YRC1000

OPERATOR’S MANUAL
FOR SPOT WELDING USING AIR GUN

Upon receipt of the product and prior to initial operation, read these instructions below
thoroughly, and retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”.
The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.

MANUAL NO. RE-CSO-A055

 DANGER
• This manual explains the various components of the YRC1000
system and general operations. Read this manual carefully and be
sure to understand its contents before handling the YRC1000.
• General items related to safety are listed in “Chapter 1.Safety” of
the YRC1000 INSTRUCTIONS. To ensure correct and safe
operation, carefully read the YRC1000 Instructions before reading
this manual.

CAUTION
• In some drawings in this manual, the protective covers or shields
are removed to show details. Make sure to install all the covers and
shields in place before operating this product.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized
modification voids the product warranty.

NOTICE
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.

ii
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.

Indicates an imminently hazardous

DANGER situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.

Indicates a potentially hazardous

WARNING situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.

Indicates a hazardous situation,

CAUTION which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.

NOTICE is the preferred signal word

NOTICE to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.

Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure

NOTE to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION”.

iii
 DANGER
• Before operating the manipulator, make sure the servo power is
turned OFF by performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence. (when in the play
mode or in the remote mode).
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN

• Observe the following precautions when performing a teaching

operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
Read and understand the Explanation of the Warning Labels before
operating the manipulator.

iv
 WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, etc., the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows.

Equipment Manual Designation

YRC1000 Controller YRC1000
YRC1000 Programming Pendant Programming Pendant
Cable between the manipulator and the controller Manipulator cable

v
 Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters or its
Pendant /Symbol Keys symbol printed on them are denoted with [ ].
ex. [ENTER]
Axis Keys [Axis Key] and [Numeric Key] are generic
/Numeric Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a
“+” sign between them,
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • • “
means that the cursor is moved to the object item and [SELECT] is
pressed, or that the item is directly selected by touching the screen.

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.

vi
 Contents

1 Spot Welding Application Using an Air Gun.................................................................................... 1-1

1.1 System Overview of Spot Welding System Using an Air Gun ........................................... 1-1

1.2 Function Keys .................................................................................................................... 1-3

1.3 Teaching ............................................................................................................................ 1-5

1.3.1 Manual Spot Welding Function............................................................................. 1-5

1.3.1.1 Manual Dry Spotting................................................................................ 1-5
1.3.1.2 Stroke Switching ..................................................................................... 1-5
1.3.1.3 Welding On/Off........................................................................................ 1-6
1.3.1.4 Resetting Alarms ..................................................................................... 1-7

1.3.2 Registering Work Instructions............................................................................... 1-8

1.3.2.1 GUNCL Instruction .................................................................................. 1-9
1.3.2.2 SPOT Instruction ................................................................................... 1-11
1.3.2.3 STROKE Instruction .............................................................................. 1-14
1.3.2.4 STRWAIT Instruction............................................................................. 1-16

1.4 Setting Welding Conditions (for Air Gun)......................................................................... 1-17

1.4.1 Settings for Manual Spot Welding ...................................................................... 1-17

1.4.2 Spot Welder Condition Data Setting................................................................... 1-19

1.4.3 Spot Gun Condition Data File............................................................................. 1-22

1.5 Spot Welding Diagnosis................................................................................................... 1-25

1.5.1 Spot Welding Diagnosis Window........................................................................ 1-25

1.5.1.1 Setting Tolerance Value ........................................................................ 1-25
1.5.1.2 Tip Hit Count Clear................................................................................ 1-26

1.6 Spot Gun Motion Control ................................................................................................. 1-27

1.6.1 Gun Motion Control ............................................................................................ 1-27

1.6.1.1 X Type Gun ........................................................................................... 1-27
1.6.1.2 C Type Gun ........................................................................................... 1-28

1.6.2 Process Timing................................................................................................... 1-30

1.6.2.1 OPERATION MODE = 0
(SINGLE GUN, OPEN → WELDING → OPEN).................................... 1-30

1.6.3 OPERATION MODE = 1

(SHORT OPEN → WELDING → SHORT OPEN).............................................. 1-31
1.6.3.1 OPERATION MODE = 2
(SHORT OPEN → WELDING → FULL OPEN) .................................... 1-32
1.6.3.2 OPERATION MODE = 3
(FULL OPEN → WELDING → SHORT OPEN) .................................... 1-33
1.6.3.3 OPERATION MODE = 4
(FULL OPEN → WELDING → FULL OPEN) ........................................ 1-34

1.6.4 Stroke Change Control Method .......................................................................... 1-35

1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun ............................. 1-35
1.6.4.2 X Double Mechanical Stopper Type...................................................... 1-35

1.6.5 I/O Allocation ...................................................................................................... 1-37

1.6.5.1 Input Allocation Window ........................................................................ 1-37

vii
 Contents

1.6.5.2 Output Allocation Window ..................................................................... 1-38

1.6.5.3 Pseudo Input Signal Window................................................................. 1-39

1.6.6 Allocation Signal Meanings................................................................................. 1-40

1.6.7 Monitor Function for Spot Welding Equipment ................................................... 1-42

1.6.8 Spot Welding Exclusive Signal Allocation List .................................................... 1-43

1.7 Instruction List.................................................................................................................. 1-47

viii
 1 Spot Welding Application Using an Air Gun
1.1 System Overview of Spot Welding System Using an Air Gun

1 Spot Welding Application Using an Air Gun

1.1 System Overview of Spot Welding System Using an Air Gun

An I/O signal diagram of a typical spot welding system is shown below.
Fig. 1-1: I/O Signal Diagram for Spot Welding System

Robot WELD COND Welder

Controller (8 bits max)
WELD
REQUEST
WELD
COMPLETION

WELD ERROR
WELD ERROR
RESET

WELD ON/OFF

GUN PRESSURE

STROKE CHANGE Welding Gun

(Single Solenoid /
Double Solenoid)
DOUBLE STROKE GUN
FULL-OPEN DETECTION
DOUBLE STROKE GUN
SHORT-OPEN DETECTION

• WELD COND (level signal)

• Sets the welding conditions for the welder.
• The output format can be set as binary or discrete.
• Can handle up to 255 conditions (for binary).

8-bit
128 64 32 16 8 4 2 1
(8) (7) (6) (5) (4) (3) (2) (1)
* Values in parentheses are for discrete.

• WELD REQUEST (level/pulse)

Outputs the start instruction to the welder.
• WELD ERROR RESET (level)
Resets the welding alarm status of the welder.
• GUN PRESSURE (level)
Outputs gun pressure instruction to the welding gun.

1-1
1 Spot Welding Application Using an Air Gun
1.1 System Overview of Spot Welding System Using an Air Gun

• STROKE CHANGE (level)

Select the stroke of the gun.
• In case of single solenoid: Change by 1 signal
• In case of double solenoid: Change by 2 signal

For details on signal contents, refer to chapter 1.6 Spot Gun

Motion Control.
SUPPLE-
MENT
For details on I/O allocation, refer to chapter 1.6.5 "I/O
Allocation".

1-2
 1 Spot Welding Application Using an Air Gun
1.2 Function Keys

1.2 Function Keys

Each function used for spot welding is allocated on [Numeric Key]s of the
programming pendant. These keys become available when the WORK
HOME POSITION is on the display.

Displays the MANUAL SPOT window.

Displays the WORK HOME POSITION window.

[FWD] + [TASK ORIGIN]

With the WORK HOME POSITION window in the teach
mode, press these keys to move the manipulator to the work
home position.
Displays the SPOT instruction in the input buffer to register
welding operations.

[INTERLOCK] + [SPOT]
With the MANUAL SPOT window displayed, press these
keys to perform manual welding.
Displays the GUNCL instruction in the input buffer to register
dry spot welding operations.

[INTERLOCK] + [GUN CLOSE]

With the MANUAL SPOT window displayed, press these
keys to perform manual dry spot welding.
[INTERLOCK] + [WELD ON/OFF]
Press these keys to turn on or off the welding ON/OFF signal.

1-3
1 Spot Welding Application Using an Air Gun
1.2 Function Keys

Instruction to change the stroke to the short open position

when using a double stroke gun:
Displays the STROKE SHORT instruction in the input buffer.

The SHORT OPEN POSITION SETTING window appears

the first time the key is pressed.
The selection No. for the short open position appears from
the second time the key is pressed.

[INTERLOCK] + [SHORT OPEN]

The movable side electrode moves to the selected short
open position.
Instruction to change the stroke to the full open position when
using a double stroke gun:
3 Displays the STROKE LONG instruction in the input buffer.

The FULL OPEN POSITION SETTING window appears the

first time the key is pressed.
The selection number for the full open position appears from
the second time the key is pressed.

[INTERLOCK] + [FULL OPEN]

The movable side electrode moves to the selected full open
position.
[INTERLOCK] + [WELD ALM RESET]
A Power Source alarm reset signal is output to the Power
Source only while these keys are held down.

The welding conditions, gun pressure and weld request are

reset with this function.

However, the following two keys are for the function keys for spot welding
with motor gun and not for spot welding with air gun.

1-4
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3 Teaching
In order to use the air gun function, first perform teaching as described
below.

1.3.1 Manual Spot Welding Function

To perform manual spot welding, carry out the following operation.
1. Press [0/MANUAL SPOT] of [Numeric Key]s.
2. Press [INTERLOCK] + [SPOT] simultaneously.
To perform manual spot welding, press these keys simultaneously while
the MANUAL SPOT window is called up.
The conditions displayed in the MANUAL SPOT window are used for
manual spot welding.
Regarding the condition setting, refer to chapter 1.4.1 "Settings for
Manual Spot Welding".
When registering the welding instruction [SPOT], the values set in the
MANUAL SPOT window are used as the initial data.

1.3.1.1 Manual Dry Spotting

To perform manual dry spotting, carry out the following operation.
1. Press [0/MANUAL SPOT] of [Numeric Key]s
2. Press [INTERLOCK] + [GUN CLOSE] simultaneously.
To perform manual dry spotting, press these keys simultaneously while
the MANUAL SPOT window is called up.
The conditions displayed in the MANUAL SPOT window are used for
manual dry spotting.
Note that the numbers specified in the MANUAL SPOT window are used
as the initial values for the gun number of the gun to be operated and the
gun number used when registering the dry spot instruction GUNCL.
While the key is being pressed, the dry spotting motion is performed.
When the key is released, the operation stops.

1.3.1.2 Stroke Switching

• Press [INTERLOCK] and [FULL OPEN] simultaneously to switch to
the full open position.
• Press [INTERLOCK] and [SHORT OPEN] simultaneously to switch
to the short open position.
Note that the numbers specified in the MANUAL SPOT window are used
as the initial values for the gun number of the gun to be operated and the
gun number used when registering the stroke switching instruction
STROKE.
AP parameter specifies whether the stroke signal should be set ON or
OFF to make the stroke full open. (The initial setting is OFF.)

1-5
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.1.3 Welding On/Off

Press [INTERLOCK] and [WELD ON/OFF] simultaneously in the teach
mode to turn on or off the welding ON/OFF signal to all connected
welders.
A user message appears when the welding ON/OFF signal is turned ON
in the teach mode.
During manual spot welding, the welding current flows only when this
message appears.
The output destination must be allocated in the spot input/output
allocation information window before this function is used.

SUPPLE-
For information on the signal allocation method, see
MENT chapter 1.6.5 "I/O Allocation".

1-6
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.1.4 Resetting Alarms

The alarm reset signal to all connected welders remains ON while
[INTERLOCK] and [WELD ALM RESET] are being pressed
simultaneously. The welding conditions, gun pressure and weld request
are reset with this function.
The output destination must be allocated in the spot input/output
allocation information window before this function is used.

SUPPLE-
For information on signal allocation method, see
MENT chapter 1.6.5 "I/O Allocation".

1-7
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.2 Registering Work Instructions

The function keys [GUNCL](GUNCL instruction), [SPOT](SPOT
instruction), [SHORT OPEN]/[FULL OPEN](STROKE instruction) can be
used for registering the work instructions.
The STRWAIT instruction is registered using [INSTRUCTION LIST].
Table 1-1: Registering Work Instructions
Specific Keys Instructions
[GUN CLOSE] GUNCL instruction
[SPOT] SPOT instruction
[SHORT OPEN] STROKE instruction
[FULL OPEN]

Instructions are registered during the teach mode when the cursor is in the
address area of the job content window.
1. Select {JOB} under the main menu.
2. Select {JOB CONTENT}.

– The JOB CONTENT window is displayed.

3. Move the cursor to the address area.

1-8
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.2.1 GUNCL Instruction

This is the dry spotting instruction. It performs dry spotting for the
specified time. The gun performs dry spotting then returns to the start
position after the time-up timer counts out. Use this instruction when
spotting is required, such as after automatic tip dressing or automatic tip
replacement.

Be sure to use this instruction in the short open status with

a double stroke gun other than X double stroke mechanical
stopper type gun.
NOTE The instruction controls only one gun at one time. Two
guns cannot perform dry spotting simultaneously. When
GUNCL instruction is executed, it takes a time for the stroke
action and dry spotting time is shortened.

 Additional Items

(1) (2) (3)

GUN#(X) T=X
GUNCL GUN NO. GUN PRESSURE TIME
X: 1 to 8 X: 0.01 to 655.35 sec.

ATT=X
ANTICIPATION CONDITION
X: 0 to 655.35 sec.

(1) Gun# (X)

Specifies a gun to be pressed.
(2) T=X
Specifies the time when the gun is closed.
(3) ATT = X
Starts execution of GUNCL X second(s) before reaching the move
instruction located immediately before it. However, it is necessary
to specify “NWAIT” to the move instruction immediately before the
GUNCL instruction.

1-9
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

 Operation Procedure

1. Move the cursor to the line before the place where the GUNCL
instruction is to be registered.
2. Press [2/GUN CLOSE] or [INSTRUCTION LIST].
3. Select the {GUNCL} instruction.
– When [2/GUN CLOSE] is pressed, the “GUNCL” instruction appears
in the input buffer line.

– When [INSTRUCTION LIST] is pressed, the instruction list dialog

appears. Select “GUNCL” from the list.

4. Move the cursor to the address area.

5. Add items and modify the number data.

6. Press [ADD], then press [ENTER].
– The GUNCL instruction is registered.

 Example

The gun pressure signal is turned ON 0.5 seconds before the manipulator
reaches the step 5 position and then turns OFF after 2 seconds (1.5
seconds after reaching there) and moves to the execution of step 6.

1-10
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.2.2 SPOT Instruction

This instruction starts the spot welding sequence. It outputs the gun
pressure signal then executes the welding sequence appropriate for the
gun type. The function key [SPOT] can be used for its registration.
The condition number used for the registration of the spot instruction is a
value set on the manual spot condition window.
Two guns can be controlled simultaneously.

Under two-gun control, this instruction is completed when

SUPPLE-
the gun with the slower welding sequence completes weld-
MENT ing. See chapter 1.6 Spot Gun Motion Control for informa-
tion on the welding sequence executed by this instruction.

 Additional Items
(1) (2) (3)
GUN#(X) MODE=X WTM=X
SPOT GUN1 NO. GUN1 ACTION MODE GUN1 WELD CONDITION
X: 1 to 8 X: 0 to 4 X: 1 to 255

(4) (5) (6)

GUN#(X) MODE=X WTM=X
GUN2 NO. GUN2 ACTION MODE GUN2 WELD CONDITION
X: 1 to 8 X: 0 to 4 X: 1 to 255

(7)
ATT=X
ANTICIPATION CONDITION
X: 0 to 655.35 sec.

(1) GUN #(X)

Specifies the number of welding condition set to the welder.
(2) MODE = X
Specifies the gun move operation mode.
In the case of double stroke, specifies the open status before and
after the welding.

Setting Data Before Welding  After Welding

0 Single Gun
1 Short Open  Short Open
2 Short Open  Full Open
3 Full Open  Short Open
4 Full Open  Full Open

(3) WTM=X
Specifies the number of welding conditions set to the welder.
(4) GUN#(X)
Specifies the second gun at two-gun control.
Cannot be omitted at simultaneous two-gun control. Do not set
when only one gun is used.
(5) MODE=X

1-11
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

Specifies the operation mode of the second gun at two-gun con-

trol. Specifies the open status before and after welding in the case
of double stroke.
Do not set when only one gun is used.
Setting data is the same as shown in the table in (2).
(6) WTM=X
Specifies the number of the welding conditions set to the second
welder at two-gun control.
Do not set when only one gun is used.
(7) ATT=X
Starts execution of SPOT X second(s) before reaching the move
instruction immediately before it. However, it is necessary to
specify “NWAIT” to the move instruction immediately before the
SPOT instruction. By omitting this item, the SPOT instruction is
executed as usual after reaching the move instruction.

 Operation Procedure

1. Move the cursor to the line before the place where the SPOT
instruction is to be registered.
2. Press [./SPOT] or [INSTRUCTION LIST].
– When [./SPOT] is pressed, the “SPOT” instruction appears in the
input buffer line.

– When [INSTRUCTION LIST] is pressed, the instruction list dialog

appears. Select {SPOT} from the list.

3. Add items and modify the number data.

4. Press [ADD], then press [ENTER].
– The SPOT instruction is registered.

1-12
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

 Examples

The sequence of the SPOT instruction is started from the short open 0.5
seconds before the manipulator reaches the position of step 5. After
completion of the sequence, the status becomes full open to move to the
execution of step 6.

If the manipulator starts moving before the gun opens when gun open
status is not verified, adjust the timing with the TIMER instruction as
shown below.

Do not use the “ATT” unless it is indispensable. As the gun

will be closed during the robot move operation by the use of
NOTE ATT, the robot might possibly move with its gun closed.
Set the ATT value after setting the ATT minimum value
(0.01 seconds) and execute a confirmatory operation.

1-13
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.2.3 STROKE Instruction

This is an instruction to alternate short open and full open of a double
stroke gun at any time other than welding.
It executes the stroke changes sequence with an X double stroke
mechanical stopper type gun, and with the other double stroke guns, it
changes the change signal to full open or to short open status.
This instruction can control only one gun at a time. Two guns cannot be
pressed at the same time.

For details on the stroke change sequence of an X double

SUPPLE- stroke mechanical stopper type gun to be executed by this
MENT
instruction, see chapter 1.6 Spot Gun Motion Control.

When using an X double stroke mechanical stopper type

gun, stroke change is enabled only at pressing. With an
NOTE execution of this instruction, the gun performs dry spotting:
the stroke can be changed while the dry spotting is exe-
cuted. (In case of the other types of guns, this instruction
only turns the stroke change signal ON/OFF.)

 Additional Items

(1) (2)
GUN#(X) LONG/SHORT
STROKE GUN NO. GUN STROKE
X: 1 to 8

(1) GUN# (X)

Specifies a gun characteristic file number of stroke to be changed.
(2) LONG or SHORT
Specifies the stroke status by alternating LONG and SHORT.

1-14
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

 Operation Procedure

1. Move the cursor to the line before the place where the STROKE
instruction is to be registered.
2. Press [-/SHORT OPEN], [3/FULL OPEN], or [INSTRUCTION LIST].
– The “STROKE GUN#(1) SHORT” instruction appears in the input
buffer line when [-/SHORT OPEN] is pressed; the “STROKE
GUN#(1) LONG” instruction appears in the input buffer line when the
key [3/FULL OPEN] is pressed.
– When [INSTRUCTION LIST] is pressed, the instruction list dialog
appears. Select {STROKE} from the list.

3. Add items and modify the number data.

4. Press [ADD], then press [ENTER].
– The STROKE instruction is registered.

 Example

Stroke is fully opened in order to avoid interference when the manipulator

reaches the position of step 5. Then the manipulator moves to step 6 to
avoid interference.

1-15
 1 Spot Welding Application Using an Air Gun
1.3 Teaching

1.3.2.4 STRWAIT Instruction

This is an instruction to verify the double stroke gun status short open or
full open, at any time other than welding. It waits until a signal to verify full
open or short open is turned ON.
This instruction can control only one gun at a time; it cannot control two
guns simultaneously.

 Additional Items

(1) (2)
GUN#(X) LONG/SHORT
STRWAIT GUN NO. GUN STROKE
X: 1 to 8

(1) GUN# (X)

Specified a gun characteristic file number of which stroke is veri-
fied.
(2) LONG or SHORT
Specifies the stroke status to be verified by alternating LONG and
SHORT.

 Operation Procedure

1. Move the cursor to the line before the place where the STRWAIT
instruction is to be registered.
2. Select the {STRWAIT} from the instruction list.

3. Add items and modify the number data.

4. Press [ADD], then press [ENTER].
– The STRWAIT instruction is registered.

 Example

Stroke is fully opened in order to avoid interference when the manipulator

reaches the position of step 5. Then the STRWAIT instruction verifies that
the stroke has become full open status and the manipulator moves to step
6 to avoid interference.

1-16
 1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

1.4 Setting Welding Conditions (for Air Gun)

1.4.1 Settings for Manual Spot Welding

 Manual Spot Window

A
B
C
D

A. TWO GUN CONTROL

Specifies whether the simultaneous control is turned ON or OFF when
using two guns.
B. GUN NO.
Specifies the gun number of the gun to be used for manual spot weld-
ing.
C. WELDING COND (WTM)
Specifies the manual spot welding condition number to be used for
welding.
D. ACTION MODE
Specifies the gun operation mode.
Shows the gun open status before and after the welding.

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 1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

 Operation Procedure

1. Press [0/MANUAL SPOT] of [Numeric Key]s.

2. Select the desired mode.

3. Select the item to be set.

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 1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

1.4.2 Spot Welder Condition Data Setting

The spot welder condition data file makes the welder-related settings
using the welding sequence I/O signal control method.

 Welder Condition Window

A
B
C
D
E
F
G

A. WELDER NO.
Welder (system) numbers are specified.
B. WELD INST OUTPUT TYPE
Specifies welder output start timing.
In the start timing, there are “PULSE”, “LEVEL”, and “START SIGNAL”.
PULSE

PRESSURE WELD COND

COMMAND OUTPUT TIME

WELDING
CONDITION

WELDING
COMMAND

WELD
COMPLETE

LEVEL

PRESSURE
COMMAND

WELDING
CONDITION

WELDING
COMMAND

WELD
COMPLETE

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1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

START SIGNAL

PRESSURE WELD COND

COMMAND OUTPUT TIME

WELDING
CONDITION

WELDING
COMMAND

WELD
COMPLETE

C. WELD INST OUTPUT TIME

When “WELD INST OUTPUT TYPE” is specified as “PULSE” or
“START SIGNAL”, set the welder condition signal to the pulse output
time.
When “WELD INST OUTPUT TYPE” is specified as “LEVEL”, the time
cannot be set.
D. WELD COND OUTPUT TYPE
Specifies welding condition output form.
There are two output forms: “BINARY” and “DISCRETE”.
E. WELD COND MAX NUM
Specifies the number of welding conditions that can be set.
When “WELD COND OUTPUT TYPE” is “DISCRETE”, the number of
welding conditions cannot be set.
F. WELD END WAIT TIME
Specifies how many seconds to monitor the welding complete signal
after the welding command is output from the SPOT instruction execu-
tion.
An alarm occurs if the welding complete signal is not received within the
set time.
G. STICK DETECT DELAY TIME
Once the welding end signal has been input, set the length of wait time
that the wire sticking signal should be observed.
After this wait time has elapsed, if a wire sticking signal has been input,
an alarm occurs.

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 1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

 Operation Procedure

1. Select {SPOT WELDING} under the main menu.

2. Select {WELDER CONDITION}.

3. Select the item to be set.

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 1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

1.4.3 Spot Gun Condition Data File

Set the type of a gun, the number of the welder to be used, etc. for
welding gun numbers 1 to 8.

 Gun Condition Window

A
B
C
D
E
F
G
H
I
J

A. GUN NO.
Sets the gun condition file number.
B. GUN TYPE
Specifies the type of the welding gun. The sequence to be executed is
specified by this value.
Four gun-types are available:
• Single Gun
• C double stroke cylinder type gun
• X double stroke mechanical stopper type gun
• X double stroke cylinder type gun
When the gun type other than the single gun is set, the new setting
items are displayed.
C. WELDER NO.
Specifies the welder to which the gun is connected.
D. OPEN MONITOR
Specifies whether the short-open status is verified or not at welding
sequence execution.
E. GUN OPEN/CLOSE SET AT STOP
Specifies the gun open/close setting for when a hold, emergency stop,
or alarm occurs during welding instruction execution.
• ON: welding instruction, welding condition, and pressure instruction
are turned off.
• OFF: welding instruction, welding condition are turned off.
F. FULL OPEN MONITOR
Specifies whether the full-open status is verified or not at welding
sequence execution.
G. CHANGE TIME (OPEN -> FULL-OPEN)
Sets the time from when the welding completion signal is received to
when the manipulator actually starts moving after becoming the short-
open status or the full-open status.
Valid when the full open monitor is OFF.

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1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

H. OPEN STROKE OUT DELAY TIME

Specifies the timing to change the stroke change signal to the short-
open status after the gun pressure instruction is output (ON) when a
mechanical stopper type gun is used. (Used when changing from the
full-open status to the short-open status.)
This function can be used when the LS pressure is not set.
I. FULL OPEN STROKE OUT DELAY TIME
Specifies the timing to change the stroke change signal to the full-open
status after the gun pressure instruction is output (ON) when a mechan-
ical stopper type gun is used. (Used when changing from the short-open
status to the full-open status.)
This function can be used when the LS pressure is not set.
J. STROKE CHANGE OUTPUT TIME
Sets the time to output the stroke change signal when a mechanical
stopper type gun is used.

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 1 Spot Welding Application Using an Air Gun
1.4 Setting Welding Conditions (for Air Gun)

 Operation Procedure

1. Select {SPOT WELDING} under the main menu.

2. Select {GUN CONDITION}.

– The GUN CONDITION window is displayed.

3. Select the item to be set.

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 1 Spot Welding Application Using an Air Gun
1.5 Spot Welding Diagnosis

1.5 Spot Welding Diagnosis

1.5.1 Spot Welding Diagnosis Window

This window shows the maintenance information for tip replacement.
It shows the set number of welds to tip replacement and the number
currently completed.

1.5.1.1 Setting Tolerance Value

1. Select {SPOT WELDING} under the main menu.
2. Select {WELD DIAGNOSIS}.

– The SPOT WELD DIAGNOSIS window is displayed.

3. Select “GUN NO.”

– Enter the desired gun number, and press [ENTER].
4. Select “TOLERANCE”.
– Input the desired tip replacement value, and press [ENTER].
IT COUNT

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 1 Spot Welding Application Using an Air Gun
1.5 Spot Welding Diagnosis

1.5.1.2 Tip Hit Count Clear

1. Select {SPOT WELDING} under the main menu.
2. Select {WELD DIAGNOSIS}.
– The SPOT WELD DIAGNOSIS window appears.
3. Select {CLEAR CURRENT POS} from {DATA}.

4. Select “YES”.
– The confirmation dialog appears.

– The current tip hit count is cleared.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6 Spot Gun Motion Control

As regards to the guns for each stroke methods, the motion control
described in chapter 1.6.1 "Gun Motion Control" can be executed.
The following gun types are available:
• X, C types single stroke method
• X type double stroke method
• C type double stroke method

1.6.1 Gun Motion Control

The ways to control the gun motions are shown on the following pages.

1.6.1.1 X Type Gun

 Single stroke

SHORT OPEN WELD SHORT OPEN

 Double stroke

SHORT OPEN WELD SHORT OPEN

FULL OPEN WELD SHORT OPEN

SHORT OPEN WELD FULL OPEN

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

FULL OPEN WELD FULL OPEN

 Stroke change

FULL OPEN WELD

1.6.1.2 C Type Gun

 Single stroke

SHORT OPEN WELD SHORT OPEN

 Double stroke

SHORT OPEN WELD SHORT OPEN

FULL OPEN WELD SHORT OPEN

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

SHORT OPEN WELD FULL OPEN

FULL OPEN WELD FULL OPEN

 Stroke change

FULL OPEN SHORT OPEN

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.2 Process Timing

1.6.2.1 OPERATION MODE = 0 (SINGLE GUN, OPEN → WELDING → OPEN)

 Gun Motion Control (With X gun, C gun, single type)

Signal Control Order Manipulator starts moving by welding completion
X X Manipulator Movement (Input) signal when "GUN OPEN" is not
specified in spot input allocation information
display.
Welding Instruction Turns ON/OFF welding instruction, welding
1 3
(Output) condition and pressure instruction simultaniously.
Anticipater Designation However, strictly speaking, output welding
Welding Conditions instruction follows immediately after welding
1 3
(Output) condition output.

Pressure Instruction
1
3 (Output)

2
Welding Completion
(Input)
Gun Short Open In case if the "GUN OPEN" is OFF, manipulator
4
Detection (Input) starts moving immediately after the OFF of the
signal.

NOTE Connect “OPEN DETECTION” signal for “GUN OPEN” sig-

nal in case of using a single gun.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.3 OPERATION MODE = 1 (SHORT OPEN → WELDING → SHORT OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

Signal Control Order

Manipulator starts moving by welding completion
X X (Input) signal when "GUN OPEN" is not specified
Manipulator Movement in spot input allocation information display.
Turns ON/OFF welding instruction, welding
1
Welding Instruction condition and pressure instruction simultaniously.
3
(Output) Anticipater Designation However, strictly saying, output welding instruction
immediately after welding condition output.
1 3
Welding Conditions
(Output)

1
Pressure Instruction
3 (Output)

2 Complete of Welding
(Input)

Stroke Change 1 Short Open (OFF) Stroke Change (Output) characteristic can be
(Output) changed by parameter (Figure shows on setting at
FULL OPEN).
Gun Short Open In case if the "GUN OPEN" is OFF, manipulator starts
Detection (Input) moving immediately after the OFF of the
. signal
4

Gun Full Open

Detection (Input)

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

Signal Control Order

Manipulator starts moving by welding completion
X X (Input) signal when "GUN OPEN" is not specified
Manipulator Movement in spot input allocation information display.

3
Welding Instruction Turns ON/OFF welding instruction, welding
1
(Output) Anticipater Designation condition and pressure instruction simultaniously.
However, strictly saying, output welding instruction
Welding Conditions immediately after welding condition output.
1 3
(Output)

1
Pressure Instruction
3 (Output)

2 Complete of Welding
(Input)
Stroke Change 1 (Output) OFF
Stroke change is of a double solenoid method
X Mechanical Stopper Type (Stroke Change 1, 2) when an x gun double stroke
mechanical stopper type is used.
Stroke Change 2 (Output) OFF
X Mechanical Stopper Type
Gun Pressure Detection
(Input) X Mechanical
Stopper Type
Gun Short Open In case if the "GUN OPEN" is OFF, manipulator
Detection (Input) starts moving immediately after the OFF of the
4
signal.
Gun Full Open
Detection (Input)

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.3.1 OPERATION MODE = 2 (SHORT OPEN → WELDING → FULL OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

Signal Control Order

X X
Manipulator Movement

1 3
Welding Instruction Turns ON/OFF welding instruction, welding
(Output) condition and pressure instruction simultaniously.
However, strictly saying, output welding instruction
Welding Conditions immediately after welding condition output.
1 3
(Output)

1
Pressure Instruction
3 (Output)
Anticipater Designation
2 Complete of
Welding (Input)
Stroke change (Output) characteristics can be
Stroke Change Short Open Full Open changed by parameter.
5
(Output)

Gun Short Open

4 Detection (Input)
When "FULL OPEN MONITOR" is OFF in spot
Gun Full Open gun condition data file operation starts elapse of
6
Detection (Input) "CHANGE TIME (OPEN -> FULL OPEN)" of spot
gun condition data file after stroke change (Output)
is output.

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

Signal Control Order

X X
Manipulator Movement

Welding Instruction Turns ON/OFF welding instruction, welding

5
1
(Output) condition and pressure instruction simultaniously.
However, strictly saying, output welding instruction
Welding Conditions immediately after welding condition output.
1 5
(Output)
Pressure Instruction
1 5
(Output)
Anticipater Designation
4 Complete of
Welding (Input)
Stroke Change 1 (Output) Full Open Stroke Change (Output) is output for the time set to
3
X Mechanical Stopper Stopper Stroke "STRK CHANGE OUT TIME(STOPPER)" of spot
Type
Change Output gun condition data file.
3
Stroke Change 2 (Output) Time
X Mechanical Stopper
Type
Gun Pressure Detection When "GUN PRESSUREDETECTION" is not set,
2 (Input) X Mechanical
Stopper Type Stroke Change (Output) is output in elapse of
Gun Short Open "FULL-OPEN STRK OUT DLY(STOPPER)" of spot
Detection (Input) gun condition data file after pressure instruction is
output.
When "FULL OPEN MONITOR" is OFF in spot gun
6 Gun Full Open condition data file, operation starts in elapse of
Detection (Input) "CHANGE TIME(OPEN -> FULL OPEN)" of gun
condition data file after stroke change (Output) is
output.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.3.2 OPERATION MODE = 3 (FULL OPEN → WELDING → SHORT OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

Signal Control Order

X X
Manipulator Movement

3 5 Welding Instruction Turns ON/OFF welding instruction, welding condition

(Output) and pressure instruction simultaniously.
Welding Conditions However, strictly saying, output welding instruction
3 5
(Output) immediately after welding condition output.

Pressure Instruction
3 5
(Output)
Anticipater Designation
Complete of
4
Welding (Input)
Stroke Change
(Output) Stroke Change (Output) characteristics can be
1
changed by parameter.
Gun Short Open When "OPEN MONITOR" is OFF in spot gun
2 6 Detection (Input) condition data file, operation starts moving after
welding completion signal (Input) is input.
Gun Full Open
Detection (Input)

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

Signal Control Order

X X
Manipulator Movement

Welding Instruction Turns ON/OFF welding instruction, welding condition

1 5
(Output) and pressure instruction simultaniously.
However, strictly saying, output welding instruction
Welding Conditions immediately after welding condition output.
1 5
(Output)

1 5
Pressure Instruction
(Output)
Anticipater Designation
4
Complete of
Welding (Input) Stopper Type
Stroke Change
3
Stroke Change 1 Output Time
(Output)

3
Stroke Change 2
(Output) When "GUN PRESSURE DETECTION" is OFF,
Stroke Change (Output) is output in elapse of
Gun Pressure "OPEN STRK OUT DLY (STOPPER)" time after
2
Detection (Output) pressure instruction is output.
Gun Short Open When "OPEN MONITOR" is OFF, manipulator starts
moving after welding completion signal (Input) is
Detection (Input) input.
Gun Full Open
Detection (Input)
6

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.3.3 OPERATION MODE = 4 (FULL OPEN → WELDING → FULL OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)
Signal Control Order
X X
Manipulator Movement

Welding Instruction Turns ON/OFF welding instruction, welding condition

3 5
(Output) and pressure instruction simultaniously.
However, strictly saying, output welding instruction
Welding Conditions immediately after welding condition output.
3 5
(Output)

3 5
Pressure Instruction
(Output)
Anticipater Designation
4
Complete of
Welding (Input)
1 7 Stroke Change
(Output)

Gun Short Open

2 6 Detection (Input)
8
Gun Full Open When "FULL-OPEN MONITOR" is OFF, manipulator
Detection (Input) starts moving after elapse of "CHANGE TIME (OPEN -
> FULL OPEN)" of gun condition data file.

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

Signal Control Order

X X
Manipulator Movement

Welding Instruction Turns ON/OFF welding instruction, welding condition

1 3
(Output) and pressure instruction simultaniously.
However, strictly saying, output welding instruction
Welding Conditions immediately after welding condition output.
1 3
(Output)

1 3
Pressure Instruction
(Output)
Anticipater Designation
2 Complete of
Welding (Input)

Stroke Change 1
(Output)

Stroke Change 2
(Output)

Gun Pressure
Detection (Input)

Gun Short Open

Detection (Input)
4
Gun Full Open When "FULL-OPEN MONITOR" is OFF, manipulator
Detection (Input) starts moving after elapse of "CHANGE TIME (OPEN -
> FULL-OPEN)" of gun condition file.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.4 Stroke Change Control Method

1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun

When OPEN (SHORT) is specified, change the stroke change signal
(general output) to short open; when FULL OPEN (LONG) is specified,
change the stroke change 1 signal (general output) to full open. However,
the stroke change signal ON/OFF characteristics depend on the AP
parameter setting.

For the use of C double gun, X double cylinder gun with

double solenoid specifications:
SUPPLE-
MENT Set signal numbers for stroke change 1 and 2 in the spot I/O
allocation information window. The inverse signal of stroke
change 1 is output as stroke change 2 signal.

1.6.4.2 X Double Mechanical Stopper Type

Stroke change signal (output) is output with double solenoid
specifications. The stroke change signal ON/OFF characteristics depend
on the AP parameter setting.

 When OPEN (SHORT) is Specified

Process Timing

Signal Control Order Stroke Change

X Response Time
X
Manipulator Movement

1
Pressure Instruction
(Output) Stopper Type Stroke
Change Output Time
3
Stroke Change 1
(Output) Stopper Type Stroke Short Open
Output Delay Time (when pressure
3
Stroke Change 2 detection OFF)
(Output)
When pressure detection is OFF, stroke is changed
2
Gun Pressure after elapse of stopper type stroke short open output
Detection (Input)
delay time.
Manipulator moves immediately without detecting
Gun Short Open when short open detection is OFF.
4
Detection (Input)

Gun Full Open

Detection (Input)

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

 When FULL OPEN (LONG) is Specified

Process Timing

Signal Control Order Stroke Change

X Response Time
X Manipulator Movement

Pressure Instruction
1
(Output) Stopper Type Stroke Full Open
Output Delay Time (when pressure
3
Stroke Change 1detection OFF)
(Output) Stopper Type Stroke
Change Output Time
3
Stroke Change 2
(Output)
Gun Pressure When pressure detection is OFF, stroke is changed
2
Detection (Input) after elapse of stopper type stroke full open output
delay time.
Gun Short Open
Detection (Input) Manipulator moves immediately without detecting
4
when full open detection is OFF.

Gun Full Open

Detection (Input)

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.5 I/O Allocation

The I/O necessary for each welder can be set in the general-purpose I/O
signal. The following signals are specified on the pseudo input signal
window.
• Timer Cooling Water Error
• Gun Cooling Water Error
• Transthermo Error
• Air Pressure Decrease
• Weld On/Off

1.6.5.1 Input Allocation Window

1. Select {SPOT WELDING} under the main menu.
2. Select {I/O ALLOCATION}.

– The input allocation window appears.

3. Specify the signal number.

– Input the numerical value of the desired signal number, and press
[ENTER].

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.5.2 Output Allocation Window

1. Select {SPOT WELDING} under the main menu.
2. Select {I/O ALLOCATION}.

– The input allocation window appears.

3. Select {DISPLAY} from {DATA}.

4. Select {ALLOCATE OUTPUT}.

– The output allocation window appears.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

5. Specify the signal number.

– Input the numerical value of the desired signal number, and press
[ENTER].

• Be sure to confirm that the allocated general-purpose sig-

nal is not used in the job. If it is used in the job, the signal
is duplicated and the job does not operate normally.
• When the output “WELDING CONDITION PARITY” is set,
the parity number is automatically output during welding
NOTE condition output. The setting of the parity whether it is odd
or even is established in the parameter.
• In case if the stroke switching signal is the double-solenoid
type (X type 2 step stroke gun mechanical stopper type),
allocate two guns; in case if it is the single-solenoid type
(other guns), allocate one gun.

1.6.5.3 Pseudo Input Signal Window

1. Select {IN/OUT} under the main menu.
2. Select {PSEUDO INPUT SIG}.

– The pseudo input signal window appears.

3. Move the cursor to “ON or “OFF”, and press [INTERLOCK] +

SELECT].
– Each time [INTERLOCK] + [SELECT] is pressed, “ (OFF)” and “
(ON)” alternate.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.6 Allocation Signal Meanings

Table 1-2: Robot Controller Input Signal

Signal Content Source Standard
Setting
WELD COMPLETE This signal specifies that welding has been completed. Welder IN13
When the welding command manual spot operation is
executed, it is used as a confirmation signal. When
there is no LS open/close confirmation, the welding
sequence ends and the next step is executed.
WELD ERR This signal specifies an error in welding results or in Welder IN14
the welder. During welding, an alarm occurs and the
robot stops.
WIRE STICK DETECT Specifies when a wire stick is detected. An alarm Wire Stick NOT USED
occurs and the robot stops. Detector,
Welder
TMR COOL WTR ERR Specifies a timer cool water error. An alarm occurs Cool Water IN9
and the robot stops. The servo power stays on. Flow Switch
GUN COOL WTR ERR Specifies a gun cool water error. An alarm occurs and Cool Water IN10
the robot stops. The servo power stays on. Flow Switch
TRANSTHERMO ERROR Specifies an error from the gun transformer is Gun IN11
transmitted directly to the robot controller. It is Transformer
normally ON (NC), and when OFF, an alarm occurs.
The servo power stays on.
WELD ON/OFF (from Interlock circuit board, etc. PLC welder ON/OFF select Interlock CN308-B6
PLC) switch. Welder status signal which outputs welder Circuit Board,
ON/OFF signal. While in the ON status, if the welder etc.
is switched OFF, spot welding is not performed.
TIP REPLACE If this signal occurs after tip replacement, turn off the Interlock IN16
COMPLETE tip replacement demand signal, and the tip hit count is Circuit Board,
cleared. etc.
GUN FULL OPEN When there is a 2 step stroke gun, this signal specifies Welding Gun NOT USED
DETECT stroke full open status. (Full Open
Status Detect
LS)
GUN OPEN DETECT The open/close confirmation LS of a single gun and Welding Gun IN15
short open confirmation LS of the 2 step stroke gun (Open/Close
are connected, and the gun open/close confirmation is Confirmation
performed. Detect LS)
GUN PRESS DETECT Specifies the gun pressure status. Welding Gun NOT USED
(Pressure
Status Detect
LS)
AIR PRESS LOW An alarm occurs if the air pressure is low. The servo IN12
power stays on.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

Table 1-3: Robot Controller Output Signal

Signal Content Source Standard
Setting
WELD COND Specifies the welding condition for the welder. Welder OUT19
(Level Signal) Binary/discrete (bit number) can be selected as the used from 4
1 (1) output format bit
2 (2) Corresponding to 255 conditions or less (Parity Bit
4 (3) (Specification) is the most significant bit).
8 (4) OUT19
16 (5) OUT20
32 (6) OUT21
64 (7) OUT22
128 (8)
WELD COND PARITY NOT USED
WELD COMMAND The start instruction is output to the welder. It is not Welder NOT USED
necessary for welders which assume the welding
condition signal is a start instruction.
WELD ERR RESET Resets the welder after welder error status. Welder OUT18
Programming pendant operation output.
WELD ON/OFF Screens the robot situation when a signal is input from Welder OUT17
the interlock circuit board, etc., and outputs.
TIP CHANGE REQUEST Specifies when the set tip hit count limit has been Interlock OUT9
reached. Circuit Board,
etc.
GUN PRESS Outputs gun pressure command. Welding Gun NOT USED
COMMAND
STROKE CHANGE When using a 2 step stroke gun, welder open/close Welding Gun NOT USED
Single Solenoid status can be changed.
Double Solenoid

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.7 Monitor Function for Spot Welding Equipment

Table 1-4: Function List

Function Content Signal Method of Use
Condition
AIR PRESS LOW When the air pressure is low and Normal: OFF This signal can be used during the
Input Signal this signal turns on, an alarm (NO) low air pressure signal in the spot
occurs. The servo power stays Signal Function input allocation display if the set
on. This function signal must be general-purpose input external
set in the Concurrent I/O input is on.
Parameter. To reset the alarm, turn the signal
off, and it will return to the alarm
reset operation.
TIMER COOL When the water cooling is low and Normal: OFF This signal can be used during the
WATER ERROR this signal turns on, an alarm (NO) low water cooling signal in the spot
GUN COOL WATER occurs. The servo power stays Signal Function input allocation display if the set
ERROR on. This function signal must be general-purpose input external
set in the Concurrent I/O input is on.
Parameter. To reset the alarm, turn the signal
off, and it will return to the alarm
reset operation.
TRANSTHERMO When a gun transformer error Normal: ON Even though usually a timer error is
ERROR occurs, this input turns off and an (NC) transmitted to the timer from the
alarm occurs. The servo power Signal Function gun, and the main signal is
stays on. This function signal transmitted from the gun
must be set in the Concurrent I/O transformer, an alarm may occur.
Parameter. Also if the pressure, full open
status, short open status signal,
etc. is transmitted from the robot
controller, the signal line from the
timer to the gun becomes a
transthermo error only. If this signal
is checked on the robot side, the
signal line transmitted to the timer
disappears, and the cable handling
is made easier.

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 1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

1.6.8 Spot Welding Exclusive Signal Allocation List

 :Connector
:Connector and terminal block
Table 1-5: Spot Welding Exclusive Signal Allocation List (20010 to 20037)
Input Input Signal Name
Signal Method No Allocation Set Allocation Set
Number
20010  EXTERNAL START EXTERNAL START
20011  - -
20012  MASTER JOB CALL MASTER JOB CALL
20013  ALARM/ ERROR RESET ALARM/ ERROR RESET
20014  - -
20015  SELECT PLAY MODE SELECT PLAY MODE
20016  SELECT TEACH MODE SELECT TEACH MODE
20017  - -
20020  INTERFERENCE 1 INTERFERENCE 1
ENTRANCE PROHIBITED ENTRANCE PROHIBITED
20021  INTERFERENCE 2 INTERFERENCE 2
ENTRANCE PROHIBITED ENTRANCE PROHIBITED
20022  - WELD ON/OFF
20023  - WELD INTERRUPT
20024  INTERFERENCE 3 INTERFERENCE 3
ENTRANCE PROHIBITED ENTRANCE PROHIBITED
20025  INTERFERENCE 4 INTERFERENCE 4
ENTRANCE PROHIBITED ENTRANCE PROHIBITED
20026  - -
20027  - -
20030  IN1 IN1
20031  IN2 IN2
20032  IN3 IN3
20033  IN4 IN4
20034  IN5 IN5
20035  IN6 IN6
20036  IN7 IN7
20037  IN8 IN8

1-43
1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

:Connector
 :Connector and terminal block
Table 1-6: Spot Welding Exclusive Signal Allocation List (30010 to 30037)
Output Input Signal Name
Signal Method No Allocation Set Allocation Set
Number
30010  DURING RUNNING DURING RUNNING
30011  SERVO ON SERVO ON
30012  MASTER JOB HEAD MASTER JOB HEAD
30013  DURING ALARM/ERROR DURING ALARM/ERROR
OCCURRENCE OCCURRENCE
30014  BATTERY ALARM BATTERY ALARM
30015  REMOTE MODE REMOTE MODE
SELECTED SELECTED
30016  PLAY MODE SELECTED PLAY MODE SELECTED
30017  TEACH MODE SELECTED TEACH MODE SELECTED
30020  IN CUBE 1 IN CUBE 1
30021  IN CUBE 2 IN CUBE 2
30022  TASK ORIGIN TASK ORIGIN
30023  INTERMEDIATE START OK INTERMEDIATE START OK
(SEQUENCE CONTINUING) (SEQUENCE CONTINUING)
30024  IN CUBE 3 IN CUBE 3
30025  IN CUBE 4 IN CUBE 4
30026  - -
30027  - -
30030  OUT1 OUT1
30031  OUT2 OUT2
30032  OUT3 OUT3
30033  OUT4 OUT4
30034  OUT5 OUT5
30035  OUT6 OUT6
30036  OUT7 OUT7
30037  OUT8 OUT8

1-44
1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

:Connector
 :Connector and terminal block
Table 1-7: Spot Welding Exclusive Signal Allocation List (20040 to 20067)
Output Input Signal Name
Signal Method No Allocation Set Allocation Set
Number
20040  IN17 IN17
20041  IN18 IN18
20042  IN19 IN19
20043  IN20 IN20
20044  IN21 IN21
20045  IN22 IN22
20046  IN23 IN23
20047  IN24 IN24
20050  IN9 TIMER COOL WATER ERROR
20051  IN10 GUN COOL WATER ERROR
20052  IN11 TRANSTHERMO ERR
20053  IN12 AIR PRESS LOW
20054  IN13 WELD COMPLETE
20055  IN14 WELD ERR
20056  IN15 GUN OPEN DETECT
20057  IN16 TIP REPLACE COMPLETE
20060  IN25 IN25
20061  IN26 IN26
20062  IN27 IN27
20063  IN28 IN28
20064  IN29 IN29
20065  IN30 IN30
20066  IN31 IN31
20067  IN32 IN32

1-45
1 Spot Welding Application Using an Air Gun
1.6 Spot Gun Motion Control

 :Connector
 :Connector and terminal block
Table 1-8: Spot Welding Exclusive Signal Allocation List (30040 to 30067)
Output Input Signal Name
Signal Method No Allocation Set Allocation Set
Number
30040  OUT17 OUT17
30041  OUT18 OUT18
30042  OUT19 OUT19
30043  OUT20 OUT20
30044  OUT21 OUT21
30045  OUT22 OUT22
30046  OUT23 OUT23
30047  OUT24 OUT24
30050  OUT9 WELD ON/OFF
30051  OUT10 WELD ERR RESET
30052  OUT11 WELD COND 1
30053  OUT12 WELD COND 2
30054  OUT13 WELD COND 3
30055  OUT14 WELD COND 4
30056  OUT15 GUN PRESS COMMAND
30057  OUT16 TIP CHANGE REQUEST
30060  OUT25 OUT25
30061  OUT26 OUT26
30062  OUT27 OUT27
30063  OUT28 OUT28
30064  OUT29 OUT29
30065  OUT30 OUT30
30066  OUT31 OUT31
30067  OUT32 OUT32

1-46
 1 Spot Welding Application Using an Air Gun
1.7 Instruction List

1.7 Instruction List

Data variables are denoted in parentheses “<>”. If multiple items are
shown in one section, select one of the items.
Table 1-9: Spot Welding Instructions
GUNCL Function Presses a gun.
Format GUN # (<gun No.>) 1-8
T=<gun pressing time (sec.)> 0.01-655.35
ATT=<anticipator condition (sec.)> 0-655.35
Example MOVL V=1000 NWAIT
GUNCL GUN # (1) T=2.0 ATT=0.5
MOVL V=1000
SPOT Function Start up the welding sequence from gun pressure.
Format GUN # (<gun 1 No.>) 1-8
MODE=<gun 1 operation mode specification> 0-4
WTM=<gun 1 welding condition> 1-255
GUN # (<gun 2 No.>) 1-8
MODE=<gun 2 operation mode specification> 0-4
WTM=<gun 2 welding condition> 1-255
ATT=<anticipator condition (sec.)> 0-655.35
Example MOVL V=1000 NWAIT
SPOT GUN # (1) MODE=2 WTM=2 ATT=0.5
MOVL V=1000
STROKE Function Alternates short open and full open of a double stroke gun at any
time than welding.
Format GUN # (<gun No.>) 1-8
LONG
SHORT
Example MOVL V=1000
STROKE GUN #(1) LONG
MOVL V=1000

1-47
YRC1000
OPERATOR’S MANUAL
FOR SPOT WELDING USING AIR GUN

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbH Robotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542

YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199

PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741

Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO. RE-CSO-A055

C Printed in Japan November 2017 17-11