Global 3 Servogun Setup Users Manual PDF

General Motors Company
Global ME - Vehicle Systems
Global 3 Servo Gun Setup Manual

Fanuc SpotTool+ 8.20 with GRS4 Customization
March 14, 2014
Rev 1.0
DOCUMENT MANAGEMENT INFORMATION
Authors:
JJ Arboleras Fanuc America Corporation

Bill Kroll Vehicle Systems
Lloyd Steed Vehicle Systems
Greg Kolanowski Extreme Automation
Sponsoring group:
GM Manufacturing Engineering – Vehicle Systems
Forward questions, comments and/or revisions to:
General Motors Company

Vehicle Systems
30300 Mound Road
Mail Code 480-109-266
Warren, MI 48090
Attn: Joseph Caporuscio
Document revisions:
Date Revision By Revision History

March 14, 2014 1.0 BK Initial Release.
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to a controlled version can be made through the GMNA Socrates website by going through the following
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1. Search
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5. Supply Power, Standards & Specifications - Global:, Global Robotics Standards
6. Global 3 Servo Gun Setup Manual
Document expiration date:
This document will expire December 2014. It may be revised, reaffirmed or withdrawn prior to this date.
Contact the organization listed above for the latest revision.
Global 3 Servogun Setup Users Manual for Fanuc SpotTool+ 8.20 with
GRS4 Customization
TABLE OF CONTENTS
Section Description Page
1. GENERAL ............................................................................................................................................. 5
1.1 SCOPE .............................................................................................................................................. 5
1.2 PURPOSE........................................................................................................................................... 5
1.3 INTENDED AUDIENCE ........................................................................................................................ 5
1.4 BACKGROUND .................................................................................................................................. 5
1.5 SETUP FLOW ..................................................................................................................................... 6
2 GUN INSTALLATION.......................................................................................................................... 7
2.1 GUN MOUNTING ............................................................................................................................... 7
3 WIZARD SETUP ................................................................................................................................... 7
3.1 GETTING STARTED ............................................................................................................................ 7
3.2 HELPS AND HINTS ............................................................................................................................. 8
3.2.1 Re-Running the wizard to correct for an incorrect response during initial setup......................... 8
3.2.2 Re-Running the wizard to add a feature ..................................................................................... 8
4 ESTABLISHING PULSE ON SERVO GUN MOTORS ...................................................................... 8
4.1 RESETTING BZAL (BATTERY ZERO ALARM) ..................................................................................... 8
4.2 ESTABLISHING PULSE ........................................................................................................................ 9
4.2.1 GSWA and SW-Series Motors.................................................................................................... 9
4.2.2 HT-Series Motor ....................................................................................................................... 9
5 MASTERING THE GUN .................................................................................................................... 10
5.1 SETTING GUN CLOSE DIRECTION ..................................................................................................... 11
5.2 MASTERING THE GUN AND SETTING AXIS LIMITS............................................................................. 11
5.2.1 Single Gun per Equipment ...................................................................................................... 11
5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal) ............................... 14
5.3 AUTOTUNING .................................................................................................................................. 16
5.3.1 Default Autotune Running ....................................................................................................... 16
5.3.2 Auto Tune Results: .................................................................................................................. 18
5.4 HELP AND HINTS ............................................................................................................................. 19
5.4.1 Collision detection alarm ........................................................................................................ 19
5.4.2 Stop Excess Error ................................................................................................................... 19
5.4.3 Autotune cannot start .............................................................................................................. 19
5.4.4 Pressure Shortage................................................................................................................... 19
6 PRESSURE CALIBRATION .............................................................................................................. 19
6.1 EQUIPMENT .................................................................................................................................... 19
6.2 PERFORMING CALIBRATION............................................................................................................. 20
6.3 HELP AND HINTS ............................................................................................................................. 24
7. OVERTORQUE PROTECTION ........................................................................................................ 26
8 SERVO GUN DIAGNOSIS ................................................................................................................. 28
9 TIP WEAR COMPENSATION........................................................................................................... 31
9.1 SETUP ............................................................................................................................................. 31
9.1.1 Enabling Tip Wear Compensation ........................................................................................... 31
9.1.2 Running Tip Wear Compensation Setup Program(s) ................................................................ 33
9.1.3 Wear Ratios ............................................................................................................................ 33
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General Motors Corporation. All Rights Reserved.
-UNCONTROLLED WHEN PRINTED-
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9.2 VIEWING TIP WEAR VALUES............................................................................................................ 33
9.3 TIP WEAR UPDATING ...................................................................................................................... 35
9.3.1 Tip Wear Routines .................................................................................................................. 35
9.3.1.1 TW_GUNS(x) x= gun number ............................................................................................ 35
9.3.1.2 CAP_WEAR ...................................................................................................................... 35
9.3.1.3 TW_UPDT(x) x= gun number ............................................................................................. 35
9.3.1.4 TW_UPDCC(x) x= gun number .......................................................................................... 35
9.3.1.5 TW_REG(x) x=gun number ............................................................................................... 35
9.3.1.6 WR_UPDAT(x)(y) x=gun number y= new tips flag ............................................................ 36
9.3.1.7 CHK_WEAR ...................................................................................................................... 36
9.3.1.8 TW_GNRST ....................................................................................................................... 36
9.3.1.9 GET_CFG .......................................................................................................................... 36
11 SET GUN CLOSE DIRECTION ..................................................................................................... 37
11.1 CARRIED +Z ................................................................................................................................... 37
11.1.1 Single Gun .............................................................................................................................. 37
11.1.2 Dual Gun Single Equipment .................................................................................................... 38
11.2 PEDESTAL +Z ................................................................................................................................. 39
11.2.1 Single Gun .............................................................................................................................. 39
11.2.2 Dual Gun Single Equipment .................................................................................................... 40
12 PRESSURE SCHEDULES .............................................................................................................. 41
12.1 BACKGROUND ................................................................................................................................ 41
12.2 ELEMENTS ...................................................................................................................................... 42
12.2.1 Weld Force ............................................................................................................................. 42
12.2.2 Gun Sag.................................................................................................................................. 43
12.2.2.1 Enabling.......................................................................................................................... 43
12.2.2.2 Setup............................................................................................................................... 44
12.2.2.3 Pushing Depth ................................................................................................................. 45
12.2.2.4 Contact Speed ................................................................................................................. 45
13 BACKUP SCHEDULES .................................................................................................................. 47
14 DISTANCE SCHEDULES............................................................................................................... 48
15 PROGRAM LISTINGS ................................................................................................................... 49
15.1 STYLE TEMPLATES .......................................................................................................................... 49
15.1.1 Carried Servo Gun.................................................................................................................. 49
15.1.2 Single Pedestal Servo Gun ...................................................................................................... 50
15.1.3 Dual Pedestal Servo Gun ........................................................................................................ 51
15.2 PROCESS PATH TEMPLATES ............................................................................................................. 53
15.2.1 Spot Process 1 Template (TMSPROC1) ................................................................................... 53
15.2.2 Spot Process 2 Template (TMSPROC2) ................................................................................... 54
15.3 MISCELLANEOUS SERVO GUN MACROS ........................................................................................... 55
15.3.1 STPR_CHK ............................................................................................................................ 55
15.3.2 CAP_WEAR............................................................................................................................ 56
15.3.3 NUM_GUNS........................................................................................................................... 57
15.3.4 TW_GUNS .............................................................................................................................. 58
15.3.5 WR_UPDAT ........................................................................................................................... 62
15.3.6 Tip Reset................................................................................................................................. 64
15.3.7 Cap Select .............................................................................................................................. 66
16 RECOVERY .................................................................................................................................... 67
16.1 RECOVERY FROM LOSS OF MASTERING ............................................................................................ 67
16.1.1 Mastering the Gun from the Master/Calibrate screen .............................................................. 67
16.2 CAP CONFIGURATION CHANGE ......................................................................................................... 68
16.2.1 Re-Run the wizard................................................................................................................... 68
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16.2.2 Mastering the Gun and Setting Axis Limits .............................................................................. 68
16.2.3 Running Tip Wear Setup ......................................................................................................... 68
16.2.4 Completing Pressure Calibration ............................................................................................ 69
16.2.5 Path Touch up ........................................................................................................................ 69
16.3 MOTOR REPLACEMENT ................................................................................................................... 69
17 SERVO GUN TOOL CHANGE OPTION ...................................................................................... 70
17.1 PURPOSE......................................................................................................................................... 70
17.2 HARDWARE/SOFTWARE REQUIREMENTS, LIMITATIONS AND RECOMMENDATIONS ............................. 70
17.3 HARDWARE SETUP PROCEDURE FOR CARRIED SERVO WELD GUN(S) ................................................ 71
17.4 RUNNING SRVO_TC.PC................................................................................................................. 74
17.4.1 SRVO_TC.PC File Execution Procedure ................................................................................. 74
17.5 PROGRAMMING AND SETUP COMPLETION ........................................................................................ 74
17.5.1 GUN ATTACH[x] ................................................................................................................... 75
17.5.2 GUN DETACH[x] .................................................................................................................. 76
17.5.3 Emergency Detach (EMGDTCH.TP)....................................................................................... 76
17.5.4 Verification of Gun(s) connections .......................................................................................... 76
17.5.5 Auto Tune and Pressure Calibration of Guns........................................................................... 76
18 TOOL CHANGE PROGRAMS SPECIFIC FOR SERVO GUN TOOL CHANGE
APPLICATIONS. ........................................................................................................................................ 77
18.1 STYLE TEMPLATE (SERVO TOOL-CHANGER) SINGLE CARRIED GUN ................................................... 77
18.2 STYLE TEMPLATE (SERVO TOOL-CHANGER) 2 CARRIED GUNS WITHIN 1 STYLE .................................. 78
18.3 STYLE TEMPLATE (SERVO TOOL-CHANGER) 1CARRIED GUN AND 1 MH END EFFECTOR ...................... 79
18.4 CAP_WEAR (SERVO TC VERSION ONLY) ..................................................................................... 80
18.5 TCCKTOOL .................................................................................................................................. 81
18.6 TCGETNUM ................................................................................................................................. 83
18.7 TCINNEST .................................................................................................................................... 84
18.8 TCEMPTY..................................................................................................................................... 87
18.9 TCCLSLID .................................................................................................................................... 89
18.10 TCOPNLID ................................................................................................................................ 91
18.11 TCLTCHTL ............................................................................................................................... 93
18.12 TCUNLTCH .............................................................................................................................. 94
18.13 TCPICKH1 ................................................................................................................................ 95
18.14 TCDROPH1 ............................................................................................................................... 98
18.15 STYLE 26 .................................................................................................................................. 100
18.16 TCTEACH ............................................................................................................................... 102
18.17 SERVO GUN TOOL CHANGE TIP WEAR SPECIFIC PROGRAMS......................................................... 103
18.17.1 TW_GUNS (SG tool change specific)................................................................................. 103
18.17.2 TW_MEM (SG tool change specific) .................................................................................. 106
18.17.3 TW_VER (SG tool change specific) ................................................................................... 107
18.18 SERVO GUN TOOL CHANGING SPECIFIC TIP DRESS PROGRAMS.................................................... 109
18.18.1 Style 29 TIP DRESS (SG tool change specific)................................................................... 109
18.18.2 TD_PROCx (SG tool change specific) ............................................................................... 110
18.18.3 TCDRESCP (SG tool change specific) ............................................................................... 112
18.18.4 TCPSTDRS (SG tool change specific)................................................................................ 114
19 TROUBLESHOOTING SERVO GUN TOOL CHANGE ............................................................ 116
19.1 THE ATTACH INSTRUCTION IS EXECUTED WHEN THE GUN IS NOT ATTACHED .................................... 116
19.2 A DIFFERENT GUN FROM THAT SPECIFIED BY THE ATTACH INSTRUCTION IS ATTACHED ..................... 117
19.3 THE ATTACHED GUN HAS BEEN DETACHED BY MISTAKE (WITHOUT USING THE DETACH INSTRUCTION)
117
19.4 THE BATTERY VOLTAGE HAS FALLEN ............................................................................................. 118
19.5 THE BATTERY RAN LOW WHILE THE GUN WAS DETACHED ............................................................... 118
20 VARIABLE LISTING (CONDENSED) ........................................................................................ 119
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20.1 $SGSYSCFG ............................................................................................................................... 119
20.1.1 $pst_ertype: Pressure Shortage Error type ............................................................................ 119
20.1.2 $allow_stdsp: Display Standalone Spot instruction................................................................ 119
20.1.3 $rel_press: Release pressure at program pause ..................................................................... 119
20.1.4 $prs_units: Pressure units..................................................................................................... 119
20.2 COMMON ERRORS ON SERVO GUN ERRORS .................................................................................... 120
20.2.1 SRVO-023: SERVO Stop error excess (G:%d A:%d) ............................................................. 120
20.2.2 SRVO-024: SERVO Move error excess (G:%d A:%d) ............................................................ 120
20.2.3 SRVO-069: SERVO CRCERR alarm (Grp:%d Ax:%d) .......................................................... 120
20.2.4 SRVO-062: SERVO BZAL alarm (Group:%d Axis:%d).......................................................... 120
20.2.5 SRVO-068: SERVO DTERR alarm (Grp:%d Ax:%d) ............................................................. 120
20.2.6 SVGN-023: Incomplete Pressure calibration ......................................................................... 121
20.2.7 SVGN-024: Incomplete Wear Down calibration .................................................................... 121
20.2.8 SVGN-032: Tip increased error ............................................................................................ 121
20.2.9 SVGN-118: Max wear exceeded ............................................................................................ 121
20.2.10 SVGN-020: Pressure shortage........................................................................................... 122
20.3 HOW TO CHECK GUN IMPEDANCE: .................................................................................................. 122
20.4 SERVO GUN AMP SETTINGS WITH GUN(S) & HARDWARE MISMATCHES .......................................... 123
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1. General
1.1 Scope
The following documentation is intended to be a reference document to aid in the setup and
installation of the robotic servo weld guns for all projects using servo guns and Fanuc SpotTool+ 8.20
with the GRS4 Customization. This documentation is intended to detail the steps necessary to install
a Tolomatic servo weld gun on to a Fanuc R-30iB robot controller. The steps outlined in this manual
will allow the intended audience to install the weld gun, calibrate, tune, and program/touchup weld
paths.
1.2 Purpose
The steps outlined in this manual will help to ensure that all servo weld guns are integrated
and setup in the same fashion so that the system is easily maintained and is fully functional to all RS
specifications as well as GCCS-2, and GCCH-1. This document is not intended to replace servo gun
manuals from Fanuc, but to simply document specific setup criteria specific to General Motors
applications, using Fanuc SpotTool+ 8.20 with the GRS4 Customization.
1.3 Intended audience

The intended audience for this document includes robot programmers, engineers, and skilled
trades responsible for setting up the servo gun robots at integration, and maintaining the equipment
once it is installed into the production environment.
1.4 Background
The servo guns that are being referenced use a Tolomatic/Aro3G motor that incorporates a
Fanuc encoder, and connectors that allow it to be controlled by the Fanuc robot. There are 7 different
motor sizes.
1. Tol SW44.
2. Tol HT23.
3. GSWA 201-202-ARO3G. REQUIRES WATER for Operation.
4. GSWA 101-Tol.
5. GSWA 102/103/202/IMA44-Tol.
6. GSWA 201/301/302/IMA33-Tol.
7. FANUC ACa8/4000is-40A/80A
All motors are driven by the same 40 amp auxiliary amplifier in the robot, as an integrated robot axis.
The basic setup has the robot arm as motion group 1, and the servo guns as group 2, and group 3 if
necessary. The control of the servo gun is integrated into the robot system, such that I/O is not
necessary to control the gun functionality, such as backup or equalization. All configured spotwelding
guns in the GM GRS4 customization will require water flow for STROKE operation.
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1.5 Setup Flow
The following flow chart is a process of the steps necessary to setup a servo gun robot
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2 Gun Installation
2.1 Gun Mounting
When mounting the gun to the robot faceplate, care should be given to the way the
connectors for the motor will route. There are 2 connectors that are used to control the Tolomatic
motor from the robot. The first is the power cable and the second is the encoder cable. These
should be positioned such that the cables and connectors are in the safest location relative to
projected path. If there’s interference it is possible to rotate the motor end cap +- 90 . See motor
documentation on rotating the connectors on the end cap.
3 Wizard Setup
The wizard allows the robot software to be configured for the specific application. The
programmer needs only answer a few questions and the software configures itself based on the
answers chosen by the programmer. This functionality has been further enhanced to include setting
up of the servo gun applications, including group and axis data that previously needed to be done
manually before running the wizard. This presented some complexity issues and has been remedied
by adding the necessary functionality to the wizard. If the application is SERVO TOOL CHANGER
please refer to Section 16 and 17.
3.1 Getting Started
Before running the wizard, some information regarding the robot and application need to be
gathered. They are as follows:
1. Robot software version.

Must be 8.20Pxx G3 03-14-14 (Update 00) or later.
An update will be necessary if the software is not up to this level.
2. Information about the application that the robot performs
Carried or Pedestal Process
3. Information about the servo guns
Motor Type
Maximum Force for the gun (NOT the maximum motor force)
Net Gear Ratio (NOT the motor ratio)
Maximum gun opening (NOT the maximum motor stroke)
Gun type: Pinch/X-style or C-style
Auxiliary Amplifier that the servo motor is attached to
4. Information on how the guns are going to be used (If multiple guns exist)
1. Dual gun single equipment
2. Dual gun Dual equipment, 1 or 2 weld controllers
a. Affects tip wear compensation and pressure schedule approach.
If the appropriate groups are not present when the wizard is run, the wizard will automatically
add the Servo Gun group and then boot back to controlled start. It is important that a full load USB
memory device with the AP1 directory be plugged into the controller when servo gun groups are
added. Once the robot has returned to Controlled start it will be necessary to re-run the wizard to
configure the robot application. To see an example of running the servo gun setup wizard please
refer to the 8.20P-xx Wizard manual-GM Customization document.
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3.2 Helps and Hints
3.2.1 Re-Running the wizard to correct for an incorrect response during initial setup
If a mistake was made in the initial setup of the wizard, the easiest way to recover is to re-run
the wizard. This will allow the robot to automatically reconfigure for the change. There is no need to
reboot back to controlled start if you are currently at controlled start. Simply rerun the wizard, making
sure to take your time. It is necessary to set Cell I/O every time the wizard is run as the robot resets
the cell interface to default when the wizard is launched.
3.2.2 Re-Running the wizard to add a feature
If it is necessary to add a feature such as a tip dresser or Transformer Over Temp switch, it is
not necessary to re-run the wizard completely. It is necessary, however, to Boot to Controlled start
and launch the Wizard. Select Item #3 ‘Add to Configuration’. This will allow the user to add the
necessary items, without having to run through the entire wizard. Prior to adding a feature, it is best
to back up the robot, in the event an error occurs. A backup all is sufficient
1. Perform a Backup All of the controller

2. Perform a Controlled Start
3. Start the wizard
a. Select Option #3 ‘Add to Configuration’
i. Follow the prompts as necessary
4. Perform a cold boot
5. Query any new DeviceNet nodes as necessary.
4 Establishing Pulse on Servo Gun Motors
Once the groups and axis are configured and the wizard run, it is necessary to master the
guns. This procedure is critical and must be followed as outlined below for each configured servo
gun.
4.1 Resetting BZAL (Battery Zero Alarm)
As is the case any time a motor is installed on the robot it will be necessary to clear the BZAL
alarm that indicates that the system has lost communication with the encoder.
The steps necessary for clearing the BZAL alarm:
1. Press [MENUS] -> [NEXT] -> [SYSTEM] -> [Master/Cal]

2. Press [FCTN] ->[3: CHANGE GROUP] (Select the Servo Gun group, either 2 or 3)
3. Press [F3: RES PCA]
4. Select [F4: YES] when prompted to ‘Reset pulse coder alarm?
5. Repeat steps 2 and 3 for all servo gun groups.
6. Cycle the power on the robot controller.
7. SRVO-075 Pulse not established will be displayed in the fault log upon power up.
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4.2 Establishing Pulse
Before the Gun can be mastered it is necessary to establish pulse with the Fanuc Encoder
that is mounted in the Tolomatic motor.
4.2.1 GSWA and SW-Series Motors
The method used to establish pulse on the SW series motor is identical to the method used
to master a standard Fanuc motor.
1. Select Group 2 for equipment 1, Group 3 for equipment 2

a. Press [FCTN]
b. Item [3: Change Group]
2. Jog Servo Gun axis until pulse is established. (The robot may indicate on the teach
pendent that 'Pulse has been Established')
a. Jog the axis in both the +X and -X direction until 'Pulse is
established'
b. For a second gun on that equipment jog the second axis in the +Y
and -Y direction until 'Pulse is established'.
4.2.2 HT-Series Motor
For the HT-series motors, because they are 4-pole rather than an 8-pole require an additional
step to establish pulse with the encoder. It is not possible to immediately jog the axis without
manually rotating the motor by hand.
To establish pulse on the HT-Series motors it is necessary to perform the following for each gun:
1. Locate the manual override key/gear on the servogun actuator.
2. Loosen the cover and slide out of the way. (Do not remove completely)
3. Using a screwdriver carefully rotate gear one complete revolution.
4. Attempt to jog the gun.
i. If successful, the gun will move, and the gun can then be mastered
ii. If unsuccessful, the robot will still indicate a pulse not established alarm.
Repeat step 3 and 4 until successful.
5. Replace cover on manual override access.
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5 Mastering the Gun
This is the recommended method to master the weld gun, because it calibrates the axis
automatically and sets the servo gun limits to the limit defined in the Wizard setup at controlled start.
This method also verifies that the gun close direction is correct such that there is commonality among
all guns and for the capability to download simulations.
To access the Gun Setup and Autotuning screen:
Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]
The following
steps must be
completed in
order.
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5.1 Setting Gun Close Direction
The first step in calibrating the gun is to set the gun close direction. This is to set the robot up
such that +X on the teach pendent closes the gun. Follow the directions and then proceed to the next
step.
1. Select [Set Gun Motion Sign], and follow instructions
Note:
For all GM servo guns we want +X to close the gun tips and -X to open the gun (+Y/-Y for the
second gun on the same Group Axis). If this is not the case, as with reverse parallel guns, it will be
necessary to go into controlled start and to change the motion sign under the axis configuration from
False to True. This should only be the case on reverse parallel guns.
5.2 Mastering the Gun and Setting Axis Limits
5.2.1 Single Gun per Equipment
1. Select [Set Gun specs, master gun]
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2. Answer [YES] When prompted if you know the gun’s tip displacement of the gun
(Gear Ratio from the gun tag)
3. Answer [YES] When prompted if you know the gun’s stroke limits (Max Open
Distance from the gun tag )
4. Follow the directions to master the gun and set limits
5. Close the Gun until the caps are touching and Press [F4:Closed]
6. Enter the Tip Displacement (This is the Value that was entered in the Wizard at
controlled start)
This will actually

master and calibrate
the gun at once,
allowing you to jog the
gun open to the axis
limit that was set off
the gun tag at
controlled start.
7. Enter the Open and Closed limits for the weld gun.
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The open limit is the value that was entered at controlled start. The closed limit
is 20mm for all guns
8. Press [F3:COMP] when complete
9. It is now necessary to Autotune the motor.
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5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal)
Because of the way Fanuc handles Dual guns on ‘1’ equipment, it is necessary to master
both guns together even though they each have their own Servo Gun Tune screen. The following will
outline the steps necessary to Setup dual guns as a single equipment.
1. Select [Set Gun Specs, Master Gun] for Gun 1
The EQUIP The INDEX

button is used to button is used to
switch between switch between
guns on different guns on the
equipment same equipment
2. Answer [YES] When prompted if you know the gun’s tip displacement of the gun
(Gear Ratio from the gun tag)
3. Answer [YES] When prompted if you know the gun’s stroke limits (Max Open
Distance from the gun tag )
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4. Follow the directions to master the gun and set limits with the following changes
Both guns associated with the active equipment must be mastered
before either gun can be Autotuned
Jog both guns closed before selecting F4 at step 1.
Enter the Tip Displacement and Limits
Jog both guns
associated with the
active Equipment to
the closed position.
Then F4 is pressed it
will master and
calibrate both guns
associated with the
Equipment, not just
the active gun
5. Repeat steps 1 - 3 for the other gun on the active equipment.

Use the Index button to switch between guns on the same equipment
This is necessary to get the gun 2 screen to indicate that everything is

set.
This is easily accomplished by using the backup keys and closing the
backups to 0mm before mastering for gun 2.
6. Once both guns are mastered, proceed to autotuning.

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

Put robot in T2 mode 100% override
2. Select [YES] to Begin
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3. Select [OK] and continue to hold [Shift] and the Deadman
4. After Auto Tuning completes, it will be necessary to cycle power for the new
parameters to take effect.
5. Repeat above steps for all configured servo guns
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5.3.2 Auto Tune Results:
Close Threshold 123 Improvements dampens the effects of the servo gun experiencing friction due to
mechanical issues. Autotuning a gun provides a summary of guns tuning results on the user screen
and instructions on how to proceed. Each gun will post results after tuning.
USER
Servo Gun Tuning Results EQ:1,GUN:1 Summarizes Standard

overtorque and close
threshold values.
Overtorque SOT 1084 (ct)
TH1,TH2, -542, -503 (ct)
TH3 -382 (ct)
Minimum Calibration Force 1600 (nwt)
Execution Date 07-MAY-10 09:54
EQ:1, GUN:1 Process Results OK
Gives indication if gun tuned ok. If the gun did not tune ok this means the gun tuned
with an SOT >1400(ct). Please check the gun mechanism for following:
C-guns need the gun slide/carriage bearings aligned.
X-guns for binding in the gun pivot bearings.
If the gun is new, stroke the gun several cycles and retune
Notify the project weld gun engineer, if you determine any of these issues.
1. There is binding on the moveable tip of the slide.
2. There are mechanical restriction or gun chassis alignment problems.
TUNEDIAG.PC creates an Autotune timestamp of up to 10 records. To view these records

select TUNEDIAG.PC, then press DATA/KAREL VARS/ TUNEDATE. This can be useful in
logging the history of how often the gun has been retuned. Note deselect TUNEDIAG.PC by
selecting another program, so future auto tunings can be recorded. Backup TUNEDIAG.VA
from MD device to view the results offline on a PC.
SVGN-044 AutoTune Successfully Complete

TUNEDIAG LINE 0 AUTO ABORTED S2 G3 JOINT
100 %
DATA\KAREL\Vars Timestamp
TUNEDATE 1/20
1 [1,1] '07-MAY-10 09:54'
2 [1,2] '1'
3 [2,1] '10-MAY-10 11:31 '
4 [2,2] '1' Gun #
5 [3,1] '10-MAY-10 11:39 '
6 [3,2] '2'
7 [4,1] '10-MAY-10 11:42 '
8 [4,2] '3'
9 [5,1] '10-MAY-10 11:49 '
10 [5,2] '1'
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TUNEDATE: Is based on the date and time on the controller. Ensure that the robot
controller is setup with the correct date and time.
5.4 Help and Hints
If autotuning fails there are a number of possible reasons. The following are a list of the
faults that can occur as well as some possible remedies to these faults.
5.4.1 Collision detection alarm

The axis limits may be swapped.
The axis limits are not set correctly.
The gun may not be mastered correctly.
Perhaps Detailed Autotune is required and value specification is need for load
ration and accel time.
5.4.2 Stop Excess Error
The axis limits may be swapped.
Gun close direction may be incorrect. Should be Plus.
+X should close the gun, if it opens the gun then the motion sign under NoBot
setup at Controlled start needs to be changed.
The gun may not me mastered correctly.
5.4.3 Autotune cannot start

Verify that the robot is in T2 mode with 100% override active.
5.4.4 Pressure Shortage

Verify Mastering
o Make sure tips are touching
Verify Servo Gun setup at controlled start under Maintenance.
6 Pressure calibration
Once the servo weld gun has been mastered and Auto Tuned, it is necessary to perform a
pressure calibration on the system such that the robot can determine the relationship of motor torque
to tip force. Pressure calibration will need to be carried out for each servo gun.
6.1 Equipment
To perform pressure calibration you will need the following items.
1. Calibrated Pressure Gauge set to tracking force rather than Peak especially for C-guns.
2. Force gauge holder assembly
a. This allows for one person pressure calibration by fixing the force gauge to the
stationary gun arm so that the operator has both hands free to run the pressure
calibration from the teach pendent.
b. It is not recommended to run pressure calibration without this assembly because it is
too cumbersome to hold the force gauge and execute the pressure commands from
the teach pendent.
NOTE:
Because the weld gun is an additional axis to the robot, this task must be performed with servo power
available to all robot axes.
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6.2 Performing Calibration
Pressure calibration is to be performed in T1 mode at 100% override. This is possible

because the force calibration takes place at 50mm/s, which is less than 250mm/s.
The following are the steps necessary to calibrate the weld pressures on a servo gun:
1. Press [MENUS] -> [Setup] -> [Servo Gun]

2. Select <*DETAIL*> under General Setup
3. Select <*DETAIL*> under Pressure Cal: (Should show INCOMP)
4. Select [F4:Yes] when prompted to start pressure calibration

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

following pressure
targets:
Set the Lowest

pressure equal to
the tip dress cutter
force
Ensure the last

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

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

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

torque to get an idea
of how the gun will
perform ~5%
starting torque
Speed Value may change

11. The speed value may change when you enter the Torque percentage. This is new for
Spottool+8.20 and Global 3 robot. This speed value is now calculated automatically
during the auto tuning process.
12. With the robot servos reset press SHIFT-[F3: Pressure] to have the robot close the gun at
whatever torque was specified. (Cursor must be on the line for the requested torque)
13. Step A. Adjust Torque (%) up or down until the desired force is achieved. When
pressure calibrating some C-Type guns, lowest pressure may require torque
percentage to be as low as or even lower than 1%. This may result in unreliable
pressure readings. Again, make sure the force gauge is set for Tracking Mode.
Contact the MAAC lead engineer if Torque Percentages are less than 1%.
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Step B. Switch the force guage to Peak Mode and with the robot servos reset press
SHIFT-[F3: Pressure] to have the robot close the gun. Record the peak pressure. If the
peak pressure is greater than the targeted pressure, this gun is experiencing significant
amount of friction. Peak values above 2000kN are abnormal and could cause damage to
the Tipdresser. Contact the weld gun engineer to service gun before proceding with the
gun setup. Note some guns may need to exercised to break them in. After the gun has
been serviced or broke in, rerun Autotune and begin pressure calibration at step 1 again.
Torque can be
adjusted in 0.1%
increments
14. Repeat steps 9 – 13a for each of the pressures in the table up to the maximum rated
force of the gun. Make sure not to exceed the rated force for the gun. The motors
are stronger than the guns.
If the necessary torque required to reach a required force exceeds the

allowed torque (Max Gun Toque (%)), it will be necessary to exit pressure
calibration by setting pressure calibration complete, and accepting/updating
the torque limits when prompted. This will update the over-torque limits. To
complete pressure calibration simply restart pressure calibration and the
limits will have been increased, allowing for the completion of pressure
calibration.
15. When torque values have been entered for all valid pressures in the table, change the
Calibration Status to complete.
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Cursor up to
INCOMP when
complete with
pressure
calibration
Press F4:COMP
to complete
pressure
calibration
16. Select [F4:COMP] to enable new parameters
17. Select [F2:END] to complete Pressure Calibration
6.3 Help and Hints
The majority of the issues that will occur during pressure calibration are errors that have to do
with the pressure calibration settings.
1. Move Error Excess

Make sure pushing depth is set less than the gauge thickness
2. Stop Excess Error
Verify gauge thickness
o When error occurs, select [POSN] if faulted position is -13.01 to -13.99,
change thickness to 14 mm.
3. Collision guard alarm
Make sure that the gauge thickness is set correctly
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4. Pressure gauge shows radically different pressures
Increase Pressuring time
5. Gun cannot achieve the lowest requested pressure in the calibration table.. This could
be indication that the gun is experiencing higher than normal friction. Accept the lowest
attainable pressure with the guage in tracking mode. Complete the remaining pressure
calibration targets ,then review the details of servo gun overtorque protection
menu(Section 7.0). If the Standard overtorque value exceeds 1400 torque counts the
gun mechanism is experiencing higher than normal resistance during and must be
checked for the following:
C-guns need the gun slide/carriage bearings aligned.
X-guns could binding in the gun pivot bearings.
A failing servo actuator.
Notify the project weld gun engineer, if you determine any of these issues.
6. Requested Torque % exceeds limit and Pressure calibration cannot be performed

This occurs when attempting to calibrate a torque that is greater than that specified
under Max Gun Toque (%). This can occur because the values that Fanuc defaults
to are conservative and assume full mechanical advantage.
1. To allow calibration to use torques greater than max torque it is necessary to
exit pressure calibration by setting pressure calibration complete and
accepting/updating the torque limits when prompted. This will update the
over-torque limits.
2. Restart Pressure calibration and the limits will have been increased, allowing
for the completion of pressure calibration.
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7. Overtorque Protection
Servo Gun OverTorque protection is part of the Servo Gun Software Option. OverTorque
Protection is designed to reduce the damage to servo guns and servo gun actuators cause by
excessive tip force. OverTorque protection monitors the motor current on the servo gun axis to
determine if an unexpected disturbance is present. It then removes servo power from the motor and
post a “Collision Detect Alarm” when a potential over torque condition is captured.
OverTorque Protection is enabled by default with a sensitivity of 100%. To optimize

OverTorque Protection the sensitivity can be increased to a max of 200% or decreased to 1. Note
that the sensitivity can only be decreased to the max force of the gun. Sensitivity can only be
modified after the servo gun has completed the Autotune process.
It is important to view the Standard Overtorque value after Autotune and Pressure calibrating
a servo gun. This value is an indirect measure of the friction in a gun as measured during Autotune.
The peak value is captured during the Autotune process. Guns that exhibit high Standard
OverTorques are subject to momentarily achieving higher than desired tip forces. This is a result of
the gun needing a large amount of torque to move, and in some cases this torque due to friction can
be larger than the desired welding or tip dress force. If this value is greater than 1400 torque counts,
this condition exists. It is normal for new guns to experience a break in period and they should be re-
Autotuned and re-pressure calibrated after being broke in. Guns with Standard Overtorques above
1400 torque counts should be evaluated for mechanical issues.
To view the Overtorque Protection Menus and the Standard Overtorque value use the following
procedure:

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3. Select <*DETAIL*> under Overtorque protection:
4. Select <*DETAIL*> under Parameter Summary and press Enter
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5. Ensure Standard Overtorque doesn’t exceed 1400 torque counts.
8 Servo Gun Diagnosis

As servo gun friction changes from its pressure calibrated state, tip forces can be affected.
This servo gun software option is used to detect changes in servo gun friction and inform the
user and cell controller via an in the cell interface.
Recommended SG Diagnosis Setup:
1. Set System Variable $SGDIAGCFG.$AUTORESET = 2. This resets the baseline

record each time SG diag is ran after the gun is Autotuned.
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3. Select <*DETAIL*> under General Setup.
4. Select <*DETAIL*> under Servogun diagnosis
5. Set up screen as follows: Enable
Enable Max
Torque Check
ONLY when
running parts at
frequency equal to
normal production.
0.8% is a % of
amplifier torque
increase where tip
forces may begin
to deviate by 10%
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Set to create SG
Diag record daily,
the next time
capwear calls
TWZRCLB2 after
9:00 per the robots
system clock.
Diag should be
scheduled after the
Program called gun is in normal
each cycle during operation(cycled).
capwear.
SGTorqAlert bit
mapped to cell
interface to alert
system of that the
torque has
increased and the
gun should be
pressure checked!
Output stays on
until manually
shutoff by user on
DO screen to
confirm alert has
been
acknowledged!!
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9 Tip Wear Compensation
Because the GM Global weld guns do not include equalizers, it is necessary to program the
stationary tip touching the metal. As the stationary tip wears through welding and tip dress, it is
necessary to determine the amount of tip wear present on each tip, and to offset the robot path to
keep the stationary tip in contact with the part throughout the life of the cap. To enable this, the robot
has certain macros that setup the tip wear compensation, and other macros that will calculate the
wear throughout the life of the cap.
There are a few things that must be remembered when running with tip wear compensation
enabled. First is that after changing the caps on the robot, it is necessary to update the tip wear,
telling the robot that it has new tips. If this is not done, the robot may bend the flange with the
stationary tip, causing damage to the part, gun, or causing collision alarms.
9.1 Setup
To setup Tip Wear Compensation it is necessary to enable compensation under Servo Gun
Setup, and to run the respective setup program for the configured servo guns. For dual guns on a
single equipment tip wear compensation is enabled or disabled for both guns
9.1.1 Enabling Tip Wear Compensation
To enable Tip Wear compensation, navigate to the Servo Gun Setup Menu for the
respective gun and enable Tip Wear Compensation.

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

will show COMP
when setup program
is run
Note: For dual guns Tip Wear compensation is Enabled/Disabled for both guns.
For 2 guns on 1
Equipment, Tip Wear
Comp, Gun Sag and
robot close direction
are under Dual Gun
Common
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ENABLE
9.1.2 Running Tip Wear Compensation Setup Program(s)
To run the tip wear setup program, simply select the appropriate setup program and run the
program from the teach pendent. Be sure that new caps are firmly seated on the gun before running
the tip wear setup routine. TW_SETGx will take the gun stroke limits from the gun setup utility to
reference cap wear. If TW_SETGx is run any other time, verify that the servo setup gun stroke
limits match the gun stroke utility setup screen. If they don’t match, manually enter the proper
stroke limits on the stroke limit screen under MENUS/SETUP/SERVO GUN/GUN STROKE LIMIT.
Note: If the robot is a Tool Changer TW_SETGx is replaced with TWSTGXTC
The setup programs (macros) are as follows:

TW_SETG1.TP for Gun 1
The tip wear setup program for Tool Changers is as follows:

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

9.2 Viewing Tip Wear values
To view the tip wear values:

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3. Select <*DETAIL*> under Tip Wear Standrd

Shows complete when
tip wear setup has been
complete
The actual measured tip

wear will show up here.
It will show 0.00
immediately after tip
wear setup is complete.
After a wear update, or a
cap change this value
may be non zero. All
measurements are
based relative to the
setup. The values may
not be zero after a cap
change, as all caps are
slightly different in length
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9.3 Tip Wear Updating
Once tip wear setup has been completed, the robot will periodically update the tip wear value
by running a tip wear routine that will close the gun and determine the total amount of wear. It will
then apply the tip wear ratio in splitting the wear between the moveable and stationary tips. The
standard software is configured to update one gun every cycle. For a single gun case, it will update
every cycle, and for a four gun case it will update each gun every 4 cycles. There is a register in the
robot that keeps track of the last gun updated and indexes to the next gun automatically.
9.3.1 Tip Wear Routines
There are several programs that are run to perform the necessary tip wear functionality. For
the most part the operator will need to do nothing with these routines as they are nested into
the code, but are listed here for completeness.
9.3.1.1 TW_GUNS(x) x= gun number
This program is run whenever the steppers are reset, or whenever new caps are placed on
the robot. This routine calls TW_UPDCC(x) for the specified servo gun.
9.3.1.2 CAP_WEAR
This program is run every cycle to update the tip wear on one of the servo guns. This routine
is typically run on the way home after entering segment 63 (clear of transfer) or during a
drop-off for a pedestal application. This routine will only update a single gun every cycle
because of the time involved ~ 4 seconds. With that said, each gun will update every 4th
cycle worst case.
9.3.1.3 TW_UPDT(x) x= gun number
This is the routine that Cap Wear calls to update the wear on a specific gun. This routine is
also called outright to update a specific gun by the tip dress routines. When this routine is
run, it will close the selected gun and measure the tip wear from the original position that was
recorded when Tip Wear Setup was done. This routine expects that each successive
measurement will show increased wear. This routine will allow the caps to grow by a small
amount (configurable) in case of a 'Cling-On' during a tip dress.
9.3.1.4 TW_UPDCC(x) x= gun number
This is the routine that TW_GUNS(x) calls to update the wear on each gun. When this
routine is run it will close the selected gun and measure the tip wear from the original position
that was recorded when Tip Wear Setup was done. This routine expects the caps to grow,
as expected with new caps.
9.3.1.5 TW_REG(x) x=gun number
This routine was added to provide enhanced servo gun tip wear information. It updates the
amount of wear during the tip dress and posts the servo gun tip approaching max wear
warning bit.
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9.3.1.6 WR_UPDAT(x)(y) x=gun number y= new tips flag
This routine updates or resets the tipwear values.
9.3.1.7 CHK_WEAR
This routine checks the tipwear values and compares them to the last known wear values to
determine if the caps were changed on a particular gun. It checks every configured gun.
This program is called from TIP_RST and is executed prior to resetting the steppers and
wear.
9.3.1.8 TW_GNRST
This program is called from TIP_RST. The program calls TW_GUNS(x) for any configured
gun that has a cap change request and different set of caps as determined by CHK_WEAR. If
different caps were detected without a cap change request or a cap change was requested
with the same caps are detected by CHK_WEAR, the user will be prompted for direction.
9.3.1.9 GET_CFG
This Karel program was developed to check the configuration of the robot to aid in the cap
changing process. It does this by gathering the cap change requests from the PLC or by
prompting the user if TIP_RST is ran manually from the TP. It is called from TIP_RST.
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11 Set Gun Close Direction
The gun close direction defines direction the tips move to close and weld. For the
moveable tip which the Fanuc software refers to as Gun, should be set to PLUS, indicating
that the positive displacement of the moveable tip closes the gun. For the Stationary tip,
which the Fanuc software refers to as Robot, needs to be set to indicate the direction that the
TCP must move to bring the stationary tip to the work piece. This setting is critical, because
it determines the direction the robot will move to place work piece on the stationary tip as it
goes through the motions that encompass a weld with a servo gun.
11.1 Carried +Z
For Carried spot welding applications, the gun Close direction (Robot) shall be
relative to the Utool of the gun and shall be +Z, for the tool as defined in RS-3.
UT: UTOOL
11.1.1 Single Gun Should be set to UT for
Carried Applications
1 (UTOOL #)
This is the Utool to use
for Close Gun Direction
(Robot)
+Z
The direction the robot
moves relative to the
UTOOL to bring the
stationary tip to the
metal
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11.1.2 Dual Gun Single Equipment
Select [Detail] to look at

Dual Gun Common
Items
UT: UTOOL
Should be set to UT for
1 (UTOOL #)
This is the Utool to use
for Close Gun Direction
(Robot)
+Z
UTOOL to bring the
metal
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11.2 Pedestal +Z
For Pedestal spot welding applications, the gun Close direction (Robot) shall be
relative to the UFrame of the gun and shall be -Z, for the tool as defined in RS-3.
11.2.1 Single Gun

UF: FRAME(RTCP)
1 (UFRAME #)
This is the UFrame to
use for Close Gun
Direction (Robot)
+Z
UFRAME to bring the
metal
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11.2.2 Dual Gun Single Equipment
Select [Detail] to look at

Dual Gun Common
Items
UF: FRAME(RTCP)
1 (UFRAME #)
This is the UFrame to
use for Close Gun
Direction (Robot)
+Z
UFRAME to bring the
metal
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12 Pressure schedules
General Motors has standardized the Pressure Schedules that are to be used for all servo
welding applications. These 16 pressure schedules are not to be modified, because they include the
best compromise between speed, performance and complexity. If a need arises that requires a
unique pressure schedule, it will be necessary to add a schedule. However, this will require buy-in
from the lead robot and welding engineers due to the fact that it affects the weld spot verification
process, and leads to uniqueness, and added complexity.
12.1 Background
The pressure schedules in the robot controls more than just the weld pressures, it also
controls the way the robot approaches a weld and departs after a successful weld. There are 99
pressure schedules available for each gun. The elements listed below are available for each of the
99 schedules.
To access the pressure schedules in the robot:

1. Press [Data]
2. Press [F1: Type] -> [Pressure]
1. Setting
Manual=True will
cause the specified
schedule to appear
in the select list
when the [Gun] U1
key is pressed by
Verify the user
These are the
2. Pressing [Gun] (non-
default
shifted) U1 will
pressure
select the next
schedules for
Pressure Schedule
all robots. Only
the forces up to in the list that is set
the max rated TRUE
force of the gun
will be present 3. Pressing [Shift] -
[Gun] U1 will cause
the weld gun to
move to close at the
defined pressure
Note: When validating pressure schedules, it is important to do so with tryout mode

DISABLED
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12.2 Elements
There are 4 elements to each pressure schedule that need to be set correctly for the servo
guns to operate in an efficient and effective manner.
1. Weld Force
The amount of force the gun will apply before welding.
2. Gun Sag
The amount of deflection (flex) on the stationary tip that is caused by closing the gun
to the prescribed pressure.
3. Pushing Depth
The maximum distance that the robot will push to build pressure.
4. Contact Speed
The speed at which the welding electrodes will contact the work piece.
12.2.1 Weld Force
The weld pressure is the tip force (weld pressure) the robot will apply before initiating the
weld controller.
To access a pressure schedule in the robot:
1. Press [Data] hard key

2. Press [F1: Type] - > [5: Pressure]
3. Cursor to select desired schedule
4. Select [F4: Detail]
5. Cursor to Weld Pressure to modify
NOTE:
Because the robot does not initiate the weld before the gun is at pressure minimal squeeze
time is necessary in the welder control.
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12.2.2 Gun Sag
The servo gun has the ability to compensate for gun deflection as the weld force increases,
allowing the stationary tip to remain in the same position as the force increases. This is especially
important on C-Guns where the stationary/fixed gun arm wants to deflect under load. By setting up
gun sag, the robot can move the stationary/fixed tip in the opposite direction of deflection, allowing for
a consistent weld location without the use of an equalizer. This is especially important because the
C-Guns do not incorporate pneumatic or spring equalization, with the exception of dual guns and hard
automatic fixture guns.
12.2.2.1 Enabling
The Gun Sag Compensation must be enabled for the robot to compensate for gun deflection.

3. Select Enable under [Gun Sag Compensation]
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12.2.2.2 Setup
1. Make sure that Gun Sag Compensation is enabled

2. Verify that the gun sag values are not 0.0mm in the pressure schedule detail page. [Gun
Sag Comp Value (mm)] will be calculated automatically from data taken during
Autotuning, and will be automatically filled into the pressure schedules once pressure
calibration is complete.
This value is
calculated
automatically after
Auto Tuning and
Pressure
Calibration are
completed
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12.2.2.3 Pushing Depth
The pushing depth indicates how far the robot will move past where it expects to build
pressure, before it faults with a pressure shortage. For example if the part thickness is set to 3mm in
the SPOT statement (SPOT[SD=10,P=1,t=3.0,S=1,ED=10]), the robot expects to build force when the
tips are 3mm apart. The pushing depth feature allows the robot to search past this point to build
pressure so that minor variations in part thickness to not cause nuisance faults. The default pushing
depth for all pressure schedules is 6mm.

5. Cursor to pushing depth to modify
Pushing depth is
6mm for schedules
1-16
12.2.2.4 Contact Speed
Contact speed indicates the speed at which the welding electrodes will contact the work
piece. This value by default is the speed that was used during the pressure calibration of the servo
gun. This value should not be adjusted except for certain applications such as tip dress that a higher
or lower contact speed is desired for the process.
Note:
Increasing the contact speed higher than that used for calibration can lead to a higher force
deviation from that calibrated.

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10. Cursor to Contact Speed percentage to modify
Optimum speed is
automatically
calculated for all
calibrated
schedules. The
default setting is
50mm/s
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13 Backup schedules
The robot has the ability to program backup positions that specify how much the gun is to
open when the specified Backup schedule is called. This offers a simplified method of
programming gun open positions, without requiring the user to jog the weld gun axis. The backup
command can be added to the standard SPOT instruction, or executed as a manual function using
the Backup Key.
There are 30 backup schedules that can be programmed for each gun.
To locate the Backup Data:
1. [DATA] -> [F1:TYPE] -> [6:Backup]
1. Setting Manual=True will

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

shifted) U2 will select the
next Backup position in the
list
3. Pressing [Shift] -
[BACKUP] U2 will cause
the weld gun to move to
the currently selected
Backup position
The Backup Schedules are pre-defined in 10mm increments. This will allow for easy
assignment of Backup Schedules without referring to the backup data. I.e. Backup No. 1 is 10mm,
BU #2 is 20mm, BU #15 is 150mm and so on. This table can be adjusted as necessary for specific
applications, but should be fine as is, with the operator setting Manual = True for those positions that
they want to access from the Backup Key.
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14 Distance Schedules
The robot has the ability to program distance schedules that specify how close the gun is to
be to the work piece as it approaches a weld. The associated parameters are for Gun (Moveable)
Robot (Stationary) tips. These distance schedules are used in the SPOT instruction to determine the
position the robot moves the caps to prior to and after a weld. All values are in addition to the part
thickness. So if you are calling a SPOT instruction with a pressure schedule that is 3mm, and you
use SD (Start Distance) =4, the tips are 11mm apart. 4mm above the part and 4mm below the part.
The same applies for ED (End Distance), which is where the robot will move the gun to after the weld.
L P[2] 1500mm/sec CNT100

SPOT[SD=4,P=1,t=4.5,S=1,ED=4] ;
There are 99 distance schedules that can be programmed for each gun.
To locate the Distance Data:
1. [DATA] -> [F1:TYPE] -> [Distance]
The Distance Schedules are pre-defined in 1mm increments for distances 1 thru 20 this will
allow for easy assignment of Distance Schedules without referring to the distance data. I.e. Distance
#1 is 1mm, Distance #10 is 10mm and so on. Distance Schedules 21-34 range from 40mm-320mm,
this allows for multiple open distances for the moveable tip.
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15 Program listings
15.1 Style templates
The following templates are unique to servo gun applications and are listed here so that the
differences can be explained and documented.
15.1.1 Carried Servo Gun
1: !************************* ;
2: !STYLE XX CARRIED WELDER ;
3: !Servo Gun TEMPLATE ;
4: !************************* ;
5: ;
6: ! Line-XX Platform-XX ;
7: ! Station XXX - Robot X ;
8: ;
9: !ECHO STYLE AND OPTION ;
10: GO[1:ManualStyle]=... ;
11: ECHO OPTION ;
12: MAINT_PROG[1]=MOV_REPR ;
13: ;
14: CALL S01POUNC ;
15: ;
16: CALL STPR_CHK ;
17: ;
18: CALL S01PROC1 ;
19: ;
20: RUN CAP_WEAR ;
21: ;
22: MOVE TO HOME ;
23: ;
24: WAIT (F[1:Capwear Complete]) ;
WAIT (F[1]
This wait allows for the tip wear
update to complete prior to the style
aborting
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15.1.2 Single Pedestal Servo Gun
1: !************************* ;
2: !STYLE XX MH 1PED SPOT ;
3: !SERVO GUN TEMPLATE ;
4: !************************* ;
5: ;
8: ;
11: ECHO OPTION ;
12: ;
13: !FFR HANDLER ;
14: IF DO[18:FFRActive]=ON,JMP LBL[10] ;
15: ;
16: CALL POUNCE ;
17: ;
18: CALL STPR_CHK ;
19: ;
20: CALL SxxPICK1 ;
21: ;
22: !CHECK FOR PROCESS BYPASSED ;
23: IF DO[66:Process1Bypassed]=ON,CALL BYPPROC1 ;
24: IF DO[66:Process1Bypassed]=ON,JMP LBL[20] ;
25: ;
26: LBL[10] ;
27: MAINT_PROG[1]=FFRPROC1 ;
28: ;
29: !********************* ;
30: !IF NO TIP DRESSERS ;
31: !CONFIGURED REMOVE THIS ; Remove this section if no
32: !SECTION ; tipdressers are configured.
33: CALL TDDMPCHK(1) ;
34: !********************* ;
35: ;
36: CALL SxxPROC1 ;
37: ;
38: !FFR HANDLER FOR PROCESS 1 ;
40: ;
41: LBL[20] ;
42: REQUEST CONTINUE ;
43: ;
44: !********************* ;
46: !CONFIGURED REPLACE ; Replace CALL TD_PD_CK with
47: !CALL TD_PD_CK WITH ; RUN CAP_WEAR if no
48: !RUN CAP_WEAR ;
tipdressers are configured.
49: CALL TD_PD_CK ;
50: !********************* ;
51: ;
52: CALL SxxDROP1 ;
53: ;
54: MOVE TO HOME ;
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55: ;
57: LBL[99] ;
15.1.3 Dual Pedestal Servo Gun
1: !************************* ;
2: !STYLE XX MH 2PED SPOT ;
3: !SERVO GUN TEMPLATE ;
4: !************************* ;
5: ;
8: ;
9: ;
12: ECHO OPTION ;
13: ;
14: !FFR HANDLER ;
15: IF DO[18:FFRActive]=ON,JMP LBL[R[160]] ;
16: ;
17: CALL POUNCE ;
18: ;
19: CALL STPR_CHK ;
20: ;
21: CALL SxxPICK1 ;
22: ;
23: !CHECK FOR PROCESS BYPASSED ;
26: ;
27: LBL[10] ;
28: R[160:FFR Process LBL]=10 ;
30: ;
31: !********************* ;
36: !********************* ;
37: ;
38: CALL SxxPROC1 ;
39: ;
42: ;
43: LBL[20] ;
44: !CHECK FOR PROCESS2 BYPASSED ;
47: ;
48: R[160:FFR Process LBL]=20 ;
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50: ;
51: !********************* ;
56: !********************* ;
57: ;
58: CALL SxxPROC2 ;
59: ;
62: ;
63: LBL[30] ;
64: ;
66: ;
67: !********************* ;
69: !CONFIGURED REPLACE ; Replace CALL TD_PD_CK with
70: !CALL TD_PD_CK WITH ; RUN CAP_WEAR if no tipdressers
71: !RUN CAP_WEAR ; are configured
72: CALL TD_PD_CK ;
73: !********************* ;
74: ;
75: CALL SxxDROP1 ;
76: ;
77: MOVE TO HOME ;
79: LBL[99]
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15.2 Process Path Templates
15.2.1 Spot Process 1 Template (TMSPROC1)
/PROG TMSPROC1
.... Default motion group
COMMENT = "SPOT PROC1 V3.0";
.... should be set to groups
DEFAULT_GROUP = 1,1,*,*,*; 1 & 2 for Process 1
CONTROL_CODE = 00000000 00000000; (1,1,*,*,*;).
/APPL
SPOT : TRUE ;
SPOT Welding Equipment Number : 1 ; Spot Welding
Equipment number
1: !************************* ;
2: !STYLE XX Spot Process1 ; should be set to 1.
3: ! SxxPROC1 TEMPLATE ;
4: !************************* ;
5: !PATH SEGMENT - BEGIN PROCESS ;
6: SET SEGMENT(50) ;
7: !Pass Body Id to Welder Control ;
8: GO[43:Weld BodyID Cnt1]=(GO[1:ManualStyle]) ;
9: UFRAME_NUM=0 ; Part Thickness added to Spot
10: UTOOL_NUM=1 ; Instruction. New for Global 3.
11:J P[1] 100% FINE ;
12:L P[2] 80mm/sec CNT50 ;
13:L P[3] 400mm/sec CNT100
: SPOT[SD=10,P=1,t=8.0,S=1,ED=10] ;
14:L P[4] 400mm/sec CNT100
: SPOT[SD=10,P=1,t=8.0,S=1,ED=10] ;
15: ;
16: !After last spot send ;
17: !part complete to welder ;
18: CALL PARTCOMP(1) ;
19:J P[5] 80% CNT50 ; New features of Global 3:
20:J P[6] 100% CNT100 ;
21: !PATH SEGMENT - All CLEAR ; Weld Body ID is now
22: SET SEGMENT(63) ; passed to Weld
23:J P[7] 100% FINE ;
controller
PARTCOMP(X) macro
created to signal the
welder the part is
finished. ( X = WC#)
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15.2.2 Spot Process 2 Template (TMSPROC2)
/PROG TMSPROC2
....
COMMENT = "SPOT PROC2 V3.0"; Default motion group
....
DEFAULT_GROUP = 1,*,1,*,*; should be set to groups
CONTROL_CODE = 00000000 00000000; 1 & 3 for Process 2
/APPL (1,*,1,*,*;).
SPOT : TRUE ;
SPOT Welding Equipment Number : 2 ;
1: !************************* ; Spot Welding

2: !STYLE XX Spot Process2 ; Equipment number
3: ! SxxPROC2 TEMPLATE ; should be set to 2. If a
4: !************************* ;
5: !PATH SEGMENT - BEGIN PROCESS ; single weld controller is
6: SET SEGMENT(55) ; used set to 1.
7: !Pass Body Id to Welder Control ;
8: GO[46:Weld BodyID Cnt2]=(GO[1:ManualStyle]) ;
9: UFRAME_NUM=0 ;
10: UTOOL_NUM=2 ;
11:J P[1] 100% FINE ;
12:L P[2] 80mm/sec CNT50 ; Part Thickness added to Spot
13:L P[3] 400mm/sec CNT100 Instruction. New for Global 3.
: SPOT[SD=10,P=1,t=8.0,S=1,ED=10] ;
14:L P[4] 400mm/sec CNT100
: SPOT[SD=10,P=1,t=8.0,S=1,ED=10] ;
15: ;
16: !After last spot send ;
17: !part complete to welder ; New features of Global 3:
18: CALL PARTCOMP(2) ;
19:J P[5] 80% CNT50 ; Weld Body ID is now
20:J P[6] 100% CNT100 ; passed to Weld
21: !PATH SEGMENT - All CLEAR ;
controller
23:J P[7] 100% FINE ; PARTCOMP(X) macro
created to signal the
welder the part is
finished. ( X = WC#)
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15.3 Miscellaneous Servo Gun Macros
15.3.1 STPR_CHK
This routine is called at pounce by all servo gun applications. It checks if the Steppers are
reset, and if so performs a tip wear update automatically. This is critical if the steppers were reset
from the DEP, or through some means that did not do a tip wear update. This routine does not check
if an update was done, but simply performs an update on all configured Servo Guns that have the
steppers reset.
1: !******************************** ;
2: !THIS MACRO RUNS TIP WEAR UPDATE ;
3: !IF IT DETECTS THAT STEPPERS ARE ;
4: !RESET ;
5: !IT CHECKS FOR ALL CONFIGURED SCR ;
6: !******************************** ;
7: ;
8: CALL NUM_GUNS ;
9: LBL[10] ;
10: !If Air gun skip tip wear update ;
11: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ;
12: !Check for Stepper Reset on Gun 1 ;
13: IF (DO[66:Process1Bypassed] OR !DI[1039:diSW1StepResetG1]),JMP LBL[20] ;
14: IF R[96:TD1 LAST SCHED]=247 OR R[96:TD1 LAST SCHED]=249 OR R[96:TD1 LAST
SCHED]=251 OR R[96:TD1 LAST SCHED]=253,JMP LBL[20] ;
15: CALL TW_GUNS(1) ;
16: !Turn on TD Request for Gun1 ;
17: DO[89:doP1TipMantReqG1]=ON ;
18: ;
19: LBL[20] ;
20: IF R[16:NUM SERVO GUNS]=1,JMP LBL[99] ;
21: !If 2 guns and 1 weld controller ;
22: IF R[16:NUM SERVO GUNS]=2 AND $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[21] ;
23: !If 2 guns and 2 weld controllers ;
24: IF R[16:NUM SERVO GUNS]=2 AND $SPOTCONFIG.$NUM_WD_CTLS=2,JMP LBL[22] ;
25: LBL[21] ;
26: ;
29: JMP LBL[23] ;
30: LBL[22] ;
33: IF DI[1103:diSW2StepResetG1]=OFF,JMP LBL[30] ;
34: LBL[23] ;
35: !Wear Skip From Predress Gun2 ;
38: !Turn on TD Request for Gun2 WC1 ;
39: IF (R[16:NUM SERVO GUNS]=2 AND
$SPOTCONFIG.$NUM_WD_CTLS=1),DO[90:doP1TipMantReqG2]=ON ;
40: !Turn on TD Request for Gun1 WC2 ;
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41: IF (R[16:NUM SERVO GUNS]=2 AND
$SPOTCONFIG.$NUM_WD_CTLS=2),DO[121:doP2TipMantReqG1]=ON ;
42: ;
43: LBL[30] ;
47: IF DI[1040:diSW1StepResetG2]=OFF,JMP LBL[20] ;
53: ;
54: LBL[40] ;
57: IF (DO[98:Process2Bypassed] OR DI[1104:diSW2StepResetG2]),JMP LBL[99] ;
63: ;
64: LBL[99:END] ;
15.3.2 CAP_WEAR
This routine is called either by the style program or by the tip dress check program for
pedestal tip dressing robots. For carried guns this routine should be called after the robot is clear of
transfer (Segment 63) and on the way home. For pedestal applications this routine should be called
before the drop off routine, so that the robot can update a gun while dropping the part off. This
routine calls NUM_GUNS which determines the number of servo guns on the robot. It then
increments a R15 by 1 and does a wear update on that gun. Once the number of guns limit is
reached it sets R15 to 0 and the updating starts back at gun 1. The Flag F1 allows this task to
competed prior to aborting the style program. See style templates for examples
1: F[1:Capwear Complete]=(OFF) ;
2: IF ($SPOTCONFIG.$STROKE_ENBL=0 OR DO[43:FFRActive]=ON),JMP LBL[99] ;
3: CALL CHK_TIPS ;
4: IF R[218:CapWear Skip]=1,JMP LBL[99] ;
5: CALL NUM_GUNS ;
6: R[15:SERVO WEAR UPDT]=R[15:SERVO WEAR UPDT]+1 ;
7: IF R[15:SERVO WEAR UPDT]>R[16:NUM SERVO GUNS],JMP LBL[10] ;
8: ;
9: CALL TW_UPD(R[15:SERVO WEAR UPDT]) ;
10: CALL TW_REG(R[15:SERVO WEAR UPDT]) ;
11: JMP LBL[20] ;
12: ;
13: LBL[10] ;
14: R[15:SERVO WEAR UPDT]=0 ;
15: ;
16: LBL[20] ;
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17: IF R[15:SERVO WEAR UPDT]=R[16:NUM SERVO GUNS],JMP LBL[10] ;
18: ;
19: LBL[99] ;
20: F[1:Capwear Complete]=(ON) ;
15.3.3 NUM_GUNS
This routine is called by CAP_WEAR and simply determines the number of servo guns active
on the robot. It puts this value in R16.
1: ;
2: !GUN 1 IS EQ1 GUN 1 ;
3: R[16:NUM SERVO GUNS]=1 ;
4: IF $spoteqsetup[1].$num_guns=1,JMP LBL[10] ;
7: LBL[10:END EQ1 CHECK] ;
8: ;
9: IF $SPOTNUMEQ=1,JMP LBL[99] ;
10: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[99] ;
11: ;
15: JMP LBL[30] ;
16: ;
17: LBL[20: RESET GUN 3] ;
20: ;
25: ;
26: LBL[99] ;
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15.3.4 TW_GUNS
This routine is called by TW_GNRST, after a cap change to run a tip wear update on all requested
configured servo guns. TW_UPDCC(X) is the tip wear program for new caps (Tip Wear Update
Caps Changed), where X is the gun number. This routine also makes sure that stroke is enabled, so
the robot does not try to update in no stroke.
1: LBL[1] ;
3: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ;
6: ;
7: IF (AR[1]=1),JMP LBL[10] ;
8: IF (AR[1]=2),JMP LBL[20] ;
9: IF (AR[1]=3),JMP LBL[30] ;
10: IF (AR[1]=4),JMP LBL[40] ;
11: IF (AR[1]>4),JMP LBL[5] ;
12: IF (AR[1]<1),JMP LBL[5] ;
13: ;
16: CALL TW_UPDCC(1) ;
17: ;
18: !VERIFY NEW/CORRECT CAP ;
19: R[20:SERVO GUN WORK]=($SGGUN1.$SETUP.$WRDWN_TIP) ;
20: R[21:SERVO GUN WORK]=($SGGUN1.$SETUP.$WRDWN_RBT) ;
21: R[28:SERVO GUN WORK]=($SGGUN1.$SGTWD.$GNWR_AT_CHG) ;
22: R[29:SERVO GUN WORK]=($SGGUN1.$SGTWD.$RBWR_AT_CHG) ;
23: ;
24: !Set Cap Wear Tip Tolerance Check ;
25: !Compare new tips to Large/Small ;
26: !tolerance based on last tip wear ;
27: CALL SETWRTOL(1) ;
28: ;
29: !Ensure New Cap is within Toleran ;
30: IF R[20:SERVO GUN WORK]>R[219:NwCapsWearUprLMT] OR R[20:SERVO GUN
WORK]<R[220:NwCapsWearLwrLMT] OR R[21:SERVO GUN WORK]>R[219:NwCapsWearUprLMT]
OR R[21:SERVO GUN WORK]<R[220:NwCapsWearLwrLMT],JMP LBL[15] ;
31: ;
32: IF (R[20:SERVO GUN WORK]-R[28:SERVO GUN WORK]<>0),JMP LBL[45] ;
34: CALL TW_REG(1) ;
35: JMP LBL[99] ;
36: ;
40: ;
46: ;
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51: ;
54: ;
58: JMP LBL[99] ;
59: ;
63: ;
69: ;
74: ;
77: ;
81: JMP LBL[99] ;
82: ;
86: ;
92: ;
97: ;
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100: ;
104: ;
105: JMP LBL[99] ;
106: ;
107: !************ FAULTS ************ ;
108: LBL[5:INVALID ARGUMENT] ;
109: UALM[1] ;
110: JMP LBL[1] ;
111: ;
112: LBL[15] ;
113: !Ensure Water is OFF ;
114: CALL WTR_OFF(1) ;
116: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[25] ;
118: LBL[25] ;
119: IF (R[219:NwCapsWearUprLMT]<>R[235:SmallCapWrUprLmt] AND
R[220:NwCapsWearLwrLMT]<>R[236:SmallCapWrLwrLmt]),JMP LBL[35] ;
120: ;
121: CALL CUSTOYN(28,40) ;
122: IF R[40:Prompt Y/N]=1,JMP LBL[99] ;
123: ;
124: CALL USERCLR ;
125: CALL USERPAGE ;
126: MESSAGE[CAP CHANGE OUT OF TOLERANCE] ;
127: MESSAGE[...] ;
128: MESSAGE[STEPPERS HAVE BEEN RESET!] ;
129: MESSAGE[CONFIRM NEW CAPS AT] ;
130: MESSAGE[NEW TIPS ERROR PROMPT] ;
131: MESSAGE[TO CONTINUE!] ;
132: DO[67:Process1Fault]=ON ;
133: UALM[49] ;
134: DO[67:Process1Fault]=OFF ;
135: JMP LBL[15] ;
136: ;
137: LBL[35] ;
138: CALL USERCLR ;
140: ;
142: MESSAGE[...] ;
143: MESSAGE[ CAP CHANGE VERIFICATION] ;
144: MESSAGE[ FAILED TIP WEAR CHECK ] ;
145: MESSAGE[CHECK GUN FOR:] ;
146: MESSAGE[1. CORRECT CAP TYPE ] ;
147: MESSAGE[2. NEW CAPS] ;
148: MESSAGE[3. SERVO GUN MASTERING] ;
149: MESSAGE[!WEAR WITH NEW CAPS NOT <2mm] ;
151: UALM[49] ;
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153: JMP LBL[1] ;
154: ;
155: LBL[45] ;
156: CALL USERCLR ;
158: ;
159: MESSAGE[...] ;
160: MESSAGE[...] ;
161: MESSAGE[ WEAR AFTER CAPCHANGE] ;
162: MESSAGE[ IS NOT ZERO] ;
163: MESSAGE[...] ;
164: MESSAGE[...] ;
165: MESSAGE[ REPLACE CAPS] ;
166: MESSAGE[...] ;
167: MESSAGE[...] ;
169: UALM[49] ;
171: JMP LBL[1] ;
172: ;
173: LBL[99] ;
174: !Ensure Water Reset ;
175: CALL RST_WTR ;
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15.3.5 WR_UPDAT
This routine is called to execute tipwear update or reset the wear values. Gun number and a new tips
flag is passed to this program depending on the robot program execution. In some cases the tipwear
is updated, in other cases it is reset with new weld caps.
2: !Program description ;
3: ! Update fixtureless wear measmt ;
4: ! Version:6.40 ;
5: ;
6: !Input parameters ;
7: ! AR[1]: Gun number ;
8: ! AR[2]: New tip ( reset wr ) ;
9: ;
10: !Data registers R[] used ;
11: ! R[10]: Work register ;
12: ! R[11]: Work register ;
13: ;
14: !Position registers used ;
15: ! PR[20]: Position at wr start ;
16: ! PR[21]: Work position register ;
17: ;
18: !Update grp mask for motn prog ;
19: ! Parm1: gun number ;
20: ! Parm2: program name ;
21: CALL TWKGPMSK(AR[1],'TW_MVGUN') ;
22: ;
23: !Write present position to PR ;
24: ! Parm1: Gun ;
25: ! Parm2: Position register index ;
26: ! Parm3: Typ(1=opndist,2=curpos) ;
27: CALL TWKWRTPR(AR[1],20,2) ;
28: ;
29: !Write open distance to PR ;
30: ! Parm1: Gun ;
32: ! Parm3: Typ(1=opndist,2=curpos) ;
33: ! Parm4: Magnitude of open dist ;
34: CALL TWKWRTPR(AR[1],21,1,25) ;
35: ;
36: !Move gun to PR ;
37: ! Parm1: Velocity label ;
39: CALL TW_MVGUN(1,21) ;
40: WAIT 0.00(sec) ;
41: ;
42: !Calibrate 0 with worn tips ;
43: ! parm1: gun number ;
44: ! parm2: data register1 ;
45: ! parm3: position register ;
46: ! parm4: data register2 ;
47: CALL TWKZRCLB(AR[1],10,21) ;
48: WAIT 0.00(sec) ;

49: ;
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50: !Reset ref to 0 before checking ;
51: !for wear error, if new tip ;
52: R[10:SERVO GUN WORK]=AR[2] ;
53: IF R[10:SERVO GUN WORK]<>1,JMP LBL[1] ;
54: CALL TWKRSWDN ;
55: LBL[1] ;
56: ;
57: !Update wear amounts ;
58: !Parm1: 0<=Robot wear ratio<=1.0 ;
59: !RbtTipWear = ( rbtwr_ratio * ;
60: ! total wear ) ;
61: !Parm2: New tip installed ;
62: IF AR[1]=1,JMP LBL[11] ;
63: IF AR[1]=2,JMP LBL[12] ;
64: IF AR[1]=3,JMP LBL[13] ;
65: IF AR[1]=4,JMP LBL[14] ;
66: ;
67: LBL[99] ;
68: !Move gun to PR ;
69: ! Parm1: Velocity label ;
71: CALL TW_MVGUN(1,20) ;
72: IF AR[1]=1 AND $SPOTCONFIG.$NUM_WD_CTLS=1 AND $SPOTNUMEQ=2,JMP LBL[98] ;
73: IF AR[1]=1 AND $SPOTEQSETUP[1].$NUM_GUNS=2,JMP LBL[98] ;
74: IF AR[1]=1 AND $SPOTCONFIG.$NUM_WD_CTLS=2 AND
$SPOTEQSETUP[1].$NUM_GUNS=1 AND DO[60:Proc2TipMaintReq]=ON,JMP LBL[98] ;
75: IF AR[1]=3 AND $SPOTEQSETUP[2].$NUM_GUNS=2,JMP LBL[98] ;
77: LBL[98] ;
78: END ;
79: ;
80: LBL[11] ;
81: CALL TWKCALC2(R[5:TW Ratio fix G1],AR[2]) ;
82: JMP LBL[99] ;
83: LBL[12] ;
85: JMP LBL[99] ;
86: LBL[13] ;
88: JMP LBL[99] ;
89: LBL[14] ;
91: JMP LBL[99] ;
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15.3.6 Tip Reset
This routine gets called to reset steppers and tip wear. This can occur either at a 'Request
Continue' with a decision code 14, or as a style 27 'Cap Change'. For pneumatic gun applications this
routine checks that the watersavers have detected a 'Cap Loss' or are bypassed before allowing the
steppers to be reset. If it detects that the configured watersavers are not tripped, or bypassed it will
prompt the user to 1. Reset anyway or 2. Skip Reset. If the watersavers were tripped, or the operator
selected reset anyway, the robot will then reset the requested steppers and watersavers. Servo Gun
applications will alway reset all configured steppers and perform a TW_GUNS which will error proof
that the caps were changed and update the wear.
1: !******************************** ;
2: !TIP RESET WELD CNTRLS ;
3: !THIS MACRO RESETS STEPPERS ;
4: !FOR ALL CONFIGURED SCRS ;
5: !IF CAP LOSS OR BYPASS DETECTED ;
6: !******************************** ;
7: !GET Current Robot Configuration ;
8: CALL GET_CFG ;
9: ;
10: IF $SPOTCONFIG.$NUM_WD_CTLS=1 OR $SPOTEQSETUP[2].$STUDWELDER=1,JMP
LBL[10] ;
11: IF DI[965:diG1WS_CapLoss]=ON AND DI[973:diG2WS_CapLoss]=ON,JMP LBL[20] ;
12: IF DI[963:diG1WS_Bypassed]=ON AND DI[971:diG2WS_Bypassed]=ON,JMP LBL[20] ;
13: IF DI[965:diG1WS_CapLoss]=ON AND DI[971:diG2WS_Bypassed]=ON,JMP LBL[20] ;
14: IF DI[963:diG1WS_Bypassed]=ON AND DI[973:diG2WS_CapLoss]=ON,JMP LBL[20] ;
16: JMP LBL[50] ;
17: ;
18: LBL[10] ;
19: IF DI[965:diG1WS_CapLoss]=ON OR DI[963:diG1WS_Bypassed]=ON,JMP LBL[20] ;
20: !Determine if Tool Changer ;
21: CALL CKDNETND(54,38) ;
22: !IF SERVO GUN and not TC SKIP CAP ;
23: IF ($sgcfg[1].$EQUIP_TYPE=2 AND R[38:DNetNode Present]=0),JMP LBL[20] ;
24: IF R[38:DNetNode Present]=0,JMP LBL[30] ;
25: IF ($sgcfg[1].$EQUIP_TYPE=2 OR DI[201:di_TCCapsCC_Mode]=ON),JMP LBL[20] ;
26: ;
27: JMP LBL[50] ;
28: ;
29: LBL[20] ;
31: CALL SG_LOADD(17) ;
32: IF R[17:SG OPTION LOADED]=0,JMP LBL[40] ;
33: !Is it a air gun (1) or a ;
34: !servo gun (2) ;
36: ;
37: !Determine Fanuc Servo ;
38: !S/W Option J665 ;
39: !If option exists T/C device ;
40: !is present, if not manual ;
41: !modification is required ;
42: CALL SGTCLOAD ;
43: IF R[163:J665 FANUC TC]=0,JMP LBL[30] ;
44: ;
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48: !Latched and Rbt Holding Gun ;
49: CALL TCGETNUM ;
50: !TW Only on Servo Spot ;
51: IF GI[17]<2 OR GI[17]>3,JMP LBL[99] ;
52: ;
53: LBL[30] ;
54: !Check servo gun wear on all ;
55: !configured guns and compare wear ;
56: !values to tolerance values ;
57: CALL CHK_WEAR ;
58: ;
59: !If requested guns pass ;
60: !measurement check reset wear ;
61: !values if not prompt user ;
62: CALL TW_GNRST ;
63: ;
64: LBL[40] ;
65: !RESET STEPPER AND WATER SAVER ;
66: !FOR WELD CONTROLLER 1 ;
67: CALL RST_STP(1) ;
68: CALL RST_WTR ;
69: ;
72: !RESET STEPPER AND WATER SAVER ;
73: !FOR WELD CONTROLLER 2 ;
74: ;
75: CALL RST_STP(2) ;
76: CALL RST_WTR ;
77: ;
78: JMP LBL[99] ;
79: ;
80: LBL[50] ;
81: IF DI[1039:diSW1StepResetG1]=ON AND R[16:NUM SERVO GUNS]=1,JMP LBL[99] ;
85: ;
86: !Is it a air gun (1) or a ;
87: !servo gun (2) ;
89: ;
90: !******************************** ;
91: !PROMT USER TO RESET ANYWAY IF ;
92: !WATERSAVERS DID NOT TRIP ;
93: !OR WERE NOT BYPASSED ;
94: !******************************** ;
95: ;
96: !******************************** ;
97: !IF BUSY ON CALL CAPLOSS, ;
98: !GO TO MENUS 9 USER SCREEN ;
99: !******************************** ;
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102: !******************************** ;
103: !IF BUSY ON CALL CAPLOSS, ;
104: !GO TO MENUS 9 USER SCREEN ;
105: !******************************** ;
106: ;
109: ;
110: LBL[99] ;
15.3.7 Cap Select
This routine is called at FFR to allow the user to select that the caps were changed or select
that a tip dress is needed. This allows the robot to reset the steppers and perform a tip wear update,
or tip dress before returning to the style to re-weld the part.
1: !******************************** ;
2: !THIS MACRO ALLOWS THE USER TO ; CUSTOLST(1,40,3) replaced CAPLOSS in
3: !SELECT IF THE CAPS WERE CHANGED ; SPOTTOOL v8.20/P04 to improve recovery
4: !AT FFR ; with user interactions.
5: !STEPPERS ARE RESET IF USER ;
6: !ANSWERS YES TO THE PROMPT ;
7: !******************************** ;
8: ;
9: !******************************** ;
10: !PROMT USER FOR DIRECTION ;
11: !IF CAPS CHANGES AT FFR ;
12: !******************************** ;
13: ;
14: CALL CUSTOLST(1,40,3) ;
15: !Caps were Changed ;
16: IF R[40:Prompt Y/N]=2,CALL TIP_RST ;
17: !Tip dress selected ;
18: IF (R[40:Prompt Y/N]=3 AND F[31:FFR PROCESS1]),DO[89:doP1TipMantReqG1]=(ON) ;
19: IF (R[40:Prompt Y/N]=3 AND F[31:FFR PROCESS1] AND
$SPOTEQSETUP[1].$NUM_GUNS=2),DO[90:doP1TipMantReqG2]=(ON) ;
$SPOTEQSETUP[1].$NUM_GUNS=1 AND
$SPOTEQSETUP[2].$STUDWELDER=0),DO[121:doP2TipMantReqG1]=(ON) ;
23: CALL USERCLR ;
24: CALL USERPAGE ;
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16 Recovery
The following are the recommended recovery procedures necessary to recover from the
most common and foreseeable errors that will occur once the servo guns are in production. It is
anticipated that this section will grow as we garner more information and additional lessons learned.
16.1 Recovery from Loss of Mastering
The steps outlined below are necessary to recover from a loss of mastering, after the robot
has been setup and programmed. It is recommended that the caps not be changed before the
following procedure, as the wear in the caps are accounted for in the recalibrate routine.
16.1.1 Mastering the Gun from the Master/Calibrate screen
This method is to be used to recover from a loss of mastering after initial setup of the servo
gun has been performed.
1. Do not replace the electrodes

The robot will use the existing cap wear to calculate correct position and update
the tip wear automatically
2. Press [MENUS] -> [NEXT PAGE] -> [SYSTEM] -> [Gun Master]
3. Select [Select F3:BZAL] to reset the battery zero alarm and cycle power
4. Re-Establish pulse with the encoder

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

9. Verify the weld path, and touch up if necessary
16.2 Cap configuration change
The steps outlined below are necessary to change from one cap configuration to another due
to product or process changes. This includes the change of cap size, say from a #2 short to a #2
long, or change from one shank style to another. It is not recommended to single axis master and
update limits on this axis, as this tends not to work, and can cause issues with tip wear.
16.2.1 Re-Run the wizard
To ensure that the transition from the original cap configuration to the new configuration is
successful and straight forward, it is necessary to delete the gun axis in question from the group, and
to re-enter the axis with the new information, paying close attention to the axis limits. The easiest
way to accomplish this is to re-run the wizard and to select YES when prompted to setup the servo
gun axis.
16.2.2 Mastering the Gun and Setting Axis Limits
Because the axis information has been updated it is necessary to re-run the gun mastering
and axis setup.
See section Mastering the Gun to re-master the gun
16.2.3 Running Tip Wear Setup
Because the mastering information has changed, particularly the master counts with the new
caps, it will be necessary to re-run tip wear setup.
See section Tip Wear Compensation to setup tip wear compensation. It may also be
necessary to update the wear ratio when changing cap configurations.
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16.2.4 Completing Pressure Calibration
Because the gun setup has changed pressure calibration has changed and should be
verified. Most likely the torque to force curve has not changed due to a simple cap change, but
should be verified. The values that were recorded during the initial setup of the pressure table are
still in the robot, and all that should be necessary is to select complete on pressure schedule setup.
There is no need to go and setup the pressure schedules again, only to verify the calibration.
See section Pressure calibration for information concerning pressure calibration.
16.2.5 Path Touch up
Because the tip configuration has been changed it will be necessary to touch up the path.
16.3 Motor Replacement
The steps necessary to recover from a motor replacement are nearly identical to those
outlined in Recovery from Loss of Mastering, with the added steps that Autotune needs to be run as
outlined in Autotuning, and pressure calibration needs to be re-run as outlined in Pressure calibration.
It should not be necessary to run Autotuning again
Steps to recover from motor replacement:
1. Replace Motor
2. Re-master the gun
3. Re-run Autotune for the specific gun
4. Re-Run Pressure Calibration
Note: This assumes that the replacement motor type is the same make and model.
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17 SERVO GUN TOOL CHANGE OPTION
17.1 Purpose
The steps outlined in this section of the manual will help the user to add servo gun axis to the
robot for tool changing applications. The robot personality on the SpotTool+ 8.20 w/GRS4
Customization will have the option +SGChanger. This option on the personality will be used by the
user to add servo gun axis to group 2 or group 3 depending on configuration.
17.2 Hardware/Software Requirements, Limitations and Recommendations
For a robot that has tool changing for carried servo weld guns enabled, the robot is
configured for a single weld gun, one weld controller and one water saver. To be able to tool change
multiple carried servo weld guns, you will need the following on the robot controller:
1. Robot controller hardware (Fanuc part # A05B-2507-C400) to support this option. Specify
this part with “kit” in syntax when ordering to receive all the parts like connectors etc.
2. All Tool changing robots will need to be upgraded to Spottool v8.20Pxx.
3. J665 Fanuc Servo Gun Change software option loaded on the robot
4. Battery packs for the Tol-O-Matic motor (1 pack per gun Tol-O-Matic part # 27509039). The
battery packs are to be purchased from Tol-O-Matic, by the gun supplier or by the line
builder.
5. Maximum of 4 servo weld guns on tool changers are currently supported by GM.
6. Guns cannot be shared between robots. For example, Robot R1’s guns cannot
be used on Robot R3 and vice versa.
7. Guns will be dropped off in their respective nests with tips opened.
8. We recommend that you teach the pick and drop paths for the weld guns in TOOL # 5 or a
tool number that is not being used. If maximum number of guns is 2, you could teach these
paths in tool number 3.
9. To avoid confusion, reserve TOOL # 1- Tool # 4 for weld gun Utool’s since by default the gun
attach routine will set the utool to the gun # it is picking and the gun equalization is based on
the utool information which will also normally default to gun number.
10. Set the dip switches representing gun number on the tool side (Node 55) of the tool
changers, prior to commencing programming.
11. Air guns and servo guns cannot be mixed on the same robot.
12. Carried weld guns and ped weld guns cannot be combined on robots with gun tool changers
13. Gen. 6 weld timer is required for multi gun tool changing
14. An Ethernet cell interface is required and the expanded I/O map required. Custom mapping
will be required on Global 1 robots.
15. Air guns use integrated dense packs, shoulder mounted valves and/or hip mounts are not
supported.
16. Whenever any gun requests / requires cap change, all caps will be changed on all guns
17. Tip dress before cap change is only required on the gun that is held at the time of cap
change, not all 4 guns. The tip dresser only needs to run once to verify cutter functionality.
18. If multiple tip dressers are required to accommodate different cap / cutter combinations,
additional steps will be required to dress before cap change.
19. One gun is held during cap change process.
20. Water saver can only verify the caps are changed on the gun that is held. Cannot error proof
that caps have been removed from all guns.
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21. All guns are dressed after cap change before next job is processed.
22. All guns are stored in the, at home, open position when on the stands.
23. Cap change must be planned activity with time allotted for it.
24. Tip dressing occurs after the current job is processed and before the next job starts. If two
guns are used on a single job and one needs to tip dress, gun that requires it is picked up
and dressed at the end of the job before next job is started.
25. If multiple tip dressers are required to accommodate different cap / cutter combinations,
additional steps will be required to dress before cap change.
26. All guns are stored in the, at home, open position when on the stands.
27. Water saver can only verify the caps are changed on the gun that is held. Cannot error proof
that caps have been removed from all guns.
28. If the PLC or Robot or WC losses memory or is reloaded, all caps must be changed and all
guns are dressed before next job. Manual intervention required
29. The robot and the PLC must track which gun is held.
30. FFR does not swap guns; FFR only applies to the gun that is held. FFR does not support tool
change for hot backup.
31. Robots will be processed to hold the high runner tool at home under normal conditions. After
cap change or tip dress the robot may have to pick up the high runner tool on the next cycle.
17.3 Hardware Setup Procedure for Carried Servo Weld Gun(s)
The procedure described here is strictly for carried servo guns on tool changers for changing
2 guns. If adding more than 2 guns, this procedure has to be repeated for guns 3 and 4. It is
recommended to discuss special cases with VS Robot Software Standards Team since every
possible combination cannot be comprehended in this manual.
1. Run the Setup Wizard for GUN #1 as described in Section 3. Run the wizard as a single
carried gun. In servo gun tool changing applications all the guns that are on tool changers
belong to the same group but with multiple axis. Typically in strict carried servo gun tool
change application, the servo guns will belong to group 2 with 2 axis, one for each gun.
2. Control Start the robot again.
3. Press [MENUS, MAINTENANCE], then press [ENTER]. The screen will indicate GROUP 1
the robot arm and GROUP 2 servo axis. GROUP 2 will require modification; this GROUP
can contain up to 3 more servo axis for a total of 4 servo guns.
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4. Cursor down to Servo Gun Axis and Press F4 [MANUAL].
5. Servo gun axis for servo guns on tool changers are added to the servo gun changing group.
In this case of 2 carried guns on tool changers, axis will be added to group 2. By running the
wizard, we have already added axis 1 to group 2 and now we need to add an additional axis
to this group.
Total Servo Gun Axes:

This value will be equal to total
number of guns. Each time an
axis is added this value will
increment.
Partial: Allows user a specific

MOTOR code, with known
parameters. Allows the use of
codes for amp number, and
brake number. Partial is used
because additional motor
6. Press [#2 Add Servo Gun Axis]. information will be entered via
gun setup utility.
Complete: User must specify

all Servo Gun motor
parameters. You will have to
enter all the motor parameters
manually.
MOTOR CODE:
Enter motor code from table
below here. Contact MAAC
N/A if the motor code is not
listed.
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7. Press [#1 Partial (Minimal setup questions)]. Enter the motor code from the table below for
the correct motor type on gun 2 etc.
Motor Code Motor Description

GRS-4 Servo Motor types
41653 Tolomatic HT12 40A
and MOTOR code.
41909 Tolomatic HT23 40A
42421 Tolomatic SW44 40A
42423 Tolomatic SW44 80A
42677 Tolomatic SWGA C-Type 40A
42679 Tolomatic SWGA C-Type 80A
42933 Tolomatic SWGA X/P 40A
42935 Tolomatic SWGA X/P 80A
43301 ARO 3G, 8-pole (40A aux)
43303 ARO 3G, 8-pole (80A aux)
43701 Tolomatic IMA33 40A
8. Partial Question Set only requires a FANUC specific 5 digit number. Please refer to the table
above for your specific motor. GM Global robots typically have 40A amplifiers. Please check
controller to verify amplifier size. If motor is not listed in the table, [#2 Complete (All setup
questions)] must be selected.
9. Press [ENTER] to acknowledge amplifier number, amp 2.

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

11. Repeat steps 5 thru 10 for the remaining number of guns
12. Press [MENUS, NEXT, SETUP SERVO GUN], and cursor to Gun Change and [ENABLE]
the feature.
13. Press [Function, Cold Start].
17.4 Running SRVO_TC.PC
To assist with set up of Servo Gun Tool Change for the Additional AXES added the PC file
SRVO_TC.PC has been created. This setup file must be run outside of the customization wizard
after the hardware was configured in Section 15.3. Run the file SRVO_TC.PC at a normal Start and it
will load the GM Standard Pressure Calibration data setup, Pressure table setup, Distance schedule
setup, additional nest I/O.
17.4.1 SRVO_TC.PC File Execution Procedure
1. Press [Select], and select the program SRVO_TC.PC from the listing.
2. Press [ENTER] on the program and ENABLE the teach pendant and hit [SHIFT FWD] to run
the program.
3. User will be prompted for total number of guns, and total number of tipdressers. Answer all
questions then cycle power on robot controller or use the teach pendant to cycle power.
17.5 Programming and Setup Completion
The gun setup and pressure calibration now needs to be completed for each gun. The pick
and drop paths must be taught and GUN ATTACH macro executed prior to finishing setup. Refer to
Section 18 of this manual for path file naming conventions. We recommend that you program the
pick and drop paths with a UTOOL number greater than the maximum number of guns. That is if we
are tool changing 2 weld guns, then program the pick path and drop paths with UTOOL number
greater than or equal to 3. Since servo gun robots uses UTOOL orientation to determine its
equalization direction and the UTOOL is set via the GUN ATTACH macro, UTOOL 1 for gun 1 and
UTOOL 2 should be used for gun 2. When performing auto tune etc., if the robot is not holding a gun,
you will see the following screen.
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17.5.1 GUN ATTACH[x]
This macro with the argument value is used to let the system know the gun number the robot
is picking up. It should preferably be called after the gun is latched to the robot side of the changer
and it attaches servo gun to the robot without the need for cycling power.
Example: GUN ATTACH [1] or GUN ATTACH [R[X]] or GUN ATTACH [AR[1]]. After servo gun is
attached, the UTOOL number is changed to the argument number (hence the need to have utool
number match the gun number) which is specified as a gun close direction of fixed side in the servo
gun setup screen.
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17.5.2 GUN DETACH[x]
This macro is used to detach a servo gun without powering off. By default, the calibration
motion type is set to “Type 7”. This can be changed on the servo gun setup page by changing the
Battery to “OFF”. By setting the calibration motion type to “Type 7” prior to detaching the servo gun,
the servo gun is closed automatically, and the gun close position is set as the reference position.
Refer to E-Doc for further clarification on other calibration types. MAAC direction is to use batteries
on servo guns, so other types of calibration types should not be use.
Example: GUN DETACH [1] or GUN DETACH [R[X]] or GUN DETACH [AR[1]]
GUN ATTACH AND GUN DETACH WILL NOT execute by backward execution (SHFT BWD).
17.5.3 Emergency Detach (EMGDTCH.TP)
This macro is used to disable the communications to servo gun axes when there is damage
to the communication of the servo gun. This macro can be executed ONLY in teach mode, followed
by a power cycle from the teach pendant to reset all servo gun attach[x] variables. After execution of
this macro the user can now manually decouple the gun and fix the communications issues with the
servo gun.
17.5.4 Verification of Gun(s) connections
Once a gun is picked up and the GUN ATTACH macro has been executed, verify that the
attached gun is correct by visiting the Gun Change Status screen.
1. Press [MENUS].
2. Select [#0 NEXT PAGE], [#4 STATUS].
3. Press F1 [TYPE].
4. Select “Gun change”.
STATUS GUN CHANGE G1 JOINT 10 %

Gun Change / EQ:1
AXS Comment Status
1 GUN[ 1:Part A ] ATTACH
2 GUN[ 2:Part B ] DETACH
3 GUN[ 3:Part C ] DETACH
4 GUN[ 4:Part D ] DETACH
17.5.5 Auto Tune and Pressure Calibration of Guns
Remove all Pressure points in the Pressure Calibration Table above the max gun pressure.
Pickup each gun and finish setup of the gun as described in Section 4 -10 of this manual
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18 Tool Change programs specific for Servo Gun Tool Change Applications.
18.1 Style template (Servo tool-changer) Single Carried Gun
1: !************************* ;
3: !WITH Tool CHANGE TEMPLATE ;
4: !************************* ;
5: ;
8: ;
11: ECHO OPTION ; TCCKTOOL(X)
12: MAINT_PROG[1]=MOV_REPR ; This routine performs a check to make sure
13: ; that the gun used for the style is correct. The
14: SET SEGMENT(7) ; user must attach the gun number to be used
15: ; for the style. If the style is triggered with the
16: !TCCKTOOL(X) represents ; wrong gun, the robot will exchange guns for
17: ! the tool needed for ; the proper gun.
18: ! the process program ;
19: CALL TCCKTOOL(1) ;
20: IF $sgcfg[1].$EQUIP_TYPE<>2,JMP LBL[1] ;
21: R[237:SkipCapWearMem]=0 ;
22: IF $MCR_GRP[2].$MACHINELOCK=0,JMP LBL[1] ;
23: !SGATTACH(X) represents ;
24: ! the tool needed for ;
26: CALL SGATTACH(1) ;
27: LBL[1] ;
28: CALL POUNCE ;
29: ;
30: CALL STPR_CHK ;
31: ;
32: CALL SXXPROC1 ;
33: ;
34: RUN CAP_WEAR ;
35: ;
36: MOVE TO HOME ;
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18.2 Style template (Servo tool-changer) 2 Carried Guns within 1 style
1: !************************* ;
3: !TOOL CHANGE TEMPLATE FOR ;
4: !MULTI-GUNS WITHIN ONE STYLE ;
5: !************************* ;
6: ;
9: ;
10: !Disable Error Recovery ;
11: $SVPRG_ENB=0 ;
12: ;
15: ECHO OPTION ;
17: ;
19: ;
20: LBL[10] ;
21: !TCCKTOOL(X) represents ;
23: ! process 1 program ;
32: LBL[1] ;
33: CALL POUNCE ;
34: ;
35: CALL STPR_CHK ;
36: ;
37: CALL SXXPROC1 ;
38: ;
39: CALL CAP_WEAR ;
40: ;
42: ;
43: LBL[20] ;
54: LBL[2] ;
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55: CALL STPR_CHK ;
56: ;
57: CALL SXXPROC2 ;
58: ;
59: RUN CAP_WEAR ;
60: ;
61: LBL[99] ;
62: MOVE TO HOME ;
64: !Enable Error Recovery ;
65: $SVPRG_ENB=1 ;
18.3 Style template (Servo tool-changer) 1carried gun and 1 MH end effector
1: !************************* ;
2: !STYLE XX Carried SG EOAT ;
3: !and Carried MH EOAT ;
4: !WITH Tool CHANGE TEMPLATE ;
5: !************************* ;
6: ;
9: ;
12: ECHO OPTION ;
14: ;
16: ;
28: ;
29: LBL[1] ;
30: CALL POUNCE ;
31: ;
32: !CHECK FOR PROCESS1 BYPASSED ;
35: ;
36: CALL STPR_CHK ;
37: ;
38: CALL SXXPROC1 ;
39: ;
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41: ;
42: CALL CAP_WEAR ;
43: ;
46: ;
47: LBL[10] ;
48: ;
50: !the tool needed for MH ;
52: ;
53: CALL SXXPICK1 ;
54: ;
55: CALL SXXDROP1 ;
56: ;
57: LBL[99] ;
58: MOVE TO HOME ;
18.4 CAP_WEAR (Servo TC Version ONLY)
2: !CAP WEAR FOR SERVO GUNS ON ;
3: !TOOL CHANGER ;
4: LBL[1] ;
5: ;
6: !Determine TC/Application ;
7: !TW Only on Servo Spot ;
8: IF GI[17:giTCAppType]<2 OR GI[17:giTCAppType]>3,JMP LBL[99] ;
9: ;
10: !Determine if Servo Spot ;
11: !Latched and Rbt Holding Gun ;
12: CALL TCGETNUM ;
13: ;
14: IF ($SPOTCONFIG.$STROKE_ENBL=0 OR DO[18:FFRActive]=ON),JMP LBL[99] ;
15: CALL CHK_TIPS ;
16: IF R[218:CapWear Skip]=1,JMP LBL[99] ;
17: IF DI[201:di_TCCapsCC_Mode]=ON,JMP LBL[99] ;
18: IF $SCR.$NUM_GROUP=2 AND $SHC_GRP[2].$SHC_ENB=0,JMP LBL[10] ;
19: IF $SCR.$NUM_GROUP>2 AND $SHC_GRP[3].$SHC_ENB=0,JMP LBL[10] ;
20: IF DI[697:diToolLatched]=ON AND DI[698:diToolUnlatched]=OFF AND R[154:Head Detect]=1
AND GI[15:giToolNumber]=R[113:Current Head],JMP LBL[20] ;
21: ;
22: MESSAGE[TOOL CHANGER FAULT] ;
23: MESSAGE[DI697 SHOULD BE ON] ; CAP_WEAR
24: MESSAGE[DI698 SHOULD BE OFF ] ; This routine performs a wear
25: MESSAGE[R[154] SHOULD BE 1] ; measurement check on the gun(s).
26: MESSAGE[AND GI[15]=R[113]] ; The program has been modified to
27: MESSAGE[RUN TCLTCHTL,THEN] ; make sure that wear is measure for
28: MESSAGE[RESUME CAP_WEAR] ; the attached gun that is read from
29: DO[35:MHFault]=ON ; the tool changer. A variable check
30: UALM[3] ; for Fanuc Tool change option is also
31: DO[35:MHFault]=OFF ; done, along with a GI[15] tool
32: JMP LBL[1] ; reading and GI[17] app. reading.
33: ;
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34: LBL[20] ;
35: CALL TW_UPD(R[113:Current Head]) ;
36: CALL TW_REG(R[113:Current Head]) ;
37: IF R[237:SkipCapWearMem]=1,JMP LBL[99] ;
38: CALL TW_MEM(R[113:Current Head]) ;
39: JMP LBL[99] ;
40: ;
41: !CAP WEAR FOR REGULAR SERVO GUNS ;
42: LBL[10] ;
43: CALL NUM_GUNS ;
44: R[15:SERVO WEAR UPDT]=R[15:SERVO WEAR UPDT]+1 ;
45: IF R[15:SERVO WEAR UPDT]>R[16:NUM SERVO GUNS],JMP LBL[30] ;
46: CALL TW_UPD(R[15:SERVO WEAR UPDT]) ;
47: CALL TW_REG(R[15:SERVO WEAR UPDT]) ;
48: JMP LBL[40] ;
49: ;
50: LBL[30] ;
51: R[15:SERVO WEAR UPDT]=0 ;
52: LBL[40] ;
53: IF R[15:SERVO WEAR UPDT]=R[16:NUM SERVO GUNS],JMP LBL[30] ;
54: ;
55: LBL[99] ;
18.5 TCCKTOOL
This routine is used to perform attached gun verification and gun swap with the required gun.
If the attached gun on the robot is not the one that the passed argument calls for, the robot will
perform a gun change with the correct gun (passed argument). You may choose to modify the path
calls, if the path naming for pick and drop is different than the one used in here. For example; if the
path name in your particular application is “S10PICK1”, than change TCPICKH1 to “S10PICK1” etc.
1: R[155:Head Selection]=AR[1] ;
2: ;
3: CALL TCGETNUM ;
4: ;
5: IF GI[15:giToolNumber]>0 AND GI[15:giToolNumber]<5 AND R[113:Current Head]>0 AND
R[113:Current Head]<5,JMP LBL[20] ;
6: JMP LBL[30] ;
7: ;
8: !DROP OFF THE HEAD ;
9: LBL[20] ;
10: IF R[113:Current Head]=R[155:Head Selection],JMP LBL[250] ;
11: SELECT R[113:Current Head]=1,JMP LBL[110] ;
12: =2,JMP LBL[120] ;
13: =3,JMP LBL[130] ;
14: =4,JMP LBL[140] ;
15: ELSE,JMP LBL[30] ;
16: ;
17: !PICK UP HEAD ;
18: LBL[30] ;
19: SELECT R[155:Head Selection]=1,JMP LBL[210] ;
20: =2,JMP LBL[220] ;
21: =3,JMP LBL[230] ;
22: =4,JMP LBL[240] ;
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23: =5,JMP LBL[250] ;
25: ;
26: LBL[110] ;
27: CALL TCDROPH1 ;
28: JMP LBL[30] ;
29: ;
30: LBL[120] ;
31: CALL TCDROPH2 ; This section will drop off the gun.
32: JMP LBL[30] ; Macro supports up to 4 total guns.
33: ;
34: LBL[130] ;
35: CALL TCDROPH3 ;
36: JMP LBL[30] ;
37: ;
38: LBL[140] ;
39: CALL TCDROPH4 ;
40: JMP LBL[30] ;
41: ;
42: LBL[210] ;
43: CALL TCPICKH1 ;
44: JMP LBL[99] ;
45: ;
46: LBL[220] ;
47: CALL TCPICKH2 ;
48: JMP LBL[99] ; This section will pick up the gun.
49: ; Macro supports up to 4 total guns.
50: LBL[230] ;
51: CALL TCPICKH3 ;
52: JMP LBL[99] ;
53: ;
54: LBL[240] ;
55: CALL TCPICKH4 ;
56: JMP LBL[99] ;
57: ;
58: LBL[250] ;
59: !Current Head = Head Selected ;
60: !If Tool APP = Spot, Check Water ;
61: IF ((GI[17:giTCAppType]=2 OR GI[17:giTCAppType]=3) AND
$SPOTCONFIG.$STROKE_ENBL=1),CALL RST_WTR ;
62: !IF not in Tool change, skip Move ;
63: IF GO[1:ManualStyle]<>26,JMP LBL[99] ;
64: MOVE TO HOME ;
65: ;
66: LBL[99:PROGRAM END] ;
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18.6 TCGETNUM
This routine performs tool attached check and returns the gun number attached to the robot
based on GI[15] which is loaded in R[113] for use by other routines.
DV_STCHK(2,55,112)
1: !******************************** ; AR[1]: Device Net Board
2: !CHECK CURRENT TOOL'S ID ; AR[2]: Node number
3: !******************************** ; AR[3]: Status and R[X] to return.
4: ;
5: LBL[1] ; This KAREL call will ensure that the robot
6: ; side of the tool changer Device Net is
7: CALL DV_STCHK(2,55,112) ; operational and ONLINE.
8: !Not online & Latched ;
9: IF R[112:DNET Node Status]<2 AND DI[697:diToolLatched]=ON AND
DI[698:diToolUnlatched]=OFF,JMP LBL[5] ;
10: ;
11: !Not online & not Latched ;
12: IF R[112:DNET Node Status]<2 AND DI[697:diToolLatched]=OFF AND
DI[698:diToolUnlatched]=ON,JMP LBL[99] ;
13: ;
14: !Online & not Latched ;
15: IF R[112:DNET Node Status]=2 AND DI[697:diToolLatched]=OFF AND
DI[698:diToolUnlatched]=ON,JMP LBL[15] ;
16: ;
17: !Check for Valid Tool# ;
18: R[113:Current Head]=GI[15:giToolNumber] ;
19: IF (R[113:Current Head]<1 OR R[113:Current Head]>4),JMP LBL[25] ;
20: ;
22: END ;
23: ;
24: ;
25: !******FAULTS******** ;
26: LBL[5:TOOL CHANGER FAU] ;
27: MESSAGE[...] ;
28: MESSAGE[TOOL CHANGER FAULT.] ;
29: MESSAGE[ TOOL SIDE OF TOOL] ;
30: MESSAGE[ CHANGER, DEVICENET] ;
31: MESSAGE[ NODE 55, IS NOT] ;
32: MESSAGE[ ONLINE. NODE 55 MUST] ;
33: MESSAGE[ BE ONLINE TO CONTINUE.] ;
34: DO[35:MHFault]=ON ;
35: UALM[1] ;
36: DO[35:MHFault]=OFF ;
37: JMP LBL[1] ;
38: ;
39: LBL[15:TOOL Latch FAU] ;
40: MESSAGE[...] ;
41: MESSAGE[TOOL LATCH FAULT.] ;
42: MESSAGE[TOOL NOT LATCHED] ;
43: MESSAGE[ Check inputs for] ;
44: MESSAGE[DI697 diToolLatched=On] ;
45: MESSAGE[DI698 diToolUnlatch=Off] ;
47: UALM[1] ;
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49: JMP LBL[1] ;
50: ;
51: LBL[25:ATTACHED TOOL # ] ;
52: MESSAGE[...] ;
54: MESSAGE[ ATTACHED TOOL] ;
55: MESSAGE[ NUMBER OUT OF RANGE.] ;
56: MESSAGE[ GUN NUMBER SHOULD BE] ;
57: MESSAGE[ 1,2,3, OR 4 ONLY.] ;
59: UALM[1] ;
61: JMP LBL[1] ;
18.7 TCINNEST
This routine will perform a tool input check to determine if a gun is in the nest. This macro
essentially will perform a “part check” for a servo gun in the nest. Reference only for robot controlled
tool nests.
1: !******************************** ;
2: !HEAD IN NEST MACRO ;
3: !******************************** ;
4: LBL[1:MAIN LOOP] ;
5: R[162:TC PlaceHolder]=AR[1] ;
6: LBL[10:RETRY LOOP] ;
7: SELECT R[162:TC PlaceHolder]=1,JMP LBL[20] ;
8: =2,JMP LBL[40] ;
9: =3,JMP LBL[70] ;
10: =4,JMP LBL[80] ;
12: ;
13: !***Nest 1 Check** ;
14: LBL[20:HEAD IN NEST1] ;
15: !Check if it has a slide ;
17: IF DI[723:diHead1InNest]=ON AND DI[725:diNest1InPos]=ON,JMP LBL[99] ;
18: JMP LBL[15] ;
19: ;
20: LBL[30] ;
21: IF DI[723:diHead1InNest]=ON,JMP LBL[99] ;
22: JMP LBL[25] ;
23: ;
24: ;
25: !***Nest 2 Check** ;
26: LBL[40:HEAD IN NEST2] ;
29: !Check # of slides ;
30: IF R[27:Num of TC Slides]=1,JMP LBL[60] ;
31: IF DI[731:diHead2InNest]=ON AND DI[733:diNest2InPos]=ON,JMP LBL[99] ;
32: JMP LBL[35] ;
33: LBL[60] ;
34: IF DI[727:(Reserved)]=ON AND DI[725:diNest1InPos]=ON,JMP LBL[99] ;
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35: JMP LBL[45] ;
36: ;
37: LBL[50] ;
39: JMP LBL[55] ;
40: ;
41: ;
42: !***Nest 3 Check** ;
43: LBL[70:NEST 3 EMPTY CHK] ;
45: JMP LBL[65] ;
46: ;
47: !***Nest 4 Check** ;
50: JMP LBL[75] ;
51: ;
52: ;
54: R[162:TC PlaceHolder]=0 ;
55: END ;
56: ;
57: ;
58: !******FAULTS******** ;
59: LBL[5:Invalid Nest Num] ;
60: MESSAGE[...] ;
62: MESSAGE[ INVALID LID SELECTED.] ;
63: MESSAGE[ LID SELECTION MUST] ;
64: MESSAGE[ BE 1 OR 2.] ;
66: UALM[3] ;
68: JMP LBL[1] ;
69: ;
70: LBL[15] ;
71: MESSAGE[...] ;
72: MESSAGE[HEAD IN NEST 1 FAULT.] ;
73: MESSAGE[HEAD IN NEST 1 INPUT] ;
74: MESSAGE[AND NEST IN POSITION] ;
75: MESSAGE[SHOULD BE ON. NEED ] ;
76: MESSAGE[DI[723] AND DI[725] ON] ;
78: UALM[3] ;
80: JMP LBL[10] ;
81: ;
82: LBL[25] ;
83: MESSAGE[...] ;
87: MESSAGE[DI[723] ON] ;
89: UALM[3] ;
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91: JMP LBL[10] ;
92: ;
93: LBL[35] ;
94: MESSAGE[...] ;
101: UALM[3] ;
103: JMP LBL[10] ;
104: ;
105: LBL[45] ;
106: MESSAGE[...] ;
113: UALM[3] ;
115: JMP LBL[10] ;
116: ;
117: LBL[55] ;
118: MESSAGE[...] ;
122: MESSAGE[DI[731] ON] ;
124: UALM[3] ;
126: JMP LBL[10] ;
127: ;
128: LBL[65] ;
129: MESSAGE[...] ;
132: MESSAGE[NEED DI[739]ON] ;
134: UALM[3] ;
136: JMP LBL[10] ;
137: ;
138: LBL[75] ;
139: MESSAGE[...] ;
142: MESSAGE[NEED DI[747]ON] ;
144: UALM[3] ;
146: JMP LBL[10] ;
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18.8 TCEMPTY
This routine will perform a tool input check to determine if a gun nest is empty. This macro
essentially will perform a “NO part check” for a servo gun. Reference only for robot controlled tool
nests.
1: !******************************** ;
2: !NEST EMPTY MACRO ;
3: !******************************** ;
8: =2,JMP LBL[40] ;
9: =3,JMP LBL[70] ;
10: =4,JMP LBL[80] ;
12: ;
13: !***Nest 1 Check** ;
17: IF DI[723:diHead1InNest]=OFF AND DI[725:diNest1InPos]=ON,JMP LBL[99] ;
18: JMP LBL[15] ;
19: ;
20: LBL[30] ;
21: IF DI[723:diHead1InNest]=OFF,JMP LBL[99] ;
22: JMP LBL[25] ;
23: ;
24: ;
25: !***Nest 2 Check** ;
29: !Check # of slides ;
31: IF DI[731:diHead2InNest]=OFF AND DI[733:diNest2InPos]=ON,JMP LBL[99] ;
32: JMP LBL[35] ;
33: LBL[60] ;
34: IF DI[727:(Reserved)]=OFF AND DI[725:diNest1InPos]=ON,JMP LBL[99] ;
35: JMP LBL[45] ;
36: ;
37: LBL[50] ;
39: JMP LBL[55] ;
40: ;
41: ;
42: !***Nest 3 Check** ;
45: JMP LBL[65] ;
46: ;
47: !***Nest 4 Check** ;
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50: JMP LBL[75] ;
51: ;
52: ;
55: END ;
56: ;
57: ;
58: !******FAULTS************ ;
60: MESSAGE[...] ;
66: UALM[3] ;
68: JMP LBL[1] ;
69: ;
70: LBL[15] ;
71: MESSAGE[...] ;
75: MESSAGE[NEED DI[723]OFF ] ;
76: MESSAGE[ AND DI[725] ON] ;
78: UALM[3] ;
80: JMP LBL[10] ;
81: ;
82: LBL[25] ;
83: MESSAGE[...] ;
86: MESSAGE[NEED DI[723]OFF ] ;
88: UALM[3] ;
90: JMP LBL[10] ;
91: ;
92: LBL[35] ;
93: MESSAGE[...] ;
97: MESSAGE[NEED DI[731]OFF] ;
100: UALM[3] ;
102: JMP LBL[10] ;
103: ;
104: LBL[45] ;
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105: MESSAGE[...] ;
112: UALM[3] ;
114: JMP LBL[10] ;
115: ;
116: LBL[55] ;
117: MESSAGE[...] ;
122: UALM[3] ;
124: JMP LBL[10] ;
125: ;
126: LBL[65] ;
127: MESSAGE[...] ;
132: UALM[3] ;
134: JMP LBL[10] ;
135: ;
136: LBL[75] ;
137: MESSAGE[...] ;
142: UALM[3] ;
144: JMP LBL[10] ;
18.9 TCCLSLID
This macro will close the tool change nest cover lid, if one exists. Reference only for robot
controlled tool nests.
1: !******************************** ;
2: !CLOSE LID MACRO ;
3: !******************************** ;
5: $WAITTMOUT=500 ;
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9: =2,JMP LBL[30] ;
10: =3,JMP LBL[40] ;
11: =4,JMP LBL[50] ;
13: ;
14: LBL[20:CLOSE LID 1] ;
15: IF R[27:Num of TC Slides]=1 AND R[154:Head Detect]=0 AND R[155:Head Selection]>0 AND
R[155:Head Selection]<5,JMP LBL[99] ;
16: DO[721:doCloseNest1]=OFF ;
17: DO[722:doOpenNest1]=ON ;
18: WAIT DI[722:diNest1Open]=ON AND DI[721:diNest1Closed]=OFF TIMEOUT,LBL[15] ;
19: JMP LBL[99] ;
20: ;
23: DO[729:(Reserved)]=OFF ;
24: DO[730:(Reserved)]=ON ;
26: JMP LBL[99] ;
27: ;
32: JMP LBL[99] ;
33: ;
38: ;
41: END ;
42: ;
43: ;
44: !******FAULTS********* ;
46: MESSAGE[...] ;
52: UALM[3] ;
54: JMP LBL[1] ;
55: ;
56: LBL[15:CLOSE LID 1 FAUL] ;
57: MESSAGE[...] ;
59: MESSAGE[ LID 1 CLOSE INPUTS] ;
60: MESSAGE[ NOT MADE. NEED] ;
61: MESSAGE[ DI[722] ON AND] ;
62: MESSAGE[ DI[721] OFF.] ;
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64: UALM[3] ;
66: JMP LBL[10] ;
67: ;
69: MESSAGE[...] ;
76: UALM[3] ;
78: JMP LBL[10] ;
79: ;
81: MESSAGE[...] ;
88: UALM[3] ;
90: JMP LBL[10] ;
91: ;
93: MESSAGE[...] ;
100: UALM[3] ;
102: JMP LBL[10] ;
18.10 TCOPNLID
This macro will open the tool change nest cover lid, if one exists. Reference only for robot
controlled tool nests.
1: !******************************** ;
2: !OPEN LID MACRO ;
3: !******************************** ;
5: $WAITTMOUT=500 ;
9: =2,JMP LBL[30] ;
10: =3,JMP LBL[40] ;
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11: =4,JMP LBL[50] ;
13: ;
14: LBL[20:OPEN LID 1] ;
15: DO[722:doOpenNest1]=OFF ;
16: DO[721:doCloseNest1]=ON ;
17: WAIT DI[721:diNest1Closed]=ON AND DI[722:diNest1Open]=OFF TIMEOUT,LBL[15] ;
18: JMP LBL[99] ;
19: ;
22: DO[730:(Reserved)]=OFF ;
23: DO[729:(Reserved)]=ON ;
25: JMP LBL[99] ;
26: ;
31: JMP LBL[99] ;
32: ;
37: ;
40: END ;
41: ;
42: ;
43: !******FAULTS********* ;
45: MESSAGE[...] ;
51: UALM[3] ;
53: JMP LBL[1] ;
54: ;
55: LBL[15:OPEN LID 1 FAULT] ;
56: MESSAGE[...] ;
58: MESSAGE[ LID 1 OPEN INPUTS] ;
63: UALM[3] ;
65: JMP LBL[10] ;
66: ;
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68: MESSAGE[...] ;
75: UALM[3] ;
77: JMP LBL[10] ;
78: ;
80: MESSAGE[...] ;
87: UALM[3] ;
89: JMP LBL[10] ;
90: ;
92: MESSAGE[...] ;
99: UALM[3] ;
101: JMP LBL[10] ;
18.11 TCLTCHTL
This macro is used to latch the robot side of the tool changer to the tool side of the tool
changer.
1: !******************************** ;
2: !LATCH TOOL CHANGER HEAD ;
3: !******************************** ;
4: ;
6: IF DI[700:diAuxPowerOKT1Ch]=OFF,JMP LBL[5] ;
7: DO[698:doUnlatchTool]=OFF ;
8: DO[697:doLatchTool]=ON ; DV_AROFF(2,55)
9: WAIT DI[697:diToolLatched]=ON TIMEOUT,LBL[15] ; AR[1] = Device Net Board
10: ; AR[2] = Node number
12: CALL DV_AROFF(2,55) ; This KAREL program call will enable
13: R[113:Current Head]=GI[15:giToolNumber] ; the Device Net error checking for
14: R[154:Head Detect]=1 ; node 55 (Tool Side of tool changer)
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15: R[158:Tool Connecting]=1 ;
16: END ;
17: ;
18: ;
19: !******FAULTS******** ;
20: LBL[5] ;
21: MESSAGE[...] ;
22: MESSAGE[AUX POWER FAULT.] ;
23: MESSAGE[ NO AUX POWER AT ROBOT ] ;
24: MESSAGE[ SIDE OF TOOL CHANGER.] ;
25: MESSAGE[ NEED DI[700] ON.] ;
27: UALM[3] ;
29: JMP LBL[1] ;
30: ;
31: LBL[15] ;
32: !Double Check before FLT ;
33: IF DI[697:diToolLatched]=ON AND DI[698:diToolUnlatched]=OFF,JMP LBL[99] ;
34: MESSAGE[...] ;
36: MESSAGE[ TOOL CHANGER FAILED TO] ;
37: MESSAGE[ COUPLE. NEED DI[697]] ;
38: MESSAGE[ ON AND DI[698] OFF.] ;
40: UALM[3] ;
42: JMP LBL[1] ;
18.12 TCUNLTCH
This macro is used to unlatch the robot side of the tool changer to the tool side of the tool
changer.
1: !******************************** ;
2: !UNLATCH TOOL CHANGER HEAD ; DV_ARON(2,55)
3: !******************************** ; AR[1] = Device Net Board
4: ; AR[2] = Node number
6: IF DI[700:diAuxPowerOKT1Ch]=OFF,JMP LBL[5] ; This KAREL program call will disable the
7: CALL DV_ARON(2,55) ; Device Net error checking for node 55
8: DO[697:doLatchTool]=OFF ; (Tool Side of tool changer). The node is
9: DO[698:doUnlatchTool]=ON ; not monitored if it is not connected to the
10: WAIT DI[698:diToolUnlatched]=ON TIMEOUT,LBL[15] ; robot.
11: ;
13: R[113:Current Head]=0 ;
14: R[154:Head Detect]=0 ;
15: R[158:Tool Connecting]=0 ;
16: !Reset Tipdress request ;
17: !for carried spotwelders ;
18: IF (GI[17:giTCAppType]=2 OR GI[17:giTCAppType]=3),DO[72:Process1Reserved]=OFF ;
19: IF (GI[17:giTCAppType]=2 OR GI[17:giTCAppType]=3),DO[96:doProc1Eq1Msg24]=OFF ;
20: END ;
21: ;
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22: ;
23: !*******FAULTS******* ;
24: LBL[5] ;
25: MESSAGE[...] ;
26: MESSAGE[AUX POWER FAULT.] ;
27: MESSAGE[ NO AUX POWER AT ROBOT ] ;
28: MESSAGE[ SIDE OF TOOL CHANGER.] ;
29: MESSAGE[ NEED DI[700] ON.] ;
30: LBL[54:MH FAULT LOGIC] ;
32: UALM[3] ;
34: JMP LBL[10] ;
35: ;
36: LBL[15] ;
37: IF DI[697:diToolLatched]=OFF AND DI[698:diToolUnlatched]=ON,JMP LBL[99] ;
38: IF DI[699:diUnlatchEnrgzed]=ON,JMP LBL[16] ;
39: MESSAGE[...] ;
41: MESSAGE[ ANTI-DROP SWITCH NOT] ;
42: MESSAGE[ MADE. DI[699] MUST BE] ;
43: MESSAGE[ ON IN ORDER TO] ;
44: MESSAGE[ UNLATCH HEAD. CHECK] ;
45: MESSAGE[ FOR SWITCH MADE, WHEN] ;
46: MESSAGE[ TOOL IS IN THE NEST.] ;
48: UALM[3] ;
50: JMP LBL[10] ;
51: ;
52: LBL[16:TOOL CHNG FAULT] ;
53: MESSAGE[...] ;
55: MESSAGE[ TOOL CHANGER FAILED TO] ;
56: MESSAGE[ UNLATCH. NEED DI[698]] ;
57: MESSAGE[ ON AND DI[697] LOW.] ;
59: UALM[3] ;
61: JMP LBL[10] ;
18.13 TCPICKH1
This routine is used to pickup gun number 1. The name of the routine can be modified to
reflect your particular naming convention. If you choose to modify the program name, make the
corresponding change to TCCKTOOL routine. There are 3 user modification areas within this routine.
1: !BEGIN PICK HEAD PROGRAM ;

2: !FOR TOOL (1) ; User Modification Area 1:
3: ; If tool nest are controlled by
4: !CHECK FOR NEST EMPTY ; PLC,modify per application the path
5: ! NOTE: REMOVE NEST EMPTY MACRO ; segments required from the PLC
6: ! IF NEST IS CONTROLLED BY ; here.
7: ! THE PLC. SEG. REQ FOR PLC NEST ;
8: ; If Tool Nests are controlled by PLC,
REMOVE TCINNEST macro call.
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9: CALL TCINNEST(1) ;
10: ;
11: !OPEN TOOL CHANGER NEST LID ;
12: !NOTE: REMOVE OPEN LID MACRO ;
13: !IF LID IS CONTROLLED BY ;
14: !THE PLC. ;
15: CALL TCOPNLID(1) ; User Modification Area 2:
16: ; If Tool Nests are controlled by PLC,
17: !MOVES TO NEST 1 FROM COMMON PT ; REMOVE TCOPNLID macro call.
18: !Modify UTOOL if required ;
19: UTOOL_NUM=1 ; UTOOL_NUM
20: ; Note: Utool number is associated
21:J P[1] 35% CNT100 ; with the GUN ATTACH instruction,
22:J P[2] 35% CNT100 ; tool changing via points should
23:L P[3] 600mm/sec FINE ; reference tool changer pin for
24:L P[4] 100mm/sec FINE ; UTOOL.
25: CALL TCLTCHTL ;
26: ;
27: !ADD DEVICE ONLINE CALLS ;
28: !WITHOUT STATUS CHECK ARG ;
29: !FOR ALL EOAT DEVICES ;
30: !CALL DV_ONLN(2,x,0) ;
31: !x = EOAT DNET Node # ;
32: ;
33: !IF TOOL CHANGE APP NOT WELDING ;
34: !SKIP WATER RESET ;
36: !RESET WATER EARLY ;
37: DO[450:doG1Wateroff]=ON ;
38: DO[449:doRstG1WaterSvr]=PULSE,1.0sec ;
39: !IF AIR GUN SKIP SG ATTACH ;
42: ;
43: LBL[10:Air Gun Setup It] ;
45: !User must set these per AG confi ;
46: !if guns differ in nodes & config ;
47: !Set to 1 if gun has bkup open de ;
48: !$SPOTEQSETUP[1].$DET_BU_OPEN[1]= ;
49: !Set to 1 if has gun stroke only ;
50: !and open gun switch ;
51: !$SPOTEQSETUP[1].$DET_BU_CL[1]=0 ;
52: LBL[20] ;
53: !MOVES TO CHECK POSITION ;
54: !NOTE: REMOVE NEST EMPTY MACRO ;
55: !IF NEST IS CONTROLLED BY ;
56: !THE PLC. ;
58: UTOOL_NUM=1 ;
59: ;
60:L P[5] 250mm/sec FINE ;
62: ;
63: CALL TCEMPTY(1) ;
64: ;
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GRS4 Customization
66: !SKIP WATER RESET and CAP WEAR ;
68: CALL RST_WTR ;
69: !IF AIR GUN SKIP WEAR ;
71: R[237:SkipCapWrMem]=1 ;
72: RUN CAP_WEAR ;
73: LBL[30] ;
74: ;
75: !CLOSE TOOL CHANGER NEST LID ;
76: !NOTE: REMOVE CLOSE LID MACRO ; User Modification Area 3:
77: !IF LID IS CONTROLLED BY ; If Tool Nests are controlled by PLC,
78: !THE PLC. ; REMOVE TCCLSLID macro call.
79: CALL TCCLSLID(1) ;
80: ;
81: !MOVES TO COMMON PT FROM NEST 1 ;
83: UTOOL_NUM=1 ;
84: ;
85:L P[7] 350mm/sec CNT100 ;
86:J P[8] 50% CNT100 ;
87:J P[9] 50% CNT100 ;
88: ;
89: !ADD DEVICE ONLINE CALLS ;
90: !WITH STATUS CHECK ;
91: !FOR ALL EOAT DEVICES ;
92: !FOLLOWED BY THE ;
93: !DEVICE AUTO RECONNECT ;
94: !OFF CALLS ;
95: !CALL DV_ONLN(2,x,1) ;
96: !CALL DV_AROFF(2,x) ;
98: ;
99: !IF TOOL CHANGE APP NOT SG WELDIN ;
100: !SKIP WEAR VERIFICATION ;
101: IF (GI[17:giTCAppType]<2 OR GI[17:giTCAppType]>3),JMP LBL[99] ;
104: CALL TW_VER(1) ;
105: LBL[99]
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18.14 TCDROPH1
This routine is used to drop gun number 1. The name of the routine can be modified to
reflect your particular naming convention. If you choose to modify the program name, make the
corresponding change to TCCHKGUN routine. There are 3 user modification areas within this
routine.
1: !BEGIN DROP HEAD PROGRAM ;

2: !FOR TOOL (1) ;
3: ; User Modification Area 1:
4: !CHECK FOR NEST EMPTY ; If Tool Nests are controlled by PLC,
5: ! NOTE: REMOVE NEST EMPTY MACRO ; modify per application the path
6: ! IF NEST IS CONTROLLED BY ; segments required from the PLC.
7: ! THE PLC. SEG. REQ FOR PLC NEST ;
8: CALL TCEMPTY(1) ; If Tool Nests are controlled by PLC,
9: ; REMOVE TCEMPTY macro call.
10: !OPEN TOOL CHANGER NEST LID ;
11: ! NOTE: REMOVE OPEN LID MACRO ;
12: ! IF LID IS CONTROLLED BY ;
13: ! THE PLC. ;
14: CALL TCOPNLID(1) ;
15: ;
17: !SKIP WATER OFF ;
19: !IF AIR GUN SKIP CAP_WEAR ;
21: !IF CAPWEAR FLAG NOT SET ; User Modification Area 2:
22: !CALL CAPWEAR BEFORE DROPING GUN ; If Tool Nests are controlled by PLC,
23: IF (!F[1:Capwear Complete]),CALL CAP_WEAR ; REMOVE TCOPNLID macro call.
24: LBL[1] ;
25: CALL WTR_OFF(1) ; UTOOL_NUM
26: LBL[10] ; Note: Utool number is associated
27: ; with the GUN DETACH instruction,
28: !MOVES TO NEST 1 FROM POUNCE ; tool changing via points should
29: !Modify UTOOL if required ; reference tool changer pin for
30: UTOOL_NUM=1 ; UTOOL.
31: ;
32:J P[1] 50% CNT100 ;
33:J P[2] 50% CNT100 ;
34:L P[3] 500mm/sec CNT100 ;
37: ;
39: !SKIP OPENGUNS BEFORE DROPOFF ;
41: CALL OPENGUNS ;
42: !IF AIR GUN SKIP SG DETACH ;
44: CALL SGDETACH(1) ;
45: LBL[20] ;
46: ;
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47: !User must add custom open/close ;
48: !commands to as required for ;
49: !for nested equipment ex. ;
50: !If Macro Open Gripper(1,2) ;
51: !If outputs ;
52: !DO[Open]=ON ;
53: !DO[Close]=OFF ;
54: ;
55: !ADD DISCONNECT COMMANDS ;
56: !ADD ALL EOAT DEVICES ;
57: !CALL DV_ARON(2,x) ;
59: ;
60: CALL TCUNLTCH ; 1
61: ;
62: !MOVES TO CHECK POSITION ;
63: ! NOTE: REMOVE HEAD IN NEST MACRO ;
64: ! IF NEST IS CONTROLLED BY ;
65: ! THE PLC. ;
67: UTOOL_NUM=1 ;
68: ;
70: ;
71: CALL TCINNEST(1) ;
72: ;
73: ;
74: !CLOSE TOOL CHANGER NEST LID ;
75: ! NOTE: REMOVE CLOSE LID MACRO ;
76: ! IF LID IS CONTROLLED BY ; User Modification Area 3:
77: ! THE PLC. ;
78: CALL TCCLSLID(1) ; If Tool Nests are controlled by PLC,
79: ; REMOVE TCCLSLID macro call.
80: !MOVES TO POUNCE FROM NEST 1 ;
82: UTOOL_NUM=1 ;
83: ;
84:J P[7] 35% CNT100 ;
85:J P[8] 50% CNT100 ;
86:J P[9] 75% CNT100 ;
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18.15 Style 26
Tool change style used to swap tools.
1: !******************************** ;
2: !STYLE 26 PLC CHANGE TOOL(S) ;
3: !******************************** ;
4: !DCD 0 Swap with backup ;
5: !DCD 1 Pick Tool/Gun 1 ;
9: !DCD 5 Drop TL/Gun return Home ;
10: ;
11: GO[1:ManualStyle]=26 ;
12: ;
13: CALL POUNCE ;
15: ;
16: !Allow Teach Exchange ;
17: IF SO[7:TP enabled]=ON,CALL TCTEACH ;
18: ;
19: IF GI[15:giToolNumber]=0,JMP LBL[1] ;
22: CALL TCGETNUM ;
23: R[162:TC PlaceHolder]=R[113:Current Head] ;
24: !Check that Held Gun ;
25: !Is Not Machine Locked ;
26: !For Servo Gun Only ;
29: =2,JMP LBL[20] ;
30: =3,JMP LBL[30] ;
31: =4,JMP LBL[40] ;
32: LBL[10:ENABLE G1] ;
34: JMP LBL[1] ;
37: JMP LBL[1] ;
40: JMP LBL[1] ;
43: ;
44: LBL[1] ;
45: !Capture DCD Code from PLC ;
46: R[151:$SHELLWRK$CURDCD]=$SHELL_WRK.$CUR_DECSN ;
47: IF R[151:$SHELLWRK$CURDCD]=0,JMP LBL[50] ;
48: !Determined Tool/Gun Action ;
49: CALL TCCKTOOL(R[151:$SHELLWRK$CURDCD]) ;
50: JMP LBL[99] ;
51: ;
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52: !******************************** ;
53: !DCD 0 will Swap Tool/Gun ;
54: !with backup. Backup MUST BE ;
55: !AN IDENTICAL Tool/Gun ! ;
56: !User must enter value of ;
57: ;
58: LBL[50:SWAP Bkup] ;
59: !Determine Tool/Gun on Robot ;
60: CALL TCGETNUM ;
61: ;
62: IF R[113:Current Head]=0,JMP LBL[15] ;
63: !User must set BACKUP GUN Numbers ;
65: =2,JMP LBL[70] ;
66: =3,JMP LBL[80] ;
67: =4,JMP LBL[90] ;
69: ;
70: LBL[60:TLGN1 Bkup] ;
71: !Set Backup gun using TCCKTOOL() ;
72: !CALL TCCKTOOL(BKUP Tool/GUN) ;
73: JMP LBL[99] ;
74: ;
78: JMP LBL[99] ;
79: ;
83: JMP LBL[99] ;
84: ;
88: ;
89: LBL[99:END] ;
90: MOVE TO HOME ;
91: END ;
92: ;
93: ;
94: !*****FAULTS******** ;
95: LBL[5:Invalid Gun Num] ;
96: MESSAGE[...] ;
98: MESSAGE[ INVALID GUN NUMBER] ;
99: MESSAGE[ R[113] AND GI[15] MUST] ;
100: MESSAGE[ BE 1, 2, 3 OR 4] ;
102: UALM[3] ;
104: JMP LBL[1] ;
105: ;
106: LBL[15:CANNOT SWAP] ;
107: MESSAGE[...] ;
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108: MESSAGE[ NOTHING IS ATTACHED] ;
109: MESSAGE[ TO ROBOT. DO NOT KNOW] ;
110: MESSAGE[ WHAT TO SWAP WITH.] ;
112: UALM[3] ;
114: JMP LBL[99] ;
18.16 TCTEACH
Used to manually swap guns. If in teach, this Karel driven menu is called to allow the user to
determine toolchange options instead of the PLC.
STYLE26 - Tool/Gun Exchange when run from the pendant in teach:
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18.17 Servo Gun Tool Change Tip wear specific programs
There are 3 Servo gun Tool change specific programs relating to tip wear that perform
specific wear tracking functions.
18.17.1 TW_GUNS (SG tool change specific)
This macro performs tip wear reset for servo gun tool change applications. It only adjusts the wear
values for the gun that the robot is holding.
1: !FOR SG GUN WITH TOOLCHANGE ONLY ;

2: LBL[1] ;
4: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ;
7: ;
8: CALL TW_UPDCC(R[113:Current Head]) ;
9: ;
11: =2,JMP LBL[20] ;
12: =3,JMP LBL[30] ;
13: =4,JMP LBL[40] ;
15: ;
22: ;
27: ;
30: ;
34: CALL TW_MEM(1) ;
35: JMP LBL[99] ;
36: ;
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43: ;
48: ;
51: ;
56: JMP LBL[99] ;
57: ;
64: ;
69: ;
72: ;
77: JMP LBL[99] ;
78: ;
86: ;
91: ;
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94: ;
99: JMP LBL[99] ;
100: ;
101: LBL[15] ;
102: !Ensure Water is OFF ;
107: LBL[25] ;
108: IF (R[219:NwCapsWearUprLMT]<>R[235:SmallCapWrUprLmt] AND
R[220:NwCapsWearLwrLMT]<>R[236:SmallCapWrLwrLmt]),JMP LBL[35] ;
111: ;
112: CALL USERCLR ;
115: MESSAGE[...] ;
116: MESSAGE[STEPPERS HAVE BEEN RESET!] ;
117: MESSAGE[CONFIRM NEW CAPS AT] ;
118: MESSAGE[NEW TIPS ERROR PROMPT] ;
119: MESSAGE[TO CONTINUE!] ;
121: UALM[49] ;
123: JMP LBL[15] ;
124: ;
125: LBL[35] ;
126: CALL USERCLR ;
128: ;
130: MESSAGE[...] ;
131: MESSAGE[ CAP CHANGE VERIFICATION] ;
132: MESSAGE[ FAILED TIP WEAR CHECK ] ;
133: MESSAGE[CHECK GUN FOR:] ;
134: MESSAGE[1. CORRECT CAP TYPE ] ;
135: MESSAGE[2. NEW CAPS] ;
136: MESSAGE[3. SERVO GUN MASTERING] ;
137: MESSAGE[!WEAR WITH NEW CAPS NOT <2mm] ;
139: UALM[49] ;
141: JMP LBL[1] ;
142: ;
143: LBL[45] ;
144: CALL USERCLR ;
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146: ;
147: MESSAGE[...] ;
148: MESSAGE[...] ;
149: MESSAGE[ WEAR AFTER CAPCHANGE] ;
150: MESSAGE[ IS NOT ZERO] ;
151: MESSAGE[...] ;
152: MESSAGE[...] ;
153: MESSAGE[ REPLACE CAPS] ;
154: MESSAGE[...] ;
155: MESSAGE[...] ;
157: UALM[49] ;
159: JMP LBL[1] ;
160: ;
161: LBL[55] ;
162: MESSAGE[ INVALID ARGUMENT] ;
163: UALM[1] ;
164: JMP LBL[1] ;
165: ;
166: LBL[99] ;
167: !Ensure Water Reset ;
168: CALL RST_WTR ;
170: ;
18.17.2 TW_MEM (SG tool change specific)
This macro records the current tip wear at tool changing nest(s) for tip wear verification.
Guns are dropped off to the nests open and this will verify an unexpected cap change
activity.
1: !This macro sets the ;

2: !cap wear memory registers ;
3: !for the servo gun tool ;
4: !change application ;
5: !for error proofing ;
6: ;
7: LBL[1:BEGIN] ;
8: R[151:$SHELLWRK$CURDCD]=AR[1] ;
9: ;
10: SELECT R[151:$SHELLWRK$CURDCD]=1,JMP LBL[10] ;
11: =2,JMP LBL[20] ;
12: =3,JMP LBL[30] ;
13: =4,JMP LBL[40] ;
15: END ;
16: ;
17: LBL[10] ;
18: R[227:G1GN Wr At Nest]=R[201:G1GN Wear Snc CC] ;
19: R[228:G1RB Wr At Nest]=R[202:G1RB Wear Snc CC] ;
20: ;
21: JMP LBL[99] ;
22: ;
23: LBL[20] ;
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24: ;
27: ;
28: JMP LBL[99] ;
29: ;
30: LBL[30] ;
33: ;
34: JMP LBL[99] ;
35: ;
36: LBL[40] ;
39: ;
40: JMP LBL[99] ;
41: ;
43: UALM[1] ;
44: JMP LBL[1] ;
45: ;
46: LBL[99] ;
18.17.3 TW_VER (SG tool change specific)
This macro is used to compare the tip wear after picking up a gun compared to the tip wear when it
was set down. This will verify that an unexpected cap change didn’t occur.
1: !This macro compares the ;

2: !cap wear memory registers ;
3: !for the servo gun tool ;
4: !change application ;
5: !for error proofing ;
6: ;
7: LBL[1:BEGIN] ;
9: IF DI[201:di_TCCapsCC_Mode]=ON,JMP LBL[99] ;
11: ;
12: SELECT R[151:$SHELLWRK$CURDCD]=1,JMP LBL[10] ;
13: =2,JMP LBL[20] ;
14: =3,JMP LBL[30] ;
15: =4,JMP LBL[40] ;
17: END ;
18: ;
19: LBL[10] ;
20: R[20:SERVO GUN WORK]=R[201:G1GN Wear Snc CC]-R[227:G1GN Wr At Nest] ;
21: R[21:SERVO GUN WORK]=R[202:G1RB Wear Snc CC]-R[228:G1RB Wr At Nest] ;
22: IF R[20:SERVO GUN WORK]>R[235:SmallCapWrUprLmt] OR R[20:SERVO GUN
WORK]<R[236:SmallCapWrLwrLmt] OR R[21:SERVO GUN WORK]>R[235:SmallCapWrUprLmt] OR
R[21:SERVO GUN WORK]<R[236:SmallCapWrLwrLmt],JMP LBL[15] ;
23: ;
24: JMP LBL[99] ;
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25: ;
26: LBL[20] ;
27: ;
31: ;
32: JMP LBL[99] ;
33: ;
34: LBL[30] ;
38: ;
39: JMP LBL[99] ;
40: ;
41: LBL[40] ;
45: ;
46: JMP LBL[99] ;
47: ;
48: LBL[15] ;
49: CALL USERCLR ;
50: CALL USERPAGE ;
51: MESSAGE[UNEXPECTED CAPWEAR] ;
52: MESSAGE[CAP CHANGE NOT DETECT] ;
53: MESSAGE[BY ROBOT] ;
54: MESSAGE[...........] ;
55: MESSAGE[EVALUATE CAPWEAR] ;
56: MESSAGE[LIMITS R[235,236] ;
57: MESSAGE[...........] ;
58: MESSAGE[ROBOT WILL REQ] ;
59: MESSAGE[CAP CHANGE ON THIS GUN] ;
60: ;
61: IF ((R[226:DNETCFG 64/256]<>1) AND (R[113:Current
Head]=1)),DO[201:SG1TipChgReq]=ON ;
65: UALM[78] ;
66: ;
67: LBL[99] ;
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18.18 Servo Gun Tool Changing specific Tip Dress Programs
Several Tip dress macros have a modified version for the Servo Gun tool change
applications.
18.18.1 Style 29 TIP DRESS (SG tool change specific)
The carried tip style for the SG tool changing application is modified to dress the currently
held gun with the TDPROCx path.
1: !TipDress Style 29 ;
2: !carried with toolchanging ;
3: MESSAGE[TIP DRESS CARRIED] ;
4: ;
6: ;
7: GO[1:ManualStyle]=29 ;
8: ;
9: ECHO OPTION ;
10: ;
12: ;
13: LBL[1] ;
14: !Determine Gun on Robot ;
15: CALL TCGETNUM ;
16: ;
18: !No TD if MH Tool/Stud ;
20: ;
22: ;
23: !Check that Held Gun ;
24: !Is Not Machine Locked ;
25: !For Servo Gun Only ;
28: =2,JMP LBL[20] ;
29: =3,JMP LBL[30] ;
30: =4,JMP LBL[40] ;
34: JMP LBL[50] ;
37: JMP LBL[50] ;
40: JMP LBL[50] ;
43: ;
44: LBL[50:SelectTpDresPath] ;
45: ;
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47: =2,JMP LBL[70] ;
48: =3,JMP LBL[80] ;
49: =4,JMP LBL[90] ;
51: ;
52: LBL[60] ;
53: CALL TD_PROC1 ;
54: JMP LBL[99] ;
55: LBL[70] ;
56: CALL TD_PROC2 ;
57: JMP LBL[99] ;
58: LBL[80] ;
59: CALL TD_PROC3 ;
60: JMP LBL[99] ;
61: LBL[90] ;
62: CALL TD_PROC4 ;
63: ;
64: LBL[99] ;
65: MOVE TO HOME ;
66: END ;
67: ;
68: !****FAULTS****** ;
69: LBL[5:Invalid Gun Num] ;
70: MESSAGE[...] ;
72: MESSAGE[ INVALID GUN NUMBER] ;
73: MESSAGE[ R[113] AND GI[15] MUST] ;
74: MESSAGE[ BE 1, 2, 3 OR 4] ;
76: UALM[3] ;
78: JMP LBL[1] ;
18.18.2 TD_PROCx (SG tool change specific)
The carried tip dress process x macros, where x equals the gun # 1-4. No two guns should
have the same tip dress path even if they are identical type guns. Note that the arguments
attached to the CUTRLMT and TCDRESCP calls are equal to the tip dress motor being used,
therefore, the user may have to modify.
1: !TIPDRESS PROCESS 1 ;
2: MESSAGE[TIP DRESS GUN1] ;
3: ;
4: !Note: CUTRLMT and DRESCAPS ;
5: !need identical arguments ;
6: !which should be in respect ;
7: !to the tipdress motor used ;
8: CALL CUTRLMT(1) ;
9: ;
10: LBL[1] ;
11: !SGTC GUN CHECK ;
12: IF SO[7:TP enabled]=OFF,JMP LBL[2] ;
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18: CALL TCGETNUM ;
19: IF R[113:Current Head]=0 AND R[113:Current Head]>4,JMP LBL[5] ;
20: LBL[2] ;
21: !PROGRAM PATH TO TD POINT ;
22: UTOOL_NUM=1 ;
23:J P[1] 70% CNT100 ;
24:J P[2] 50% CNT100 ;
25: ;
26: LBL[10:Staging Pt] ;
27: !Teach G1 Staging Pt @50mm ;
28: !Opening for Servo Guns ;
29:L P[3] 500mm/sec CNT100 ;
30: ;
31: !Teach G1 Aiming Pt @50mm ;
32: !Opening for Servo Guns ;
33:L P[4] 200mm/sec CNT100 ;
34: ;
35: !Teach Firing Pt. ;
37: ;
38: CALL TCDRESCP(1) ;
39: ;
40: !COPY G1 Aiming Pt @50mm ;
41:L P[4] 400mm/sec CNT10 ;
42: ;
43: !COPY G1 Staging Pt @50mm ;
44:L P[3] 400mm/sec CNT10 ;
45: ;
46: !Check if DVG is Bypassed OR ;
47: !NOT Adaptive Capable ;
48: IF R[459:DVGEnabled]=0 AND DI[1077:diSW1AdaptiveCap]=OFF,JMP LBL[20] ;
49: CALL TDVERIFY(1) ;
50: IF (R[40:Prompt Y/N]=1),JMP LBL[10] ;
51: ;
52: LBL[20] ;
53: !PROGRAM RETURN PATH ;
54:J P[6] 50% CNT100 ;
55:J P[7] 70% CNT100 ;
56: CALL TCPSTDRS ;
57: ;
59: END ;
60: ;
61: LBL[5:FAULTS] ;
62: MESSAGE[...] ;
63: MESSAGE[NO GUN ] ;
64: MESSAGE[OR INVALID TOOL TYPE] ;
65: MESSAGE[ ATTACH GUN ] ;
66: MESSAGE[BEFORE ATTEMPTING] ;
67: MESSAGE[A TIP DRESS] ;
68: MESSAGE[... ] ;
70: UALM[1] ;
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72: JMP LBL[1] ;
18.18.3 TCDRESCP (SG tool change specific)
This is the carried servo gun tool change macro listing that dresses the caps for the gun number
equal to argument X. Note that for carried servo gun tool changing the following weld schedules are
used for tipdressing:
Gun # Predress Tipdress

1 247 248
2 249 250
3 251 252
4 253 254
1: !UPDATES TIPDRESS POSITION ;

2: !toolchanging specific ;
3: LBL[1] ;
4: PR[8:TipDress Pos]=LPOS ;
5: LBL[10] ;
6: CALL RST_WTR ;
8: ;
9: SELECT R[151:$SHELLWRK$CURDCD]=1,CALL TD_1_ON ;
10: =2,CALL TD_2_ON ;
11: =3,CALL TD_3_ON ;
12: =4,CALL TD_4_ON ;
14: ;
16: =2,JMP LBL[50] ;
17: =3,JMP LBL[80] ;
18: =4,JMP LBL[110] ;
20: ;
21: !*****Dress Gun1******** ;
22: LBL[20] ;
23: !Turn off FFR During TD ;
24: $SVPRG_ENB=0 ;
25: IF DI[1039:diSW1StepResetG1]=ON,JMP LBL[30] ;
26: ;
27: !TIP DRESS SCHEDULE 248 ;
28:L PR[8:TipDress Pos] 1500mm/sec CNT100
: SPOT[SD=1,P=97,t=10.5,S=248,ED=20] ;
29: JMP LBL[40] ;
30: ;
31: LBL[30] ;
32: !PRE-DRESS SCHEDULE 247 ;
: SPOT[SD=1,P=96,t=10.5,S=247,ED=20] ;
34: ;
35: LBL[40] ;
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36: CALL TD_CHK(AR[1]) ;
37: IF AR[1]=1 AND R[90:TD1 RETRY]=1,JMP LBL[10] ;
41: CALL TD_OFF ;
42: ;
43: !Turn Turn ON FFR AFTER TD ;
44: $SVPRG_ENB=1 ;
45: END ;
46: ;
47: !*****Dress Gun2******** ;
48: LBL[50] ;
50: $SVPRG_ENB=0 ;
52: ;
: SPOT[SD=1,P=97,t=10.5,S=250,ED=20] ;
55: JMP LBL[70] ;
56: ;
57: LBL[60] ;
: SPOT[SD=1,P=96,t=10.5,S=249,ED=20] ;
60: ;
61: LBL[70] ;
67: CALL TD_OFF ;
69: $SVPRG_ENB=1 ;
70: END ;
71: ;
72: !*****Dress Gun3******** ;
73: LBL[80] ;
75: $SVPRG_ENB=0 ;
76: ;
78: ;
: SPOT[SD=1,P=97,t=10.5,S=252,ED=20] ;
81: JMP LBL[100] ;
82: ;
83: LBL[90] ;
: SPOT[SD=1,P=96,t=10.5,S=251,ED=20] ;
86: ;
87: LBL[100] ;
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93: CALL TD_OFF ;
94: ;
96: $SVPRG_ENB=1 ;
97: END ;
98: ;
99: !*****Dress Gun4******** ;
100: LBL[110] ;
102: $SVPRG_ENB=0 ;
103: ;
105: ;
: SPOT[SD=1,P=97,t=10.5,S=254,ED=20] ;
108: JMP LBL[130] ;
109: ;
110: LBL[120] ;
: SPOT[SD=1,P=96,t=10.5,S=253,ED=20] ;
113: ;
114: LBL[130] ;
120: CALL TD_OFF ;
121: ;
123: $SVPRG_ENB=1 ;
124: END ;
125: !************ FAULTS ************ ;
127: UALM[1] ;
128: JMP LBL[1] ;
18.18.4 TCPSTDRS (SG tool change specific)
This macro updates the cap wear after the caps have been dress for gun X. It differ from
regular servo gun post dress in that calls TW_MEM for tip wear error proofing with multi
guns.
1: !TC POST DRESS GUN(X) ;

2: ;
3: LBL[1] ;
4: !Determine Gun on Robot ;
5: CALL TCGETNUM ;
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6: ;
8: =2,JMP LBL[20] ;
9: =3,JMP LBL[30] ;
10: =4,JMP LBL[40] ;
12: END ;
13: ;
14: LBL[10:Gun1] ;
16: R[22:SERVO GUN WORK]=R[201:G1GN Wear Snc CC] ;
17: R[23:SERVO GUN WORK]=R[202:G1RB Wear Snc CC] ;
18: CALL TW_UPD(1) ;
21: JMP LBL[50] ;
22: ;
23: LBL[20:Gun2] ;
30: JMP LBL[60] ;
31: ;
32: LBL[30:Gun3] ;
39: JMP LBL[70] ;
40: ;
41: LBL[40:Gun4] ;
48: JMP LBL[80] ;
49: ;
50: ;
52: UALM[1] ;
53: JMP LBL[1] ;
54: ;
55: LBL[50] ;
56: DO[89:doP1TipMantReqG1]=OFF ;
57: JMP LBL[99] ;
58: LBL[60] ;
60: JMP LBL[99] ;
61: LBL[70] ;
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63: JMP LBL[99] ;
64: LBL[80] ;
66: LBL[99] ;
19 Troubleshooting Servo Gun Tool Change
19.1 The attach instruction is executed when the gun is not attached
Phenomenon: The gun is not actually attached. So, a communications alarm such as
"SRVO-068 DTERR alarm" occurs on the pulse coder. Correct this by Remedy 1 or Remedy
2 below according to the present conditions.
Remedy 1 :
Turn the machine lock ON in the servo gun operation group (normally, group 2) in the Test
Cycle screen.
Move the robot by manual feed so that the robot and gun are physically attached.
1. Turn the controller OFF then ON again.
2. The gun pulse values and mastering data are lost. So, first move the gun by
manual feed to cancel the "SRVO-075 Pulse not established" alarm.
3. Then, carry out gun 0 position mastering and calibration manually.
4. The gun pulse values and mastering data are lost. So, move the gun by manual
feed to cancel the "SRVO-075 Pulse not established" alarm.
5. Carry out gun 0 position mastering and calibration manually. The gun 0 position
may be an approximate position.
6. Execute the detach instruction to temporarily detach the gun. Also, physically
detach the gun from the robot. Otherwise, the gun will not be calibrated at the
next attach operation.
7. Execute the attach instruction again to attach the gun. Calibration this time is
carried out at the reference position to restore the position.
8. Battery mounted gun. The gun is attached and positioned, so it can be used as
it is.
Remedy 2 :
1. Directly change the system variable to detach the gun. To do this, set the following
system variable to "0":
$SCR_GRP[servo gun operation group No. (normally, 2)].$AXISORDER[all 1 to 9] = 0
2. Turn the controller power OFF then back ON.
3. The robot starts up with the gun in a detached state. Move the robot by manual feed to
physically attach the robot and gun.
4. Execute the attach instruction to attach the gun.
5. The gun can be used as it is after it is attached regardless of the battery type.
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19.2 A different gun from that specified by the attach instruction is attached
Phenomenon
The gun is attached to the robot, but the gun’s current position is the wrong value.
Remedy
The following describes an example where gun 2 (actually attached gun) is attached to gun 1
(gun No. taught by the attach instruction).
1. In this state, the gun cannot be detached from the robot by the detach instruction.
So, directly change the system variable to detach the gun. To do this, set the
following system variable to "0":
$SCR_GRP[servo gun operation group No. (normally, 2)].$AXISORDER[all 1 to 9] =

0
2. Turn the controller power OFF then back ON.

3. The gun starts up in a detached state.
4. Execute the attach gun[2] instruction to attach gun 2. (In this state, gun 2 should
be physically connected to the robot.)
When gun 2 is a battery-less gun and the calibration motion type is 1 or 2:

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

Gun 2 can be used as it is.
5. Gun 1 can be used as it is by executing the attach instruction to attach the gun.
19.3 The attached gun has been detached by mistake (without using the detach instruction)
Phenomenon
The gun is not actually attached. So, a communications alarm such as "SRVO-068
DTERR alarm" occurs on the pulse coder. Correct this by Remedy 1 or Remedy 2 below
according to the present conditions.
Remedy 1
Same as Remedy 1 of C-1
Remedy 2
Same as Remedy 2 of C-1
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19.4 The battery voltage has fallen
Phenomenon
The "SRVO-065 BLAL" alarm has occurred with the gun in an attached state.
Remedy
1. Change the battery with the gun attached.

2. The gun can be used as it is.
19.5 The battery ran low while the gun was detached
Phenomenon
The "SRVO-062 BZAL" and "SRVO-075 Pulse not established" alarms occurred when
the gun was attached.
Remedy
When the reference position has not been set:
1. Press F3:RESET_PULSE in the Calibration screen, and select YES.

3. Move the gun by manual feed to cancel the "SRVO-075 Pulse not established"
alarm.
4. Carry out gun 0 position mastering and calibration manually.
When the reference position has been set:
5. Press F3:RESET_PULSE in the Calibration screen, and select YES.

7. Move the gun by manual feed to cancel the "SRVO-075 Pulse not established"
alarm.
8. Move the gun by manual feed to the reference position marked by a line marking
or alignment mark.
9. Execute 3 QUICK MASTERING in the Calibration screen.
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GRS4 Customization
Touch torque
Increase the value from about ±2, and calculate the value at which erroneous
detection of contact occurs. The sign of touch torque is the sign that is currently
displayed at Touch torque at the Calibration Setup screen on the right.
Note
After confirming the sign in this screen, teach it to the program. Do not
make a mistake when entering the sign. If you do so, contact with the
open limit may not be detected.
20 Variable Listing (Condensed)
The following are variables that relate to servo guns.
20.1 $SGSYSCFG
20.1.1 $pst_ertype: Pressure Shortage Error type
0 = The pressure shortage error is posted as a warning (programs do not pause )

1 = The pressure shortage error is posted as a pause error.
20.1.2 $allow_stdsp: Display Standalone Spot instruction
FALSE = Editor does not display standalone spot instruction

TRUE = Editor will display standalone spot instruction
20.1.3 $rel_press: Release pressure at program pause
0 : Keep pressure at paused

1 : Release pressure at paused
20.1.4 $prs_units: Pressure units
This variable indicates how pressure data is displayed (and entered).

The internal representation and stored values are in kgf.
1 = lbf
2 = Newton
0,other kgf ( default )
119
GRS4 Customization
20.2 Common Errors on Servo Gun Errors
20.2.1 SRVO-023: SERVO Stop error excess (G:%d A:%d)
Cause: When the servo stopped, the position error was abnormally large.
Remedy:
1. Check the ARM1 cable for connectivity, and that no bent pins exist.
2. Check voltage on ARM1 cable (approx100-300Vac when commanded to move).
3. Check that gear ratio is set correctly and matches gun tag. Press Menu’s then Type
select Autotune the value will under Tip Displacement.
4. If a disconnection is not found, replace the servo amplifier or the servo motor.
Cause: Robot encounter SERVO Move error excess during the pressurization of a weld.
This could indicate that the robot would have to exceed the gun close limit to achieve
the desired pressure.
Remedy: Increase the gun closed limit in small increments. Standard limit is 20mm do not
increase beyond 25mm. (Contact Lead Robotics Engineer if problem persists)
*BEWARE: GUN DAMAGE CAN OCCUR BY BLINDLY INCREASING THIS LIMIT*
20.2.2 SRVO-024: SERVO Move error excess (G:%d A:%d)
Remedy: Take the same action as for SRVO–023
20.2.3 SRVO-069: SERVO CRCERR alarm (Grp:%d Ax:%d)
Cause: The serial data has been disturbed during communication.

Remedy:
1. Check for loose connection on the ARP1 cable. Then reboot robot.
2. Check cable routing (isolate cable from 480v cables and RM1 robot cable) to reduce
interference.
3. Check for water intrusion in ARP1 connector at servo motor and inside servo gun end
cap. Common for vertical mounted ped guns where bushing is facing upward.
4. Replace servo gun motor.
20.2.4 SRVO-062: SERVO BZAL alarm (Group:%d Axis:%d)
Cause: This alarm is issued when the battery for backing up the absolute position data of the
pulse coder is not connected. The battery cable inside the robot might have become
disconnected.
Remedy: Correct the cause of the alarm, by pressing MENU’S then SYSTEM select GUN
MASTER press F3 and reboot robot. Mastering will need to be performed at this
point.
20.2.5 SRVO-068: SERVO DTERR alarm (Grp:%d Ax:%d)
Cause: The serial pulse coder did not return serial data in response to a request signal.
Remedy:
1. Make sure that the ARP1 connector on the servo gun is securely connected and check
for bent pins.
2. Check that the shielding of the robot interconnection cable (for the pulse coder) and
check that cable is not run with 480v cables.
3. Replace the robot ARP1 cable (for the pulse coder).
4. Replace the pulse coder.
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GRS4 Customization
20.2.6 SVGN-023: Incomplete Pressure calibration
Cause: Incomplete pressure calibration.

Remedy:
1. Go to the Servo Gun Setup: General Setup Page.
2. Select Pressure Cal. and complete the Pressure Calibration process.
20.2.7 SVGN-024: Incomplete Wear Down calibration
Cause: Incomplete Wear Down calibration.

Remedy:
1. Change Caps with New Caps.
2. Check Zero Position of the Servo Gun and Master if necessary.
3. Run TW_SETG1
20.2.8 SVGN-032: Tip increased error
Cause: The tip wear down value exceeds the increased error.
Remedy:
1. Check to ensure the CORRECT Weld Tips are on the Weld Gun.
2. If the Weld Tips are not correct, change them, and run Cap_chng/Reset Steppers.
3. If the Weld Tips are correct, run Capwear and verify the gun is closing completely during
the Capwear routine.
4. If the Servo Gun Does not close completely while running Capwear, apply lubricant to the
shaft, exercise the Servo Gun and retry Step 3.
5. If the Servo Gun still does not close the gun may need to be recalibrated (Auto
Tuned/Pressure Cal). Pay close attention to the Gun Impedance Value before and after
Auto Tuning. If the Gun Impedance Value increased significantly, the Servo Gun may
have a bind or the Servo Motor may need to be replaced.
6. If a bind is suspected on a C-Type Weld Gun, check the Guide Rod (Slide on Global) on
the Movable Side for straightness, wear and heat. Repair/Replace Guide Rod and re-run
Step 5.
7. If the Servo Motor seems excessively noisy or the shaft of the motor is excessively
warm/hot, remove the Servo Motor. If the Servo Motor is Noisy, replace the Motor.
Inspect the Bushing (Slide on Global) for weld debris, which may cause the increased
Gun Impedance.
20.2.9 SVGN-118: Max wear exceeded
Cause: The maximum tip wear amount has been exceeded.

Remedy:
1. Inspect weld tips for excessive heat and abnormal wear, and inspect weld gun arms for
cracks.
2. If Weld Tips appear normal replace and run Cap_Chng/reset steppers.
3. If there appears to be excessive heat on the weld tips, check for adequate water flow and
check the water tube inside the weld shank.
4. If there appears to be abnormal wear, check the tip dress path, weld pressure at tip
dress, and the tip dress cutter.
5. If weld gun arm is cracked, replace gun arm, check servo gun mastering, and verify all
process/tipdress paths.
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GRS4 Customization
20.2.10 SVGN-020: Pressure shortage
Cause: Actual pressure is less than the requested pressure.

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

2. Select Setup then hit ENTER
3. Press Type[F1]
4. Select Servo gun
5. Cursor down to 2nd line (General Setup) then hit ENTER
6. Cursor down to Overtorque Protection then hit ENTER
7. Press OK
8. Select Parameter Summary then ENTER
9. Verify item 1 (Display Units) is in TorqCt if not Select F4 to change
10. Gun Impedance is displayed in the row stating “Std. Overtorque Value”.
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GRS4 Customization
20.4 Servo Gun Amp Settings with Gun(s) & Hardware Mismatches
When a controller is equipped with additional amp channels than the amount being used by
the application, the additional amp channels have to be mapped to eliminate hardware
mismatches. For example, if a robot controller has a single amp as amp 1 and dual amp as
amp 2 but is only configured for 1 gun on each amp, the additional amp channel must be
configured by setting the following system variables:
$SCR.$ATR[9]=9
$SCR.$ATRATTRIB[9]=0
123

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General Motors Company

Global ME - Vehicle Systems

Global 3 Servo Gun Setup Manual

March 14, 2014

JJ Arboleras Fanuc America Corporation

GM Manufacturing Engineering – Vehicle Systems

Forward questions, comments and/or revisions to:

General Motors Company

Date Revision By Revision History

Additional Copies of this Document may be obtained from:

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Section Description Page

1.3 Intended audience

2.1 Gun Mounting

3.1 Getting Started

1. Robot software version.

3.2 Helps and Hints

3.2.2 Re-Running the wizard to add a feature

1. Perform a Backup All of the controller

4 Establishing Pulse on Servo Gun Motors

4.1 Resetting BZAL (Battery Zero Alarm)

The steps necessary for clearing the BZAL alarm:

1. Press [MENUS] -> [NEXT] -> [SYSTEM] -> [Master/Cal]

4.2 Establishing Pulse

4.2.1 GSWA and SW-Series Motors

1. Select Group 2 for equipment 1, Group 3 for equipment 2

4.2.2 HT-Series Motor

5 Mastering the Gun

To access the Gun Setup and Autotuning screen:

Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]

5.1 Setting Gun Close Direction

1. Select [Set Gun Motion Sign], and follow instructions

5.2 Mastering the Gun and Setting Axis Limits

5.2.1 Single Gun per Equipment

1. Select [Set Gun specs, master gun]

This will actually

8. Press [F3:COMP] when complete

9. It is now necessary to Autotune the motor.

1. Select [Set Gun Specs, Master Gun] for Gun 1

The EQUIP The INDEX

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

This is necessary to get the gun 2 screen to indicate that everything is

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

5.3.1 Default Autotune Running

1. Select [3: Auto Tune] and Press [Shift] & [F3:EXEC]

2. Select [YES] to Begin

3. Select [OK] and continue to hold [Shift] and the Deadman

5.3.2 Auto Tune Results:

Servo Gun Tuning Results EQ:1,GUN:1 Summarizes Standard

TUNEDIAG.PC creates an Autotune timestamp of up to 10 records. To view these records

SVGN-044 AutoTune Successfully Complete

5.4 Help and Hints

5.4.1 Collision detection alarm

5.4.3 Autotune cannot start

5.4.4 Pressure Shortage

To perform pressure calibration you will need the following items.

Pressure calibration is to be performed in T1 mode at 100% override. This is possible

1. Press [MENUS] -> [Setup] -> [Servo Gun]

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

3. Select <DETAIL> under Overtorque protection:

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

4. Select <DETAIL> under Servogun diagnosis

3. Select <DETAIL> under Tip Wear Standrd