wire feed
control is enabled automatically and should not be changed..
Note Direct wire feed control is effective only if the weld controller is configured to use the wire
feed signals during welding.
Enabling Direct Wire Feed Control
By default, direct wire feed control is disabled. If you are using Lincoln Electric PowerWave x55/R
welding equipment connected with ArcLink, direct wire feed control is enabled. In this case, the feed
5–37
forward/backward setting is automatically setup and should not be changed. You enable and disable
direct wire feed control using the "Feed forward/backward" entry on the SETUP Weld Equipment
screen, shown in Figure 5–10 . Direct wire feed control is enabled when the value is ENABLED;
otherwise, it is disabled.
Figure 5–10. Enabling Wire Feed Control on the SETUP Weld Equipment Screen
SETUP Weld Equip

Welder: General Purpose MIG (Volts, WFS)
Process: MIG
Process control: VLT+WFS
Feeder: General Purpose
Timing
5 Arc start error time: 2.00 sec
6 Arc detect time: .06 sec
7 Arc loss error time: .25 sec
8 Gas detect time: .05 sec
9 Gas purge time: 0.00 sec
10 Gas preflow time: 0.00 sec
11 Gas postflow time: 0.00 sec
Wire feed control is available for both MIG and TIG welding.
Assigning Direct Wire Feed Control Outputs
If you want to use direct wire feed control, you must assign the direct wire feed control outputs:
• Feed forward - Controls wire feed in the forward direction

• Feed backward - Controls wire feed in the backward direction
Use Procedure 5-10 to assign wire feed control outputs.
Procedure 5-10 Assigning Wire Feed Control Outputs
Steps
1. Press MENU.
2. Select I/O.
5–38
5. Press F3, IN/OUT, until the I/O Weld Out screen is displayed.
6. Move the cursor to a wire feed control output. See the following screen for an example.
I/O Weld Out

5 [ ] WO[ 3] U OFF
9 [ ] WO[ 7] U OFF
10 [ ] WO[ 8] U OFF
11 [Burnback ] WO[ 0] U ***
12 [Feed forward ] WO[ 0] U ***
13 [Feed backward ] WO[ 0] U ***
I/O Weld Out

WELD SIGNAL TYPE #
1 [Feed backward ] WO[ 0]
8. Move the cursor to the port number.

9. Type the port number you want to assign and press ENTER.
10. Press PREV or press F2, MONITOR.
The output signal is assigned.

11. Repeat Step 6 through Step 10 for both wire feed control outputs.
After you have assigned both signals, the screen will be similar to the following.
I/O Weld Out

5 [ ] WO[ 3] U OFF
9 [Feed forward ] WO[ 7] U OFF
10 [Feed backward ] WO[ 8] U OFF
11 [Burnback ] WO[ 0] U ***
12 [ ] WO[ 0] U ***
13 [ ] WO[ 0] U ***
5–39
5.5.9 Remote Wire Inch Control
You can define two digital input signals for remote control of wire inching. The signals names appear
in the I/O Weld In screen when the remote wire inch function is enabled.

Use Procedure 5-11 to enable this feature. Then, use Procedure 5-12 to define the input signals.
Finally, use Procedure 5-13 to set the remote inch speed prior to using this function.
Procedure 5-11 Enabling Remote Wire Inch

1. Press MENU.
2. Select SETUP.
4. Select Weld System. You will see the SETUP Weld System screen. At the bottom of this screen
you will find the following items.
SETUP Weld System

19/19
Other Functions
14 On-The-Fly: ENABLED
15 Weld from teach pendant: ENABLED
16 Runin: DISABLED
17 Wire burnback/retract: DISABLED
18 Remote gas purge: DISABLED
19 Remote wire inch: ENABLED
5. Move the cursor to remote wire inch and use the function keys to enable or disable this function.
Procedure 5-12 Configuring Remote Inch Inputs

1. Press MENU.
2. Select I/O.
4. Press F3, IN/OUT, until the I/O Weld In screen is displayed.
5. Move the cursor to the Remote inch fwd input.
5–40
I/O Weld In
WELD SIGNAL TYPE #
11 [Remote inch fwd ] DI[ 1]

a. Move the cursor to the port type (DI, for example).
and press ENTER.
• If the assignment is valid, the message, “Port assignment is valid,” is displayed.

• If the assignment is not valid, the message, “Port assignment is invalid,” is displayed.
11. To unassign remote arc enable, set the port number to zero.
12. Repeat steps Step 5 through Step 11 for the Remote inch bwd signal.
13. If you have made any changes to the configuration of either input, you must turn off the
controller and then turn it on again for the changes to take effect.
Procedure 5-13 Setting Remote Wire Inch Speed

1. Press MENU.
2. Select SETUP.
4. Select Weld Equip. You will see the SETUP Weld Equip screen. In this screen you will find
the following items.

2 Remote wire inch speed: 250 IPM
5. Move the cursor to Remote wire inch speed and set the value.
5–41
5.5.10 Weld External Output Function
The Weld External Output Function can be configured to output useful weld signals to an external
device such as PLC. This function is standard in ArcTool. The I/O screen to setup this function
is shown below.
WELD EXTERNAL OUTPUT

SIGNAL INPUT OUTPUT
1 Arc enable ******** DO[ 0]
2 Weld simulated ******** DO[ 0]
3 AS failed ******** DO[ 0]
4 Arc loss ******** DO[ 0]
5 Power fault ******** DO[ 0]
6 Gas fault DI[ 67] DO[ 0]
7 Wire fault DI[ 68] DO[ 0]
8 Water fault DI[ 69] DO[ 0]
9 Touch detect DI[ 66] DO[ 0]
[ TYPE ] HELP
Each of the signals are described in Table 5–12 . Follow the setup procedure described in Procedure
5-14 to begin using this function.
Table 5–12. Signal Descriptions
Signal Description
Arc enable This signal represents the weld enable/disable state for this weld equipment. When this signal is
ON, welding is possible with this equipment. The weld enable/disable state is also displayed on
the TEST CYCLE Arc screen.
Weld simulated This signal represents the weld simulation state for this weld equipment. When this signal is
ON, the weld I/O for this equipment is simulated and welding is not possible. This state is also
displayed in the TEST CYCLE Arc screen.
AS failed This signal is turned ON when an Arc Start fails. The alarm “ARC-013 Arc Start failed” is posted at
the same time. When this alarm is reset, this signal is turned OFF.
Arc loss This signal is turned ON when Arc Loss is detected. The alarm “ARC-018 Lost arc detect” is
posted at the same time. When this alarm is reset, this signal is turned OFF.
Power fault This signal is output when it is impossible to communicate with the weld equipment. This signal is
also output when an abnormality occurs in the weld equipment.
Gas fault An external sensor is necessary to use this signal. This signal is output according to the state of
the input signal allocated to the [Gas fault] item of weld I/O input screen. This signal is invalid
when the input signal is not assigned. This signal doesn’t depend on the setting of the [Gas
shortage] item on the SETUP weld system screen.
5–42
Table 5–12. Signal Descriptions (Cont’d)
Signal Description
Wire fault An external sensor is necessary to use this signal. This signal is output according to the state of
the input signal allocated to the [Wire fault] item of weld I/O input screen. This signal is invalid
when the input signal is not assigned. This signal doesn’t depend on the setting of the [Wire
Water fault An external sensor is necessary to use this signal. This signal is output according to the state of
the input signal allocated to the [Water fault] item of weld I/O input screen. This signal is invalid
when the input signal is not assigned. This signal doesn’t depend on the setting of the [Coolant
Touch detect The Touch detect signal is output according to the state of the Touch sensing input signal. The
Touch detect signal is ON while the wire contacts the work-piece and the Touch sensing output
signal is ON.
Procedure 5-14 Setup of Weld external output function

1. Press the [MENU] key and select the [I/O].
2. Press the F1[TYPE] and select [Weld Ext DO]. The following screen is displayed.
WELD EXTERNAL OUTPUT

SIGNAL INPUT OUTPUT
1 Arc enable ******** DO[ 0]
2 Weld simulated ******** DO[ 0]
3 AS failed ******** DO[ 0]
4 Arc loss ******** DO[ 0]
5 Power fault ******** DO[ 0]
6 Gas fault DI[ 67] DO[ 0]
7 Wire fault DI[ 68] DO[ 0]
8 Water fault DI[ 69] DO[ 0]
9 Touch detect DI[ 66] DO[ 0]
[ TYPE ] HELP
3. Set the external output signal corresponding to each usage. When you set OUTPUT to 0, the
output signal is invalid. If the specified output is a weld signal to the welder the warning
message: “This NO. is already used as Weld Output” is displayed. When the specified output
signal does not exist, the message “Port assignment is invalid” is displayed.
Caution
In step 3 above, the assignment of the specified output signal takes effect
immediately. Therefore, there is a possibility that the signal is turned ON
immediately after the assignment.
5–43
4. Note that the [Gas fault], [Wire fault], and [Water fault] output signals require the assignment of
input signals from external sensors in the weld I/O input screen. Please refer to Table 2–18 for
information on how to configure a Weld Input signal in the Weld I/O screen.
5.6 WELD PROCEDURES

A weld procedure is a file that defines how a weld is to be performed. It contains weld schedules,
weld I/O definitions and scaling information, and other unique setup items that enable features and
adjust timing. A weld procedure can be modified, copied, saved, loaded or deleted as a file.
Weld procedures at one time were optional, however beginning with R30iB they are standard in
ArcTool. They provide the basis for a simpler, more flexible programming environment that has fewer
menus and improved TP program instructions.
The Weld Schedule Data menu, the Weld Process Data menu, and the Weld Process Setup menu are
not present with Weld Procedures. They are replaced by the Weld Procedure Data menu. Some items
previously found in the Weld System Setup menu and the Weld Equipment Setup menus are now in
the Weld Procedure Data menu. For example, the Runin enable/disable setting was a global setup
item in the Weld System setup menu. Runin can now be set locally within each weld procedure. This
provides greater control and flexibility.
Prior to weld procedures, there was one table of weld schedules in ArcTool. With the multi-process
feature enabled each weld schedule was associated with one of eight defined weld process definitions
by a weld process number. The relationship between the weld schedule and the weld process is clearer
in a weld procedure. The weld schedule table and the weld process definition are both part of one
entity, the weld procedure.
You can define and use multiple weld procedures. Each procedure will have its own set of weld
schedules.
Weld procedures are equipment based. A set of weld procedures exist for each of the defined weld
equipment when the multi-equipment option is used.
A weld procedure contains three weld schedules when it is first created. The number of schedules
can be adjusted from 1 to 32 in each procedure independently. The number can be changed without
cycling power, but not while executing weld programs. Each weld procedure contains a set of Runin,
Burnback, Wirestick, and On-The-Fly (OTF) weld schedules.
Weld procedures utilizes theTP instructions Weld Start and Weld End. ArcTool can still be configured
to operate with Arc Starts and Arc Ends and to use weld schedules instead of weld procedures.
However, Weld Procedures are the preferred technique. New features such as Weld ID and Process
Logger and other future features will only be supported within the weld procedures context.
5–44
5.6.1 Weld Procedures Data Menu
The Weld Procedure Data menu is designed to provide easy access to all the important weld data in
one menu. It uses a Tree View to display and hide portions of the data. The elements of the tree which
can be expanded are indicated by a“+”. This changes to a “-“ when that tree element is expanded.
DATA Weld Procedure 1

1/9
+Procedure 1 [ ]
+Mode 18 [Rapid Arc ]
+Schedules
---------------------------------------
+Procedure 2 [ ]
+Mode 19 [PulseSoft ArMix]
+Schedules
---------------------------------------
+Procedure 3 [ ]
+Mode 20 [CV ]
+Schedules
[ TYPE ] DETAIL [ CMND ][ VIEW ] HELP
The screen above shows a list of weld procedures with all the trees collapsed. The screen below is the
same menu with the first tree in Weld Procedure 1 expanded to display setup information specific
to Procedure 1
5–45

1/21
-Procedure 1 [ ]
Weld equipment: 1
Manufacturer: Lincoln Electric
Model: PowerWave+ArcLnk
File name: AWE1WP01
Schedules: 3
Runin: DISABLED
Burnback: ENABLED
Wirestick resets: 1 ENABLED
Ramping: DISABLED
Heatwave: ENABLED
Gas purge: 0.35 sec

Gas preflow: 0.00 sec
Gas postflow: 0.00 sec
Arc Start pre-time: 0 msec
Arc End pre-time: 0 msec
Strike wire feed speed: 80 IPM
The tree expands and collapses when the ENTER key is pressed while the cursor is positioned on the
“+” and “-“. The DETAIL function key can be used to expand the tree if the cursor is at the “+”. The
PREV key can be used to collapse a tree view. The PREV key works with the cursor at the “-“ and
when the cursor is located in the menu detail.
Compared to the Arc Start programming method, the Weld Procedure Data menu replaces the Weld
Schedule Data menu, the Weld Process Data menu, and the Weld Process Select menu. It also includes
many setup items from the Weld System and the Weld Equipment Setup menus.
The number of weld schedules can be changed within each weld procedure This operation does not
require a controlled start. It does require a confirmation.
The other two tree elements in a Weld Procedure (Mode and Schedules) are both shown expanded
in the screen below.
5–46

6/19
+Procedure 1 [ ]
-Mode 18 [Rapid Arc ]
Process GMAW-P
Wire .045 in Steel
Gas Ar CO2
Search
Process: GMAW
Mode: Pulse
Wire: Steel
-Schedules
Schedule # IPM Speed Time

Runin 300.0 1.0 0.00
Schedule 1 300.0 1.0 35.0 0.00
Schedule 2 300.0 1.0 35.0 0.00
Schedule 3 300.0 1.0 35.0 0.00
Burnback 300.0 1.0 0.05
Wirestick 300.0 1.0 0.10
OnTheFly 5.0 0.0 1.0
The Mode number allows direct entry of the weld mode number if it is known. The menu also
supports choosing search parameters and performing a search of the weld equipment database for
matching modes. The SEARCH command is located within the [ CMND ] function key list.
The search parameters process, mode, and wire each have a choice of “All to widen the search.
The list of weld schedules includes the Runin, Burnback, Wirestick, and OnTheFly schedules only
if the features are enabled.
The weld schedule table has a detail level. Press the DETAIL function key to show the additional
weld schedule parameters in more detail.
5–47
DATA Weld Procedure

3/7
1 Weld Procedure 1 [ ]
[Rapid Arc GMAW-P # 18]
[.045 in Steel Ar CO2 ]
2Weld Schedule 1 [Schedule ]

3Wire feed 300.0 IPM
4Trim 1.000
5Wave Control 0.00
6Travel speed 35.0 IPM
7Delay Time 0.00 sec
Feedback Voltage 0.0 Volts
Feedback Current 0.0 Amps
[ TYPE ]SCHEDULE HELP >
[ TYPE ] COPY CLEAR >
The SCHEDULE function key can be used to jump to a different schedule while remaining at the
detail level. The NEXT key yields the additional function keys COPY and CLEAR. Press the PREV
key to exit the weld schedule detail menu and return to the weld schedule table within the weld
procedure menu.
5.6.2 The VIEW Function Key
The [ VIEW ] function key provides the choices shown below.
DATA Weld Procedure 1 JOINT 10 %

1/3
+Procedure 1 [ ]
+Schedules
__________________
| 1 One/Many |
| 2 Jump |
| 3 Collapse |
-----+ +-----
[ TYPE ] DETAIL [ CMND ]| VIEW | HELP
The first item, One/Many, toggles the display between a list of many procedures and a display of
one procedure.
5–48
The second entry, Jump, allows you to quickly display a specific weld procedure by entering the
number of the weld procedure. Jump can be used in either the “One” or the “Many” display mode.
The third entry, Collapse, closes all open tree elements in the menu.
5.6.3 The CMND Function Key
The [ CMND ] function key provides a list of commands which allow you to manipulate the weld
procedure data.

1/3
+Procedure 1 [ ]
+Schedules
__________________
| 1 Select WP |
| 2 Copy WP |
| 3 Search |
| 4 Copy Sch |
| 5 Clear Sch |
| 6 Delete WP |
-----+ +-----
[ TYPE ] DETAIL | CMND |[ VIEW ] HELP
• Select WP selects the weld procedure at the cursor location as the active weld procedure. This
results in the welding I/O definitions for this weld procedure to become active. This may result
in the Weld I/O screen, the Weld Status screen, and the OTF screen changing to display new
names for some fields.
• Copy WP allows you to copy the weld procedure at the cursor location to a new weld procedure.
You are prompted to enter a number for the destination. It does not permit overwriting an existing
procedure. This can be accomplished by first deleting the destination procedure and then using
the copy command.
• Search is used with ArcLink based weld equipment to locate a welding mode.
• Copy Sch allows you to copy a weld schedule at the cursor location to a different weld schedule.
This works by overwriting existing schedules. It does not add weld schedules.
• Clear Sch will clear the data in the weld schedule at the cursor position. Confirmation is required
before the operation is completed.
• Delete WP allows you to delete the weld procedure at the cursor location. Confirmation is
required before the operation is completed.
5–49
5.6.4 Weld Start and Weld End Programming
Weld procedures use new welding instructions in the editor: Weld Start and Weld End. These are
used in place of Arc Start and Arc End. This is required because the instruction must include a weld
procedure number and a weld schedule number, not just a schedule number. The new instructions are
helpful in determining at a glance if a robot or a program uses weld procedures or not.
TEST
1/4
1:J P[1] 100% FINE
2:J P[2] 40% FINE
: Weld Start E1[1,1]
3:L @P[3] WELD_SPEED FINE
: Weld End E1[1,1]
[End]
POINT WELD_ST WELD_PT WELDEND TOUCHUP>
Notice that the function keys also reflect that arc weld procedures are in use. Pressing F2, WELD_ST,
illustrates that the default program lines contain the new instructions. Changes made to these lines
are saved in a file specifically for use with weld procedures and are not saved to the file associated
with Arc Start programming.
Weld Start def men JOINT 10 %

1 J P[] 40% FINE Weld Start E1[1,1]
2 J P[] 100% FINE Weld Start E1[1,1]
3 L P[] 250cm/min FINE Weld Start E1[1,
4 L P[] 100.0inch/min FINE Weld Start E
TEST
1/4
1:J P[1] 100% FINE
2:J P[2] 40% FINE
: Weld End E1[1,1]
[End]
POINT ED_DEF WELD_PT WELDEND TOUCHUP>
Teach Pendant programs containing either instruction set can be loaded on a controller at the same
time. Programs containing Arc Start and Arc End can execute welding only when the weld procedures
5–50
are disabled. Programs containing Weld Start and Weld End can execute welding only when weld
procedures are enabled.
5.6.4.1 Schedule Format
The first parameter in the Weld Start and the Weld End instruction is the Weld Procedure number.
This number is checked when it is entered to verify that procedure is present on the controller. The
editor will not allow entering an invalid number.
1:J @P[1] 40% FINE

: Weld Start[1,1]
[End]
Enter procedure number.

REGISTER VALUE [CHOICE]
The second parameter in the Weld instructions is the weld schedule number in the weld procedure.
The weld schedule number is checked to verify that the schedule exists within the specified weld
procedure. Note weld procedures can have a different number of weld schedules.
1:J @P[1] 40% FINE

: Weld Start[1,1]
[End]
Enter schedule number.

5.6.4.2 Register Format
Either, or both, of the two paramaters can be changed to the Register format.
1:J @P[1] 40% FINE

: Weld Start[R[…],1]
[End]
Enter register number.

5–51
5.6.4.3 Value Format
Weld instructions can also be specified in the Value format. Note that the value format does not
support the ramping and HeatWave capabilities described in the next sections.
1:J @P[1] 40% FINE

: Weld Start[0,0.0IPM,0.000,
: 0.00,0.0s]
[End]
Enter procedure number.

5.6.4.4 Changing Weld Schedules
The Weld Start instruction can be used to change weld schedules in the middle of a weld. This is
shown on line 3 below. Also note the Weld End instruction on line 4 uses another weld schedule
to complete the craterfill sequence.
1:J P[1] 100% FINE

2:J P[2] 40% FINE
: Weld Start[1,1]
3:L P[3] WELD_SPEED CNT100
: Weld Start[1,2]
: Weld End[1,3]
5.6.4.5 Changing Weld Procedures and Process Switching
The Weld Start instruction supports changing weld procedures in the middle of a weld. The two weld
procedures involved at the change can both have the same weld process definition or they may
have different weld process definitions.
1:J P[1] 100% FINE

2:J P[2] 40% FINE
: Weld Start[1,1]
3:L P[3] WELD_SPEED CNT100
: Weld Start[2,1]
: Weld End[2,1]
5–52
5.6.4.6 Multiple Weld Equipment
If the multi-equipment option is present the weld equipment number is included in each Weld
instruction.
1:J P[1] 100% FINE

2:J P[2] 40% FINE
: Weld End E1[1,1]
5.6.4.7 Synchronized Weld Starts
The weld starts of multiple equipment can be synchronized by correctly setting the equipment
synchronization field at the end of each instruction.
1:J P[1] 100% FINE

2:J P[2] 40% FINE
: Weld Start E1[1,1,E2]
3: Weld Start E2[1,1,E1]
: Weld End E1[1,1]
5: Weld End E2[1,1]
5.6.5 Using Arc Ramping with Weld Procedures
Arc Ramping is now standard on ArcTool. Ramping is enabled by default. It can be disabled
at controlled start by way of the system variable $AWERAMP. Refer to Section 5.10.1.1 for a
description of these fields.
$AWERAMP[1] 1/7
1 $RAMP_ENABLE TRUE
2 $RAMP_HOLD FALSE
3 $TIME_FACTOR 1
4 $RAMP_CRATER TRUE
5 $RAMP_TO_POS TRUE
6 $TIM_RMP_RSM FALSE
7 $POS_RMP_RSM TRUE
When arc ramping is enabled, ($aweramp[1].$ramp_enable = TRUE) , the weld procedure menu
includes a setup item for turning ramping ON/OFF within any weld procedure. If ramping is disabled
globally ($aweramp[1].$ramp_enable = FALSE), then this menu item is not displayed.
5–53

1/14
-Procedure 1 [ ]
Weld equipment: 1
File name: AWE1WP01
Schedules: 3
Runin: ENABLED
Burnback: ENABLED
Ramping: ENABLED
If ramping is enabled in a weld procedure the Ramp column is added to the weld schedule table. Each
weld schedule can be configured to use ramping using F4, [CHOICE], in the Ramp column.

4/9
+Procedure 1 [ ]
-Schedules
Schedule # IPM Speed Time Ramp

Schedule 1 300.0 1.0 35.0 0.00 None
Schedule 2 300.0 1.0 35.0 0.00 Posn
Schedule 3 300.0 1.0 35.0 0.20 Time
Burnback 300.0 1.0 0.05
Wirestick 300.0 1.0 0.10
[ TYPE ] DETAIL [ CMND ][CHOICE] HELP
There are five choices for ramping.
None Ramping is not used.

Posn Ramping is position based. The duration of the ramp is the duration of the motion
following the Weld Start.
Time Ramping is timed. The time is specified in the weld schedule.
Hold Ramping is timed. The time is specified in the weld schedule. Motion is held until
the ramp time completes.
CDep Constant Deposition is used. This is an optional feature. Refer to for more information.
5–54
5.6.6 Using HeatWave with Weld Procedures
HeatWave is an ArcTool option that permits you to vary the weld command signals throughout the
weave cycle. Refer to Chapter 18 HEATWAVE SYNC for more information on HeatWave. Weld
procedure support for HeatWave began in ArcTool version V7.50-3.
The HeatWave option can be used with Weld Procedures. When HeatWave is enabled,
($awscfg.$weave_synch = TRUE) an additional setup field appears in the weld procedure menu. This
setup item allows you to enable or disable HeatWave for each weld procedure independently.

1/15
-Procedure 1 [ ]
Weld equipment: 1
File name: AWE1WP01
Schedules: 3
Runin: DISABLED
Burnback: ENABLED
Ramping: DISABLED
Heatwave: DISABLED
When HeatWave is enabled for a particular weld procedure each weld schedule in that weld procedure
can independently have a HeatWave mode of Step, Ramp, or None. This choice is in the DETAIL
level of the weld schedule. This display shows the LEFT, CENTER, and RIGHT weld schedule data
that is used on the left, center, and right sides of the weave.
5–55
DATA Weld Procedure

1/9
1 Weld Procedure 1 [ ]
[Rapid Arc GMAW-P # 18]
[.045 in Steel Ar CO2 ]
2 Weld Schedule 1 [Schedule ]

3 Ramp None
4 Heatwave mode None
Left Center Right

Wire feed 300.0 300.0 300.0 IPM
Trim 1.000 1.000 1.000
Wave Control 0.00 0.00 0.00
8 Travel speed 35.0 IPM

9 Delay Time 0.00 sec
[ TYPE ]SCHEDULE HELP >
5.6.7 Configuring the Weld Procedures Option
You configure ArcTool to use Weld Procedures by enabling it in the controlled start menu and then
doing a cold start.
Procedure 5-15 Configuring the Arc Weld Procedures Option
Conditions
• The Arc Weld Procedures option is installed.
Steps
1. Perform a Controlled start.

a. If the controller is on , turn it off.
c. While still pressing PREV and NEXT on the teach pendant, turn the power disconnect
circuit breaker to ON. You will see a screen similar to the following.
5–56
---------- CONFIGURATION MENU ----------

1 Hot start
2 Cold start
3 Controlled start
4 Maintenance
Select >
d. After the configuration menu appears on the screen, release the PREV and NEXT keys.
e. Select 3, Controlled start.
ArcTool Setup E1
1/11
1 F Number: F00000

5 Weld speed: 50

Press FCTN then START (COLD) when done.
[ TYPE ] CHECK HELP
f. When the Controlled start menu above appears, press MENUS and select 4, Variables.
Then cursor to the system variable $AWSCFG and press ENTER.
SYSTEM Variables
$AWSCFG 9/13
1 $LOOP_TIME 16
2 $TOT_ARC_EQ 1
3 $NUM_ARC_SCH 32
4 $GLOBAL_ER FALSE
5 $AWSTAT_NOTP FALSE
6 $MULTI_PROC TRUE
7 $WEAVE_SYNCH FALSE
8 $STITCH_ENA FALSE
9 $WLD_PRC_ENA TRUE
10 $INCH_W_SHFT TRUE
11 $WP_MAX_SCH 100
[ TYPE ] TRUE FALSE
g. Cursor to $WLD_PRC_ENA and use the function keys to enable (or disable) the feature.
5–57
2. When you are finished, press FCTN.

3. Select START (COLD). The controller will perform a Cold start. When it is finished, the
UTILITIES Hints screen is displayed.
Enabling Weld Procedures changes which arc data menus are displayed and how teach pendant
programs are edited and execute. The weld schedule data screen, the weld process data screen, and
the weld process setup screen are replaced by the weld procedure data screen. The Arc instructions
available for teaching in the teach pendant editor become Weld instructions. Existing programs
containing Arc Start and Arc End are not modified and they cannot execute welding. Attempting
to execute an Arc Start results in the error “ARC-061 Illegal instruction”. These programs can be
edited to use Weld instructions in place of the Arc instructions.
You can later re-configure ArcTool to not use Weld Procedures by disabling it at controlled start and
then doing a cold start. The menus will change again and the editor operation will also change.
Programs containing Weld Start and Weld End will not execute welding. Attempting to execute a
Weld Start results in the error “ARC-061 Illegal instruction”. These programs can be edited to use Arc
instructions in place of the Weld instructions.
5.7 WELD SCHEDULE DATA without WELD PROCEDURES
Note With Weld Procedures, the Weld Schedule Data menu is replaced by the Weld Procedure Data
menu. The documentation for weld schedule data is included for legacy support for users who do not
choose to use the benefits of Weld Procedures.
Arc welding uses weld schedules to control welding conditions. A schedule defines the information
that determines how the welding will be performed.
You can access weld schedules from the DATA menu. There are two screens associated with weld
schedules: the Weld Sched SCHEDULE screen and the Weld Sched DETAIL screen.
The Weld Sched SCHEDULE screen allows you to view and set limited information for multiple
schedules at once. DETAIL allows you to view and set the complete information for a single schedule.
You display the detail screen by pressing the function key F2, DETAIL. You return to the schedule
screen by pressing the F2, SCHEDULE, function key or by pressing PREV.
You can define up to 200 weld schedules (if the HeatWave option is loaded and enabled, the maximum
is 70). By default, 32 weld schedules are available.
If you want to change the number of available weld schedules, use Procedure 5-16 .
Note The information displayed on this screen will vary depending on your arc welding system setup.
Table 5–13 lists and describes each weld schedule item.
5–58
Use Procedure 5-17 to display and edit weld schedules. Use Procedure 5-18 to copy weld schedules.
Use Procedure 5-19 to clear weld schedule information. Refer to Section 5.14 for more information
on weld controller program select.
Table 5–13. Weld Schedule Items
weld Process Description
Weld schedule [number] [comment] These items show the number of the schedule for
which the information is currently being displayed and
the comment about the schedule.
Program select [number] [comment] (This item is These items show the number and name of the
entitled “Process Select when using Lincoln Electric weld controller program that is to be used with this
x55/R welding equipment schedule. You can change the Program select number
on this screen. You cannot change the comment.
When you change the number, the comment will
change to correspond to the comment defined in the
SETUP Weld Prog screen.
Command Voltage (Volts) This item is the voltage amount.
Command Current (Amps) This item is the amperage.
Command Wire Feed This item is the wire feed speed.
Trim (for Pulsed GMAW procedures) This item is a reference command for arc length in
pulsed GMAW.
Arc Control (for Lincoln PowerWave x55/R equipment) This item is a reference command for pulsed GMAW
procedures that affects arc stiffness.
Travel Speed This item is the speed at which the robot will move
during welding, in units defined on the SETUP Weld
System screen.
Delay Time This item is the amount of time to delay during crater
fill during Arc End. If the ramping option is installed
and enabled, Delay Time is the time it takes to change
from the current setting to a specified setting during
Arc Start.
Feedback Voltage This item indicates the feedback voltage of the last
weld.
Feedback Current This item indicates the feedback current of the last
weld.
Procedure 5-16 Defining the Number of Weld Schedules
Steps
1. Perform a Controlled start:
5–59
a. If the controller is on, turn it off.

c. While still pressing PREV and NEXT on the teach pendant, press the ON button on the
operator panel. You will see a screen similar to the following.
----------- CONFIGURATION MENU ----------

1 Hot start
2 Cold start
3 Controlled start
4 Maintenance Select >
d. Release all the keys.

e. Select Controlled start and press ENTER. You will see a screen similar to the following.
ARCTOOL SETUP CONTROLLED START MENUS

1 F number: F00000

5 Weld speed: 40

Press FCTN then START (COLD) when done
8 Multi-process: ENABLED
9 Number of weld schedules: 32
10 Number of weld equipment: 2
2. Move the cursor to Number of Weld Schedules.

3. Type a new number between 16 and 200 (between 16 and 70 if HeatWave is enabled).
4. Press FCTN.
5. Select START (COLD) and press ENTER.
After the Cold start has completed, the controller is ready to use. The number of schedules
available will match the number of schedules you defined in this procedure.
5–60
Procedure 5-17 Displaying and Editing Weld Schedules
Steps
1. Press DATA.
3. Select Weld Sched. You will see a screen similar to the following.
Note The screen you see will vary depending on the kind of weld equipment you are using.
DATA Weld Sched

Volts IPM IPM COMMENT
1 20.0 200.0 20.0
2 20.0 200.0 20.0
3 20.0 200.0 20.0
4 20.0 200.0 20.0
5 20.0 200.0 20.0
6 20.0 200.0 20.0
7 20.0 200.0 20.0
8 20.0 200.0 20.0
9 20.0 200.0 20.0
4. To edit a schedule, move the cursor to the item you want to change, type the new value,
and press ENTER.
5. To add a comment:
a. Move the cursor to the to the comment line and press ENTER.
b. Press the appropriate function keys to type the comment and press ENTER.
6. Press F2, DETAIL to display more information about a single schedule. See the following
screen for an example.
DATA Weld Sched

1 Weld Schedule: 1 [ Weld Schedule 1 ]
2 Program select: 1 [ Program 1 ]
3 Command Voltage 20.0 Volts
4 Command Wire feed 200.0 IPM
7. To display the schedule screen again , press F2, SCHEDULE, or press PREV.
5–61
Procedure 5-18 Copying Weld Schedules
Steps
1. Display the DATA Weld Sched screen. ( Procedure 5-17 , Step 1 through Step 3 )
2. Press NEXT, >.
3. Move the cursor to the schedule you want to copy.
4. Press F2, COPY.
5. Enter the schedule number to which you want to copy the data.
6. Press ENTER. The data will be copied, but the comment will not be copied.
Procedure 5-19 Clearing Weld Schedule Information
Steps
1. Display the DATA Weld Sched screen. ( Procedure 5-17 , Step 1 through Step 3 )
2. Move the cursor to the schedule you want to clear.
3. Press NEXT, >.
4. Press F3, CLEAR.
5. To continue, press F4, YES. Otherwise, press F5, NO.
If you press F4, YES, the data will be cleared, but the comment will remain.
5.8 WELD PROCESS DATA without WELD PROCEDURES
Note The Weld Process Data menu is not available with Weld Procedures. The following
documentation is intended for legacy support.
ArcTool provides four additional weld schedules that are dedicated to specific weld processes. They
are used for all welds if the features are enabled: If you are using Lincoln Electric PowerWave
x55/R welding equipment connected with ArcLink and you have enabled the Multi-Process feature,
there can be 32 additional weld schedules assigned in groups of four for each of the eight process
modes supported by this equipment.
• Runin - The Runin weld schedule controls the arc start characteristics. Refer to Section 5.3.7 .
• Burnback - The Burnback weld schedule controls the wire condition after an arc end or an error
shutdown. Refer to Section 5.3.7 .
• Wirestick - The Wirestick weld schedule is used to attempt to break a wirestick. Refer to
Section 5.3.2 .
5–62
• On-the-Fly - The parameters in the On-the-Fly weld schedule are used to increment and
decrement the weld parameters during welding. Refer to Section 5.3.7 and Section 11.3 .
Refer to Table 5–14 for a description of the items you will see on the schedules.
Table 5–14. Weld Process Data Items
Schedule item description
Command Voltage (Volts) This item indicates the voltage amount.
Command Current (Amps) This item indicates the amperage.
Command Wire Feed (IPM) This item indicates the wire feed speed.
Trim (Pulsed GMAW equipment) This item is a reference command for arc length in
Pulsed GMAW.
Arc Control (Lincoln Electric PowerWave x55/R This item is a reference command that affects arc
equipment only) stiffness.
Travel Speed This item defines the speed at which the robot will
move during welding, in units defined on the SETUP
Weld System screen .
Delay Time This item defines the amount of time the Runin,
Burnback, or Wirestick schedule is used. Delay time
has no meaning for On-the-fly.
Use Procedure 5-20 to display and edit weld process data.Use Procedure 5-21 to copy these
schedules.Use Procedure 5-22 to clear schedule information.
Procedure 5-20 Displaying and Editing Weld Process Data
Steps
1. Press DATA.
3. Select Weld Process.
Note The screen you see will vary depending on the kind of weld equipment you are using.
Note If you are using Lincoln Electric PowerWave x55/R weld equipment with the
Multi-Process feature enabled you will see eight sets of the following screens. Each set is
allocated to one of the eight process modes that are available with this equipment.
5–63
DATA Weld Process

Volts IPM IPM
1 20.0 200.0 0 Runin
2 20.0 0.0 0 Burnback
3 20.0 0.0 0 Wirestick
4 0.1 5.0 1 OnTheFly
4. To edit a schedule, move the cursor to the item you want to change, type the new value,
and press ENTER.
5. Press F2, DETAIL, to display more information about a single schedule. See the following
screen for an example.
DATA Weld Process

Schedule: 1 [Runin ]
6. To display the schedule screen again , press F2, SCHEDULE, or press PREV.
Procedure 5-21 Copying Schedules
Steps
1. Display the DATA Weld Process screen. ( Procedure 5-20 , Step 1 through Step 3 )
2. Press NEXT, >.
3. Move the cursor to the schedule you want to copy.
4. Press F2, COPY.
5. Enter the schedule number to which you want to copy the data.
6. Press ENTER. The data will be copied, but the comment will not be copied.
Procedure 5-22 Clearing Schedule Information
Steps
1. Display the DATA Weld Process screen. ( Procedure 5-20 , Step 1 through Step 3 )
2. Move the cursor to the schedule you want to clear.
3. Press NEXT, >.
5–64
4. Press F3, CLEAR.

5. To continue, press F4, YES. Otherwise, press F5, NO.
If you press F4, YES, the data will be cleared, but the comment will remain.
5.9 ARCTOOL RAMPING WITH WELD PROCEDURES
5.9.1 Overview
ArcTool Ramping function gradually increases or decreases the parameters in a program at a specified
rate. This function includes the following three functions.
- Weld Parameter Ramping
- Speed Ramping
- Weave Ramping
This function is an ArcTool standard function, and this is enabled by default
Warning
This function is not performed during gas purge, runin, burnback, or

wire stick reset
5.9.2 Weld Parameter Ramping
The weld parameter ramping allows you to gradually increase or decrease a welding parameter
(Voltage, Current, etc) in specified section. It is possible to increase / decrease a welding parameter
smoothly. As this weld parameter ramping, there are following modes.
• Time Ramping
• Position Ramping
• Hold Ramping
• Constant Deposition (Refer to Chapter 14 ARC CONSTANT DEPOSITION )
Additionally, you can increase or decrease multiple commands simultaneously.
Please refer to following figure that shows the overview of weld parameter ramping, weld parameter
command is shown in the following chart based on this TP program and weld procedure
5–65

1/10
 Procedure 1 [ ]
- Schedules
Schedule # Volts Amps Speed Time Ramp
Runin 25.0 200.0 1.00
Schedule 1 30.0 260.0 100.0 2.00 Time
Schedule 2 20.0 140.0 70.0 0.00 Posn
Schedule 3 17.0 100.0 0.0 1.00 Time
Burnback 20.0 0.0 0.10
Wirestick 20.0 0.0 0.10
MAIN1
1/6
1: J P[1] 50% FINE
2: L P[2] 100mm/sec FINE
: Weld Start[1,1]
3: L P[3] WELD_SPEED CNT100
: Weld Start[1,2]
4: L P[4] WELD_SPEED FINE
: Weld End[1,3]
5: J P[1] 100% FINE
[END]
Figure 5–11. Sample program of Weld Parameter Ramping
Time Ramping
In Time Ramping, you specify the ramping time(sec) in weld schedules. The command values
increase or decrease from the previous command(this is weld parameter commands before changing)
5–66
to current command(this is weld parameter commands after changing) during the delay time set into
weld start instruction(Please refer to “A” in the Fig. 9.2(a)).
Position Ramping
In Position Ramping, the command values increase or decrease from the previous command(this is
weld parameter commands before changing) to current command(this is weld parameter commands
after changing) till reaching the next taught position after the weld start instruction(Please refer to
“B” in the Fig. 9.2(a)).
Hold Ramping
Hold Ramping is basically the same as Time Ramping(That is, the command values increase or
decrease from the previous command to current command during the delay time set into weld start
instruction). Please refer to following figure about the difference. Hold Ramping is used in the
case of first weld start instruction only.
Figure 5–12. Robot Operation at the Beginning of Welding
Ramping At the first Weld Start(use “Time” or “Hold” ramping)
In the first weld start instruction (not for changing weld schedules), the ramping is decided whether
it is executed or not by the setting of runin enable/disable. If Runin is enabled and the ramping is
set to “Time” or “Hold” in the weld schedule that is used by the first weld start instruction, arc
welding starts with runin schedule that is set in specified weld procedure number. After runin finishes,
command values gradually increase or decrease to the weld schedule that is taught by the first weld
5–67
start instruction. If runin is disabled, arc welding starts with weld schedule that is taught by the first
weld start instruction. So the ramping is not executed at the first weld start.
Figure 5–13. Ramping at the First Weld Start
Ramping At the Weld End(use “Time” ramping)
In the crater fill of weld end instruction, it is possible to setup the ramping whether it is executed or
not. If the ramping is set to “Time” in the weld schedule that is used by the weld end instruction,
command values gradually increase or decrease to the weld schedule (crater fill schedule) that is
taught by weld end instruction.
Weld Parameter Ramping is not performed during wire stick reset.
Figure 5–14. Ramping during Crater Fill
5–68
Procedure 5-23 How to Enable Weld Parameter Ramping

1. Press Menu.
2. Select [DATA].
4. Selects the appropriate Weld Procedure
5. Move the cursor to Procedure and press the ENTER key. Move the cursor to RAMPING and
change it to enabled.

1/14
- Procedure 1[ ]
Weld equipment: 1
Manufacturer: General Purpose
Model: MIG(Volts, Amps)
File name: AWE1WP01
Schedules: 3
Runin: DISABLED
Burnback: ENABLED
Ramping: DISABLED
Gas purge: 0.35 sec
Gas preflow: 0.00 sec
Gas postflow: 0.00 sec
[ TYPE ] DETAIL [CMND] [VIEW] HELP
If the setting item of [Ramping] is not displayed, please repower after changing following
system variables to TRUE.
• $AWERAMP[ i ].$RAMP_ENABLE ( “i” is the equipment number) Enable or disable of

Weld Parameter Ramping.
• $AWERAMP[ i ].$RMP_TO_POS Enable or disable of Position ramping.
Note
1. If $RAMP_ENABLE is FALSE, Weld Parameter ramping does not work even if

$RMP_TO_POS is TRUE. If you change those system variables, please repower the
robot controller.
2. Speed Ramping is always TRUE regardless of these system variables.
6. Move the cursor to [Schedules] and press ENTER key. Following screen is displayed.
5–69

1/10
+ Procedure 1 [ ]
- Schedules
Schedule # Volts Amps Speed Time Ramp
Runin 25.0 200.0 1.00
Schedule 1 30.0 260.0 100.0 2.00 None
Schedule 2 20.0 140.0 70.0 0.00 None
Schedule 3 17.0 100.0 0.0 1.00 None
Burnback 20.0 0.0 0.10
Wirestick 20.0 0.0 0.10
[ TYPE ] DETAIL [CMND] [VIEW] HELP
7. When you move the cursor to “Ramp” of weld schedule number that is used by weld start
instruction and press the F4[CHOICE], following menu is displayed. Please select the desired
mode. If “Time” or “Hold” are selected, please set the ramping time(This setting can be also
executed in the weld schedule detailed screen). The “CDep” choice is described in .
1 None
2 Posn
3 Time
4 Hold
5 CDep
6
7
8
8. Teach the weld start instruction in the program edit screen and specify the weld schedule number
that is set to weld parameter ramping.
Ramping starts before previous Ramping finishes
If Time Ramping is used, there is a possibility that the next weld start instruction is executed while the
command values gradually increase or decrease(before arriving at the weld schedule of weld start
instruction that is performed now). In this case, current ramping is interrupted. For the next motion,
command values will change depending on the following cases.
• Weld parameter ramping is specified in the next weld start instruction The command value is
gradually changed from the value during ramping command last values to the value of the next
weld start instruction.
• Weld parameter ramping is not specified in the next weld start instruction The command value is
immediately changed to the value of the next weld start instruction.
5–70
• A user can create the program using this characteristic. To avoid the interruption of ramping,
please allow sufficient time before the next motion instruction, or use the position ramping.
Or please use the wait instruction.
5.9.3 Speed Rampint
In the Speed Ramping, it is possible to increase or decrease the robot motion speed gradually while
the robot moves from the starting position to the destination position.
Figure 5–15. Speed Ramping
Note This function does not support ’A’ type motion instructions.
Procedure 5-24 Speed Ramping Programming

1. Within the program editor, enter the starting speed for ramping.
MAIN1
1/3
1: J P[1] 100% FINE
[END]
[INST] [EDCMD] >
2. Move the cursor to the end of the motion instruction on line number 2.
3. Press F4[CHOICE] and select [RampTo] from the menu.
5–71
Motion Modify 3
1 Offset/Frames
2 PSPD
3 Offset,PR[]
4 Incremental
5 RampTo
6 RampTo R[]
7 Tool_Offset
8 –next page--
4. [RampTo (…)] is added to motion instruction. Input the speed value you want to reach finally
(destination speed). The speed unit of RampTo becomes the same as the speed unit of the
motion instruction.
MAIN1
2/3
1: J P[1] 100% FINE
: RampTo (…)
[END]
ENTER Pamp Speed.
s [INST] [EDCMD] >
Speed ramping uses the same speed unit specified in the motion instruction. In the example above, the
ramp function uses the mm/sec as its end speed units. The maximum allowed speed is 500mm/sec or
1181 inch/min. If the ramp speed exceeds 500 mm/sec, the controller will generate a warning error
message and the ramp is not applied.
The speed ramp function only supports three types of speed units: mm/sec, cm/min and inch/min. If
an incorrect speed unit is specified in the motion instruction (sec, msec, deg/sec), the speed ramp
function will post a warning error and the ramp is not applied.
Speed ramping can be used with WELD_SPEED, register, and register-indirect speed specifications.
5.9.4 Weave Ramping
You can use the weave ramping function to change the weave frequency and weave amplitude on each
motion instruction. The weave motion will start with one set of frequency and amplitude (start weave
parameters) and end with another set of weave frequency and amplitude (end weave parameters).
The intermediate weave points use the interpolated frequency and amplitude of the start weave
parameters and the end weave parameters. The following figure depicts a sine weave motion with
ramping of weave amplitude and weave frequency.
5–72
Figure 5–16. Weave Amplitude and Frequency Ramp
5.9.4.1 Programming Weave Ramping
You can specify weave ramping through motion option menu. Select WV[] from the menu, and the
motion line will show
2:L P[2] 100mm/sec Fine WV[…]
Type the weave schedule number and press ENTER to complete the editing. The weave ramping
instruction requires a preceding Weave pattern instruction. If the weave ramping instruction is
executed while not weaving a warning error will occur and the ramp will not be applied.
Once weave ramping is completed, the weave amplitude and weave frequency will remain constant
until the next weave instruction or another weave ramp instruction is executed. For example, when
this program is run
1:J P[1] 100% Fine

2:Weave Sine[1]
3:L P[2] 20mm/sec CNT100 WV[2]
4:L P[4] 20mm/sec CNT100
the weave motion on line 4 uses the weave amplitude and weave frequency that are specified in
weave schedule 2.
5.9.5 When to Ramp
Use the following guidelines to determine when and how to ramp welding parameter values:
5–73
At the Start of a Weld
• When runin is enabled, ramping on the initial Arc Start of a weld begins at the runin weld
parameters and ends at the programmed weld schedule values. If runin is disabled, ramping has
no effect on the initial Arc Start. The initial values are equal to the final values, so there is no need
to ramp. Subsequent weld schedule changes in the weld can use ramping.
• Ramping can be executed simultaneously with robot motion, or prior to robot motion. The
system variable, $AWERAMP.$RAMP_HOLD, enables and disables holding program and
motion execution during the first Arc Start ramp.
In the Middle of a Weld
• Ramps can be performed at each weld schedule change, if desired. Unlike the initial Arc Start, a
weld schedule change does not hold program or motion execution. Motion and program execution
continue normally regardless of ramping. To stop motion in the middle of a weld ramp is normally
not desirable. If you want to do this, add a WAIT instruction to the program.
• Since motion and program execution is not held during a weld schedule change ramp, it is
possible for a timed ramp to be terminated by another weld schedule change before the ramp has
completed. There is no harm in this, and it might be desirable in some applications. If you want to
prevent terminating a ramp early, make sure adequate time is provided in the subsequent motion
instruction or WAIT instruction or use the ramp to a position technique.
At the End of a Weld
• To downramp at the end of a weld while moving, use an Arc Start with reduced weld parameter
values.
• To downramp at the end of a weld while not moving, use an Arc End with reduced weld
parameter values.. The time specified in the Arc End schedule controls the craterfill time and
will ramp if $ramp_crater = TRUE.
5.9.6 Resuming after a Fault
Welding can be resumed after a fault occurs. If runin is enabled, the runin values are used to start
the arc. After runin completes, the weld schedule in progress at the time of the fault is begun. If
that weld schedule specifies ramping, ramping will during the resume. Control of program and
motion execution during resume is similar to the initial Arc Start of a weld meaning the variable
$RAMP_HOLD will apply at the resume position.
The values of the weld parameters after runin are either the original weld schedule values or the
values of the ramp at the time of the pause. There are two system variables for this purpose. One
variable is for timed ramps and the other is for position-based ramps.
$AWERAMP[n].$TIM_RMP_RSM If TRUE, timed ramps resume at paused values. If FALSE,

timed ramps resume from the runin values.
5–74
$AWERAMP[n].$POS_RMP_RSM If TRUE, position based ramps resume at paused values. If

FALSE, position-based ramps resume from the runin values.
The following graph is an example of resuming a position-based ramp with $POS_RMP_RSM =

TRUE. The arc starts on resume with the runin values, and then after the runin time expires, the ramp
transitions to the value of the parameter at the time of the pause error. The ramp continues from this
value to the programmed value during the remainder of the move.
Figure 5–17. Resuming a Position-Based Ramp with $POS_RMP_RSM = TRUE.

FALSE. The arc starts on resume with the runin values, and then after the runin time expires, the ramp
continues from this value to the programmed value during the remainder of the move.
5–75
Figure 5–18. Resuming a Position-Based Ramp with $POS_RMP_RSM = FALSE
5.9.6.1 Speed Ramp Resume After a Fault
When original path resume is set to true, the robot will move back to the point on the path when it was
paused and resume with the same speed when it was paused. It will reach the destination position with
the specified ramp to speed.
When original path resume is set to false, the robot will move from the current position to the
destination position with the speed before paused and reach the destination position with the specified
ramp to speed.
5.9.6.2 Weave Ramp Resume After a Fault
After the motion is resumed, the weave will resume its frequency and amplitude before the fault, and
complete the motion with the specified weave frequency and amplitude.
5–76
5.9.7 On-the-Fly
The on-the-fly utility is temporarily disabled during a ramp. When parameters are ramped, the
on-the-fly screen will show the command values changing. If you use the increment or decrement
function keys, a warning message will be displayed. Refer to Section 11.3.6 for more information on
the on-the-fly utility.
5.9.8 Thru-Arc Seam Tracking
Thru-arc seam tracking will not function properly if you program a weld parameter ramp during
tracking. It is recommended that you use ramping only in the non-tracking portions of a weld. You
can turn off tracking during the ramp and then turn it on again with a new and appropriate tracking
schedule. Refer to Chapter 20 THRU ARC SEAM TRACKING (also known as TAST MULTIPATH
PACK) for more information on thru-arc seam tracking.
5.10 ARCTOOL RAMPING WITHOUT WELD PROCEDURES
5.10.1 Overview
ArcTool ramping includes three related ramping features:
1. weld parameter ramping,

2. speed ramping, and
3. weave ramping.
You can use these features individually or you can combine them.
5.10.1.1 Weld Parameter Ramping Overview
The weld parameter ramping option allows you to gradually increase or decrease a welding parameter
• over a specified period of time or

• during a specific motion.
With this option, you can program welds that have one or more ramps. The ArcTool software will
steadily increase or decrease the command weld parameters either over the time or the motion you
specify. The result is smooth transitions of arc welding parameters from one value to another.
5–77
The welding parameter ramping option allows you to ramp all of the weld schedule command signals.
You can choose to increase or decrease a parameter or leave it constant.
There is no menu for setup of the weld parameter ramping option. Ramping is controlled with system
variables.
• $AWERAMP[n].$RAMP_ENABLE enables and disables ramping.

• $AWERAMP[n].$RAMP_CRATER enables and disables ramping during the craterfill time
of an Arc End.
• $AWERAMP[n].$RMP_TO_POS enables and disables ramping to a position.
$RAMP_ENABLE overrides $RAMP_CRATER and $RMP_TO_POS. You must cycle controller

power after changing $RAMP_ENABLE for the Arc Start VALUE format instructions to display the
time field.
Note Ramping is not performed during gas, purge, runin, burnback, or wirestick reset.
Figure 5–19. Ramping Example using Data Monitor Chart
The graph above is a screen capture of a Data Monitor Chart display. The data was captured during
the execution of the program below.
1: Sample Start[1]
2:J P[1] 50% FINE
5–78
3:J P[2] 20% FINE

: Arc Start E1[25.0Volts,250.0IPM,1.0s]
4:L P[3] 50.0inch/min CNT100
: Arc Start E1[30.0Volts,300.0IPM,99.0s]
5:L P[4] 50.0inch/min FINE
: Arc End E1[25.0Volts,250.0IPM,0.5s]
6:J P[1] 100% FINE
7: Sample End
The top two lines in the graph are weld parameters. The third and fourth lines are the program line
number and the robot move distance, respectively.
The first ramp is a time-based ramp that lasts for one second. It completes before the motion on line 4
completes. The second ramp is position-based and last the same time as the move to P[4] on line 5.
The third ramp is during the Arc End craterfill time.
5.10.1.2 Speed Ramping Overview
You can use the speed ramping function to specify a motion based on smooth speed change throughout
the motion segment (instead of constant speed) from the starting position to the destination position.
The following program has speed ramping specified on line 3.
1:J P[1] 100% FINE

2: Sample Start[2]
3:L P[2] 100mm/sec FINE RampTo(200)
4: Sample End
The motion on line three starts with a speed of 100mm/sec. As the robot approaches P[2], the speed
gradually increases to around 200 mm/sec.
Figure 5–20. Robot Speed Profile with Ramping
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Without the RampTo instruction on line 3 the speed is 100 mm/sec.
1:J P[1] 100% FINE

2: Sample Start[2]
3:L P[2] 100mm/sec FINE
4: Sample End
Figure 5–21. Robot Speed Profile without Ramping
Limitations on the speed ramping function:
• For short distance motion (time to complete the motion is shorter than the time it required to
accelerate/decelerate to the specified speed). The controller will post a warning message without
applying the speed ramp.
• When the motion is orientation dominated, the controller will post a warning error message and
the speed ramping is not applied.
• Speed is not ramped during backward motions.
• Speed is not ramped in dry run mode.
5.10.1.3 Weave Ramping Overview
You can use the weave ramping function to change the weave frequency and weave amplitude on each
motion instruction. The weave motion will start with one set of frequency and amplitude (start weave
parameters) and end with another set of weave frequency and amplitude (end weave parameters).
The intermediate weave points use the interpolated frequency and amplitude of the start weave
parameters and the end weave parameters.
Figure 5–22 depicts a sine weave motion with ramping of weave amplitude and weave frequency.
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Figure 5–22. Weave Amplitude and Frequency Ramp
Limitations of the weave ramping function:
• Weave ramping does not support backward motion.

• Weave ramping option is not compatible with adaptive weave option.
• Weave ramping only partially supports TAST (Through Arc Seam Tracking). It supports
amplitude ramping, but does not support ramping of the weave frequency.
5.10.2 Programming Ramping
5.10.2.1 Programming Weld Parameter Ramping
You program ramping by specifying a ramping time value in a weld schedule.
1 Weld Schedule: 2 [****************]

2 Voltage 30.00 Volts
3 Wire feed 300.0 IPM
You can also specify the ramp time in an Arc Start or an Arc End instruction:
3:J P[2] 100% FINE

: Arc Start [22.0Volts,250.0IPM,1.0s]
There are two weld parameter ramping techniques:
• Ramp over time: the weld parameters ramp for a specified time.
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• Ramp to a position: the weld parameters ramp during a motion to a position.
Which technique is used depends on the time value you specify. Most time values will result in
ramping over the specified time. The exception is 99 seconds. Position-based ramping is programmed
by specifying the time value as 99.0 seconds. The 99 seconds indicates that the ramp is as long
as the motion (not 99 seconds). It is important to understand that the ramp motion is the motion
AFTER the Arc Start.
You can specify ramping in any Arc Start of a weld; the initial Arc Start or any weld schedule change.
Runin must be enabled for the initial Arc Start to have a starting value for the ramp.
You can specify ramping during an Arc End. The time used in an Arc End weld schedule is called
the craterfill time. Ramping can occur during this time if $AWERAMP[n].$RAMP_CRATER =
TRUE. There is no motion during a craterfill ramp.
5.10.2.2 Programming Speed Ramping
You can specify speed ramping through the motion option menu, select RampTo from the menu, and
the motion line will show:
2:L P[2] 100mm/sec Fine RampTo(…)
Type in the speed and press the ENTER key to complete the editing.
Speed ramping uses the same speed unit specified in the motion instruction. In the example above, the
ramp function uses the mm/sec as its end speed units. The maximum allowed speed is 500mm/sec or
1181 inch/min. If the ramp speed exceeds 500 mm/sec, the controller will generate a warning error
message and the ramp is not applied.
The speed ramp function only supports three types of speed units: mm/sec, cm/min and inch/min. If
an incorrect speed unit is specified in the motion instruction (sec, msec, deg/sec), the speed ramp
function will post a warning error and the ramp is not applied.
Speed ramping can be used with WELD_SPEED, register, and register-indirect speed specifications.
5.10.2.3 Programming Weave Ramping
You can specify weave ramping through motion option menu. Select WV[] from the menu, and the
motion line will show
2:L P[2] 100mm/sec Fine WV[…]
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Type the weave schedule number and press ENTER to complete the editing. The weave ramping
instruction requires a preceding Weave pattern instruction. If the weave ramping instruction is
executed while not weaving a warning error will occur and the ramp will not be applied.
Once weave ramping is completed, the weave amplitude and weave frequency will remain constant
until the next weave instruction or another weave ramp instruction is executed. For example, when
this program is run
1:J P[1] 100% Fine

2:Weave Sine[1]
4:L P[4] 20mm/sec CNT100
the weave motion on line 4 uses the weave amplitude and weave frequency that are specified in
weave schedule 2.
5.10.3 When to Ramp
Use the following guidelines to determine when and how to ramp welding parameter values:
At the Start of a Weld
• When runin is enabled, ramping on the initial Arc Start of a weld begins at the runin weld
parameters and ends at the programmed weld schedule values. If runin is disabled, ramping has
no effect on the initial Arc Start. The initial values are equal to the final values, so there is no need
to ramp. Subsequent weld schedule changes in the weld can use ramping.
• Ramping can be executed simultaneously with robot motion, or prior to robot motion. The
system variable, $AWERAMP.$RAMP_HOLD, enables and disables holding program and
motion execution during the first Arc Start ramp.
In the Middle of a Weld
• Ramps can be performed at each weld schedule change, if desired. Unlike the initial Arc Start, a
weld schedule change does not hold program or motion execution. Motion and program execution
continue normally regardless of ramping. To stop motion in the middle of a weld ramp is normally
not desirable. If you want to do this, add a WAIT instruction to the program.
• Since motion and program execution is not held during a weld schedule change ramp, it is
possible for a timed ramp to be terminated by another weld schedule change before the ramp has
completed. There is no harm in this, and it might be desirable in some applications. If you want to
prevent terminating a ramp early, make sure adequate time is provided in the subsequent motion
instruction or WAIT instruction or use the ramp to a position technique.
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At the End of a Weld
• To downramp at the end of a weld while moving, use an Arc Start with reduced weld parameter
values.
• To downramp at the end of a weld while not moving, use an Arc End with reduced weld
parameter values.. The time specified in the Arc End schedule controls the craterfill time and
will ramp if $ramp_crater = TRUE.
5.10.4 Resuming after a Fault
Welding can be resumed after a fault occurs. If runin is enabled, the runin values are used to start
the arc. After runin completes, the weld schedule in progress at the time of the fault is begun. If
that weld schedule specifies ramping, ramping will during the resume. Control of program and
motion execution during resume is similar to the initial Arc Start of a weld meaning the variable
$RAMP_HOLD will apply at the resume position.
The values of the weld parameters after runin are either the original weld schedule values or the
values of the ramp at the time of the pause. There are two system variables for this purpose. One
variable is for timed ramps and the other is for position-based ramps.
$AWERAMP[n].$TIM_RMP_RSM If TRUE, timed ramps resume at paused values. If FALSE,

timed ramps resume from the runin values.
$AWERAMP[n].$POS_RMP_RSM If TRUE, position based ramps resume at paused values. If

FALSE, position-based ramps resume from the runin values.

TRUE. The arc starts on resume with the runin values, and then after the runin time expires, the ramp
transitions to the value of the parameter at the time of the pause error. The ramp continues from this
value to the programmed value during the remainder of the move.
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Figure 5–23. Resuming a Position-Based Ramp with $POS_RMP_RSM = TRUE.

FALSE. The arc starts on resume with the runin values, and then after the runin time expires, the ramp
continues from this value to the programmed value during the remainder of the move.
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Figure 5–24. Resuming a Position-Based Ramp with $POS_RMP_RSM = FALSE
5.10.4.1 Speed Ramp Resume After a Fault
When original path resume is set to true, the robot will move back to the point on the path when it was
paused and resume with the same speed when it was paused. It will reach the destination position with
the specified ramp to speed.
When original path resume is set to false, the robot will move from the current position to the
destination position with the speed before paused and reach the destination position with the specified
ramp to speed.
5.10.4.2 Weave Ramp Resume After a Fault
After the motion is resumed, the weave will resume its frequency and amplitude before the fault, and
complete the motion with the specified weave frequency and amplitude.
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5.10.5 On-the-Fly
The on-the-fly utility is temporarily disabled during a ramp. When parameters are ramped, the
on-the-fly screen will show the command values changing. If you use the increment or decrement
function keys, a warning message will be displayed. Refer to Section 11.3.6 for more information on
the on-the-fly utility.
5.10.6 Thru-Arc Seam Tracking
Thru-arc seam tracking will not function properly if you program a weld parameter ramp during
tracking. It is recommended that you use ramping only in the non-tracking portions of a weld. You
can turn off tracking during the ramp and then turn it on again with a new and appropriate tracking
schedule. Refer to Chapter 20 THRU ARC SEAM TRACKING (also known as TAST MULTIPATH
PACK) for more information on thru-arc seam tracking.
5.11 WEAVING
5.11.1 Overview
This section contains information on the following:
• Weave setup - Section 5.11.2

• Wrist axis weaving (option) - Section 5.11.3
• Weave schedules - Section 5.11.4
• Weaving on Multi-robot systems - Section 5.11.5
Weaving motion is performed between Weave Start and Weave End instructions. Once weaving
motion is started by Weave Start instruction, weaving motion is continued up to the execution
of Weave End instruction.
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Figure 5–25. Weaving Example
The weaving instructions includes:
-Weave (pattern) [i] instruction
-Weave (pattern) [Hz, mm, sec, sec] instruction
-Weave End instruction
-Weave End [i] instruction
To chose the proper weave instruction, Select F1 [INST] to display the related submenu, then select
[Weave] from the submenu.
5.11.2 Weave Setup
Weave Setup allows you to adjust the parameters that control weaving. For most applications, the
default settings should be fine and there is no reason to change them.
Figure 5–26 shows an example of the SETUP Weave screen. Table 5–15 lists and describes each
weave setup condition. The default weave settings described can be used for most applications.
Examples of weaving are also shown in Table 5–15 .
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Figure 5–26. SETUP Weave Screen
SETUP Weave
NAME VALUE
1 Weave Enable Group Mask [1,*,*,*,*,*,*,*]
2 Dwell delay type: Move
3 Frame type: Tool&Path
4 Elevation: 0 deg
5 Azimuth: 0 deg
6 Center rise: 0.0 mm
7 Radius: 0.0 mm
8 Blend weave end: YES
9 Robot Group: 1
10 Peak output port DO: 0
11 Peak output pulse: .10 sec
12 Peak output shift: 0.00 sec
Power OFF then ON to enable changes.
Table 5–15. Weave Setup Items
item Description
Weave enable group This item enables weaving on multi-group systems. Only robot motion groups can
mask be enabled to weave. If there are multiple robots in your system, the weave enable
group mask will be automatically set for each robot group during installation.
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Table 5–15. Weave Setup Items (Cont’d)
item Description
Dwell delay type This item allows the arc welding system to use either a stop dwell delay or a move
dwell delay. Dwell delay increases weld penetration at the joint sidewalls during
weaving. The stop dwell delay causes the robot to cease all motion at the weave
peak for the length of time specified by the weave schedule. Note that Stop Dwell
Delay is supported for Multi-group Coordinated motion, but it is not supported for
Multi-group non-Coordinated motion.
The move dwell delay causes the robot to cease lateral motion but continue forward
motion at the weave peak for the length of time specified by the weave schedule.
DWELL DELAY STOP

Direction of robot travel
Peak
Peak Direction of weave

DWELL DELAY MOVE
Direction of robot travel
Peak
This time is controlled by the weave

schedule R_DW (right delay) and Peak
L_DW (left delay) parameters Direction of weave
5–90
item Description
Frame type This item allows you to set the reference frame that the arc welding system uses to
define the weave frame. Weaving always uses the TOOL frame as its reference
frame. However, you can choose to use the tool data or the tool&path data.
The tool&path is the most commonly used reference frame. This reference frame is
especially helpful when weaving around a corner, because the weave stays parallel
to the y-vector of the tool. Tool&path uses x defined by the path motion and z defined
by the tool frame. y is perpendicular to both x and z.
Use of the tool as a reference frame is important for welding with simultaneous table
motion that requires the weave to be relative to the moving part. For example, if you
are welding a cylindrical part that is rotating, your weld is actually a spiral. In this
case, you do not want to use the path of the robot to weld, because you want the
weld to follow the surface of the part. Tool uses the x, y, and z defined by the tool.
+Z +Y
+X
+Z
+Y
+X
Elevation This item allows you to change the angle of the y component of the weave vector with
respect to the weave frame xy-plane. This allows you to change the weaving plane
without changing tool orientation about the x-axis. For example, setting elevation to
90 wil cause the weave motion in the tool Z direction (up and down).
0 +Y
+X
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item Description
Azimuth This item allows you to enter the angle between the y component of a weave vector
and the weave frame y-axis. This allows you to change the angle of the weave if you
cannot rotate the tool. This changes the y alignment relative to x.
+Y
0
+X
Center Rise This item allows you to specify the distance, in millimeters, that the weave vector
will raise above the plane of the weave.
Radius This item allows you to specify the weaving distance for circular weaving. Radius
provides a means to elongate the circle. Radius is only valid for circular weaving. If
the radius is set to zero, the arc welding system uses amplitude only to specify the
weaving distance. This results in a more rounded circle.
Blend weave end This item allows you to set whether the weave between segments of the weld (taught
positions) is smooth. If set to ON, the weave maintains a regular pattern from the
weave start to the weave end and can not pass through every taught point. The OFF
setting would be typically used for weaving around sharp corners.
BLENDING = ON
WEAVE START
WEAVE END
P0 P 1 P2 P3
BLENDING = OFF
WEAVE START
WEAVE END
P0 P 1 P2 P3
Robot group This item allows you to select the robot group whose peak output parameters can
be displayed and configured.
Peak output port DO This item allows you to assign a digital output signal. If assigned, a digital output
signal will be sent to the weld interface and power supply at each weave peak. For
multi-group weaving, a separate port DO can be assigned for each group.
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item Description
Peak output pulse This item allows you to set the pulse length, in seconds, of the peak output port DO
signal. For multi-group weaving, a separate peak output pulse can be assigned
for each group.
Peak output shift This item allows you to shift forward, in seconds, the peak output port DO. You might
need to shift forward the signal due to robot deceleration. For multi-group weaving, a
separate peak output shift time can be assigned for each group.
Use Procedure 5-25 to set up weaving.
Procedure 5-25 Setting Up Weaving
Steps
1. Press MENU.
2. Select SETUP.
3. If the Weave screen is not displayed, press F1, [TYPE].
4. Select Weave. You will see a screen similar to the following.
SETUP Weave
NAME VALUE
1 Weave Enable Group Mask [1,*,*,*,*,*,*,*]
4 Elevation: 0 deg
5 Azimuth: 0 deg
7 Radius: 0.0 mm
9 Robot Group: 1
5. Move the cursor to the selection you want to change and enter the new value.
Note Figure 5–26 shows the screen for a single group system. When additional groups are
setup, the selectable item number increases to include items for those groups. Weaving can only
be used on robot groups.
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5.11.3 Wrist Axis Weaving (option)
Wrist axis weaving is an option you can use that provides greater weaving frequency. The performance
of wrist axis weaving depends on proper torch and configuration settings. The weave plane that is
generated when using wrist axis weaving is limited because the weaving motion is generated only in
axes 4 and 5. As such some arm configurations will result in weave azimuth and elevation angles that
are unusable for welding. In general, wrist axis weaving can be used when the weld path is oriented
parallel to either the robot world x or y axes.
To use wrist axis weaving, you must
• Enable wrist axis weaving.

• Set the tolerance angle.
You do this by setting wrist axis weaving system variables.
Enabling Wrist Axis Weaving $WVWRIST.$WRIST_ENB
$WVWRIST.$WRIST_ENB enables wrist axis weaving. The default value is FALSE. Set this to
TRUE to enable wrist axis weaving.
Setting the Tolerance Angle$WVWRIST.$RUN_ANG$WVWRIST.$TOL_ANG
$WVWRIST.$RUN_ANG returns the actual angle between the TOOL Z-X plane and the TOOL
Z-PATH during execution, as shown in Figure 5–27 . This variable is updated dynamically.
• $RUN_ANG will be the same for all paths executed in a fixed TOOL Z-PATH plane.
• The best weave pattern occurs when $RUN_ANG is less than 10°.
• Decreasing $RUN_ANG can be achieved by reteaching path points by moving to the existing
points, and then rotating about TOOL Z to change the wrist orientation.
$WVWRIST.$TOL_ANG allows you to specify the upper limit for $RUN_ANG. The default
value is 10°. When $RUN_ANG reaches its limit value, the robot will stop executing and display
the error message, "run_ang exceeds tol_ang."
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Figure 5–27. $RUN_ANG
+Z TOOL Z-X plane

+Y
TOOL Z-PATH plane
$RUN_ANG
+X
Path
Using Wrist Axis Weaving
The highest weaving frequency can be achieved by using a SIN 2[] weaving pattern.
Wrist axis weaving uses the same teach pendant program weave instructions.
Wrist axis weaving supports all weaving functions except
• Wrist weaving does not support coordinated motion.

• Wrist weaving does not support the center rise function.
• Wrist axis weaving is not supported on DualARM systems.
• Wrist axis weaving is not supported on MIG EYE or Servo Robot tracking.
5.11.4 Weave Schedules
Weave Schedules allow you to define a set of weave parameters to use during welding.
You can access weave schedules from the DATA menu. There are two screens associated with weave
schedules: the Weave Sched table screen and the Weave Sched detail screen.
Use Procedure 5-26 to define weave schedules.
Weave Schedule Table Screen
The DATA Weave Sched table screen allows you to view limited information for nine schedules at
once. See Figure 5–28 for an example of this screen and Table 5–16 for a description of each item on
the screen.
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Figure 5–28. DATA Weave Sched Table Screen
DATA Weave Sched

1/10
FREQ(Hz) AMP(mm) R_DW(sec) L_DW(sec)
1 1.0 4.0 .100 .100
2 1.0 4.0 .100 .100
3 1.0 4.0 .100 .100
4 1.0 4.0 .100 .100
5 1.0 4.0 .100 .100
6 1.0 4.0 .100 .100
7 1.0 4.0 .100 .100
8 1.0 4.0 .100 .100
9 1.0 4.0 .100 .100
Table 5–16. Weave Schedule Items
item description
FREQ( Hz) This item defines the frequency of the weave in cycles per second.
AMP (mm) This item defines the distance from the centerline of the weave
pattern to either peak.
R_DW (sec) This item defines the amount of time the robot delays at the right
side of the weld.
L_DW (sec) This item defines the amount of time the robot delays at the left
side of the weld.
Table 5–17. DATA Weave Sched Screen Items
ITEM DESCRIPTION
Schedule # This item is the schedule number.
FREQ This item defines the frequency of the weave in cycles per second.
Units: Hz
AMP This item defines the distance from the centerline of the weave pattern to either peak.
Units: mm
R_DW This item defines the amount of time the robot delays at the right side of the weld.
Units: sec
L_DW This item defines the amount of time the robot delays at the left side of the weld.
Units: sec
5–96
Weave Schedule Detail Screen
The DATA Weave Sched detail screen allows you to view complete information for a single weave
schedule. See Figure 5–29 for an example of this screen and Table 5–18 for a description of each
item on the screen.
Figure 5–29. DATA Weave Schedule DETAIL Screen
DATA Weave Sched

1/4
Weave Schedule: 1
1 Frequency: 1.0 Hz
2 Amplitude: 4.0 mm
3 Right dwell: .100 sec
4 Left dwell: .100 sec
5 L pattern angle: 90.0 deg
6 Robot Group Mask: [1,*,*,*,*,*,*,*]
Table 5–18. Weave Schedule DETAIL Display
item description
Frequency This item specifies the weave frequency in cycles per second. The
valid range of frequency is from 0.1 to 10 Hz. For conventional
6-Axis weaving and 0.1 to 30 Hz for Wrist Axis Weaving. The actual
frequency that will be achieved depends on several factors including
weave amplitude and dwell time. This parameter is not an absolute
value for weave frequency. It is a reference value where higher
numbers result in faster weaving.
Amplitude This item is the distance from the centerline of the weave pattern
to either peak. The valid range of amplitude is from .1 to 25.0
millimeters.
Right Dwell This item is the amount of time the robot delays at the right side of
the weld. The valid range of right dwell is from 0.0 to 32 seconds.
Left Dwell This item is the amount of time the robot pauses at the left side of
the weld. The valid range of left dwell is from 0.0 to 32 seconds.
L pattern angle This item generates a torch motion in a right angle shape. This
pattern can be useful for fillet and v-groove weld joints.
Robot Group Mask This item enables weaving on multi-group system in this weave
schedule. If there is no group enabled in this item, the system will
check the group mask of TP program and turn on weave for all the
groups that is configured in the weave general setup menu.
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Table 5–19. DATA Weave Sched DETAIL Screen Items
ITEM DESCRIPTION
Weave Schedule # This item is the schedule number.
Frequency This item specifies the weave frequency in cycles per second. The actual frequency that
Units: Hz will be achieved depends on several factors including weave amplitude and dwell time. This
Range: 0.1 - 10 (6-axis)0.1 - parameter is not an absolute value for weave frequency. It is a reference value where higher
30 (Wrist axis) numbers result in faster weaving.
Amplitude This item is the distance from the centerline of the weave pattern to either peak.
Units: mm
Range: .1 - 25.0
Right Dwell This item is the amount of time the robot delays at the right side of the weld.
Units: seconds
Range: 0.0 - 32
Left Dwell This item is the amount of time the robot pauses at the left side of the weld.
Units: seconds
Range: 0.0 - 32
L pattern angle This item generates a torch motion in a right angle shape. This pattern can be useful for fillet
and v-groove weld joints.
Robot Group Mask This item enables weaving on multi-group system in this weave schedule. If there is no group
enabled in this item, the system will check the group mask of TP program and turn on weave
for all the groups that is configured in the weave general setup menu.
Procedure 5-26 Using Weave Schedules
Steps
1. Press DATA.
3. Select Weave Sched. You will see a screen similar to the following.
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DATA Weave Sched

1/10
1 1.0 4.0 .100 .100
2 1.0 4.0 .100 .100
3 1.0 4.0 .100 .100
4 1.0 4.0 .100 .100
5 1.0 4.0 .100 .100
6 1.0 4.0 .100 .100
7 1.0 4.0 .100 .100
8 1.0 4.0 .100 .100
9 1.0 4.0 .100 .100
4. Set the values of FREQ, AMP, R_DWL, L_DWL for up to 10 schedules as needed.
5. To copy schedule information from one schedule to another:
a. Press NEXT, >.
b. Move the cursor to the schedule you want to copy.
c. Press F2, COPY.
d. Enter the schedule number to which you want to copy the data.
e. Press ENTER. The data will be copied, but the comment will not be copied.
6. To clear the information you have entered for a schedule:
a. Move the cursor to the schedule.
b. Press NEXT, >.
c. Press F3, CLEAR.
d. Decide whether to continue:
• To clear the schedule, press F4, YES. The data will be cleared, but the comment
will remain.
• If you do not want to clear the schedule, press F5, NO.
7. Press F2, DETAIL to display more information about a single schedule.
Weave schedules are not group based. In DualARM systems, special care needs to be exercised
when using WEAVE instructions in the welding Section 5.11.2 program. Please refer to Section
5.11.5 regarding the use of weaving for DualARM.
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5.11.5 Multi-Group Weave
The WEAVE instruction can be used in multi-robot programs. For weaving to occur in a given robot
group, the Weave Enable Group mask must be setup to include that robot group (refer to Section
5.11.2 for a description of Weave setup parameters). By default, all robot groups in a multi-robot
system are enabled for weaving. If you need to change the default setting, use Procedure 5-27 .
Procedure 5-27 Enabling Weave for Group 2 Robot
Steps
1. Press MENU and select SETUP.

2. Press F1, [TYPE], and select WEAVE. You will see a screen similar to the following.
SETUP Weave
1/11
NAME VALUE
1 Weave Enable Group Mask [1,1,*,*,*,*,*,*]
4 Elevation: 0 deg
5 Azimuth: 0 deg
7 Radius: 0.0 mm
9 Robot Group: 1
3. Move the cursor to select Weave Enable Group Mask.

4. Move the cursor to the group bit of the mask you want to change.
5. Select F4, 1, to enable a bit of the group mask or F5, *, to disable the group from weaving.
There are two ways that weaving is applied to robot motion:
• Weave applies to executing one robot group
Weave schedule data or "direct value" are supported for both robot groups. When a program
group mask only includes one robot group, then only that robot executes the weave instruction.
• Weave applies to executing two robot groups
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For cases where two programs execute simultaneously, and each program’s group mask
includes only one of robot groups, both robots can execute weaving. In this case each
robot can use different weave schedule numbers or different direct value entries. This
includes normal programs with multi-tasking and also master and slave DualARM programs
executing in a multi-tasking manner.
When one program executes and it contains both robot groups, both robots will weave. In
this case, the weave schedule or direct value parameters are applied to both robots.
Limitations:
• For master slave DualARM programs with multi-tasking, the slave robot motion can have
different filter lengths applied to it, which will alter the programmed frequency or amplitude when
weaving is executed. A change in the slave or master program speed or a change to the slave
program weave schedule data may be needed to correct this. In some cases, the programmed
weave cannot be executed on the slave robot.
• Wrist axis weave is not supported on DualARM systems.
5.12 CUSTOMIZED WEAVING
5.12.1 Overview
The term weaving refers to arc welding in which the welding torch cyclically sweeps right and
left at a certain angle with the direction of welding. Weaving is intended to increase the width of
beads, thereby intensifying the strength of welding. Customized weaving is weaving that uses the
set weaving pattern by the customer.
5.12.2 Customized Weaving Instruction
The customized weaving instruction directs the robot to perform weaving set by the user. Once started
by the customized weaving start instruction, weaving continues until the weaving end instruction is
executed. The following six customized weaving instructions can be used:
• Weave Cust1[i]
• Weave Cust1[Hz, mm, sec, sec]
• Weave Cust2[i]
• Weave Cust3[i]
5–101
To teach the weaving instructions to the robot, click F1 [INST] to display the related submenu,
then select [Weave] from the submenu.
Instruction Joint10%
1 Miscellaneous 5 Track Offset
2 Weave 6 Offset Frames
3 Skip 7 Program control
4 Payload 8 ---next page---
WELD_1
Note The following restrictions are placed on Customized Weaving Pattern. “L pattern angle” and
“Radius” are disabled It is impossible to use TAST, AVC, RPM & Mpass, MIG EYE.
Weave Cust1[i]
The Weave Cust1[i] instruction starts weaving according to a weaving condition and pattern specified
beforehand.
Figure 5–30. Weave Start Instruction
Weave Cust1[i]
Weavin g conditi on (1 to 10)
Weave Cust1[ 3] Weaving conditi on
Weaving conditi on number DATA Weave Sched G1 JOI NT 10%
1/10
Frequency 1.0Hz
FREQ(Hz) AM P(mm ) R_DW(SEC) L_DW (SEC)
Amplit ude 4.0mm
1 1.0 4.0 0.00 0.00
R_Dwell 0.0sec
L _Dwell 0.0sec 2 1.0 4.0 0.00 0.00
3 1.0 4.0 0.00 0.00
Weave Cust1[Hz, mm, sec, sec]
The Weave Cust1[Hz, mm, sec, sec] instruction starts weaving by directly specifying weaving
conditions such as a frequency, amplitude, R_dwell, and L_dwell.
5–102
Figure 5–31. Weave Cust Instruction Example
Weave Cust 1[Hz, mm, s ec, sec]
Frequency (0.0 t o 99.9Hz) R_dwell (0. 0 to 1.0sec)

Amplit ude (0.0 t o 25.0mm ) L_dwell (0.0 to 1 .0sec)
Exa mple Weave Cust1[1. 0Hz, 4.0mm, 0.0sec, 0.0sec]
5.12.3 Weaving Pattern Setting
This section explains about the weaving pattern setting. Customized weaving pattern can be set up
to three in maximums, and can give a name to each pattern. (Refer to “Weaving Pattern Setting by
KAREL” in Chapter 4 when you want to set more weaving pattern.) Three set weaving patterns can
be used by Weave Cust1, Weave Cust2, and Weave Cust3 of the weaving instruction. Weave Cust1,
Weave Cust2, and Weave Cust3 set the triangle type and the sine type as default. The setting of the
weaving pattern has some limitations. The following explains the setting method and the limitation of
the setting.
• The number of phases of weaving pattern is up to ten.

• The value of X, Y, and Z is component of the unit vector. To set the weaving pattern shown in
Figure 5–32 and Figure 5–33 component of X, Y, and Z set as shown in Figure 5–34 .
• Y component of all the unit vectors is multiplied by amplitude, and Z component of all the unit
vectors is multiplied by center rise. Basically, use Z component at the position of Y=0.
• The total of the component of all the unit vectors at the weaving cycle should be 0. When the
end point of the weaving cycle is origin, the total of the component of all the unit vectors at the
weaving cycle becomes 0.
• Dwell time can be set up to two per one pattern, and can be set to the all phase.Dwell time of
two(R_Dwell and L_Dwell) per one phase cannot be set. Weaving stops during the set dwell time
at the position in which the check box was turned on. When R_Dwell is set, turn on the check box
of R_Dwell, and when L_Dwell is set, turn on the check box of L_Dwell. Refer to Figure 5–34 .
• Input the number of totals of phases of the weaving cycle to "Total of phases".
• When the end point of the weaving cycle is not the origin, the start phase must be used. When
start phase is set, turn on the check box of Start phase. Totals of the component of all the unit
vectors at the weaving cycle except the unit vector of start phase should be 0. Refer to Figure
5–35 and Figure 5–36 .
• Push “Confirm” button of the screen of Weave Cust Setup when you want to confirm the set
weaving pattern. Refer to Figure 5–35 .
5–103
Note If you cannot set the weaving pattern to match the following conditions, you will see the
error screen then you have to re-set them again.
• Dwell time cannot be set up to more than two per one pattern.
• Dwell time of two(R_Dwell and L_Dwell) per one phase cannot be set.
• The total of the component of all the unit vectors should be 0.
Figure 5–32. Triangle Weaving
X X : Direction of weldin g
2 (1,1,0)
Direction L_dwell R_dwell

of welding
Y
1 (0,-1,0) 4 (0,-1,0) 3 (-1,1,0)
Figure 5–33. Triangle Weaving
5–104
Figure 5–34. Triangle Weaving Pattern Setup
5–105
Figure 5–35. Diamond Weaving
X
2 (1,1,0)
X
Y
1 (1,-1,0) 3 (-1,1,0)
Direction
of welding
4 (-1,-1,0)
Y S (-1,0,0)
Start Phase
Figure 5–36. Diamond Weaving Pattern Setup
5–106
Figure 5–37. Triangle on the screen of Weaving Pattern Confirm
5–107
Figure 5–38. Weave Pattern Confirm - Diamond
5.12.4 Weaving Pattern Setup
Procedure 5-28 Weaving Pattern Setup

1. Press MENU.
2. Select SETUP.
3. Select WEAVE CUST. You will see a screen similar to the following.
5–108
Figure 5–39. Weaving Pattern Setup
5–109
Figure 5–40. Weaving Pattern Setup
4. Press the EDIT button of the weaving instruction that wants to set the weaving pattern. Push the
Demo button when you want to see the weaving pattern that has already been set. When the Edit
button or the Demo button of Weave Cust1 is pressed, the following screen is displayed.
5. Type 2 to page number of Weave Cust1 Setup when you want to use six phases or more.
The following screen is displayed.
5–110
Figure 5–41. Weave Pattern Custom Setup
6. Press Confirm button of the screen of Weave Cust Setup. The following weaving pattern
confirm screen can be displayed.
5–111
Figure 5–42. Weaving Pattern Confirmation
7. Press Save when you want to save the set weaving pattern. The following screen is displayed.
When Yes button is pushed, the data of the previous weaving pattern is automatically deleted.
5–112
Figure 5–43. Weaving Pattern Save
5.12.5 Weaving Pattern Setting by KAREL
This section explains the method of setting the weaving pattern by using KAREL. The weaving pattern
can be made by inputting directly the data of the weaving pattern to the KAREL variables. There are
ten KAREL programs cust_wv*.pc (* is 1 to 10.). cust_wv*.pc set the sine type as default. If TP
program calls cust_wv*.pc before executing the weaving instruction, the you can use the weaving
pattern that set by KAREL. At this time, the weaving instruction executed after cust_wv*.pc is called
should be Weave Cust3. The data of cust_wv*.pc that is called in the TP program is overwriten to the
data of Weave Cust3 instruction. When the “Demo” button of the Weave Cust3 in Weaving Pattern
Setup screen is pushed, the weaving pattern that you defined can be displayed.
5.12.5.1 KAREL Variables
The following parameter is set, and the weaving pattern is made.
• PAT_NAME: Name of the weaving pattern

• USE_START: Start phase (True: enable, False: disenable)
5–113
• S_VECTOR_X,Y,Z: Component of unit vector xyz of start phase.

• S_DWELL_R,L: Dwell time of start phase (True: enable False: disenable)
• NUM_PHASE: Total of the phase
• VECTOR*_X,Y,Z: Component of unit vector* xyz (* is 1 to 10.)
• DWELL*_R,L: Dwell time (True: enable False: disenable)
5.12.5.2 KAREL Variables SETUP
Use Procedure 5-29 to set up KAREL Variables.
Procedure 5-29 KAREL Variables Setup

1. Change the system variable $KAREL_ENB from 0 to 1 to enable the KAREL variables setup.
a. Press MENU.
b. Select SYSTEM.
c. Press F1, [TYPE].
d. Select Variables.
e. Select $KAREL_ENB, and set it to 1.
You will see a screen similar to the following.
SYSTEM Variables
198/515
195 $JOB_GROUP UJR_GRP_T
196 $JPOSREC_ENB 0
197 $KANJI_MASK 0
198 $KAREL_ENB 1
199 $KCL_LIN_NUM TRUE
200 $KCL_RPCOUT *uninit*
201 $KEYLOGGING 2
202 $LANGUAGE ’ENGLISH ’
203 $LASTPAUSPOS [5] of JOINTPOS9
204 $LN_DISP LN_DISP_T
205 $LOAD_DEVICE ’MC:’
2. Select KAREL program cust_wv*.pc:

a. Press SELECT.
b. Press F1, [TYPE].
c. Select KAREL Progs. You will see a screen similar to the following.
5–114
Select
1036072 bytes free 5/33
No. Program name Comment
4 CUSTWV10 PC [ ]
5 CUST_WV1 PC [ ]
6 CUST_WV2 PC [ ]
7 CUST_WV3 PC [ ]
8 CUST_WV4 PC [ ]
9 CUST_WV5 PC [ ]
10 CUST_WV6 PC [ ]
11 CUST_WV7 PC [ ]
12 CUST_WV8 PC [ ]
13 CUST_WV9 PC [ ]
3. Set the KAREL Variables.

a. Press DATA.
b. Press F1, [TYPE].
c. Select KAREL Vars.
d. Press ENTER. You will see a screen similar to the following.
DATA KAREL Vars

CUSTWV1 1/60
1 PAT_NAME ’CUST_WV1’
2 USE_START FALSE
3 S_VECTOR_X 0.000
4 S_VECTOR_Y 0.000
5 S_VECTOR_Z 0.000
6 S_DWELL_R FALSE
7 S_DWELL_L FALSE
8 NUM_PHASE 4
9 VECTOR1_X 0.000
10 VECTOR2_X —1.000
11 VECTOR3_X 0.000
KAREL program cust_wv1.pc shown below is an example that when the weaving pattern of
Figure 5–32 and Figure 5–33 is made by using the KAREL variables.
5–115
PAT_NAME ’Triangle’
USE_START FALSE
S_VECTOR_X 0
S_VECTOR_Y 0
S_VECTOR_Z 0
S_DWELL_R FALSE
R_DWELL_L FALSE
NUM_PHASE 4
VECTOR1_X 0
VECTOR1_Y —1
VECTOR1_Z 0
DWELL1_R TRUE
DWELL1_L TRUE
VECTOR2_X 1
VECTOR2_Y 1
VECTOR2_Z 0
DWELL2_R TRUE
DWELL2_L TRUE
VECTOR3_X —1
VECTOR3_Y 1
VECTOR3_Z 0
DWELL3_R TRUE
DWELL3_L TRUE
VECTOR4_X 0
VECTOR4_Y —1
VECTOR4_Z 0
DWELL4_R FALSE
DWELL4_L FALSE
VECTOR5_X 0
VECTOR5_Y 0
VECTOR5_Z 0
DWELL5_R FALSE
DWELL5_L FALSE
VECTOR6_X 0
VECTOR6_Y 0
VECTOR6_Z 0
DWELL6_R FALSE
DWELL6_L FALSE
|
|
VECTOR10_X 0
VECTOR10_Y 0
VECTOR10_Z 0
DWELL10_R FALSE
DWELL10_L FALSE
5–116
Caution
There are the following limitations in the weaving pattern setting by KAREL.
When Weave Cust3 instruction is executed by the teach pendant program and
the following limitations are not filled, the robot ABORT.
• Do not set 1 to the Karel variable “NUM_PHASE”.

• Do not set all 0 to Karel variable “VECTOR*_X,Y,Z”. (*=1 to Num_phase)
Procedure 5-30 Call of KAREL program cust_wv*.pc from the Teach Pendant
1. Create the following teach pendant program
4: Arc Start[1]
3: WEAVE CUST3[1]
1: J P[1] 100% FINE
2: J P[2] 100% FINE
7: WEAVE END
6: Arc End
8: J P[1] 100% FINE
[END]
2. KAREL program cust_wv*.pc is called before WEAVE CUST3[1] is executed.

a. Move the cursor to END.
b. Press the F1 (INST) key. Then, the control instruction menu is displayed.
c. Select CALL.
d. Select CALL program.
e. Press the F3 (KAREL) key. Then, the KAREL program list is displayed. Select
cust_wv*.pc.
5: Arc Start[1]
3: CALL CUST_WV1
4: WEAVE CUST3[1]
1: J P[1] 100% FINE
2: J P[2] 100% FINE
8: WEAVE END
7: Arc End
9: J P[1] 100% FINE
[END]
5–117
Note
• It is necessary to call cust_wv*.pc before WEAVE CUST3 is executed.

• The data of cust_wv*.pc is reflected only in WEAVE CUST3 instruction.
5.13 EXTENDED WEAVING
5.13.1 Weave Schedule
Weaving schedule can change Frequency, Amplitude, and Dwell time at each weaving instruction.
Weaving schedule can be set on the Weaving Schedule screen (Up to 16 weaving schedules can be set
). Moreover, Weave (pattern) [Hz, mm, sec, sec] instruction specifies frequency, amplitude, dwell
time of weaving conditions directly. Refer to Section 5.11.4 for details.
5.13.2 Extended Weaving Schedule
When extended weaving schedule is used, Elevation, Azimuth, Center rise, and Radius of the
Weaving setting screen can be set as a weaving schedule. An extended weaving schedule is defined
with [DATA – Weave Sched] on the weaving schedule screen. Weave (pattern) [Hz, mm, sec, sec]
instruction cannot be specified.
Refer to Section 5.11 for details of Elevation, Azimuth, Center rise, and Radius.
Procedure 5-31 Displaying the DATA Weave Schedule Screen

1. Press MENU.
2. Select DATA.
3. Select Weave Sched. You will see a screen similar to the following.
5–118
DATA Weave Sched

1/10
1 1.0 4.0 .100 .100
2 1.0 4.0 .100 .100
3 1.0 4.0 .100 .100
4 1.0 4.0 .100 .100
5 1.0 4.0 .100 .100
6 1.0 4.0 .100 .100
7 1.0 4.0 .100 .100
8 1.0 4.0 .100 .100
9 1.0 4.0 .100 .100
10 1.0 4.0 .100 .100
4. Press F2, DETAIL, to set the extended weaving schedule. To return to the list screen, press the
ENTER.
Figure 5–44. Extended Weave Schedule Screen
Extended weavi ng schedule
5. To set an item, move the cursor to the setting field, then type a desired value.
6. To switch to another weld schedule detail screen, press F2 (SCHEDULE), then enter the desired
schedule number. The weld schedule detail screen of the specified number is displayed.
7. When copying a set schedule, press F2 (COPY) on the next page, then enter a copy destination
schedule number.
8. When deleting a set schedule, press F3 (delete) on the next page.
5–119
5.14 WELD CONTROLLER PROGRAM SELECTION
5.14.1 Overview
Some weld controllers allow you to select different programs (also referred to as modes, procedures,
or databases) using one or more digital inputs. Some weld controllers even allow you to change
programs during welding. The content and operation of the weld controller programs depend on the
characteristics and configuration of the weld controller.
Note If you are using Lincoln Electric PowerWave x55/R welding equipment connected with
ArcLink, weld controller progam selection is supported using the Multi-Process feature of this
equipment. The following information only applies to welding equipment connected with analog and
digital I/O. See the Lincoln Welding Equipment section in this chapter for more details regarding
Multi-Process setup.
ArcTool provides the weld controller program selection feature to allow you to select weld
controller programs from the robot controller.
• You must enable weld controller program selection using a system variable setting.
• You must assign the three Prg Select welding digital outputs (WO) . The states of these three
outputs determine which weld controller program is selected.
• Eight programs correspond to the Prg Select outputs. You can change the names of the programs
in the SETUP Weld Prog screen. You can also select a program manually. When you select a
new program, the appropriate Prg Select outputs are set for you.
• You can specify the weld controller program to use in a weld schedule . When the schedule is
executed, the appropriate Prg Select outputs are set for you.
• The currently selected weld controller program is also displayed on the STATUS Weld screen .
5.14.2 Enabling Weld Controller Program Selection
Before you can use weld controller program selection, you must enable it. Use Procedure 5-32 to
enable weld controller program selection.
Procedure 5-32 Defining the Number of Weld Schedules
Steps
1. Press MENU.
5–120
3. Select Variables. You will see a screen similar to the following.
SYSTEM Variables
1 $ANGTOL [9] of REAL
2 $APPLICATION [3] of STRING [21]
3 $AP_MAXAX 0
4 $AP_PLUGGED 2
5 $AP_TOTALAX 16777216
6 $AP_USENUM [32] of BYTE
7 $ASCII_SAVE FALSE
8 $AUTOINIT 2
9 $AWECFG AWECFG_T
10 $AWEOFT AWEOFT_T
4. To move quickly through the information, press and hold down the SHIFT key and press
the down or up arrow keys.
5. Move the cursor to $AWEPCR and press ENTER.
6. Move the cursor to PRG_SEL_ENA.
7. Set the system variable:
• To enable weld controller program selection, press F4, TRUE.

• To disable weld controller program selection, press F5, FALSE.
5.14.3 Assigning Weld Controller Program Selection Outputs
Before you can use weld controller program selection, you must assign the three Prg Select welding
digital outputs (WO). These signals are set ON of OFF in different combinations to select a weld
controller program. The eight weld controller programs are listed on the SETUP Weld Prog screen (
Section 5.14.4 ) . Refer to Table 5–20 for a description of the output signals that correspond to
each of the weld controller programs.
Table 5–20. Weld Controller Program Output Settings
Weld Controller Program Output Setting

Number
Prg Select 1 WO Prg Select 2 WO Prg Select 3 WO
1 OFF OFF OFF
2 ON OFF OFF
5–121
Table 5–20. Weld Controller Program Output Settings (Cont’d)
3 OFF ON OFF
4 ON ON OFF
5 OFF OFF ON
6 ON OFF ON
7 OFF ON ON
8 ON ON ON
Figure 5–45 shows an example of how the output signals are used to tell the weld equipment which
program to execute.
Figure 5–45. Weld Controller Program Select Example
Controller
Weld Equipment
Process I/O
board
Prg Sel 1
Prg Sel 2
Prg Sel 3
Timing Diagram
Program 1 Program 2
Prg Sel 1
Prg Sel 2
Prg Sel 3
You can assign the weld controller program selection outputs to any available digital output signals.
Use Procedure 5-33 to assign weld controller program selection outputs.
Procedure 5-33 Assigning Weld Controller Program Selection Outputs
Steps
1. Press MENU.
2. Select I/O.
5–122
3. If the I/O Weld screen is not displayed, press F1, [TYPE].

4. Select Weld.
5. Press F3, IN/OUT, until the I/O Weld Out screen is displayed.
6. Move the cursor to the Prg Select output you want to assign. See the following screen for an
example.
I/O Weld Out

8 [Wire stick alarm ] WO[ 6] U OFF
9 [ ] WO[ 0] * OFF
10 [Burnback ] WO[ 0] * ***
11 [Feed forward ] WO[ 0] * ***
12 [Feed backward ] WO[ 0] * ***
13 [Prg Select 1 ] WO[ 0] * ***
14 [Prg Select 2 ] WO[ 0] * ***
15 [Prg Select 3 ] WO[ 0] * ***
I/O Weld Out

WELD SIGNAL TYPE #
1 [Prg Select 3 ] WO[0]
8. Move the cursor to the port number.

9. Type the port number you want to assign and press ENTER.
10. Press PREV or press F2, MONITOR.
The output signal is assigned.
After you have assigned the signal, the screen will be similar to the following.
5–123
I/O Weld Out

8 [Wire stick alarm ] WO[ 6] U OFF
9 [Prg Select 3 ] WO[ 7] * OFF
10 [Burnback ] WO[ 0] * ***
11 [Feed forward ] WO[ 0] * ***
12 [Feed backward ] WO[ 0] * ***
13 [Prg Select 1 ] WO[ 0] * ***
14 [Prg Select 2 ] WO[ 0] * ***
15 [ ] WO[ 0] * ***
11. Repeat Step 6 through Step 10 to assign the remaining two Prg Select output signals.
5.14.4 Selecting Weld Controller Programs
The SETUP Weld Prog screen contains a list of eight weld controller programs. On this screen, you
• Select the current weld controller program name and number. When you do this, the appropriate
Prg Select outputs are set.
• Change the names of the weld controller programs listed, if desired
Use Procedure 5-34 to select weld controller programs.
Table 5–21. SETUP Weld Prog Screen Items
1 MIG (Volts, WFS) Program 1 0
Column 1 Column 2 Column 3
ITEM DESCRIPTION
Column 1 The first column displays the equipment setup for the
associated program. In the screen shown in Step 4 of
Procedure 5-34 , all the programs are for use with a
general purpose MIG welding power supply.
5–124
Table 5–21. SETUP Weld Prog Screen Items (Cont’d)
Column 2 The second column is the program name field. It

is a comment field that allows you to associate a
name with the program on the welding power supply
Note: If you are using a Lincoln Electric PowerWave
455 power supply, the comment is automatically
updated with a process description when searching
and selecting programs in the Weld Equipment Setup
screen.
Column 3 The third column is the decimal value of the binary

code which is set on the program select digital outputs
when that program is selected. Note: If you are using
a Lincoln Electric PowerWave 455 power supply, the
number in the right column is the PowerWave 455
weld procedure number. It is not communicated to
the PowerWave 455 with the three program select
outputs. Instead, it is sent as a DeviceNet or ArcLink
explicit message.
Procedure 5-34 Selecting Weld Controller Programs
Conditions
• You have assigned the three Prg Select welding digital output signals. ( Procedure 5-33 )
Steps
1. Press MENU.
2. Select SETUP.
4. Select Weld Prog. You will see a screen similar to the following.
SETUP Weld Prog

Selected Program: 1 [Program 1 ]
5–125
5. To select the current program , move the cursor to the program you want and press F3,
SELECT.
When you select the program, the corresponding digital output you assigned will be set ON.
6. To change the name of a program , move the cursor to the program name you want to change,
press ENTER, and press the appropriate keys to enter the name you want.
5.14.5 Specifying a Weld Controller Program in a Weld Schedule
When you use the weld controller program select feature, you can specify the weld controller program
to use in the weld schedule. This is displayed only on the DATA Weld Sched DETAIL screen. See
Figure 5–46 .
Figure 5–46. DATA Weld Sched DETAIL Screen
DATA Weld Sched

1 Weld Schedule: 1 [ Weld Schedule 1 ]
2 Program Select 1 [ Program 1 ]
5 Travel Speed 0 IPM
In the weld schedule, you can move the cursor to the Program select number and type the number
of the program you want to select. You cannot change the comment for the Program select. When
you change the Program select number, the comment will change to the comment defined on the
SETUP Weld Prog screen ( Section 5.14.4 ).
When the schedule is executed, the appropriate Prg Select outputs are set for you.
Refer to Section 5.7 for detailed information on weld schedule setup.
5–126

Setting Up Arctool

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Setting Up Arctool

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Chapter 5

Chapter 5 SETTING UP ARCTOOL ......................................................................... 5–1

5.6.6 Using HeatWave with Weld Procedures ..................................................... 5–55

5.15.10 Selecting Multiple Weld Processes ........................................................ 5–136

5.2 WELD EQUIPMENT SELECTION

1. Perform a Controlled start.

---------- CONFIGURATION MENU ----------

ARCTOOL SETUP CONTROLLED START MENUS

2 Welding setup: USA

6 Manufacturer: Lincoln Electric

See the following screen for an example of selecting General Purpose.

General Purpose weld controller models:

See the following screen for an example of selecting Lincoln Electric.

Lincoln Electric controller models:

Miller Electric controller models:

3. When you are finished setting equipment information, press FCTN.

5.3 WELD SYSTEM SETUP

• Monitoring functions - Section 5.3.2

Procedure 5-2 Setting up the Weld System

SETUP Weld System

NAME VALUE UNITS

5.3.2 Monitoring Functions

Table 5–1. Monitoring Functions

Table 5–1. Monitoring Functions (Cont’d)

5.3.3 Weld Restart Function

Table 5–2. Weld Restart Function Items

5.3.4 Scratch Start Function

Table 5–3. Scratch Start Function Items

Retry Maximum retry count of scratch start process.

Successful Scratch Start

See Figure 5–2 .

Figure 5–2. Successful Scratch Start

Unsuccessful Scratch Start

See Figure 5–3 .

Figure 5–3. Unsuccessful Scratch Start

P[1] P[2] P[3]

Scratch Start During Resume of the Weld

See Figure 5–4 .

Figure 5–4. Scratch Start During Resume of the Weld

Scratch Distance and Closely Taught Positions

See Figure 5–5 .

Figure 5–5. Scratch Distance and Closely Taught Positions

P[1] P[2] P[3]

Arc Start Forward

5.3.5 Repeat Touch Retry Function

Table 5–4. Retry touch retry function

Arc Retry Set enabled/disabled repeat touch retry function

Retry Maximum retry count of repeat touch retry function

5.3.6 Weld Speed Function

Table 5–5. Weld Speed Function Items

5.3.7 Other Functions

Table 5–6. Other Functions

Table 5–6. Other Functions (Cont’d)

Table 5–6. Other Functions (Cont’d)

12 [Remote inch fwd ] DI[ 1] U OFF

5.4 WELD EQUIPMENT SETUP

Table 5–7. Weld Equipment Setup Items