Ford FANUC R30iA R30iB NextGen E

VEHICLE OPERATION STRUCTURE AND STANDARDS
(VOSS)
FORD Robot Programming Guide - FANUC Implementation

Next Gen - Integrated Ethernet Safety for R-30iA and R-30iB
Controllers
Appendix 2SWG – Dual Servo Weld Gun

Table of Contents
1 Servo Weld Gun Setup and Programming ............................................................... 11
1.1 SERVO GUN TERMINOLOGY..................................................................................................................11
1.2 SPOT POSITION PROGRAMMING ...........................................................................................................14
1.2.1 Single Gun Weld for R-30iA Controllers ......................................................................................14
1.2.2 Single Gun Weld for R-30iB Controllers ......................................................................................15
1.2.3 Dual Gun Weld for R-30iA Controllers ........................................................................................16
1.2.4 Dual Gun Weld for R-30iB Controllers ........................................................................................17
1.3 PRESS MOTION INSTRUCTION...............................................................................................................18
1.3.1 Single Gun for R-30iA Controllers ...............................................................................................18
1.3.2 Single Gun for R-30iB Controllers ...............................................................................................19
1.3.3 Dual Gun for R-30iA Controllers .................................................................................................19
1.3.4 Dual Gun for R-30iB Controllers .................................................................................................20
1.4 SERVO GUN TOOL TIP ORIENTATION (TOOL FRAME) ........................................................................21
1.5 SERVO GUN TEACHING TECHNIQUES ...................................................................................................22
1.6 SERVO GUN BACKUP POSITION............................................................................................................24
1.7 SERVO GUN PRESSURE TABLE..............................................................................................................26
1.8 GUIDELINES FOR GUN STROKE CLOSE LIMIT .......................................................................................27
1.8.1 Gun Stroke Close Limit Setup Procedure .....................................................................................27
1.9 SERVO GUN SETUP AND AUTO-TUNING UTILITY ...................................................................................30
1.9.1 Preparation for Auto-Tuning ........................................................................................................30
1.9.2 Gun Setup Utility ..........................................................................................................................30
1.9.3 Auto-Tuning ..................................................................................................................................34
1.10 PRESSURE CALIBRATION ......................................................................................................................37
1.10.1 Overview ..................................................................................................................................37
1.10.2 Pressure Calibration Procedure ..............................................................................................37
1.11 TIP WEAR DOWN COMPENSATION ........................................................................................................42
1.11.1 Overview ..................................................................................................................................42
1.11.2 Preparations for Using Tip Wear Down Compensation ..........................................................43
1.11.3 TWO-STEP Measurement Method ...........................................................................................45
1.11.4 ONE-STEP Measurement Method ...........................................................................................47
1.11.5 OPERATIONAL SETTINGS AND ALARM PROCESSING .....................................................49
1.11.6 RECOVER FROM LOSS OF MASTERING .............................................................................54
1.11.7 PRESSING ON NEW TIPS.......................................................................................................55
1.11.8 ACTIVE STROKE LIMIT PROTECTION ................................................................................57
1.12 PART THICKNESS CHECK FUNCTION .........................................................................................59
1.12.1 Thickness Check Calibration ...................................................................................................60
1.12.2 Thickness Check General Setup ...............................................................................................61
1.13 TWO SERVO GUN APPLICATIONS ..........................................................................................................64
2 FANUC / ARO Equalizer Single Point Lesson ....................................................... 65
2.1 GENERAL SETUP PROCEDURES...........................................................................................................65
2.2 EQUALIZER SETUP (DETAIL) ..............................................................................................................67
2.3 FANUC DATA REGISTER SETTINGS ..................................................................................................70
2.4 SPOT WELDING PROGRAM ADJUSTMENT (DETAIL) ............................................................................71
2.4.1 Adjust SPOT Termtype / CNT value .............................................................................................71
2.4.2 Adjust Start and End distance values............................................................................................71
2.4.3 Adjust End distance Termtype ......................................................................................................71
2.4.4 Adjust Equalizer Trigger Position ................................................................................................72
2.4.5 Tip Dress Programming ...............................................................................................................73
Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

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3 Servo Nut / Bolt Weld Applications ........................................................................ 74
3.1 OVERVIEW OF ADDITIONAL FEATURES .................................................................................................75
3.2 OVERVIEW OF SETUP REQUIREMENTS ..................................................................................................75
3.3 INITIAL GUN SETUP .............................................................................................................................76
3.4 SERVO GUN GENERAL SETUP SCREEN ITEMS ........................................................................................78
3.5 THICKNESS CHECK SETUP ...................................................................................................................79
3.6 PRESSURE CALIBRATION ......................................................................................................................81
3.7 DISTANCE SCHEDULES ........................................................................................................................82
3.8 PART THICKNESS SETTING IN PRESSURE SCHEDULES ............................................................................82
3.9 SPOT POSITION PROGRAMMING ...........................................................................................................83
3.10 MISSING NUT DETECTION & MISPLACED OR EXTRA NUT DETECTION ..................................................85
3.11 ELECTRODE SETDOWN / PROJECTION COLLAPSE DETECTION ...............................................................86
3.12 STATUS OF THICKNESS & SETDOWN .....................................................................................................87
3.13 NEW VARIABLES / ADJUSTABLE SETTINGS FOR NUT WELDING APPLICATION FEATURE...........................88
3.14 NOTES FOR CARRIED BOLT WELDERS................................................................................................88
4 Servo Tip Dress........................................................................................................ 89
4.1 OVERVIEW...........................................................................................................................................89
4.2 TIP DRESS SETUP MENU ......................................................................................................................89
4.3 EXECUTION OR OPERATION SEQUENCE ................................................................................................93
4.4 DEFAULT SERVO TIP DRESS SCHEDULE SETTINGS ................................................................................93
4.5 TIP DRESS SCHEDULE ADJUSTMENTS & CHARTING FEATURES..............................................................95
4.5.1 Adjusting the Minimum Torque Increase Threshold...................................................................102
4.6 SERVO TIP DRESSER AMPLIFIER CONFIGURATIONS ............................................................................107
5 Spot Program Touchup Function ........................................................................... 109
5.1 PROGRAM TOUCH UP OVERVIEW .......................................................................................................109
5.2 SPOT PROGRAM TOUCHUP EXECUTION PROCEDURE..........................................................................110
5.3 PROGRAM TOUCHUP SETUP ..............................................................................................................113
5.4 SPOT PROGRAM TOUCHUP STATUS SCREENS ......................................................................................119
5.5 SPOT PROGRAM TOUCHUP CHART FEATURE ......................................................................................122
5.5.1 Touchup Chart Screenshot..........................................................................................................132
5.6 SPOT PROGRAM TOUCHUP DISABLE INSTRUCTION ...........................................................................133
5.7 PROGRAM TOUCHUP SINGLE STEP MODE ..........................................................................................136
6 Style Sample Teach Pendant Programs ................................................................. 138
6.1 ASCII UPLOAD .................................................................................................................................138
6.2 PG21 – CARRIED WELD OPERATIONS ONLY ......................................................................................139
6.3 PG21 – PEDESTAL WELD OPERATION WITH TIP DRESS DUMP ............................................................142
6.4 WELD01 FOR R-30IA CONTROLLERS ................................................................................................151
6.5 WELD01 FOR R-30IB CONTROLLERS ................................................................................................153
6.6 WELD02 FOR R-30IA CONTROLLERS ................................................................................................155
6.7 WELD02 FOR R-30IB CONTROLLERS ................................................................................................157
6.8 TPDRSMAC – TIP DRESS DUMP WITH SERVO TIP DRESSER MACRO ................................................159
6.9 TPDRSMAC – TIP DRESS DUMP WITH SERVO TIP DRESSER FOR SIMULTANEOUS WELDERS MACRO .164
6.10 TPDRSMC2 - TIP DRESS DUMP WITH SERVO TIP DRESS MACRO .....................................................169
6.11 TPDRSMC2 - TIP DRESS DUMP WITH SERVO TIP DRESS FOR SIMULTANEOUS WELDERS MACRO ......174
6.12 PEDTDMACS - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESSER MACRO FOR R-30IA
CONTROLLERS ...................................................................................................................................180
6.13 PEDTDMACS - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESSER MACRO FOR SIMULTANEOUS
WELDERS WITH R-30IA CONTROLLERS ...............................................................................................183
6.14 PEDTDMACS - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESSER MACRO FOR R-30IB
CONTROLLERS ...................................................................................................................................186

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6.15 PEDTDMACS - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESSER MACRO FOR SIMULTANEOUS
WELDERS WITH R-30IB CONTROLLERS ...............................................................................................189
6.16 PEDTDMC2S - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESS MACRO FOR R-30IA
CONTROLLERS ...................................................................................................................................192
6.17 PEDTDMC2S - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESS MACRO FOR SIMULTANEOUS
WELDERS WITH R-30IA CONTROLLERS ...............................................................................................195
6.18 PEDTDMC2S - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESS MACRO FOR R-30IB
CONTROLLERS ...................................................................................................................................198
6.19 PEDTDMC2S - PEDESTAL TIP DRESS DUMP WITH SERVO TIP DRESS MACRO FOR SIMULTANEOUS
WELDERS WITH R-30IB CONTROLLERS ...............................................................................................201
6.20 TPWEARC1 - TIP WEAR COMPENSATION ..................................................................................204
6.21 TPWEARC2 - TIP WEAR COMPENSATION ..................................................................................207
6.22 TW_UPD01 - TIP WEAR UPDATE GUN 1 .....................................................................................210
6.23 TW_UPD02 - TIP WEAR UPDATE GUN 2 .....................................................................................212
6.24 TIP_MEAS1 – GUN 1 TIP WEAR CUTTER WARNING ..........................................................................214
6.25 TIP_MEAS2 – GUN 2 TIP WEAR CUTTER WARNING ..........................................................................217
6.26 WELD1ENB MACRO ......................................................................................................................220
6.27 WELD1DIS MACRO .......................................................................................................................221
6.28 WELDHOME MACRO FOR R-30IA CONTROLLERS ..........................................................................222
6.29 WELDHOME MACRO FOR R-30IB CONTROLLERS ..........................................................................223
6.30 WELDHOM2 MACRO FOR R-30IA CONTROLLERS ...........................................................................225
6.31 WELDHOM2 MACRO FOR R-30IB CONTROLLERS ...........................................................................226
6.32 WELDONCE MACRO .....................................................................................................................228
6.33 WELDONC2 MACRO .....................................................................................................................229
6.34 MANWELD1 MACRO FOR R-30IA CONTROLLERS ...........................................................................230
6.35 MANWELD1 MACRO FOR R-30IB CONTROLLERS ...........................................................................231
6.36 MANWELD2 MACRO FOR R-30IA CONTROLLERS ...........................................................................232
6.37 MANWELD2 MACRO FOR R-30IB CONTROLLERS ...........................................................................233
6.38 PG08 – MANUAL TIP DRESS FOR CARRIED APPLICATION FOR R-30IA CONTROLLERS .........................234
6.39 PG08 – MANUAL TIP DRESS FOR CARRIED APPLICATION FOR R-30IB CONTROLLERS .........................241
6.40 PG08 – MANUAL TIP DRESS FOR PEDESTAL DUMP APPLICATION FOR R-30IA CONTROLLERS .............248
6.41 PG08 – MANUAL TIP DRESS FOR PEDESTAL DUMP APPLICATION FOR R-30IB CONTROLLERS .............256
6.42 PG09 – MINOR MAINTENANCE POSITIONS .........................................................................................264
6.43 PG10 OR PG06 – AUTO TIP DRESS WITH SERVO TIP DRESSER FOR CARRIED APPLICATION FOR R-30IA
CONTROLLERS ...................................................................................................................................266
6.44 PG10 OR PG06 – AUTO TIP DRESS WITH SERVO TIP DRESSER FOR CARRIED APPLICATION FOR R30IB
CONTROLLERS ...................................................................................................................................271
6.45 CGTDMACS – CARRIED SERVO GUN WITH SERVO TIP DRESSER MACRO FOR R-30IA CONTROLLERS
.........................................................................................................................................................276
6.46 CGTDMACS – CARRIED SERVO GUN WITH SERVO TIP DRESSER MACRO FOR R-30IB CONTROLLERS
.........................................................................................................................................................280
6.47 CGTDMC2S – CARRIED SERVO GUN #2 WITH SERVO TIP DRESSER MACRO FOR R-30IA CONTROLLERS
.........................................................................................................................................................284
6.48 CGTDMC2S – CARRIED SERVO GUN #2 WITH SERVO TIP DRESSER MACRO FOR R-30IB CONTROLLERS
.........................................................................................................................................................288
6.49 OPNGUN – OPEN SERVO GUN POSITION MACRO ...........................................................................292
6.50 CLSGUN – CLOSE SERVO GUN POSITION MACRO ...........................................................................293
6.51 OPNGUN2 – OPEN SERVO GUN 2 POSITION MACRO ......................................................................294
6.52 CLSGUN2 – CLOSE SERVO GUN 2 POSITION MACRO ......................................................................295
6.53 BLOWOFF – TIP DRESS SPIN AND BLOWER PROGRAM ......................................................................296
6.54 BLOWOFF2 – TIP DRESS SPIN AND BLOWER PROGRAM 2 .................................................................297
6.55 HOME_IO – RESET INPUT/OUTPUT MACRO ...................................................................................298
7 Software I/F Panels ................................................................................................ 300
7.1 SPOT SWG MENU ............................................................................................................................300
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8 PMC Logic (S-Logic) (2) SWG with Servo Tip Dresser for R-30iA Controllers . 302
9 PMC Logic (S-Logic) (2) SWG with Servo Tip Dresser for R-30iB Controllers . 303
10 PMC Logic (S-Logic) SWGBolt + SWGNut for R-30iA Controllers................... 304
11 PMC Logic (S-Logic) SWGBolt + SWGNut for R-30iB Controllers................... 305

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Revision History
Revision Modification Date Description
1.0 Initial Release
1.1 2012-11-15 Added sentence about checking if one tip is wearing
faster than the other in the TIP_MEAS1 and
TIP_MEAS2 sections.
Added tip wear check logic in TIP_MEAS1 and
TIP_MEAS2 programs.
R[83] defined as Maximum Tip Wear.
Tip Wear Warnings Set OFF in PG10/PG06 auto tip
dress programs.
Changed registers for TIP_MEAS2 that were using
TIP_MEAS1 registers.
Added Increment for Register [49] in CGTDMACS and
Register [59] CGTDMC2S.
Adjusted output for TIP_MEAS1 and TIP_MEAS2.
Added note that the Servo Tip Dresser will not spin in
STEP mode in CGTDMACS, CGTDMC2S,
PEDTDMACS, PEDTDMC2S.
Changed start and end distance schedules from 94 to 2
in PEDTDMACS, PEDTDMC2S, CGTDMACS,
CGTDMC2S.
Made tip dress instruction stand alone in PEDTDMACS
and PEDTDMC2S.
Copied logic for New tips from Carried to Pedestal
programs PEDTDMACS and PEDTDMC2S.
Added E-Stop Recovery during tip dress in
TPDRSMAC.
Added jump around resistance check logic in PG10.
Corrected dual pedestal tip dress issue in PG08 (Ped),
TPDRSMAC and TPDRSMC2.
Added Servo Tip Dresser Amplifier Configurations
section.
Added section: Guidelines for Gun Stroke Close Limit.
Updated and added other information for servo nut fault
codes.
Updated PMC: Removed Y1020.4 RO 5 TD Enable 1
output coil and Y1020.6 RO 7 TD Enable 2 output coil.
Updated PMC: Created Prompt Box Rung for Resume
Tolerance in LEVEL2. Y73.0
Updated PMC: Added Y1020.4 RO 5 TD Enable 1
output coil to rung with output coil Y0109.0 DO 873
TD1 ENB. Added Y1020.6 RO 7 TD Enable 2 output
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coil to rung without coil Y109.1 DO 874 TD2 ENB.
Updated PMC: Added rungs to detect SVGN-320 and
SVGN-326 errors. (output coils R0385.0 and R0386.0).
Added R386.1 rung for both SVGN latch. Added
SVGN-320 and SVGN-326 elements to filtered faults.
Added R386.1 to R1404.5 Drop Auto Fault.
Updated PMC: Added SRVO-408 filtering. Added
safety chain fault error decoding to send a bit to the
PLC.
1.2 2012-11-16 Corrected pressure schedule for new tip in
PEDTDMC2S.
1.3 2012-12-21 Updated Section 1.5 for weld position teach distance.
Added logic in TPDRSMC2 for E-stop Recovery.
Created direct Exit Zones in HOME_IO.
Updated PMC: Modified D0004.1 Remote No Stroke
OK WC1 to use nutfeed application bypass correctly.
An AND was added with DO 388 NUTFD APP
Y0048.3 to have NOT DO 387 Y0048.2 WLD2 APP
and an OR with DO 387 Y0048.2 WLD2 APP AND
DO 406 Y0050.5 NTFD 2APP.
Updated PMC: Created R0.7 Part Present in MH.
Added not R0.7 to y126.7 contact. Created K13.1 No
Tool SS Reset Contact.
Updated PMC: Added K0016.1 (VAC 4 ON PB) and
K0016.2 (BLOWOFF 4 ON PB) to rung output
D0612.1 (MH IF PB TO) in INTERFACE logic.
1.4 2013_01_14 Fixed Clear Zone 14 bit in HOME_IO.
Added parenthesis in stationary tip measurement logic
in TIP_MEAS1 and TIP_MEAS2.
1.5 2013-03-18 Changed New Tip comment in PG10.
Added R-30iB programs for WELD01, WELD02,
PEDTDMACS, PEDTDMC2S, WELDHOME,
WELDHOM2, PG08, PG10/PG06, CGTDMACS,
CGTDMC2S.
Added R-30iB PMC.
Corrected the “OPEN GUN”, “OPEN GUN2” and
“CLOSE GUN2” names in numerous programs due to
having unmatched name.
Removed TW_PRS01 from TPWEARC1 and
TW_UPD01. Removed TWPRS02 from TPWEARC2
and TW_UPD02. Also removed the OPEN GUN
instruction in TW_UPD01 and TW_UPD02.
Added a text box at the beginning of CGTDMACS and
CGTDMC2S for R30iA and R30iB which describes
how to setup and teach tip dress for carried guns so that
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tip wear offsets will be applied during tip dress.
Added Spot and Press Motion Instruction definitions
and terminology to section 1.2 and 1.3 respectively.
Corrected parenthesis logic in TIP_MEAS1 and
TIP_MEAS2.
1.6 2013-05-06 Corrected logic in TIP_MEAS1 and TIP_MEAS2 that
caused change requests for both moveable and fixed tips
when only one of them was required.
Corrected DI[154] in TPDRSMC2. Was DI[122] which
is for Controller 1.
Added support for simultaneous welders, including
PEDTDMAC and PEDTDMC2 for simultaneous
welders for R-30iA and R-30iB. Created new
TPDRSMAC and TPDRSMC2 macros to only allow
one welder to run tip dressing at a time for simultaneous
welders.
Changes were made for the blower to be controlled
outside of PMC via TP Programs. TP Logic is used to
spin the dresser and blower after tip dressing.
BLOWOFF(2) is called from
CGTDMACS/CGTDMC2S or
PEDTDMACS/PEDTDMC2S. See note block at
beginning of these macros for more information. The
PMC, dated 2013-04-15, appended to this guide is
required for the change to take effect.
Updated PMC: Removed Blower outputs Y1020.4 (RO
5) and Y1020.6 (RO 7) from PMC. Blower is now
controlled through TP Programs.
Added TW_PRS01 with additional logic to
TPDRSMAC and TPDRSMC2 to allow new tips to be
pressed in a pedestal application.
Added logic in PG08 to call MANWELD1 and
MANWELD2 so that PG08 can execute spot
instructions for either equipment 1 or 2 when the robot
controller is setup with separate gun motion groups.
1.7 2013-07-08 Created an iB section for the nutweld variables. Also,
modified the opening paragraph of the nut welding
section to inform the user on how to confirm an iB robot
is a SWGNUT welder.
Added date reference in the note for BLOWOFF control
change in CGTDMACS, CGTDMC2S, PEDTDMACS
and PEDTDMC2S.
Added a new TP Program PG09 which is a Minor
Maintenance program, similar to PG08.
Added a section called Two Servo Gun Applications.
Page 8 of 305
Explaining the two different ways a robot can be
configured when its application consists of two servo
guns and that Fanuc should know how to setup dual
SWG robots (e.g. simultaneous or not).
Removed logic from TPDRSMAC for R[49]=0,
DO[438]=0, and DO[439]=0, in the section where the
wear amount is reset for a new tip
Removed logic from TPDRSMC2 for R[59]=0, in the
section where the wear amount is reset for a new tip.
1.8 2013-08-07 Updated iA PMC: Modified logic for rung with output
R0388.0 OPSFTY_FLT_LATCH. Added a rung for
this modification that has output R0388.1 F1008.1
DELAY ON.
Updated iB PMC: Removed logic for fault decoding for
SRVO 379-385 alarms (R387.1 - R87.7). Removed
comments for R387.1 - R387.7. Modified comment for
R387.0 for new R30iB fault description. Modified logic
for rung with output R0388.0 OPSFTY_FLT_LATCH.
Added a rung for this modification that has output
R0388.1 F1008.1 DELAY ON.
1.9 2013-12-20 Added logic to CGTDMACS, CGTDMC2S,
PEDTDMACS and PEDTDMC2S to prevent the
Blowoff Macro from being executed if the tip dress
enable is OFF.
2.0 2013-03-26 Added note that Max # of Cuts in the Tip Dress Setup
must be zero.
Removed Carried Nut Reference from Notes for Carried
Bolt Welders section.
Added PMC Logic for SWGBolt + SWGNut. R-30iA
and R-30iB controllers.
2.1 2014-06-24 Added Logic to PG21 Pedestal for Abort Pick
Changed $sggun#.$setup.$dither_sw setting to 4 for
R30iB controllers
Updated iB PMC: Facility code reset logic modified.
Updated iB PMC: Modified R388.1 comment. D4.2
Remote No Stroke OK WC2 logic modified to account
for SWG+SWGNUT applciations (SWG standard logic
change).
Updated Tip Dress Dump Logic in TPDRSMAC and
TPDRSMC2 Macros
Updated PG08 Pedestals to Inhibit Redundant Tip Dress
on new caps
Updated HOME_IO to disable Dump Advance Signals
is a tip dress is not in progress
Updated HOME_IO to reset Robot at Minor
Page 9 of 305
Maintenance;
Added DO[587:RBT AT MINMAINT]=OFF
2.2 2015-01-30 Added Second Program Verify to Main Style Programs
Corrected settings for $sggun#.$setup.$dither_sw to
show a value of 2 for R30iA and a value of 4 for R30iB
Updated (Minor) Maintenance Programs:: Moved
position at which the at (Minor) Maintenance position
signal is turned off to come immediately after the wait
for the PLC (Minor) Maintenance clear signal.
Updated PMC: Added Couple and Decouple pass
through signals to Tool Change Subprogram ;;;;
Corrected Logic for weld controller two to utilize cap
change request #2
2.3 2016-02-12 Updated IO Comments for DO118 and DO150
DO[118:WLD CTRL1 TD ENABLE]
DO[150:WLD CTRL2 TD ENABLE]
Added Section on Adjusting the minimum torque
threshold for servo tip dressers
Updated PMC: Added TC Cover Open/Close to the
Interface Anti-Tiedown Logic
Updated PMC: 2015-10-30 : Added Logic to allow for
Robot Cycle Start from Multiple Home Positions;
Added Logic to require a TP Interface button press to
(Un)Lock the Tool Changer while in Teach; Added
Logic to not allow the signal for the Lock Command to
go low when the Tool Change Application Bit is
inactive
Added Notes to TIP_MEAS to further indicate its use
and the information that is relayed from the Robot to the
PLC during the program.
Updated PMC: 2016-03-30 : Added
DI[111:AUTOTIPCHG] to the Pulled Tip Bypass rung
to allow for the PLC to disable the check to allow
Automatic Cap change

Page 10 of 305
1 Servo Weld Gun Setup and Programming
1.1 Servo Gun Terminology
• Group 1 = Robot Servo System

• Group 2 = Servo Gun Servo System (NOBOT axis)
• Movable Tip, Servo Tip, Gun Tip = The tip attached to the part of
the servo weld gun that moves when group 2 is jogged
• Fixed Tip, Robot Tip = The tip attached to the part of the servo weld
gun that does not move when group 2 is jogged
• Fixed tip makes sense in context of pedestal ( stationary ) gun
• Tuning - The process of setting servo parameters to optimize the

performance of the servo motor.
• Calibration - process of establishing a relationship between a range
of servo motor torque commands and the resultant force that is
created between the tips of the servo gun
• Pushing Depth - Set in each pressure schedule. This is the
maximum distance the movable tip should move past the zero
position when trying to build pressure. This value can not exceed the
stroke limit for the gun axis.

Page 11 of 305
• Tip Wear Compensation - an adjustment to the locations of the
automatically generated positions for a spot instruction to account
for the change in the geometry of the weld caps. Measured by
calling a “tipwear” program. Adjustment is made to the fixed tip
location and to the Group 2 master position (which defines the
movable tip zero position).
• Gun Sag - Set in each pressure schedule. This is the distance the
fixed jaw of the weld gun deflects for the specific amount of tip
force requested. This value should be increased as tip force
increases.
• Servo Gun Tuning is the process of measuring the response of the
servo system under various commands and using the responses to
optimize the performance of the servo gun. Servo gun tuning is
necessary to determine the mechanical characteristics of the weld
gun and to identify the motor’s torque output.
• Pressure Calibration is the process of establishing the relationship
between a range of servo motor torque commands and the resultant
pressures that are created between the tips of the servo gun

Page 12 of 305
• Fine Motion
Use Fine termination type to get to the exact
position taught. Using FINE will achieve longer
Cycle Time on the process.
• Continuous Motion
Use Continuous termination type for the most
efficient movement around obstacles. Program
the position near the obstacle and then adjust the
termination type value as needed.

Page 13 of 305
1.2 Spot Position Programming
Spot welding instructions tell the robot when and how to weld. The instruction can be
configured for single or dual guns.
1.2.1 Single Gun Weld for R-30iA Controllers
The instruction initiates the spot weld for a single gun using the specified parameters, after
the robot completes the move to the specified position:
This is included with the welding position in the same statement, for example:
10:L P[2] 2000mm/sec CNT50 SPOT[SD=1,EP=0,P=1,S=1,EP=0,ED=1]
Definition of Parameters
SPOT[SD=*,EP=*,P=*,S=x,EP=*,ED=*]
SD Start Distance This is for defining the distance between the weld tips when
approaching the weld position. This number represents the distance schedule
number to use. In the schedule, the clearances are defined separately for the gun
tip and the robot tip.
EP Equalization Pressure. The first EP is for the equalization pressure prior to weld
initiation, the second EP is the value after completion of the weld. (valid values
are 0=Off, 1 = On)
P Valve Pressure – This is the pressure schedule number that is used to define the
squeezing on the part.
S Weld Schedule # - This number is sent to the weld controller when the specified
squeeze pressure is reached.
ED End Distance – This is for setting the gap opening of the weld tips after the weld
completes. . This number represents the distance schedule number to use. In the
schedule, the clearances are defined separately for the gun tip and the robot tip.

Page 14 of 305
1.2.2 Single Gun Weld for R-30iB Controllers
The instruction initiates the spot weld for a single gun using the specified parameters, after
the robot completes the move to the specified position:
This is included with the welding position in the same statement, for example:
10:L P[2] 2000mm/sec CNT50 SPOT[SD=1,EP=0,P=1,t=0.0,S=1,ED=1]
SPOT[SD=*,EP=*,P=*,t=*,S=x, ED=*]
SD Start Distance This is for defining the distance between the weld tips when
approaching the weld position. This number represents the distance schedule
number to use. In the schedule, the clearances are defined separately for the gun
tip and the robot tip.
EP Equalization Pressure. The EP is for the equalization pressure prior to weld
initiation (valid values are 0=Off, 1 = On)
P Valve Pressure – This is the pressure schedule number that is used to define the
squeezing on the part.
t Thickness – This is the thickness of the work piece to be welded (for R-30iB
controllers ONLY).
S Weld Schedule # - This number is sent to the weld controller when the specified
squeeze pressure is reached.
ED End Distance – This is for setting the gap opening of the weld tips after the weld
completes. This number represents the distance schedule number to use. In the
schedule, the clearances are defined separately for the gun tip and the robot tip.

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1.2.3 Dual Gun Weld for R-30iA Controllers
Spot Weld Instruction Format
The basic spot instruction format is designed to allow you to selectively weld with one or
both of the guns. The spot instruction includes a unique weld schedule parameter for both
Gun A and Gun B.
The basic format is shown below:
SPOT [SD=a,b, EP =c,d, P=e,f, S=g,h, EP=i,j, ED=k,l]
a: Start Distance schedule for Gun A
b: Start Distance schedule for Gun B
c: Equalization Pressure for Gun A prior to weld execution
d: Equalization Pressure for Gun B prior to weld execution
e: Valve Pressure schedule for Gun A
f: Valve Pressure schedule for Gun B
g: Welding schedule number assigned to Gun A
h: Welding schedule number assigned to Gun B
i: Equalization Pressure for Gun A after weld completion
j: Equalization Pressure for Gun B after weld completion
k: End Distance schedule for Gun A
l: End Distance schedule for Gun B
If either Gun A or Gun B is assigned the welding schedule (0), that gun will not operate
during the welding sequence. Instead, it will stop closing at the Start Distance, wait for the
welding operation to complete, and then open to the End Distance.

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1.2.4 Dual Gun Weld for R-30iB Controllers
Spot Weld Instruction Format
The basic spot instruction format is designed to allow you to selectively weld with one or
both of the guns.
The basic format is shown below:
SPOT [SD=a, EP =b, P=c, t=d, S=e,f, ED=h]
a: Start Distance schedule for Gun
b: Equalization Pressure for Gun prior to weld execution
c: Valve Pressure schedule for Gun
d: Welding Thickness number assigned to Gun for R-30iB Controllers ONLY
e: Welding schedule number assigned to Gun A
f: Welding schedule number assigned to Gun B
h: End Distance schedule for Gun
If either Gun A or Gun B is assigned the welding schedule (0), that gun will not operate
during the welding sequence. Instead, it will stop closing at the Start Distance, wait for the
welding operation to complete, and then open to the End Distance.

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1.3 Press Motion Instruction
The Press Motion instruction is intended to perform pressurization of the servo gun without
performing welding. This instruction is commonly used for tip dressing/grinding operations.
The Press Motion instruction does not open the gun or perform welding after pressurization
is completed.
Like spot welding instructions, the Press motion instruction carries out tip wear
compensation and arm deflection compensation when it is used as a motion option.
1.3.1 Single Gun for R-30iA Controllers

Stand Alone format:
1: PRESS_MOTN [SD=m, P=n]
Motion Option format:

1: L P[1] 2000mm/sec FINE Press_motn [SD=1, P=1]
 Pressurization is performed according to the Start distance and pressure schedule

numbers specified.
 The pressurization instruction can be used as both motion option and standalone
instructions.
 Motion option instruction
The additional-operation instruction controls both movable and stationary tips
during a pressurization sequence. It also performs tip wear compensation and
gun deflection compensation.
 The pressurization instruction performs only pressurization it does not open the gun.
So, it is necessary to teach Pressuring time and gun opening separately. (See the
sample program.)
1: L P[1] 100mm/sec FINE Line 1: Closes to pressure at taught posn
: Press_motn [SD=1, P=2]
2: WAIT 2.00sec Line 2: Pressuring time
3: L P[2] 100mm/sec FINE Line 3: Gun Opening

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1.3.2 Single Gun for R-30iB Controllers
Stand Alone format:
1: PRESS_MOTN [SD=m, P=n, t=k]

1: L P[1] 2000mm/sec FINE Press_motn [SD=1, P=1, t=0.0]
 Pressurization is performed according to the Start distance, pressure schedule and

thickness numbers specified.
 The pressurization instruction can be used as both motion option and standalone
instructions.
 Motion option instruction
The additional-operation instruction controls both movable and stationary tips
during a pressurization sequence. It also performs tip wear compensation and
gun deflection compensation.
 The pressurization instruction performs only pressurization it does not open the gun.
So, it is necessary to teach Pressuring time and gun opening separately. (See the
sample program.)
1: L P[1] 100mm/sec FINE Line 1: Closes to pressure at taught posn
: Press_motn [SD=1, P=2, t=0.0]
2: WAIT 2.00sec Line 2: Pressuring time
3: L P[2] 100mm/sec FINE Line 3: Gun Opening
1.3.3 Dual Gun for R-30iA Controllers

The basic press motion instruction format is also designed to allow you to selectively
pressurize with one or both guns. The SEL parameter may not exist on your robots.
PRESS_MOTN [SD=i P=n, <SEL=(a,b]>]
i : Start Distance schedule number assigned to Gun 1

n: Pressure schedule number assigned to both guns
a: Pressure enable bit for Gun A
b: Pressure enable bit for Gun B
Each pressure enable bit is set to (1) or (0). If a pressure enable bit is set to (1), the
gun associated with that bit will pressurize. If the pressure enable bit is set to (0), the
gun will not close or pressurize. Instead, it will stop closing at the Start Distance and
wait for the press motion to complete on the other gun. If both enable bits are set to
(1), both guns will pressurize.

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1.3.4 Dual Gun for R-30iB Controllers
The basic press motion instruction format is also designed to allow you to selectively
pressurize with one or both guns. The SEL parameter may not exist on your robots.
PRESS_MOTN [SD=i, P=n, <SEL=(a,b]>, t=k]
i : Start Distance schedule number assigned to Gun 1

n: Pressure schedule number assigned to both guns
a: Pressure enable bit for Gun A
b: Pressure enable bit for Gun B
k: Thickness number assigned to both guns
Each pressure enable bit is set to (1) or (0). If a pressure enable bit is set to (1), the
gun associated with that bit will pressurize. If the pressure enable bit is set to (0), the
gun will not close or pressurize. Instead, it will stop closing at the Start Distance and
wait for the press motion to complete on the other gun. If both enable bits are set to
(1), both guns will pressurize.

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1.4 Servo Gun Tool Tip Orientation (TOOL FRAME)
The weld tool tip orientation should be the following for Robot Utool Frame. This
orientation method will help with the Offline Programs. Use Right Hand Rule.
Moveable Tip
Z+ Stationary Tip towards
Y+
X+
Swallows Metal
Stationary Tip

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1.5 Servo Gun Teaching Techniques
When moving the servo gun manually, you must remember on the robot teach pendant to
change to GROUP 2, and to use +X or –X (single servo gun). -X closes the gun while +X
opens the gun. If there are multiple servo guns, the second gun uses +Y and –Y, the third
servo gun +Z and –Z, etc…
Moveable Tip
--X +X
Fix Tip

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The following illustration shows how to teach a weld position, where the FIX TIP is taught
on the surface of the metal unless there is an equalizer, in which case it is to be taught 3-5mm
away from the surface.
Moveable Tip
Metal
Fix Tip
Servo weld guns use a series of calculated positions to close and open the gun while the robot
is moving to and away from the taught weld position. These calculated positions are based
on settings within Pressure Schedules in the robot software. The taught location of a SPOT
instruction is always reached by the robot regardless of playback speed or the settings in the
pressure schedule. However, much like close and open anticipation times for an air gun, the
termination types of these calculated servo gun positions can effect when the weld tips reach
and begin to grip the metal surface. If the weld tips reach the metal surface too late, the
overall cycle time may increase. However, if the weld tips reach the metal surface too soon,
the tips may drag across the metal or grab the metal and flex as the robot is finishing the
move to the taught weld position. This will cause the appearance of the robot not reaching
the taught position when actually, the robot has reached the position, but the gun has pulled
the part out of position.
Just like conventional air guns, the termination types of the calculated servo gun positions
may need to be adjusted for the gun tips to close at the right time to minimize cycle time
while not dragging the tips across the metal or flexing the gun shanks.

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1.6 Servo Gun Backup Position
A Backup Position is defined as the final gun servo tip opening before moving away from a
weld position. The stationary tip of the gun will have the air gap distance defined by the
pressure schedule (Pressure End position). Since servo guns allow for a number of different
backup positions, a table is setup to select the different distances.
The table below shows the scheme used for setting up the backup positions.
Table 1: Backup Positions

Backup Number Backup Position Manual Enabled
1 10mm True
2 20mm False
3 30mm False
4 40mm False
5 50mm True
6 60mm False
7 70mm False
8 80mm False
9 90mm False
10 100mm False
11 110mm False
12 120mm False
13 130mm False
14 140mm False
15 150mm False
Etc… Etc… False
29 290mm False
30 0mm (Gun Closed) True
There are a possible 30 different backup positions. The actual gun opening distance will
dictate how many of the backup positions are required.
The Manual Enabled setting dictates which of the backup positions can be used with the
"Backup" hardkey on the teach pendant. This hardkey allows the user to manually move the
gun to a specific backup position in teach mode with out going through the welding process.
The backup position used on a particular weld is indicated by the BU field in the Spot
command of the robot program In dual gun applications on the FORD V.O. Standards, both
guns use the same backup position. Therefore, the backup position field will only display
one parameter for both single and dual gun applications.

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SERVO GUN DATA G1 JOINT 10 %
BACKUP / EQ:1 Gun:1 1/30
No. Comment Stroke(mm) Manual
1 [ ] 100.000 TRUE
2 [ ] 40.000 TRUE
3 [ ] 10.000 TRUE
4 [ ] 0.000 FALSE
5 [ ] 0.000 FALSE
6 [ ] 0.000 FALSE
7 [ ] 100.000 FALSE
8 [ ] 0.000 FALSE
9 [ ] 0.000 FALSE
[ TYPE ] EQUIP GUN RECORD CLEAR
• Setting Manual=True will cause the

specified gun open distance to appear in
the select list when the user presses the
BACKUP key

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1.7 Servo Gun Pressure Table
NOTE1: Although schedules 81-87 have been pre-populated by Fanuc for pressure (tip
force) checks, the parameters may be altered and used for welding, if necessary. Please notify
Ford VO and local plant Welding Engineering if the parameters are altered for welding.
NOTE2: If schedules 81-87 are used for welding and then adjusted to perform pressure
checks, you must set the parameters back for welding.
Table 2: Pressure Table
ROBOT PRESSURE TABLE
INDEX PRESSURE (LBF) PART THICKNESS MANUAL

1
2
3
4
5
6
7
8
81 USED FOR PRESSURE CALIBRATION 15.0


94 USED FOR TIP DRESS WITH NEW TIP

95 USED FOR TIP DRESS WITH OLD TIP
96 USED FOR TIP RESISTANCE CHECK
For all R30iB and for R30iA with System Customization S115 installed
254
255

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1.8 Guidelines for Gun Stroke Close Limit
The default setting for max gun stroke is 20 mm. Total cap wear limits may be close
to this value which may be too close to the max stroke value. The following is a
detailed procedure to adjust the guns stroke close limit so small deviations will not
put the gun close to the max gun stroke setting.
1.8.1 Gun Stroke Close Limit Setup Procedure

1. Press MENU.
2. Select [6] SETUP.
3. Select [7] Servo Gun.
4. Scroll to “2 General Setup: <*DETAIL*>”. Press Enter.

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5. Scroll to “10 Gun Stroke Limit: <*DETAIL*>”. Press Enter.
6. Scroll to “2 Close stroke limit (mm) : XX.X”. Press Enter.
7. Type in value no greater than 90% of rated limit or no higher than 50 mm then
press Enter.
Note
 Never set close stroke limit more than 90% of guns
rated limit.
 Never set higher than 50 mm.

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8. Press F4, [END] when finished.
After setting the limit, confirm that the gun can wear through cap without getting
stroke limit error.
 Remove cap after setting the limit and carefully jog the gun to where the cap
adapters almost touch.
 Confirm there is no MOTN-017 Axis Limit Error. If there is an error, confirm
gun mastering and reduce close stroke limit. Consult gun manufacturer for
root cause.

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1.9 Servo Gun Setup and Auto-Tuning Utility
This section is extracted from the FANUC Robotics SYSTEM R-30iA Controller
Servo Gun Setup and Operations Manual
The FANUC servo gun software provides a special program to tune the servo
parameters for the gun without the aid of special tuning equipment, or user
intervention. This is called Auto-tuning.
The Gun Setup utility ensures that the servo gun is set up correctly before you
autotune the gun. If you try to autotune a gun that is set up incorrectly it can cause
damage to the gun. This utility will take you through some basic setup steps before
the actual tuning exercises are initiated. This includes:
 MOTION SIGN CONFIRMATION
 MASTERING
 TIP DISPLACEMENT RATIO SETTING
 AXIS LIMIT (Stroke Limit) SETTING
1.9.1 Preparation for Auto-Tuning

Note
If the BZAL or Pulse Not Established faults exist, they need to be

reset before jogging and mastering of the gun axis can be
executed. Go to the Gun Master screen to reset the BZAL. Refer to
the Gun Master Utility in the Appendix of the Servo Gun Manual for
details.
1.9.2 Gun Setup Utility

9. Press MENUS.
10. Select UTILITIES.
11. Press F1, [TYPE] and select Gun Setup. You will see a screen similar to the
following.

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UTILS Gun Setup G2 JOINT 10 %
EQ:1 Gun:1 1/2
1.Set gun motion sign: INCOMP
2.Set Gun specs, master gun INCOMP
Tip Displacement: 5.00(mm/rev)
Open stroke limit: -999.00(mm)
Close stroke limit: 999.00(mm)
3.Auto Tune: INCOMP
4.Thickness Check calibration: INCOMP
Press enter to perform this step.

[ TYPE ]EQUIP SKIP RESTART
Note
The F3 key, SKIP, can be used to set the status of Steps 1-2 to
complete (COMP) without actually performing the tasks. This
can be done if the user is certain that these items have been set
correctly during the controlled start axis setup and that
mastering has already been executed. In this case, Skip ahead
to Step 17 of this procedure after these items are set to COMP.
12. Press F4, RESTART to set steps 1-2 to incomplete if they are not already.
13. Move the cursor to item 1 and press ENTER. You will see a screen similar to
the following.
Set Motion Sign G2 JOINT 10 %
EQ:1 Gun:1 1/1
1.HOLD the SHIFT key and SLOWLY Jog
the Servo Gun movable tip using the
+X key (+Y if 2nd gun of dual gun).
2.Did the gun OPEN or CLOSE? *****
USE F4 or F5 to make selection.
3.Press F3 COMP when finished.
[ TYPE ] COMP OPEN CLOSE
Note
This screen will allow you to set the gun motion sign. The gun
should always close when you press the jog key [+ or -] that
matches the Close Direction (Gun) set on the servo gun
general setup screen. This step will set the internal motion
sign variable to make this happen.
14. Follow the steps listed on this screen in order.

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15. When you are finished, press F3, COMP. Item 1 status is now complete. You
will see a screen similar to the following.
EQ:1 Gun:1 1/1
1.Set gun motion sign: COMP
2.Set Gun specs, master gun INCOMP
3.Auto Tune: INCOMP
Move the cursor to item 2, and press ENTER. You will see the following prompts.
Do you know your gun’s Tip
Displacement?
[YES] [NO]
Do you know your gun’s Stroke Limits?

[YES] [NO]
If you answer yes to the 1st prompt you will need to enter the tip displacement
ratio directly. If you answer no, you will move the gun to the maximum
opening, measure and type in the distance.
If you answer yes to the 2nd prompt you will need to type in the close and
open stroke limits directly. If you answer no, you will record the open stroke
limit by moving the gun open to that position.
The screen that follows will look different, depending on the response to the
prompts above.
You will see one of the following screens

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16. Follow each of the steps carefully and in order. Then press F3, COMP when
done.
Upon completion of Step 2, you will see a series of prompt boxes to inform
you of the gun setup changes needed. When asked to respond YES or NO,
please respond YES unless a mistake was made in the previous screen or it
is certain that the change in the prompt box should not be made to this gun.
Power may need to be cycled after finishing this step for the setup changes to
take effect before auto-tuning the gun.

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After you have completed items 1 and 2, you are ready to tune the gun.
1.9.3 Auto-Tuning
Once Steps 1-2 are complete, Press SHIFT+-- F3 <EXEC> to start the auto tuning
process.
EQ:1 Gun:1 1/2
2.Set Gun specs, master gun COMP
3.Auto Tune: INCOMP
[ TYPE ]EQUIP EXEC SKIP RESTART
Note
The following conditions must be met for the tuning process to

start from the Gun Setup Utility:
 Not in STEP mode
 No faults exist
 No holds exist
 Servo gun is not in machine lock
 The control reliable key-switch is in AUTO or T2.
 Gun is in STROKE mode

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Note
After AutoTuning is started, the servo gun will perform the

following by opening and closing the gun:
 Acceleration settings
 Inertia measurements
 Friction measurements
 Spring constant measurements
 Pressure control gain settings
If Auto-tuning completed successfully a screen similar to the following should appear

and power will have to be cycled for the changes to take effect. .
EQ:1 Gun:1 1/2
2.Set Gun specs, master gun COMP
3.Auto Tune: COMP
If AutoTuning did NOT complete successfully (indicated by status FAILED

instead of COMP), then try the following and attempt the Auto Tune step again:
 Increase max gun pressure
 Make sure axis limits are set properly.
 Increase max gun speed up the recommended limit.
 Check motor selection
 Set $SYSGSCFG.$SHO_ATN_CFG = TRUE to enable the custom detail
screen for tuning. The user can specify non-default settings for the tuning
program and re-perform tuning
 Re-perform autotuning until it completes successfully.

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Note
Step 4 of the Gun Setup Utility - Thickness Check Calibration

- cannot be done until Pressure Calibration is complete.
Thickness Check Calibration is only required if the Part
Thickness Check function will be needed.
Refer to the Part Thickness Check section of the Servo Gun
manual for details on performing Thickness Check Calibration

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1.10 Pressure Calibration
This section is extracted from the FANUC Robotics SYSTEM R-30iA Controller
Servo Gun Setup and Operations Manual
1.10.1 Overview
During pressurization operations such as the Spot or Press_Motion instruction, the
servo system will refer to the user entered pressure calibration data to set the speed
used for tip contact and the motor torque held during the pressurization period.
Calibration should be carried out with a certified and calibrated force/pressure gage.
It is important to validate the calibration data by periodically checking the tip
pressure. If the calibration data no longer produces the desired results, a new
calibration should be performed. Consult with the servo gun manufacturer for
recommendations on calibration settings and frequency.
The calibration will calculate the following two relational equations to carry out
pressurization operations:
1. Relationship between actual pressure (Kgf) to motor torque (%)
2. Relationship between operation speed to actual pressure (Kgf)
1.10.2Pressure Calibration Procedure

Apply pressure with two or more torques and operation speeds specified. The
relationships are calculated internally by the system from the actual measured
pressure values
 A pressure gauge (load cell) for measuring the pressure between tips is
needed for adjustment.
 To obtain a more accurate relational equation for torque-to-pressure, set the
torque value at which the actual pressure to be used is generated and then
perform the measurement.
 Set the speed at values which reduce the overshoot of pressure to a
minimum value.

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SETUP Spot Weld G1 JOINT 10 %
Pressure calibration/EQ:1 Gun:1 2/11
1 Calibration Status: INCOMP
3 Pressuring Time(sec): 1.5
4 Thickness of Gauge(mm): 12.7
6 Gun Open Value(mm): 0.0
Torque(%) Speed(mm/sec) Pressure(Kgf)
7 0.0 % 100 mm/sec 0.0 Kgf
8 0.0 % 100 mm/sec 0.0 Kgf
[ TYPE ] CANCEL PRESSURE COMP INCOMP
Measurement Procedure
1. Bring the fixed side tip into contact with the base of the load cell.
2. Go to the Servo Gun General Setup screen.
GENERAL / EQ:1 Gun:1 11/12
11 Pressure Cal: COMP <*DETAIL*>
12 Tip Wear Standard: COMP <*DETAIL*>
[ TYPE ] EQUIP GUN
3. Select Pressure Cal.

(Move the cursor to <*DETAIL*> and press the ENTER key.)
4. The Start Message screen is displayed. Select F4 YES.
5. The Pressure Calibration screen is displayed.
G2 JOINT 10 %
To perform pressuring motion,
press SHIFT + F3:PRESSURE key.
After pressuring motion,
set the measured pressure value.
Do you start calibration?
YES NO
6. Set the following items.

PRESSURE CALIB / EQ:1 Gun:1 1/10
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 1.5
3 Thickness of Gauge(mm): 12.7
6 5.0 % 100 45.0 Kgf
7 10.0 % 100 110.0 Kgf
[ TYPE ] CANCEL PRESSURE

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Table 3: Pressure Calibration Settings
Item Description
Pressuring Time
Pressuring time (*2). Sets the time required for measurement.
(sec):
Thickness of
Thickness of gauge (*3)
Gage (mm):
Gun Open Value Gun axis open value after pressuring ends (*5) The maximum
(mm): stroke in the open direction is set as the standard value.
Specify the torque (*6) used for pressuring as a percentage of the
Torque (%)
maximum torque.
Contact speed of the gun axis.
Speed (mm/sec): Set the contact speed so that overshoot during pressuring falls
within the allowable range.
7. After you have specified Torque (%), press the Shift key and F3 PRESSURE.
Pressuring is carried out.
PRESSURE CALIB / EQ:1 Gun: 10/10
: :
6 10.0 % 20 mm/sec 141.0 Kgf
7 20.0 % 40 mm/sec 186.0 Kgf
8 30.0 % 60 mm/sec 206.0 Kgf
9 40.0 % 80 mm/sec 250.0 Kgf
10 50.0 % 100 mm/sec 272.0 Kgf <— Enter the measured
Pressure in this
[ TYPE ] CANCEL PRESSURE field

Page 39 of 305
Note
Move the cursor to the Torque line before executing the

pressuring operation. If the cursor is on a line that does
not designate the torque, the pressuring operation is not
carried out.
To prevent gun damage, start measurement from as small
a torque value as possible.
Note
 Consult with gun manufacturer to determine the best

contact speed for the gun tips.
 Speed can generally be increased with increasing

torque. The rigidity of the gun mechanism should be
considered too, so as to keep the impact force
acceptable. More rigid guns may require lower contact
speeds. Typical values for contact speed are between
25mm/sec – 125mm/sec.
 A very low contact speed may increase time required

to execute the pressuring operation
8. Enter the pressure that you read in the Pressure column.

9. Specify the torque and carry out the measurement for other lines in the same
way.
 Up to 10 (minimum two) torque and operation speed values can be set.
 To cancel pressure adjustment midway, press F2 CANCEL.
10. After measuring the pressure several times, move the cursor to Calibration
Status, and press F4 COMP to finish the Pressure Calibration. The resulting
calibration table is displayed after the calculation.
11. Press either F2 END or the PREV key to end pressure adjustment.

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12. To re-adjust the pressure, select F5 INCOMP in this screen. You can now re-
adjust the pressure.
SETUP Servo Gun G2 Joint 100%

Pressure Calibration
Equipment number:1 Gun: 1
Calibration Status: COMP
Point Torque Speed Pressure

1 10.0% 50mm/sec 96.0 kgf
2 20.0% 50mm/sec 188.0 kgf
3 30.0% 50mm/sec 275.0 kgf
4 40.0% 50mm/sec 370.0 kgf
[ TYPE ] END COMP INCOMP

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1.11 Tip Wear Down Compensation
1.11.1 Overview
Tip Wear Compensation is used to compensate for changes at the servo gun tips. These
changes include wear resulting from welding, dressing, etc. and growth resulting from tip
change, electrode change, etc. Tip Wear Compensation adjusts the final position of both
weld tips when executing the SPOT or PRESS_MOTN instruction.
It is necessary to measure the amount of tip wear down in order to use this function. The tip
wear compensation functions are controlled by macro instructions that are included with the
Servo Gun software option and TP programs that initiate the macro instructions. The TP
programs are pre-set to perform a specific tip wear function on gun #1. These programs can
be copied or re-named by the user for special cases such as:
 Multi-gun systems
 To support a customer specified TP program naming convention
 To support indirect argument assignments
The macro programs should generally not be re-named or deleted since they are used as
sub-routines of the main tip wear programs.
TIP WEAR MEASURING METHODS
Two standard methods of tip wear measurement are available that do not require external
sensors. They are called TWO STEP and ONE-STEP. Only one method can be used for
each robot. Two-Step is default choice and more accurate.
 TWO-STEP (i.e. fixture-based, fixture-touch) —> First, the gun is closed and re-
mastering is done. Next, the gun is brought to a rigid plate/fixture in the cell, often
mounted on the tip dresser, and the moving tip closes to the fixture (fixture-touch)
while the gun opening is measured. The unique wear amount on each tip is
determined accurately using this method.
The two-step method is the most accurate, since the unique wear of each tip is
determined. This is the default method.
 ONE-STEP (i.e. fixture-less, tip-to-tip) —> The gun is closed and re-mastered. The
fixture-touch step is skipped so, only the combined wear of both tips is determined.
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Each tip’s unique wear amount is then estimated by applying the user-defined “wear
ratio”.
TIP WEAR TASKS
With both methods, there are two main tasks for using tip wear compensation:
1. INITIAL SETUP – do this once, to initialize tip wear reference data*
2. UPDATE – do this after initial setup, every time a new tip wear measurement is
needed
* Initial Setup must be run again if mastering data is lost due to a BZAL (Battery Zero
Alarm) or CMAL alarm, change in gun geometry or change in gun friction when using
Two-Step method. Read the Recovery from Loss of Mastering Data section for more
detail on running the initialization after a BZAL or CMAL alarm.
STANDARD TIP WEAR PROGRAM LIST
The following TP programs are included in the TP program list when the Servo Gun option is
installed. Use these programs to perform the tip wear initial setup and update tasks, as well
as a few other common functions if needed.
Table 4: Standard Tip Wear Programs
Default TP Macro Instruction Function
program name used
The following programs are always loaded
Initialize tip wear data for the 2-step method on gun 1.
TW_SET01 TW_SETUP(1)
Must specify the gun number in the macro program call.
Measure the tip wear using the 2-step method for gun 1.
TW_UPD01 TW_UPDAT(1,0) Must specify the gun number and the tip condition (new
or used) in the macro program call.
Move the robot to the positions required for each step in
the 2-step method. This is a sub-routine called by
TW_MV2PT N/A
TW_SETUP and TW_UPDAT and should not be re-
named!
If $SGSYSCFG. $LOAD_TWD=6, the following programs are loaded
Initialize tip wear data for the 1-step method on gun 1.
WR_SET01 WR_SETUP(1)
Must specify the gun number in the macro program call.
Measure the tip wear using the 1-step method for gun 1.
WR_UPD01 WR_UPDAT(1,0) Must specify the gun number and tip condition (new or
used) in the macro program call.
TW_PRSRT Press new tips onto the gun tip holder by opening and
TW_PRS01
(1,500,2,4,1,10,5,15,) closing the gun with pressure several times.
This document describes how to use the TP & macro programs and Tip Wear UIF screens
to properly measure and compensate for tip wear.
1.11.2Preparations for Using Tip Wear Down Compensation

Preparation for this function
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 Complete servo gun AutoTune and pressure calibration
 Set Tip Wear Comp to ENABLE in Servo gun general setup screen
 Install new tips before measurement setup
Note
Robot and gun positions will change slightly from the originally
taught position at execution of the SPOT and Press Motion with tip
wear compensation. Be sure the robot arm and gun arms do not
interfere with tooling and fixtures when tip wear amount is large.
Preparation of TWO-STEP
Prepare a fixture for detecting the moving tip position in the fixture-touch step of the
measurement If the fixture deflects while the tip presses against it, the measurement error
may increase. Please prepare a fixture as rigid as you can. (As a standard, movable tip will
press the fixture with 100-200 kgf of pressure.).
Preparation of ONE-STEP
It is necessary to set load-option for using the One-step measurement method. Set the
system variable: $SGSYSCFG. $LOAD_TWD=6, then cycle power.
Confirmation of register and position register number

The macro programs for tip wear down measurement use R[10] and PR[20],PR[21] as the
default registers. Don’t use these registers for another purpose. These registers can be
changed in the macros, however it is generally not necessary to change.
Table 5: Tip Wear Macros
Macro Name Used Register Used Position Register
TW_SETUP R[10] PR [21]
TW_UPDAT R[10] PR [21]
WR_SETUP R[10] PR [20], PR [21]
WR_UPDAT R[10] PR [20], PR [21]

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1.11.3 TWO-STEP Measurement Method
Procedures for TWO-STEP Measurement
The Two-Step measurement uses the macro programs TW_SETUP and TW_UPDAT to
perform the initial setup and update tasks respectively.
1.11.3.1 Initial Setup

1. Teach two positions in TW_MV2PT
Note
a) Notice the following for teaching positions.

b) TW_MV2PT is pre-installed in controller.
c) Please refer to the label comment of TW_MV2PT for gun
number & teaching position
d) The positions should be taught such that movement
from P[1] to P[2] or vice-versa does not cause any
collision
e) These are the same points the robot will move to for the
measurement of tip wear during production. Be sure to
consider this when calling the tip wear update program in
production.
2. Copy program TW_SET01、to a new program (name) if necessary, and modify the
instructions. Ex) TW_SET02.TP : for setup gun 2
TW_SET01 LINE 0 T2
ABORTED G1 JOINT 10%
5: ;
6: !Use the following call for ;
7: !fixture-based wear measurement ;
8: !Parm1: gun number ;
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9: !CALL TW_SETUP( 1 ) ; <— Set Correct Gun
10: CALL TW_SETUP(1)
3. Place new tips on the gun and check the zero position of the gun. The tips should
just touch at the zero position. Re-master the gun axis using the Gun Master Screen
if the zero position needs adjustment.
4. Execute the user program that was copied from TW_SET01.TP for each gun. Check
teaching positions and gun axis speed, then execute it finally with override 100%
(AUTO mode or T2 mode).
1.11.3.2 Update Tip Wear Measurement
1. Copy program TW_UPD01、to a new program (name) if necessary, and modify the
instructions.
TW_UPD01 LINE 0 T2

16: !fixture-based wear measuremt ;
18: !Parm2: new tips ;
19: !CALL TW_UPDAT( 1, 0 ) ;
20: CALL TW_UPDAT(1,0) ; <–Normally set ’0’ for worn tip
^ Set ’1’ after installing new
POINT SPOT TOUCHUP
Set correct gun
2. Set the arguments correctly for the wear measurement that is required. The
arguments may be specified indirectly by using data register.
3. Run the TW_UPDAT macro any time an updated measurement is needed:
 After tip change (set new tips parameter)
 After tip dress
 After pre-determined number of welds or parts

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Note
Teach position[1] and position[2] for each gun
Note
Execute SETUP & UPDATE program for each gun in the

system
1.11.4 ONE-STEP Measurement Method

Procedures for ONE-STEP Measurement
The One-Step measurement uses the macro programs WR_SETUP and
WR_UPDAT to perform the initial setup and update tasks respectively.
1.11.4.1 Initial Setup
1. Copy WR_SET01、to a new program (name) if necessary, and modify the

instructions.
Ex) WR_SET02.TP : for setup gun 2
WR_SET01 LINE 0 T2
5: ;
7: !fixture-based wear measurement ;
9: !CALL WR_SETUP( 1 ) ; <— Set correct gun
10: CALL WR_SETUP(1)
2. Place new tips on the gun and check the zero position of the gun. The tips
should just touch at the zero position. Re-master the gun axis using the Gun
Master Screen if the zero position needs adjustment.

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3. Execute the newly created program. Only the gun should move. Check gun
axis speed, and then execute it finally with override 100% (AUTO mode or T2
mode).
1.11.4.2 Update Tip Wear Measurement

1. Set wear ratio (This step is not necessary if default wear ratio (=0.5) is used.)
The wear ratio is defined as the fraction of total wear that is assigned to the
robot tip
a. Open the program WR_UPDAT
b. Find the line that calls twkcal2, as shown (highlighted) below
c. Set the 1st argument to the wear ratio you desire. (Default = 0.5, equal
wear on each tip)
WR_UPDAT
60/66
53: LBL[1]
54:
55: !Update wear amounts
56: !Parm1: 0<=Robot wear ratio<=1.0
57: !RbtTipWear = ( rbtwr_ratio *
58: ! total wear )
59: !Parm2: New tip installed
60: CALL TWKCALC2(.5,AR[2]) <–0: all wear is assigned
61: to the moving tip
62: !Move gun to PR 1: all wear is assigned
63: ! Parm1: Velocity label to the robot tip
0: Wear ratio <1: wear is
assigned to both tips
2. Copy WR_UPD01、to a new program (name) if necessary, and modify the

instructions.
Ex) WR_UPD02.TP : for update gun 2
WR_UPD01 LINE 0 T2

16: !fixture-based wear measuremt ;
18: !Parm2: new tips ;
19: !CALL WR_UPDAT( 1, 0 ) ;
20: CALL WR_UPDAT(1,0) ; <— Normally set ’0’ for worn tip
| Set ’1’ after installing new
Set correct gun
3. Set the arguments correctly for the wear measurement that is required. The
arguments can be specified indirectly by using data register.
4. Run the WR_UPDAT macro any time an updated measurement is needed.:

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 After tip change (set new tips flag)
 After tip dress
 After pre-determined number of welds or parts
Note
Execute SETUP & UPDATE for each gun in the system
1.11.5 OPERATIONAL SETTINGS AND ALARM PROCESSING
1.11.5.1 Tip Wear Standard

Table 6: TIP WEAR STANDARD Detail Screen Items lists and describes the items
in the Tip Wear Standard detail screen.
Table 6: TIP WEAR STANDARD Detail Screen Items
ITEM DESCRIPTION
This item displays the present wear amount of each tip. The values can be
Tip Wear
changed, but it is recommended to not change them here, use a tip wear
Value
measurement program instead
This item displays COMP if the fixture-touch setup/initialization has been
Detect
executed and displays the load measured during initialization to accurately detect
Load
the fixture
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ITEM DESCRIPTION
Master This item displays COMP if the tip wear reference master has been executed and
Count displays the pulsecoder count of that reference position
This item displays COMP if the fixture-touch reference open position is valid
Opening
and displays the opening that was recorded as the reference open position during
(mm)
initialization.
1.11.5.2 Tip Wear Detection

Items in this screen are used to specify how tip wear measurement is executed and
how to process tip wear related alarms. Table 7: TIP WEAR DETECTION Screen
Items lists and describes the Tip Wear Detection screen items.
SETUP\Servogun\
1 Tip Wear Down Comp: DISABLE
2 Gun Sag Compensation: DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z ]
5 Max Motor Torque(%): 82.4
6 Max Pressure(kgf): 500.0
7 Max Part thickness: DISABLE
8 Thickness (mm): 0.0
9 Tip stick detect delay(ms): 0
10 Tip Wear Detection: <*DETAIL*>
11 Pressure Cal: COMP <*DETAIL*>
12 Tip Wear Standrd: COMP <*DETAIL*>
13 Thickness check: <*DETAIL*>
14 Servo Gun MWV: <*DETAIL*>
15 Gun Stroke limit: <*DETAIL*>
16 OverTorque protection: <*DETAIL*>
SETUP\Spot\Weld\
TIP WEAR DETECT / EQ:1 Gun:1 1/11
1 Common setup: <*DETAIL*>
2 Detection type: LOAD

3 Margin of load(kgf): 35
4 Tip speed(mm/sec): 70
5 Mis-detect toler.(mm): 5.00
Maximum wear down check(Gun)

6 Max wear down value(mm): 5.00
7 Inform signal: DO[ 0]
8 Increased error(mm): 1.00
Maximum wear down check(Robot)
9 Max wear down value(mm): 5.00
10 Inform signal: DO[ 0]
11 Increased error(mm): 1.00
Table 7: TIP WEAR DETECTION Screen Items

ITEM DESCRIPTION

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ITEM DESCRIPTION
The following items are where details related to the 1st step (re-master) of tip wear
measurement are specified.
This item allows you to access the following items for first step of tip wear
Common Setup
measurement..
Number of the pressure schedule to use for the re-master step of tip wear
Pressure
measurement. Do not use this schedule for other tasks or for welding
Schedule
(default = 98)
Number of the start distance schedule to use for the re-master step of tip
Start distance
wear measurement. Do not use this schedule for other tasks or for welding
Schedule
(default = 98)
Open Gun at ENABLE/DISABLE, specifies whether the gun is opened to the start
Restart distance before retry after a mis-detection. (default = ENABLE)
Retry times No. of times the re-master step is re-tried when a mis-detection is observed
The following items are where details related to the 2nd step (fixture-touch) of tip
wear measurement are specified
LOAD or DO are available. The standard tip wear measurement programs

Detection Type assume the LOAD technique is used. DO (Digital Output) requires an
external visual sensor to measure wear instead of a fixture-touch.
This is the amount of force(load) in addition to the gun friction (measured
during tip wear setup/initialization) that will be applied to detect the fixture
Margin of Load
touch. This value is set automatically by the software based on the servo
gun max pressure, but the user can override this value.
Set by default to 30mm/sec. This is the maximum speed the tip will close to
the fixture at during the fixture-touch step of a two-step measurement. The
Tip Speed user can increase this value experimentally if needed. This value must be
(mm/sec) set before running the TW_SETUP program, so that TW_SETUP uses the
same fixture touch speed that TW_UPDAT uses. Using the same tip speed
for each measurement is critical for accurate results.
The following items must be specified for each form of tip wear measurement.
Set by default to 5 mm. This is how much total tip growth (both tips
combined) is acceptable between the “reference tips” and the present tips
(“reference tips” are the tips that were used during initialization). If a tip
Mis-detect toler
growth in excess of this amount is observed it will be deemed a mis-
(mm)
detection and the measurement will be re-tried by the number of times
listed in the “Common Setup” before posting a “Tip Wear Down
misdetection’ fault. Typical values are between 5-10 mm.
Maximum Wear This item specifies the maximum wear that can be measured on either the
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ITEM DESCRIPTION
Down Value gun tip or the robot tip before the Maximum Wear Exceeded Warning and
(gun and robot) Inform Signal [DO] is activated. Typical values are between 5 - 7 mm.
Inform Signal This is the digital output that is turned on when the measured wear exceeds
(gun and robot) the specified Maximum Wear Down Value.
This is the maximum tip growth that can be observed (compared to the
previous tip wear measurement) before the Tip Increased Error fault is
Increased error asserted. The only case where a longer tip would be expected is at tip
(gun and robot) change. When the new tip’s parameter is set to 1, the tip wear amount will
be compared to zero when calculating a tip increased error, not the previous
tip wear measurement. Typical settings for this item are 2 - 5 mm.
Calculating Maximum Wear Exceeded Alarm
The servo gun software determines the total wear down value by calculating the
change in tip length from the reference tips (with no wear) to the current tips (with
wear). This wear down amount is used to automatically adjust the gun stroke limits
and the robot position for welding operations.
However, you can choose when to turn on the Maximum Wear Exceeded alarm and
DO.
You can decide to turn on the alarm when
 this total wear down value exceeds the user-specified maximum wear down
value,
 or when the wear since last tip change exceeds the user-specified maximum
wear down value.
Set the following system variable to control when to turn on the Maximum Wear
Exceeded alarm and DO:
$SGSYSTWD.$CAP_WR_TYP
1 (default) = current tip length is compared to reference tip length for computing
Maximum Wear Exceeded alarm
2 = current tip length is compared to tip length at last tip change for computing
Maximum Wear Exceeded alarm
If you set $SGSYSTWD.$CAP_WR_TYP to 2, then when you change tips you must
measure wear by doing the following:
1. fully seat the tips onto the tip holder
2. set the new tip flag in the tip wear update program
3. run the tip wear update program (with the new tip flag set).
Setting Maximum Wear Down Values
Servo Guns are designed to move a set distance past where the tips touch with new
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tips, before reaching their end of travel. Consult with the weld gun manufacturer to
learn about this “close stroke limit” for your gun. With this in mind, it is best to set the
maximum wear down values so that the Maximum Wear Exceeded warning and DO
is asserted once the wear amount is large enough that the gun could be nearing its
close stroke. If the gun reaches the close stroke limit, an Axis Limit fault is asserted.
To calculate the best setting, use the following equation:
MW=SL-GD+PT
where,
SL = stroke limit in mm past where the tips meet
GD = gun deflection at maximum rated gun force
PT = typical part thickness
MW = maximum total wear allowable
A typical example is:
SL=20mm
GD=5mm
PT=2mm
MW=17mm total wear
If an even distribution of wear between tips is considered, then each tip can have a
maximum wear of 8.5mm before the gun would reach its end of stroke. In this case,
setting the Max wear down value of each tip to about 7mm or less is good so the
warning is displayed in time to make a tip change without damaging the gun.
Note
The Tip Increased error informs the user that the tip wear
program observed the tips touching each other or the fixture
before it did on the previous wear measurement (by an
amount >= tip increased error(mm) setting). When this
happens consider the following possible causes:
 A cutting chip from tip dressing operation remained on

the tip making it longer. Remove the cutting chip.
 New tips were placed on the gun, but the new tips flag
was not set in the update program. Set the new tips
flag and run the update program again.
 The fixture-touch tip speed was slower than it was
during the previous wear measurement. Keep the
fixture-touch tip speed consistent.
 The fixture-touch or re-master position was mis-

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detected (sensed too soon). This can happen if the
fixture position has shifted relative to the robot, the gun
friction has changed or the Margin of Load is set too
small. When using the two-step measurement,
increase the Margin of Load if the fixture does not
bend. If this does not work execute the Setup
Procedure and determine why the gun friction has
changed.
1.11.6 RECOVER FROM LOSS OF MASTERING

When mastering data is lost for the servo gun, the tip wear reference data gathered
during the initial setup is invalidated and must be recovered. Mastering data is lost
when the BZAL or CMAL alarm occurs, typically caused when the pulsecoder cable
is disconnected or damaged.
Note
The procedures in this section must be executed to recover

the tip wear data after mastering data is lost
There are (2) methods available to re-master the gun and recover the tip wear data.
1. Standard Master - Place new tips on the gun and use the Standard master
operation (tip wear amount is reset to zero)
2. Re-Calibration Master - Keep the same tips on the gun and use the Re-
Calibration master operation (tip wear amounts will not be changed)
Both master operations are performed by accessing the Gun Master Screen (MENU-
SYSTEM-GUN MASTER):
 Choice 1, Standard Master, requires the user to run the tip wear update
program afterwards to accurately recover the robot/fixed tip wear amount.
Also, the user should check the stroke limits if the length of the newly placed
tips are different than the tips used when tip wear initial setup was done.
 Choice 2, Re-Calibration Master, requires the tip wear values to already be
accurate since they will not be changed. The tip wear values may change a
little when the tip wear update program is run later, since the mastering
position set by the user could differ a little from the master position the tip
wear update program will find.

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1.11.6.1 Re-Master Procedure
1. Reset the pulsecoder fault, BZAL or CMAL, using the Gun Master Screen,
and cycle power
2. Jog the tips until they just touch
3. Press the soft-key (F-key) associated with the re-master operation you have
selected. Press NEXT on the teach pendant to see the Re-Calibration choice.
Standard Master:
a. Press F4, EXEC, if new tips were placed on the gun and the Standard
Master operation will be done.
b. Press F4, YES, to confirm tips are new and closed.
Re-Calibration Master:
c. Press F9, RECALIB, if the same worn tips are used and the Re-
Calibration Master operation will be done (press the NEXT key to get
to a 2nd screen where the F9, RECALIB, key is seen).
d. Press F4, YES, to confirm tips were not changed and they are closed.
4. If the Standard Master operation was done, run the tip wear update program
and confirm the stroke limits are OK.
5. Return to normal operation
1.11.7 PRESSING ON NEW TIPS

After changing to new tips, it is good practice to be sure the tips are fully pressed on
the tip holder before returning to welding or updating the tip wear amount. It is
necessary to run this macro. The macro program TW_PRSRT can perform this
function automatically. This macro and the TW_PRS01 template program are loaded
with the load-option by setting $sgsyscfg.$load_twd=6.
The program will squeeze the tips together several times, so the tips are pressed
fully onto the tip holder.
You must specify (8) parameters for TW_PRS01 to define how the routine executes.
Table 8: TW_PRS01 Parameters describes each parameter; Table 9: Pressing
Sequence with Default Settings [CALL TW_PRSRT(1,500,2,4,1,10,5,15)] and Table
10: Pressing Sequence with Custom Settings [CALL
TW_PRSRT(1,300,1,6,1,10,5,10)] provide a few examples of the pressing operation
with different parameters. This macro or template program can be run anytime, but
is best to run after changing tips and before getting an updated tip wear
measurement.
TW_PRS01
1: !PROGRAM NAME: TW_PRSRT;

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2: !Program function: ;
3: ! Compress caps after tip change ;
:
8: !Parameters supplied to TW_PRESS ;
9: !1: Equipment number ;
10: !2: Force end value (Kgf) ;
11: !3: Number of steps ;
12: !4: Number of repititions ;
13: !5: Dwell time (ms) ;
14: !6: Register number R[#] ;
15: !7: PrePress margin ;
16: !8: Max growth ;
17: CALL TW_PRSRT(1,500,2,4,1,10,5,15)
Table 8: TW_PRS01 Parameters

NOTE: For parameters 2, 3 and 4 it is important to use values either provided by Ford
or the servo gun manufacturer.
Parameter Default Description
Parameter 1 –
Default = Create a CALL instruction for each equipment if there are multiple
Equipment
1 ones.
Number
The maximum force that will be applied during the tip pressing
Parameter 2 –
Default = operation. If the value specified here exceeds the max pressure for
Force End Value
500 the gun, the software will limit the pressure to the Max Pressure,
(kgf)
automatically.
Specifies how many sets of squeezing repetitions will be performed.
Parameter 3 – Default =
The force during step n, will be equal to:
Number of Steps 2
(Parameter 2) * [n/(Parameter 3)]
Parameter 4 – Default = 4 The number of repetitions performed during each step.
Default =
Number of The total number of squeezing repetitions is equal to: (Parameter 3) *
4
Repetitions (Parameter 4)
Squeezing time of each repetition.
Dwell Time (ms) 1 (ms)
Register used to track program status internally. R[10] is the standard
register for tip wear measurement, so it is generally unnecessary to
Register Number 10
change this
Parameter 7 –
Default =
PrePress Margin Defines an extra open distance required to reach the pressing speed
5
(mm)
Defines the maximum expected increase in length between (2) worn
Parameter 8 – Max Default = tips and (2) new tips. The actuator pos
Growth (mm) 15 ition between repetitions is equal to: Worn tips zero position +
(Parameter 7) + (Parameter 8)
TIP PRESSING EXAMPLE SEQUENCES

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Table 9: Pressing Sequence with Default Settings [CALL
TW_PRSRT(1,500,2,4,1,10,5,15)]
Step Operation Critical Parameters
#
Parameter 2 * (1/Parameter
Gun Closes to pressure, 250kgf
3)
Pressure is held for 1ms Parameter 5
Step 1
Gun opens to 20mm compared to worn tips zero
Parameter 7+8
position
Above steps are repeated (4) times Parameter 4
3)
Step 2
Parameter 7+8
position
Above steps are repeated (4) time Parameter 4
Table 10: Pressing Sequence with Custom Settings [CALL
TW_PRSRT(1,300,1,6,1,10,5,10)]
Step Operation Critical Parameters
#
3)
Step 1
Parameter 7+8
position
Above steps are repeated (6) times Parameter 4
1.11.8 ACTIVE STROKE LIMIT PROTECTION

The servo gun stroke limits are determined by calculating the difference between the
present zero position and the reference zero position, then comparing that to the
Gun Stroke Limits (found on the servo gun general setup page). This is required to
keep the moving tip from extending beyond the physical stroke limit of the servo
actuator, even with worn tips. Tip Wear Compensation does this automatically.
Please note the following about the stroke limit protection:
1. The close stroke limit is the distance past the reference zero position (not the
present zero position) that the gun axis can advance
2. If either robot tip or gun tip is worn, a tip opening distance larger than the
open stroke limit is not allowed.

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3. When mastering data is lost, the gun stroke limits are invalid and one of the
procedures from the “Recovery from loss of mastering” section must be used
to recover the proper stroke limits
See the visual example below:
Table 11: Summary of Stroke Limit Behavior

Wear value Stroke Limit value
Close Stroke Limit Open Stroke limit
Original Close Stroke Limit MINUS Original Open Stroke Limit (does
Total Wear > 0
total tip wear not increase with tip wear)
Total Wear < 0 Original Close Stroke Limit (does Original Open Stroke Limit (does
(growth) not increase with tip growth) not decrease with tip growth)
Due to the active stroke limit protection that Tip Wear Compensation provides, the
following procedure must be followed to disable the active stroke limit control when
tip wear compensation is no longer required, after it was already initialized:
Procedure to disable Tip Wear Compensation and its active stroke limit
control:
1. Set Tip Wear Comp to DISABLE on Servo Gun General Setup Page.
2. Set the sysvar $SGGUN#.$SGTWD.$PHASE = 0 (where # is the gun
number).
3. Place New Tips on the gun and re-master.
4. Set the Gun Stroke Limits to the proper value if they are not already.

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1.12 PART THICKNESS CHECK FUNCTION
Part Thickness checks can be carried out with the servo gun during execution of
Motion Option and Standalone SPOT instructions and the Press_Motion instruction.
The part thickness check will perform a measurement to determine the Measured
Part Thickness and compare it to the Specified Part Thickness. When the measured
value is outside of the user-specified tolerance a warning or fault can be issued, and
an output can be asserted. Thickness checks can be enabled for all spot and
press_motion instructions or only when directly specified.
Target applications for Part Thickness check include detection of:
 Missing part
 Incorrect part
Note
Compensation for wear on the welding tips (Tip wear

compensation) and bending in the gun arms (Gun Sag
compensation) are required for accurate part thickness
measurement. See the appropriate sections for details on each of
these compensation functions.
The user must complete the “Thickness Check Calibration” item on the Gun Setup
Utility for the part thickness function to be enabled. In addition, the user is required
to:
1. Accurately set the tip displacement ratio for the gun (mm/motor revolution).
2. Keep gun tips accurately mastered so tips touch exactly at zero position. Tip
wear compensation programs are typically used to achieve this.
3. Fixed tip of gun must be in gentle contact with the metal surface during
thickness check. Accurate teaching and gun sag compensation are typically
required.
DEFINITIONS:
Measured Part Thickness = position of the gun tips minus expected gun deflection
when the thickness check is performed.
Specified Part Thickness = part thickness from the specified pressure schedule (or
THK_VAL condition if used). This is compared to the Measured Part Thickness to
determine if the measured thickness is out of tolerance.

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1.12.1 Thickness Check Calibration
Thickness Check Calibration Procedure
1. Press MENUS.
2. Select UTILITIES.
3. Press F1, [TYPE] and select Gun Setup. You will see a screen similar to the
following.
EQ:1 Gun:1 15/15
1. Set gun motion sign: COMP

2. Set gun specs master gun COMP
Tip Displacement: 7.5 (mm/rev)
Open Stroke Limit: —110.00(mm)
Close Stroke Limit: 20.0(mm)
3. Auto Tune: COMP
4. Thickness Check Calibration:INCOMP
[ TYPE ] EQUIP# RESTART HELP>
4. Complete Steps 1-3 of the Gun Setup utility. Refer to the Servo Gun Setup
Utility sections in the Servo Gun Manual
5. Complete Pressure Calibration. Refer to the Pressure Calibration section in
the Servo Gun Manual.
6. Be sure that the tips touch at the zero position exactly (+/- 0.1mm). It is best
to complete Tip Wear Compensation Setup/Initialization since tip wear
compensation is needed, and provides for accurate zero position mastering of
the gun tips.
7. Select the appropriate equipment and gun number using the F-keys.
8. Move the cursor to select Step 4, “Thickness Check Calibration”.
Note
Before starting the Thickness Check Calibration the following items

must be confirmed:
 The gun tips must be accurately mastered. Use Tip

Wear Compensation Setup program to achieve this. (any
error in mastering will lead to a direct error in part thickness
measurement)
 Items 1-3 of the Gun Setup Utility must be complete
 Pressure Calibration must be complete

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9. Press Shift + F3 (EXEC) to initiate the calibration. The following prompt box
may appear when you do this.
Thickness Check Calibration Exercises will
begin
10. Select YES and press enter. The selected gun will open and close 4 times to
perform the calibration. The robot will not move during this process.
Once the Thickness Check Calibration is complete, part thickness checking can be
used. The next step is to setup and define the part thickness operation desired.
1.12.2 Thickness Check General Setup

Thickness Check General Setup Procedure
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE] and select Servo Gun. Then select the General Setup
page.
3 Close Direction (Gun) : PLUS
4 Close Direction (Robot) UT: 1 [+Z]
5 Max Motor Torque (%) : 100.0
6 Max Pressure (Kgf) : 500.0
7 Tip stick detect distance (mm) :
8 Tip Wear Detection <*DETAIL*>
9 Pressure Cal : COMP <*DETAIL*>
10 Tip Wear Standard: COMP <*DETAIL*>
11 Thickness Check <*DETAIL*>
[ TYPE ] EQUIP GUN ENABLE DISABLE
4. Scroll to the Thickness check item and press enter to see the Thickness
Check screen.
SPOT_1A2 LINE 0
SETUP\Servo\gun
THICKNESS CHECK / EQ:1 Gun:1 1/8
1 Thickness check: DISABLE

2 Thickness check mode: ON RQST
3 Check at 0kgf: DISABLE
4 Settling time delay (ms): 0
5 Alarm severity: WARN
6 Under thickness limit (mm): 0.2
7 Over thickness limit (mm): 0.2
8 Thickness out of tolerance: DO[ 0]
[ TYPE ] EQUIP GUN ENABLE DISABLE

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5. Using the table below as a guideline, set up each item on the Thickness
Check page to specify the part thickness check operation that you desire.
Table 12: THICKNESS CHECK Screen Items lists and describes the Thickness
Check screen items related to the setup and measurement method for part thickness
check function.
Table 12: THICKNESS CHECK Screen Items
Item Description
This setting specifies whether thickness checking is enabled. In the case
of on request mode, this becomes thickness check permissive.
Thickness
ENABLE — >checking is done based on thickness check mode selected
check
below
DISABLE — >(default) checking is globally disabled and never done.
This item specifies whether every spot should be checked or only those
spots that are preceded by the condition, TCHK_RQD.
ALL — >if thickness check is set to ENABLE, checks are done for every
Thickness
spot and press motion that is not preceded by the TCHK_SKP condition.
check Mode
ON_RQST (“on request”) — > (default) if thickness check is set to
ENABLE, checks are done only for each spot and press motion that is
preceded by the TCHK_RQD condition.
This item specifies whether thickness should be checked with no pressure

in the gun. An additional step is added to relax the gun in this case.
ENABLE — >the weld pressure will be set to a minimum value (i.e. the
Check at
0kg gun is relaxed) prior to checking thickness. After the measurement is done
the gun will close to weld pressure before welding.
DISABLE — >(default) check is performed when gun reaches the
specified weld pressure. This is the faster of the two measurement styles.
This item specifies a delay after achieving pressure, before reading

thickness value. Adding a delay might improve the repeatability of the
Settling time measurement but will increase the time required to complete the
delay (ms) measurement.
Range of Settings: 0-9999 — >(default = 0) time in ms that system will
wait after pressure is achieved before checking the part thickness.

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Item Description
This item specifies the severity level of the message that is posted when
an out-of-tolerance condition is detected.
WARN — >(default) if thickness check yields an out-of-tolerance value, a

Alarm warning message is posted but the program and weld will execute
severity normally
FAULT — > if thickness check yields an out-of-tolerance value, a fault will

be issued that will immediately stop the robot and pause the program. No
welding will be done.
This item specifies the maximum deviation from specified thickness in the
negative direction. For example, if:
 Specified thickness = 2.0
Under
thickness  under thickness limit = 0.5
limit (mm)  Measurements < 1.5mm are out of tolerance
Range of Settings: 0-99.9mm — > (default = 0.5mm) A value of 0.5mm or

higher is recommended for most users.
This item specifies the maximum deviation from the specified thickness in
the positive direction. For example, if:
 Specified thickness = 2.0
Over
thickness  over thickness limit = 0.5
limit (mm)  Measurements >2.5mm are out of tolerance
Range of Settings: 0-99.9mm — > (default = 0.5mm) A value of 0.5mm or
higher is recommended for most users.
The output number (DO index) asserted, when a thickness alarm occurs. The
Thickness out specified output will turn on for the duration specified by the system variable
of tolerance $sggun#.$setup.$tc_almiopls (default=500ms) when an out-of-tolerance part is
DO [144:G1] detected.
DO[176:G2]
Range of Settings: 0 -> 999 — > (default = 0)

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1.13 Two Servo Gun Applications
There are two different ways a robot can be configured when its application consists
of two servo guns. The robot can be configured so that the guns can only weld at
separate times, or it can be configured so that the guns can weld separately or
simultaneously. For both of these configurations, each gun will have its own weld
controller.
Generally, simultaneous or dual gun setup is designed to be used with twin guns
that will be welding at the same time. Some characteristics of this setup are below.
 The guns will be in the same motion group as axis 1 and axis 2.
 The guns will share the same tool frame.
 The motion system will require that the guns use the same speed for items
such as max tip speed.
 For pressure calibration both guns must use the same contact speed
If the robot does not have a twin gun configuration and will not be welding at the
same time, the robot will be configured to have a different motion group for each
gun, with each gun being axis one for its respective motion group.
When a robot is ordered that will have two servo guns, Fanuc needs to know if the
robot’s two guns will be welding separately or will require a simultaneous setup.
Please be sure to include this when ordering a robot with this application.

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2 FANUC / ARO Equalizer Single Point Lesson
( IF APPLICABLE )
2.1 General Setup Procedures
Setup & Operation of ARO’s Analog Proportional Equalizer on FANUC Robot
Phase 1 Implementation : Direct Entry of Pressure PSI value to Spot Instruction
1. Install and Setup Equalizer Control Hardware & Software

a. Ensure equalizer is wired & plumbed
b. Ensure analog card is setup in robot controller by FANUC personnel
c. Ensure analog equalizer control software is installed and setup by FANUC
personnel
Example: Robot Register R[210] to R[216] have new comments & values (refer to
table 1).
2. Setup the Equalizer – refer to information from ARO in the next section for detailed
directions
a. Adjust locking pressure regulator (C) so gun remains locked when upside-down
b. Define the min & max pressure settings for the proportional regulator (B).
i. Set these values initially to 0 & 65 psi.
ii. Enter these pressures to FANUC data registers R[213:MAX] &
R[214:MIN]
c. (Optional) Adjust the exhaust control valve (E) to adjust equalizer retract speed
3. Adjust the Robot Spot Welding Program

a. Touchup each spot position so there is a 3-5mm gap between the stationary
electrode tip and sheet metal when the equalizer is retracted/locked
b. Set the equalizer pressure needed for each spot instruction

i. Move robot through weld path in Teach mode and stop at each spot

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ii. Manually type in a pressure to GO[1] and adjust until gun properly
equalizes
1. adjust the “pressure boost” setting in data register R[215] if needed
iii. Enter the correct equalizing pressure value to SPOT instruction EP
field
c. Validate the new path and equalizing performance. To achieve the ideal path and
equalizer timing, you may need to try some of the following modifications:
i. adjust CNT value of spots to maintain correct path and to adjust gun
closing & equalizer timing
ii. adjust distance schedule values to maintain proper part clearance
iii. adjust before and after weld equalizer trigger timing from spot
equipment setup screen
iv. touchup points near the spot position to maintain proper part clearance
NOTE: if gun won’t equalize at max pressure you will need to reduce locking pressure or
increase max pressure (F_1) in the proportional regulator then update the FANUC data
register R[213: MAX]

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2.2 Equalizer Setup (Detail)

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NOTE: The maximum and minimum pressures defined on the regulator must be entered
to the robot data registers. Be sure they always match. Also, the max pressure of the
regulator cannot be set at a value above the incoming line pressure, otherwise pressure
output will become inaccurate

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2.3 FANUC Data Register Settings
Data registers are used to define the proportional regulator setup to the FANUC robot
software. There is also a few control features specified in these registers.
It’s possible to confirm the equalizer software has been installed by checking the data
registers for the appropriate comments and default values. When installed, the comments of
the data registers will match what is shown in the table below.
Table 13: Analog Equalizer Control Data Registers (Phase 1)

FANUC Data Register Value Function
(default/range)
R[210: EQ ENABLE FUNCT] 0 / 0,999 Set to 999 and cycle power to disable the
analog equalizer control software
R[211: EQ ANALOG 0 / 0-1000 Display Only – has no affect on operation.
(TICKS)] Shows the target value for the analog output
that controls the regulator (used mainly for
debug)
R[212: EQ PRESS (PSI)] 0 / min-max Display Only – has no affect on operation.
Shows the target pressure for the proportional
regulator (used mainly for debug)
R[213: 65 / 10-130 Required User Input - Used to inform the
MAXREGULATR(PSI)] equalizing software of the maximum pressure
specified on the proportional regulator
R[214: MINREGULATR(PSI)] 0 / 0-130 Required User Input - Used to inform the
equalizing software of the minimum pressure
specified on the proportional regulator
R[215: EQ 3 / 0-10 Extra pressure that will be added to the
PRESSBOOST(PSI)] requested equalizing pressure for a fraction of
a second after firing the equalizer. It’s
intended to help overcome initial friction in
the equalizer and help shift the gun position as
the tips are closing. Set to zero to disable the
pressure boost. This can be adjusted for
different spots by changing the register value
in the robot TP program.
R[216: EQ STATCPRS(PSI)] 5 / 5-65 Pressure that proportional regulator will rest
at between welds. This can be adjusted for
different spots by changing the register value
in the robot TP program. Set the register
before the spot weld and the pressure in the
regulator after that weld will return to the
register value.
NOTE: The maximum and minimum pressures defined on the regulator must be entered to
the robot data registers. Be sure the settings in the data registers always match what’s
defined on the regulator, otherwise pressure output will be inaccurate.

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NOTE: The max pressure defined in the regulator should not be set at a value above the
incoming line pressure, otherwise pressure output could be inaccurate.
2.4 Spot Welding Program Adjustment (Detail)

In some cases, after offsetting the teaching position for each spot by 3-5 mm to allow
clearance for the equalizer to shift position, it’s only necessary to adjust the CNT value of the
SPOT slightly to achieve the proper gun closing and equalizer trigger timing.
However, to maintain the proper path, it may not be possible to alter the CNT value
significantly. Also, if there is not much clearance between the gun and the part/tooling at a
given spot location, the positions near the welding position could require adjustment. This
includes the start and end distance values specified in the spot instruction – which control
how far the gun is open before and after the spot weld.
Consider the following adjustments when trying to optimize the gun/robot path and equalizer
trigger timing. Please note, these changes can alter the gun & robot path slightly and may
affect cycle time.
2.4.1 Adjust SPOT Termtype / CNT value

Increasing the CNT value of the spot will cause the gun to start closing to the spot weld
position earlier in the robot transfer. It will also activate the equalizer valve sooner,
especially if the equalizer trigger is set to “START_SD”.
Decreasing the CNT value will delay the gun close and will cause the gun & robot to be
closer to the spot position before triggering the equalizer valve. Decreasing CNT may also
increase cycle time.
2.4.2 Adjust Start and End distance values

It may be necessary to increase the gun value and decrease the robot value by 3-5 mm each in
the distance schedules. This will help to maintain the most similar path that existing before
offsetting the spot position by 3-5mm
2.4.3 Adjust End distance Termtype

Lowering the End distance term type from the default of CNT100 – will cause the gun to
open more before starting the robot transfer away from the spot. Since the equalizer is
retracted after the gun opens a few mm following the spot, this will also cause the equalizer
to retract with slightly different timing and with the robot closer to the spot welding position.
Lowering the CNT of the end distance term type will increase cycle time slightly in most
cases.

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2.4.4 Adjust Equalizer Trigger Position
To adjust the equalizer trigger timing before the spot weld (i.e. activating the equalizer),
adjust the before pressure trigger position. This is the position in the gun closing sequence
when the equalizer valve will be energized.
To adjust the equalizer trigger timing for after the spot weld (i.e. retracting the equalizer),
adjust the after pressure trigger distance value. This is how many millimeters the gun must
open from the sheet metal before turning off the equalizing valve.
These items can be changed from the spot equipment setup screen on the robot pendant. If
you change these items from the screen, the change is global and will affect every spot. To
change on a spot-by-spot basis (or for a group of spots) adjust the system variables in the TP
program as described in the table below. For a description of all possible trigger settings (not
just the ones described below), press the HELP key on the robot pendant when viewing the
spot equipment setup screen, or refer to the servo gun manual.
Table 14: Before Pressure Trigger Position

Value Variable Description
START_SD $SPOTEQSETUP[1].$EPB4_TRGEVT This triggers the equalizer as soon as the gun begins moving
=1 towards the start distance position of the spot instruction.
When robot transfer time is short and the equalizer needs
more time to energize, this setting may work better than
NEAR SD. The exact trigger timing will vary with start
distance value and with term type used on the spot
instruction. Typically, this event will occur early in the
robot transfer to the spot.
NEAR_SD $SPOTEQSETUP[1].$EPB4_TRGEVT This is the default choice. This is far and away the most
=2 commonly used setting. But, this trigger timing may not be
early enough when the start distance is small and/or the
equalizing pressure required is relatively high. The exact
timing will vary slightly with start distance value and with
term type used on the spot instruction. This trigger will
occur near the actual start distance position, after the robot
transfer is nearly done and the gun has started to close.
Table 15: After Pressure Trigger Distance (mm)

Value Variable Description
5 $SPOTEQSETUP[1].$EPAF_TRGDST=5 This defines how many millimeters from the part surface at
which the gun will need to be open to before the equalizer is
de-energized. This defaults to 5mm because the teaching
position is with stationary tip ~5mm from part surface. This
setting is designed to ensure the moving tip will not strike
the part when the equalizer retracts.
However, it can be OK to lower this value all the way to

zero, since the equalizer takes time to de-energize for the
retract. NOTE: If this value is set larger than how far the
gun opens after the spot, the equalizer will not retract.

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2.4.5 Tip Dress Programming
(Optional modification to support equalizing during tip dress with Carried Gun Only!)
The tip dress program uses the Press_Motn instruction to achieve tip force. The Press_Motn
instruction doesn’t directly include a parameter for equalization pressure. If the gun needs to
equalize during the tip dress, modify the TP program to set to equalization group output
(GO[1]) to the equalization pressure required. Refer to the example below with the
modifications highlighted:
CGTDMAC macro program for tip dressing:

24: ! At Tip Dresser Position
25: L P[5] 500 mm/sec FINE
26:
27: ! Start Dresser motor
28: DO[118:WLD CTRL1 TD ENABLE] = ON
29: ;
30: WAIT .50(sec) ;
31:
51: !CLOSE GUN ON DRESSER ;
52: GO[1:Equalization Valve] = 30
53: ;
54: PRESS_MOTN[SD=1,P=95] ;
55: WAIT 1.00 sec
56:
59: ! Open Gun, Turn off dresser
60: GO[1:Equalization Valve]=0
61: L PR[95] 100 mm/sec FINE
NOTE: PG08 Manual Tip Dress for Carried Application

The Tip Dress programs PG08 also require modification for the Equalizer. These changes
are already included in the sample programs later in this document. Look for the word
“Equalizer” to see the affected areas.

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3 Servo Nut / Bolt Weld Applications
The servo driven nut welding guns use the same servo gun software option as conventional
spot welding guns. However, for full application functionality the nut weld gun robots must
have the extra nut welding feature installed. For the R-30iA robots, hat can be confirmed by
finding the program named “sgextdef” on the robot program list accessible from the select
menu on the robot teach pendant. This is commonly referred to as the SG Nutweld Feature.
Another way to validate this feature is the ability to access the SETDOWN (THK) CHECK
screen under the SETUP Servo gun menu on the teach pendant . This procedure works for
both R-30iA and R-30iB robots. In order to get to this screen, the user must follow these
steps:
1. Press Menu on the teach pendant. Select SETUP. Press F1 [TYPE] and select Servo
Gun. The teach pendant will now display the SETUP Servogun menu.
2. On the Setup Servogun menu, scroll down to General Setup and select <*DETAIL*>
and press ENTER. The teach pendant will now display the GENERAL menu.
3. On the GENERAL menu, scroll down and select Thickness check and select
<*DETAIL*> and press ENTER. The teach pendant will now display the
Thickness Check menu.
4. Press Next on the teach pendant. If the robot is configured as a servo nut application,
the teach pendant will display a SETDOWN (THK) CHECK menu. The screen
should look similar to the figure below.
There are some different setup & programming procedures that must be followed to achieve
proper performance. There are also some additional items which may require adjustment
from the FANUC iPendant to achieve the required fault detection and fault recovery unique
to the nut welding application.

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This section describes the differences between the conventional spot weld gun and the nut
weld gun setup.
3.1 Overview of Additional Features

 Automatic Nut Load I/O Sequence for Spot Instruction
 Automatic Re-load Attempt Sequence for Missing Nut
 Nut Detection and Projection Collapse Detection Measurements
 Projection Collapse (i.e. electrode setdown) setup & status screen items
Nut detection and projection collapse will be detected using position feedback from the servo
gun axis. To promote accurate nut detection and projection collapse measurements, it is
critical that the gun is properly set up and programmed to permit accurate position
measurements as described within this section.
3.2 Overview of Setup Requirements
The remaining sections describe the setup & programming requirements and describes the
I/O points and alarm messages associated with the SG Nutweld feature. The following
setup items are required and will be covered in more detail in the remaining sections:
 Complete All Items on Gun Setup Utility

 Set Robot Close Direction to FIX
 Enable Thickness Check (refer to the details in this guide for explanation)
 Determine Proper Under/Over Thickness Limits
 Pressure Calibrate with 25 mm/sec speed
 Set Robot (mm) Value to zero in all Distance Schedules
 Accurately Define Part Thickness in Pressure Schedules (refer to the details in this
guide for explanation)
 Use FINE term type for SPOT and teach extra approach position
 Define Min & Max Projection Setdown Limit

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3.3 Initial Gun Setup
Mastering
The gun master (i.e. zero) position should be a position near where the tips are fully closed
that can be set very repeatable. For the nut weld guns used on this program, it should be
possible to set the master position the same as for a conventional spot weld gun - which is
where the rigid surface of each tip just touches the other.
Gun Setup Utility

The same gun setup utility and AutoTuning items should be used to set up the nut welding
guns. It’s necessary to complete each item on the screen, including the Thickness Check
Calibration.

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NOTE: Dithering OFF Before AutoTuning
Please disable the servo gun dithering feature before AutoTuning the gun - if not already
disabled.
Table 16: Dithering Setting

Description System Variable Name Controller Value
Dithering OFF $sggun#.$setup.$dither_sw R30iA 2
Dithering OFF $sggun#.$setup.$dither_sw R30iB 4
NOTE: # in the variable name represents the gun #. Please set this var for all guns which are
nut weld guns on each robot.
A value of 2 (or 4 for R30iB), disables the dithering feature. Initial testing of the
FANUC/ARO nut weld system showed enhanced follow-up performance when this feature is
disabled.
Max Pressure Setting Before AutoTuning

Nut welding guns may have very high max pressure/force ratings. In most cases, the gun can
be Auto-Tuned with no special considerations. However, to achieve the most appropriate
AutoTuning results, it’s could be helpful to temporarily reduce the max pressure to be no
more than 30% higher than the maximum welding force for the application in which the gun
will be used.
Example:
 Gun Max Rated Electrode Force / Pressure = 2000 lbf
 Max Nut welding pressure for the target application = 1000 lbf
 Set Max Gun Pressure on servo gun setup screen to a value between 1000 - 1300 lbf
before AutoTuning (instead of 2000 lbf)
The max pressure can be set back to the full gun max rated pressure after AutoTuning if
desired.
Confirm Gun is OK for Pressuring Operation during AutoTuning

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The gun will fully close to the zero master position and apply force during AutoTuning.
Therefore be sure it’s OK to apply force at this position. For the nut weld guns used on
this program, it should be OK to apply force at the master position. If not, place an adapter
between the tips which is OK to apply force against. The gun would need to be temporarily
re-mastered before AutoTuning so the temporary master position is where the tips touch this
adapter.
Thickness Check Calibration

The thickness check calibration is a firm requirement for the nut welding application. The
pressure calibration must be finished before the thickness check calibration can be done.
3.4 Servo Gun General Setup Screen Items

Robot Close Direction
To avoid mis-programming the nut weld position, the robot close direction should be set to
FIX. This prevents the “start distance” position - SD parameter in spot instruction - from
having a gap between the fixed electrode tip and the welding part.
The nut feeder’s “lizard tongue” is fired once the start distance (SD) position is
reached. Therefore, the sheet metal must be resting on the fixed electrode tip surface at the
start distance position. Setting the robot close direction to FIX ensures this -- assuming the
spot position was recorded during teaching with the sheet metal resting on the fixed tip.
The FIX setting is a safety measure against the operator inadvertently setting the start
distance position to have a gap between the fixed tip and sheet metal by setting the robot
(mm) value of a distance schedule to a non-zero value. When Robot Close direction is set to
FIX, even with a non-zero value in the robot (mm) value of the distance schedule, the start
distance position for the spot instruction will be treated as if the robot (mm) value in the
distance schedule is zero. This will help to prevent a case where the nut feeder’s “lizard
tongue” is fired before the sheet metal is resting on the fixed tip surface.
Setting the Robot close direction to FIX, also prevents the robot from applying any tip wear
and gun sag compensation – even if the items on the screen show they are enabled.
It is still possible to set the robot close direction back to UF –Z for a pedestal welder and UT
+Z for a carried welder if tip wear or gun sag compensation are required. If this is done,
great care must be taken to ensure the robot (mm) value in each distance schedule is always
zero. Otherwise, the lizard tongue will be extended before the sheet metal is resting on the
fixed electrode tip surface.

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Tip Wear & Gun Sag Compensation
When the Robot Close Direction is set to FIX – as recommended – there is no gun sag or tip
wear compensation applied at the spot position, even when these items are enabled on the
setup screen.
Tip Wear Compensation - When using an electrode with recessed welding surface it will
not be possible to use the servo gun software to directly measure tip wear on this recessed
surface.
Gun Sag Compensation – The fixed arm bending amount of the nut weld guns is typically
<< 1mm, even at full welding force. Therefore, it’s typically unnecessary to have gun sag
compensation. If gun sag compensation is required, the item on the servo gun general setup
screen must be enabled and the robot close direction must not be FIX, it must be UF –Z for a
pedestal welder and UT +Z for a carried welder. The appropriate UFrame or UTool must be
taught to the fixed electrode tip surface.
3.5 Thickness Check Setup

Thickness check must be enabled with the settings shown below:
The Under thickness limit and Over thickness limit should be optimized to detect missing
nuts or a misplaced nut condition.
When using the cong-ming style electrode with recessed welding surface it will not be
possible to use the servo gun software to directly measure tip wear. Therefore, the under
thickness limit must be set large enough to permit this surface to wear without causing a mis-

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detection of missing nut. But, it cannot be set too large, otherwise a missing nut could go
undetected.
For the cong-ming electrode please use the diagram below as a guideline for the initial under
and over thickness limits:

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3.6 Pressure Calibration
Contact Speed
The nut weld guns are typically extremely rigid. Therefore, it’s recommended to keep the
contact speed low to avoid pressure overshoot. 25 mm/sec is the recommended speed to use
in the pressure calibration table, this was determined from initial testing and should be
sufficient for most applications.
Using a pressure gauge with a peak capture mode could assist in finding what contact speeds
generate too much overshoot.
Pressure Measurements
The pressure calibration process is no different for a nut welding gun that a conventional spot
weld gun. However, depending on the pressure/force gauge used, it may be necessary to
place an adapter between the tips to ensure proper contact with the gauge. Be sure to set the
“Thickness of Gauge (mm)” item in the pressure calibration screen to the height of the entire
gauge + adapter stack up. This is shown as “H” in the diagram below:
NOTE: SDI (sendev.com) – which makes the gauges most commonly used for measuring
spot weld pressures are available with adapters to support these measurements and also
makes a nut weld version with through hole & larger throat.

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3.7 Distance Schedules
The Robot (mm) value MUST be set to zero for all distance schedules to ensure proper
positioning of the welding part when the nut request output is fired.
WARNING: If the Robot (mm) value is not set to zero, the lizard tongue could be
extended before the sheet metal is properly positioned.
3.8 Part Thickness Setting in Pressure Schedules

The part thickness value entered in the pressure schedules must represent the position that
will be read by the servo gun axis when new tips come in contact with the proper metal and
nut combination. This value is how far the tip flats will be separated when the nut and sheet
metal are in place.
Proper setting of the part thickness value is critical for the servo gun software to be able to
perform the nut detection.
The proper setting for the part thickness value will differ from the true nut + sheet metal
thickness in the case of electrode tips which have a recess for the nut, such as the “cong
ming” electrode. The depth of the recess must be subtracted from the nut + sheet metal
stackup height when setting the part thickness value.
You can also determine the part thickness value manually, by placing the proper nut + sheet
metal combination between new and correctly mastered tips, then carefully jog the tips
together until the tips are touching the metal under low force. Then record the servo gun axis
position as the part thickness. The value (T) in the diagram below is the proper setting for
the part thickness:

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3.9 Spot Position Programming
Nut Load I/O Sequence
The I/O exchange required to request a nut feed (DO[] - Nut Feed Request) and wait for the
Lizard Tongue to retract (DI[] – Nut Load Attempted) are managed automatically by the spot
instruction for the servo nut weld systems. The following occurs when the I/O points are
configured according to the I/O bitmap:
 Nut Request output fires once robot reaches start distance position of SPOT
instruction
 Gun closes to weld after Nut Load Attempted input is ON
NOTE: If the Nut Load Attempted input is ON when the robot reaches the spot position,
the Nut Request output will be skipped (not turned on) and the gun will close.

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When the Nut Request Output is turned on the software will wait for 5.0 seconds for the Nut
Load Attempted input. If the input does not turn on in time, the robot will fault:
 SVGN-035 Pressure Enable Timeout
The 5.0 second wait time can be adjusted from system variable as described in the variables
section below.
FINE Term Type Required for SPOT

The Nut Feed Request output is fired automatically once the start distance position of the
spot is reached. Therefore. the SPOT instruction must be programmed with FINE
termination type - in addition to having a zero value for the robot (mm) value of the
distance schedule.
WARNING: The SPOT must be programmed with FINE term type for nut weld
application. Otherwise, the lizard tongue could be extended before the sheet metal is
properly positioned.
Extra Approach & Retract Position Required

Since the robot (mm) value in the distance schedule must be zero, additional positions must
be taught as needed to get the sheet metal onto and off the fixed electrode tip and positioning
pin.
NOTE: The SG nutweld feature is designed to treat the spot positions as FINE term type,
even if the programmer inadvertently programs the spot position with a CNT term type.
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3.10 Missing Nut Detection & Misplaced or Extra Nut Detection
Once the nut is fed, the gun closes to begin the spot welding sequence. Before the weld is
started, the part thickness is measured (assuming the thickness check is enabled as described
previously). The thickness measured is compared to the target thickness which is defined in
the pressure schedule. If the deviation is larger than the under or over thickness limit the
weld does not start. Instead, the following alarm or fault will be asserted:
o SVGN-039 Thickness Out-of-Tolerance (alert)
o SVGN-040 Thickness Out-of-Tolerance (fault)
SG Nutweld software includes a new feature to open the gun before the robot faults and retry
the nut feed sequence when the nut isn’t detected. These features are controlled by the
settings described below and default to the proper settings for this project:
Table 17: Nutfeed Settings

Variable Name ([x]=equipment #)
R-30iA R-30iB Proper
Item Description
Value
Fault for Thickness Out-of-Tol Thickness Check Screen Alarm Severity FAULT
SGEXTDEF – $SGCFG[ # ].
Gun Open Before Faulting sgxtracfg[x].opn_4tc_alm $THKERR.$OPN_4TC_ALM TRUE
Number of Automatic Retries for Nut SGEXTDEF – $SGCFG[ # ].
sgxtracfg[x].retry_lm $THKERR.$RETLMTHK1LO 3
Feed
Number of Automatic Gun Recloses $SGCFG[ # ].
SGEXTDEF –
for Nut out-of-position (too sgxtracfg[x].extra_long[1]
$THKERR. 3
thick/cockeyed) .$RETLMTHK1HI
When the thickness alarm severity is set to “fault” and the gun open before faulting feature is
turned on, the following will occur for out-of-tolerance part thickness measurements:
 If thickness is under tolerance the gun will open and retry the nut load & detect
sequence before faulting (according to the settings listed in the Nutfeed Settings table
above). When the robot faults, the following alarms are posted:
o SVGN-320 Thickness1 error requires reset
o SVGN-328 Thickness1 undertol
o Nut Detection Fault digital output is turned ON.
 If thickness is over-tolerance the gun will open and retry the gun close sequence
before faulting (according to the settings listed in the Nutfeed Settings table above).
When the robot faults, the following alarms are posted:
o SVGN-320 Thickness1 error requires reset
o SVGN-329 Thickness1 overtol
o Nut Detection Fault digital output is turned ON.
NOTE: Please refer to the variables section for the complete list of variable settings
required to achieve the proper fault detection operation.

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Options will be available on the pendant HMI to restart the spot sequence with or without a
nut load request
3.11 Electrode Setdown / Projection Collapse Detection

The SG Nutweld software includes measurement of the electrode setdown / projection
collapse that occurs during the weld. A new setup screen is available to specify the operation
of this feature.
This screen – shown below - is accessed by pressing the NEXT key when viewing the
Thickness Check screen from the Servo Gun General Setup page.
Table 18: Setdown Check Settings

Screen Item Description
Setdown Check enable or disable the setdown measurement
Setdown alarm severity warn or fault when setdown is out-of-range
Setdown tolerance min (mm) minimum acceptable setdown for any weld. If setdown is less than this
value, the appropriate alarm/fault and digital outputs will be asserted
Setdown tolerance max (mm) maximum acceptable setdown for any weld. If setdown is more than this
value, the appropriate alarm/fault and digital outputs will be asserted
Setdown ok message enable or disable an alarm message written to the pendant alarm banner and
alarm log after each in-tolerance setdown measurement. The message
includes the setdown value for tracking purposes
Setdown alarm pulsetime(ms) duration of the pulsed in/out of tolerance outputs defined below
Setdown in tolerance DO digital output to pulse when setdown is in-tolerance
Setdown out of tolerance DO digital output to pulse when setdown is out-of-tolerance
Reset Required/ Projection digital output to turn on when the robot faults after an out-of-tolerance
Fault DO setdown measurement. This output is only asserted when the severity is set
to fault and stays on until the robot fault is reset and the program resumes
Please refer to the project I/O bit-map for proper setting of the DO’s. Typically, only a
“Reset Required” DO needs to be specified, so the PLC knows the robot has faulted.

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When the weld is completed successfully, the thickness of the finished part is checked and
compared to the pre-weld measured part thickness to determine how much the nut
projections collapsed. When the projection collapse is out of the range specified by the min
& max setdown tolerances, the following alarm or fault will be asserted:
o SVGN-321 Thickness After Weld NOT ok (alarm or fault)
When the setdown alarm severity is set to “fault” and the gun open before faulting feature is
turned on (which are the recommended settings for this program), the gun will open before
faulting and the following alarms will appear on the pendant alarm banner:
o SVGN-326 Thickness2 error requires fault reset
o SVGN-330 Setdown under tolerance
o SVGN-331 Setdown over tolerance
o Reset Required (a.k.a. Projection Fault) digital output is turned ON
NOTE: Please refer to the variables section for the complete list of variable settings
required to achieve the proper fault detection operation.
Options will be available on the pendant HMI to restart the spot sequence.
3.12 Status of Thickness & Setdown

The servo gun status screen has items to display the results of the pre-weld & post-weld
thickness check and the measured electrode setdown as shown below:
Table 19: Thickness Check Settings

Screen Item Description
Program name / Program line TP program name & line number for the thickness check results displayed
Specified Thickness(mm programmed thickness from the pressure schedule
Observed Thickness(mm result of pre-weld part thickness measurement
Thickness after weld (mm) result of post-weld part thickness measurement
Setdown (mm) change in thickness from pre-weld to post-weld

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3.13 New Variables / Adjustable Settings for Nut Welding
Application Feature
Table 20: Nut Welding Application Settings
Variable Name
Item Typical
Description R-30iA R-30iB Value Comments
Nut Request Output
$spoteqio[x].$ do_tof_i[1] 193
Index refer to project bitmap
Nut Load Attempted
$spoteqio[x].$di_pen_i 195
Input Index refer to project bitmap
Nut Load Attempted
$spoteqsetup[x].$pen_tmout 5000
Timeout (ms)
Nut Present Output
$SGGUNx.$SETUP.$TC_ACTIOIDX 195
Index refer to project bitmap
Nut Detection Fault
$SGGUNx.$SETUP.$TC_DETIOIDX 201
Output Index refer to project bitmap
TRUE=opens gun
Gun Open Before SGEXTDEF – $SGCFG[ # ].
TRUE before faulting for
Faulting sgxtracfg[x].opn_4tc_alm $THKERR.$opn_4tc_alm
thickness alarms
$SGCFG[ # ].
Number of Missing SGEXTDEF –
$THKERR. 3
Nut Retries sgxtracfg[x].retry_lm
.$RETLMTHK1LO
Number of Cockeyed $SGCFG[ # ].
SGEXTDEF –
Nut Re-closes for $THKERR. 3
sgxtracfg[x].extra_long[1]
gun .$RETLMTHK1HI
$SGGUN#.
Projection Setdown SGEXTDEF -
$THKCHK. TRUE
Check Enable sgxtragun[x].thk2_chkenb
.$THK2_CHKENB
Minimum OK $SGGUN#.
SGEXTDEF -
Setdown distance $THKCHK. 0.3 proper setting TBD by
sgxtragun[x].thk2_tol_lo
(mm) .$THK2_TOL_LO welding group
Maximum OK $SGGUN#.
SGEXTDEF -
Setdown distance $THKCHK. 0.8 proper setting TBD by
sgxtragun[x].thk2_tol_hi
(mm) .$THK2_TOL_HI welding group
$SGGUN#.
$THKCHK. TRUE TRUE = Fault ; FALSE
Alarm Severity sgxtragun[x].thk2_chksev
.$THK2_CHKSEV = warning only
$SGGUN#.
$THKCHK. 199
Fault Output Sgxtragun[x].thk2res_ldo
.$THK2RES_LDO
R30iA =2*
Dithering OFF $sggun1.$setup.$dither_sw
R30iB =4* set before autotuning
*initial testing showed this setting improved weld follow-up performance
3.14 Notes for Carried Bolt Welders

The following Digital Outputs will be forced on by the PLC if the robot is a Carried Bolt
Welder:
 DI[193:NUT FEED HOME 1]

 DI[194:NUT FEED HOME 2]

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4 Servo Tip Dress
4.1 Overview
Servo gun TIPDRESS is a new instruction that allows you to close, pressurize and open a
servo gun without welding. It can be used in coordination with a tip dressing operation on a
standard tip dresser, or with a servo driven tip dresser. A servo driven tip dresser is controlled
using FANUC software option R708 - Servo Tip Dresser Control - which will provide more
advanced feedback and control of the dressing operation.
The TIPDRESS[SD=1, P=2, TD=1, ED=1] instruction when executed will act like a
SPOT[SD=1, P=2, SD=1, ED=1], except no welding operation will be done, instead the
following will be executed:
• Close the gun using the specified start distance in the (SD=) field.
• Start up the servo motor and if configured for start of dress, turn on the blowoff valve
identified in the TIPDRESS SETUP menu.
• Wait until servo motor is at speed specified in the schedule assigned in the Tip Dress (TD=)
field, then close the gun at the pressure specified in the Pressure (P=) field.
• Once pressure is achieved, do one of the following:
1. If end of dress type in the dress schedule is TIME, then hold pressure for the time
specified in the schedule assigned in the Tip Dress (TD=) field.
2. If end of dress type in the dress schedule is REVS, then hold pressure for the number
of cutter head revolutions specified in the schedule assigned in the Tip Dress (TD=) field.
• Once the Tip Dress time or number of revolutions has expired, turn on the blow off valve if
configured for End of dress, open the gun to the end distance specified in the (ED=) field,
and then turn off the blowoff valve.
• Increment the guns tip dress count, and increment the tip dressers cutter count.
4.2 Tip Dress Setup Menu

Below is the TIPDRESS SETUP menu. This screen is accessed by going to MENU-SETUP-
Tip Dress from the FANUC iPendant
This screen defines all the servo tip dresser setup & schedule parameters. Only the tip
pressure for the TIPDRESS instruction is defined elsewhere - that’s still defined in the
Pressure schedules just like for a SPOT instruction.

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Servo Tip Dresser Setup Menu
The SETUP menu is broken up into 3 sections.

 Dresser Settings
 Gun Settings
 Sched(ule) Settings
1) Dresser info
• Dresser #: You can enter the dresser number you want to configure here.
• Current number of cuts. This item is incremented automatically after each successful
dress. You can reset this count on this screen by cursoring to the item and setting it to 0.
• Max # of cuts: This is the maximum cuts for the cutter blade to perform before it
requires to be changed. When current cuts is greater than max cuts, then the system will
post a Fault or Warning depending on the Max cuts alarm severity setting.
NOTE: Ford standard is to always set Max # of cuts to zero. The number of dresses
is managed on the PLC, not the robot.

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• Max Cuts Alarm Sev.: This is the severity of the alarm which occurs when the max
number of dresses on the specified dresser is exceeded. It can be a Fault or Warning.
• Blow off Valve: This is the index of the DOUT to control the blowoff valve when a
dress is being performed.
• Fault output: This is the index of the DOUT that will turn on when there is a
TIPDRESS error, and the severity has been configured as a FAULT. The user is
responsible to reset this output.
• Alert output: This is the index of the DOUT that will turn on when there is a
TIPDRESS error, and the severity has been configured as an Warning. The user is
responsible to reset this output.
• Send Schedule to WC: (This is an optional setting that will only be displayed if
$SGTDCFG.$DSP_WSCHD = TRUE.) If Send Schedule to WC = TRUE, then when a
tip dress is executed, a weld will actually be performed, and the tip dress time will be
determined by the weld complete time. Some customers fire a special weld schedule that
does not pass current for the dressing operation. This item is here to support that
operation. If this item is displayed, then another optional item will be displayed in the
TIP DRESS schedule section which will determine which weld schedule to fire.
• Max Free Torque: Free torque is defined as the torque required to spin the dresser
servo motor at the requested dressing speed with no load applied by the gun tips. This
item represents the maximum free torque that can occur before on the Max Free Torque
Exceeded alarm is issued. Excessive free torque can be an indication the dresser gears are
wearing out or need re-greasing.
• Max Free Torqe Sev: This is the severity of the Max Free Torque exceeded alarm. It
can be a Fault or Warning.
• Last Dress # of REVS: The following 3 items will report the number of cutter
revolution during the last dress. They are status items not adjustable by the user.
• Contact to Force: This is the number of revolutions of the cutter head from the time
the servo gun contacts the cutter head until force is achieved.
• Force to End of Dress: This is the number of revolutions of the cutter head from the
time force is achieved with the servo gun until the end of the dress is detected.
• Dress End to Gun Open: This is the number of revolutions of the cutter head from the
time the dress ends until the servo gun releases the cutter head.
NOTE: When you are done configuring the Dresser section, you can put the cursor on
the minus sign in front of the Dresser #, and press enter. This will collapse the dresser
setup section on the menu so you don’t have to see so much info once you have
configured a section.
2) Gun info
• Gun #. A servogun is mapped to a dresser, so when a servogun is used, the system
knows which dresser to control. Here you can enter the gun number to configure.
• Dresser number for gun. This maps the gun to a specific dresser so that when this gun
executes a TIPDRESS instruction, the correct dresser can be controlled.
• Current # of dresses. This item is incremented automatically after each successful
dress. You can reset this count on this screen by cursoring to the item and setting it to 0.

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• Max number of dresses. This is the maximum dresses for this gun’s tips to perform
before they require to be changed. When current dresses is greater than max dresses, then
the system will post a Fault or Warning depending on the Max dress alarm severity
setting.
• Max Dress Alarm Sev. This is the severity of the alarm which occurs when the max
number of dresses is exceeded. It can be a Fault or Warning.
NOTE: When you are done configuring the Gun section, you can put the cursor on the
minus sign in front of the Gun #, and press enter. This will collapse the Gun setup section
on the menu so you don’t have to see so much info once you have configured a section.
3) Schedule info
• Sched #: You can enter the tip dress schedule number you want to configure here.
• Step #: There is always at least one step in your dress schedule, and that is the default.
The maximum number of steps in a schedule is 3. Set $sgtdcfg.$numstepsdsp to the
number of steps you want your schedule to have.
• Duration (ms) OR # of REVS: This is the duration in ms for the dress if end of dress
type is TIME. This time begins once pressure is achieved with the servo gun tips. Or
this is the number of revolutions of the cutter head. This # of REVS begins once pressure
is achieved with the servo gun tips.
• Speed (rpm): This is the speed of the cutter head - not the motor shaft - in rpm’s for
step #1 of the dress.
• Rotation: This is an option item only displayed if R708 is installed. This is the
direction of rotation of the cutter head. Positive is the cutting direction. It can be positive
or negative, but it must always be positive for step #1 of the dress. You can have a multi-
step dress schedule, for ex. 3 steps, step 1 is a rough cut, step 2 is a fine cut, and step 3 is
a reverse direction to knock off any burs on the weld tips.
• Torque Max increase%: This is the upper limit of dresser torque allowed during Step
#1 of the dress. The units are % of the amplifiers maximum torque output above the
measured free spinning torque. If the torque increases from the free torque by more than
this value anytime during Step 1 of the dress, then a fault or warning is posted depending
on Max/Min alarm Sev. The Torque Max Increase % is represented on the tip dress chart
by the red horizontal line.
• Torque Min increase %: This is the lower limit of dresser torque required during Step
#1 of the dress. The units are % of the amplifiers maximum torque output above the
measured free spinning torque. This is the percent increase above the free spinning torque
which is required to determine a dress has been done. If the torque does NOT reach this
minimum value during Step 1 of the dress, then a fault or warning is posted depending on
Max/Min alarm Sev. The Torque Min Increase % is represented on the tip dress chart by
the green horizontal line.
• Max/Min Alarm Severity: This is the severity of the alarm which occurs when the
dresser motor torque does not fall within the range specified by the Torque Max/Min
increase items during the 1st step of the tip dress. It can be a Fault or Warning.
• End of Dress Method: TIME or REVS: This item allows the user to configure what
determines the end of a dress. It can be time based, or it can be number of revolutions of
the cutter head.
• Weld Schedule: (This is an optional setting that will only be displayed if
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$SGTDCFG.$DSP_WSCHD = TRUE.) If Send Schedule to WC = TRUE, then when a
tipdress is executed, a weld will actually be performed, and the servo gun pressure will be
maintained until the weld complete signal is received. Some customers fire a special weld
schedule that does not pass current. This allows them to control tip dress counts in the
weld controller. This is the value of the weld schedule to fire with this tip dress schedule.
• Comment: Allows you to associate a comment with this tip dress schedule.
NOTE: When you are done configuring the Schedule section, you can put the cursor on
the minus sign in front of the Sched #, and press enter. This will collapse the schedule
setup section on the menu so you don’t have to see so much info once you have
configured a section.
4.3 Execution or Operation Sequence
Teach a macro that moves the servo gun over to the tip dresser so that the servo gun is lined
up and will close on the tip dresser. Now teach a TIPDRESS instruction. The tip dress
instruction can be used as a motion option to a point or as a standalone instruction. The
motion option is used is used to coordinate the movement of the robot and gun (and tip
dresser servo motor when R708 is used), same as a motion option spot instruction.

L P[1] 1000mm/s CNT50 TIPDRESS[SD=1, P=1, TD=1, ED=1]
Stand-alone format:
TIPDRESS[SD=1, P=1, TD=1, ED=1]
The pressure schedule you use should have the tip dress cutters part thickness specified and
the weld pressure should be your desired dressing pressure. Execute your macro with the
TIPDRESS instruction in it, and the system will automatically control the servo tip dresser
cutting operation.
4.4 Default Servo Tip Dress Schedule Settings

The screen shots below represent what FANUC, Ford & Changer-Dresser decided were good
starting values for the dresser settings. It’s still the integrator and end-user responsibility to
adjust the settings as needed to achieve the desired cutting and warning/fault detection
performance.
Note: All the torque settings shown below are in units of % amplifier max current.
1 = 1% of amplifier current
100 = 100% of amplifier current
Default settings shown here assume the amplifier is the FANUC aiSV40, which is 40 amp-peak
max current (100 = 40amps-peak).
If the amplifier used is the FANUC aisv20 – which is 20 amp max current – you should consider
the default torque settings to be double what is shown here

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Tip Dresser Settings
New Tip Schedule = Tip Dress Schedule 1
Used Tip Schedule = Tip Dress Schedule 2

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4.5 Tip Dress Schedule Adjustments & Charting Features
The duration, speed and tip pressure can be adjusted to achieve the desired dressing results.
 Duration and Speed are adjusted from the tip dress setup screen
 Tip Pressure is adjusted from the pressure schedule data screen
Max Free torque, Torque Max Increase % and Torque Min Increase % can be adjusted to
increase or decrease the sensitivity to the servo dresser’s motor torque output for determining
when to issue a warning/fault and not turn on the Tip Dress OK bit. The definition of each of
these items and how they affect whether a warning/fault occurs is explained in the previous
section.
Use both the dress results (by visual inspection of the tips) and the charting features
described in the next section to determine if the torque items need adjustment.
In addition to the default settings that are loaded to the robot, there is a background logic
program called STD_P_CK this is continuously running on the controller. This program
monitors and limits the values the user can enter to some items on the tip dresser setup
screen. The limits are shown in the table below:
Table 21: Tip Dresser Limits

Item Max Value Min Value
Duration (ms) 5000 250
Speed (rpm) 450 200
Torque Max increase % 45 (90) 2 more than min increase %
Torque Min increase % 2 less than max increase % 2 (4)
Note: value in parenthesis are for 20A servo amplifier
If it is necessary to change these limits or turn off the limits, the STD_P_CK program needs
to be turned off from background logic, then it can be modified if desired.
The charting features of the servo tip dress function are very useful for determining the ideal
settings for the Max Free Torque, Torque Max & Torque Min Increase % values.
Last Dress / Master Dress Chart
Pressing F2 CHART from the Tip Dresser setup screen will display the following screen.
This screen menu has it’s own help menu, pressing the help key on the iPendant from the
screen will explain the chart features. The features include:
• SET_MAST - can be used to save the current chart as the "Master Chart" which can be
recalled at
any time by pressing the SHO_MAST button
• SHO_MAST / SHO_LAST - use this button to toggle between showing the results from
the last dress done and the master dress.

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Last Dress Chart
Dress summary chart and log file
For each dress that occurs, a record is written to the summary log. The log will hold
approximately the last 130 dresses. Items logged in the summary file are as shown below:
• GUN_NUM - servo gun number

• TD_SCHED - tip dresser schedule number
• MAX_TORQ - max motor torque (% of amplifier current) from dresser motor which
was measured during 1st step of dress
• MIN_TORQ - min motor torque (% of amplifier current) from dresser motor which was
measured during 1st step of dress
• FREE_TORQ - motor torque (% of amplifier current) from dresser motor which was
measured when dresser motor reached dressing speed
• TIPDRESS_DIST - distance the servo gun tips (mm) moved forward from the time tip
pressure was achieved until dress is done
• TIPCNTC_DIST - position of servo gun tips (mm) when the dresser motor torque
increased enough to determine the servo gun tips were in contact with the cutter blades
• TIME_DATE - time/date of the dress, according to the robot system clock.
This summary info also has a chart menu so you can see the result of the last several dresses,
including any trends. This provides the user with graphical data to help them setup their
torque alarm thresholds in the Tip Dress schedule. For example, the user can review the
results from the 1st 10 dresses that occur in production or during initial setup/runoff, then use
that to determine the best alarm settings for max, min, and free torque in the tip dress
schedule.

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• This summary data provides info related to the dress process, but also info related to the
dresser so trends can be seen like dresser gearbox issues. Press F3 SUM_CHAR on the
TipDress setup menu to display the summary chart. See below for chart sample.
Dress Summary Chart
• The items from the summary log which appear on the chart are shown above. The chart
is filtered according to the Gun# and Sched# selected with the F2 and F4 keys.
• The [DISPLAY] button F5, can be used to toggle on/off each of the (5) display items.
• This summary log is saved in the file named TDSUMLOG.DG . It is saved on the MD:
device and is backed up during a "backup all of above", and it is also viewable or
downloadable via the robot homepage from a web interface.
Using the Charts to Determine How to Adjust the Max Free Torque
The default value for Max Free Torque is set based on measurements taken at the Changer &
Dresser factory for the servo tip dressers.
Most units run-off by Changer & Dresser had a free torque value at the factory between 1-
2%.
Therefore a value of 4% (8% for a 20A amplifier) was set as the default value for Max Free
Torque. This means the free torque will have to roughly double from the factory value
before a Max Free Torque warning will occur.
 Increasing the Max Free Torque value will reduce the detection sensitivity to a
change in free torque caused by mechanical or electrical failure in the tip dresser
system

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 Decreasing the Max Free Torque value will increase sensitivity and warn you of a
change earlier
The summary chart can show the free torque trend over the last 100+ dresses to help you
determine a good setting for the Max Free Torque.
Using the Charts to Adjust the Torque Max & Min Increase values
The summary chart can show you the trend of the min and max torque increase values over
the last 100+ dresses. This can be helpful for deciding where to set the min and max torque
increase values.
The last dress chart will show you a detailed plot of the torque from the last dress with lines
to represent the warning/fault levels for max & min torque increase.
A simple way to determine where to set the max & min torque increase is to make a dress on
used tips that achieves the desired dress results. Then, view the last dress chart. You can see
where the current warning/fault levels are based on the green & red horizontal lines. You
can change the Torque Max & Min increase % items on the setup screen and see how the
lines that determine the warning/fault levels change.
 Adjust the Torque Max Increase % until there is a good safe margin between the
highest point on the blue torque plot and the red line
 Adjust the Torque Min Increase % until the green line is just under the blue torque
plot during the dressing time
The (2) charts below describe the various parts of the tip dress chart and represent typical /
good settings for Torque Max & Min increase %.
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Additional Servo Tip Dresser Information
Summary Web Diag
Summary Web Detail
Mis-teach/chatter/bad alignment detection
• A feature exists to detect mis-teach/chatter/bad tip alignment issues which can affect the
dressing operation.
• This feature detects first tip contact on dresser cutter and records servo gun tip position
at this first contact. It then compares this value to the part thickness from the Pressure
schedule used for the dress.

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• For example, cutter thickness is ~10mm, so during normal operation, the servo gun tip
should contact the cutting blade with approximately a 10 mm opening.
• If dresser position is out-of-alignment with the servo gun tips for any reason then tip
contact occurs with the servo gun tips open more, since tips cannot press all the way
down into the cutter initially. The servo gun may make initial contact with the cutting
blade with a ~15 mm opening.
• Using this detection capability, it is possible to detect this mis-alignment issue which
often leads to chatter and less than optimal dressing conditions.
• This tip contact distance is also recorded and plotted in the summary file, so issues
which creep in over time can also be traced.
• The "Early Blade Contact Detected" alarm or fault occurs when early contact is
detected. There are system variables which control the setting used to determine if an
alarm or fault should be issued.
Advanced users may find it possible to adjust these settings to achieve the most accurate
detection:
 $sgtdset[].$cntct_fctor - contact is detected when dresser motor torque is greater than
free torque by this factor. Default = 2.5, which means contact is determined when
dresser motor toque spikes to 2.5 times the measured free torque.
 $sgtdset[].$cntct_thrsh - the position of the servo gun tips are recorded when contact
is detected. When contact occurs more than this many mm before the part thickness
position is reached, the alarm "Early Blade Contact Detected" will occur. Default = 3
(mm).
 $sgtdset[].$cntct_sev - this is the severity of the "Early Blade Contact Detected"
alarm. FALSE=warning, TRUE=fault. Default=False.
No Chatter Dress

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Chatter Dress
4.5.1 Adjusting the Minimum Torque Increase Threshold

This section will explain how to adjust the minimum torque threshold for Servo Tip
Dressing. In some cases the Servo Tip dresser operates with a lower minimum torque
threshold than as previous.
The typical minimum threshold is 4 (or 2), however in some cases it may become necessary
to lower the threshold to as low as 1. This section will explain how to edit the Back Ground
Logic (BG-Logic) Program(s) (STD_P_CK and STD_P_CK2) that are associated with the
threshold to allow for values less than 4 (or 2)to be entered.
*** As current Ford standard does not allow for values less than 1, under no
circumstances should the threshold be set lower than 1 without approval from a Ford
VO representative and notification of Fanuc.
The process to adjust the BG-Logic is: (1) Stop the Program, (2) Edit the Program, (3)
Restart the Program
*** The example below will show the changes for the STD_P_CK BG-Logic Program
only.
*** Dual guns with two servo tip dressers will have the STD_P_CK2 however
the method and changes made will be identical.
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4.5.1.1 Stopping the Program
Press Menu  6 Setup  BG-Logic
This will bring you to the following screen::

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Once here, cursor over the program and Press F3 STOP and the statue indicator will chang to
show that the program is stopped.

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4.5.1.2 Editing the Program
The program itself can be modified like any other teach pendant program.
Press Select to bring up the listing of programs on the robot.
Depending on your current robot setting you may have to make the macros visable.
To accomplish this, press F1 Type  Macro.

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This will make all of the macros including STD_P_CK visable. Cursor to STD_P_CK in the
listing and hit enter.
This is the section of the program that needs to be modified::
Make the following modification to the program::
This will now allow for values as low as 1 to be entered for the minimum.
4.5.1.3 Restarting the Program
To restart the background program, follow the same steps as stopping but Press F2 Run
instead of F3 Stop. After starting the Background Logic, cycle power on the robot and ensure
that the program remains active.

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4.6 Servo Tip Dresser Amplifier Configurations
The servo tip dresser configuration depends on the auxiliary amplifier configurations in the
controller. Refer to the following information for the configurations based on either a single
40/80 amplifier or separate 80 and 20 amplifiers.
NOTE: These are the two most common configurations and are for an ARO 3G 80A gun
with a Fanuc biS8/3000 (20A or 40A) servo tip dresser. Your configuration may be different
based on robot model and applications.
NOTE: Software amplifier and FSSB settings should match the hardware setup in the robot.
NOTE: Tip dressers can be configured from a controlled start using the maintenance
function.
Table 22: Common Auxiliary Amplifier Configurations and Variable Settings for
Single Weld Guns with a Single Servo Tip Dresser
Auxiliary Amp Configurations

Slot 2: 80 Amp
Slot 2: 40/80 Amp Slot 3: 20 Amp
FSSB 1
Servo Amp Number 2
Gun Hardware Start - Group 2 8 7
Brake Number 0
FSSB 1
Hardware Start 7 8
Amp Number 2 3
Maximum Amplifier Current 5 10
Maximum Motor Current 5 10
Amp Type 2 2
Servo Gear Ratio 5.000
Tip Maximum Speed 450.000
Dresser Motor Direction TRUE
Process Acceleration Time 80
Axis
Load Ratio 2.000
Brake Number 0
$sgtdset[1].$max_freetrq 4 8
$sgtdsch[1].$maxinc[1] 40 80
$sgtdsch[1].$mininc[1] 3 6
$sgtdsch[2].$maxinc[1] 40 80
$sgtdsch[2].$mininc[1] 5 10

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Examples of Status/Motor Screen: The Group 1 Motors will vary on the robot model.
Table 23: 40/80 Example

GR AX MOTOR ID AND INFO
1 1 1 ACaM30/4000i 160A H1 DSP1-L
2 1 2 ACaM40/4000i 160A H2 DSP1-M
3 1 3 ACaM40/4000i 160A H3 DSP1-J
4 1 4 ACaM12/4000i 40A H4 DSP1-K
5 1 5 ACaM12/4000i 40A H5 DSP1-L
6 1 6 ACaM12/4000i 40A H6 DSP1-M
7 0 1 biS8/3000 40A H DSP -
8 2 1 ARO 3G 80A H DSP -
Table 24: 80/20 Example

GR AX MOTOR ID AND INFO
1 1 1 ACaM30/4000i 160A H1 DSP1-L
2 1 2 ACaM40/4000i 160A H2 DSP1-M
3 1 3 ACaM40/4000i 160A H3 DSP1-J
4 1 4 ACaM12/4000i 40A H4 DSP1-K
5 1 5 ACaM12/4000i 40A H5 DSP1-L
6 1 6 ACaM12/4000i 40A H6 DSP1-M
7 2 1 ARO 3G 80A H DSP -
8 0 1 biS8/3000 20A H DSP -

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5 Spot Program Touchup Function
5.1 Program Touch Up Overview

The spot program touchup function automatically /continuously executes the spot point
touchup function at each spot instruction attached to a position and automatically corrects
position error in the robot close/open direction. The spot point touchup function could be
used to touchup the entire program, but program touchup function has benefits:
1. Reduced time to touchup an entire program - the following operations are required at
each point, with spot point touchup
• Move (jog) robot to point
• Initiate AutoTouchup
• Accept (confirm) new point
2. Both Text and graphical feedback of describe changes
3. A log file for archival
Touchup Sequence

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NOTE: PR[90] is the default position register for robot motion during the spot program
touchup motion sequence. Don’t use this PR for another purpose. The register number of this
PR can be changed on the Gun Teach Setup screen. Refer to the section on "Spot program
touchup function setup for more details.
Prerequisite initial setup
The following setup items must be completed prior to spot program touchup.
• AutoTuning
• Pressure Calibration
• Setting the tool coordinate system
• Tip wear standard
• Thickness check calibration
• Tip wear detection
5.2 Spot Program Touchup Execution Procedure

Spot program touchup executes when program touchup mode is enabled. Enable program
touchup mode, using the procedure below:
If Teach Pendant is Enabled...
1. Press the MENU key to display the Screen menu.

2. Press 2 TEST CYCLE
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Spot Prog Touch. The spot program touchup screen appears.
5. Press F4 ENABLED. The program touchup mode is enabled.

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6. Execute the program to be touched up. When the spot instructions executes, spot
program touchup executes automatically.
If Teach Pendant is Disabled...

2. Press 5 I/O.
4. Select Cell Interface. The cell input screen or cell output screen appears.
5. To switch between the input screen and the output screen, press F3 IN/OUT.
6. Move the cursor to Prg tch mode EQ1 in the CELLIO input screen, and allocate the
input signal. (Refer to the Spot tool + manual for more information about the cell
interface I/O.)
7. Move the cursor to Prg tch stat EQ1 in the CELLIO output screen, and allocate the
output signal.
8. Cycle Power for the I/O changes to take effect.

9. Turn on Prg tch mode EQ1 input to enable program touchup mode. Prg tch stat EQ1
output automatically turns on when program touchup mode is enabled.
10. Execute the program to be touched up. When the spot instruction executes, spot
program touchup automatically executes.

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NOTE: Spot program touchup process does not execute during the following instructions.
However, if spot program touchup is active the process corresponding to the application
instruction executes as if no-stroke mode is active (i.e. process is disabled)
• Press Motion instruction
• Tip Dress Instruction
• Spot instruction with SpotProgTouch_Dsb attached (Refer to the chapter for "Spot
program touchup disable instruction".
Also, spot program touchup does not execute for standalone application instructions (i.e.
instructions that are NOT attached to motion.
NOTE: Program touchup mode state changes from ENABLED to DISABLED at the
following times:
If Teach Pendant is enabled:
• When program touchup mode is disabled on the spot program touchup screen
• When the TP enable switch changes to disabled (The case where Prg tch mode EQ1 has
been turned on is excluded.)
• When gun operation changes to NOSTROKE (Refer to the chapter for the soft panel.)
• When power is interrupted
• When equipment type changes to air gun
If Teach Pendant is disabled:
• When Prg tch mode EQ1 is turned off

• When Prg tch mode EQ1 is not correctly allocated
• When the TP is switched to enabled
• When gun operation changes to NOSTROKE (Refer to the chapter for the soft panel.)
• When the equipment type changes to air gun
NOTE: Spot program touchup, cannot be performed on multiple arms simultaneously (in
multi-arm system).

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5.3 Program Touchup Setup
Use the following procedures to properly setup the sport program touchup function.

2. Press 4 SETUP.
4. Select Servo Gun. The Servo Gun Setup screen appears.
5. Move the cursor to General Setup <*DETAIL*> and press ENTER key. The General
Setup screen appears.
6. Move the cursor to Gun Teach Setup <*DETAIL*> and press ENTER key. The Gun
Teach Setup screen appears.

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Normally, it is not necessary to alter configurations items for spot program touchup. Only
change a setup value if necessary.
Table 25: Gun Touchup Setup Descriptions

Item Description
This item specifies the offset used for gun tip
position at touchup. Actual position recorded at
Gun offset @record(mm)
touchup is: (panel thickness + gun offset record) *
gun open poliarity.
This item specifies robot speed non-search motion

(for example the move to new touchup position).
Speed of offset Note that Speed of offset motion is override-
motion(mm/sec) independent. I.E. robot speed is the specified
speed whether the override % is 1% or 100% (for
example).
This item specifies the position register number

that is used internally. For MOTION DURING
Position register (PR[#]) SPOT PROGRAM TOUCHUP. Treat this position
register as reserved for program touchup (don't
use it for another purpose).

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This item specifies the tolerance for minimum
allowable thickness. For example, if conditions
are:
Under thickness tolerance: 0.5
Specified thickness = 2.0mm
Under thickness
Observed thickness:
tolerance(mm)Default
1.8mm: OK
value:2.0mm
1.4mm: NG
If observed thickness is less than the minimum
allowable thickness touchup is canceled, and the
following warning is generated: SVGN-239
Thickness error.
This item specifies the tolerance for maximum

allowable thickness. For example, when the Over
thickness tolerance is 0.5:
OK: Specified thickness = 2.0 mm, Observed
Over thickness tolerance(mm) thickness = 2.3 mm
Default value:0.5mm NG: Specified thickness = 2.0 mm, Observed
thickness = 2.6 mm
If the measured thickness is greater than the
maximum allowable thickness the following
warning is generated SVGN-239 Thickness error.
This item specifies whether thickness check is

Execute Thickness check
performed during spot point touchup.
This item is the tolerance value for the maximum
allowable position error correction. If position error
Max position err correct(mm)
correction is larger than this tolerance value,
Default value: 2.0mm
touchup is canceled, and following warning is
generated: SVGN-237 Position error.
This item is the tolerance value for the minimum

allowable position error correction. If position error
Min position err correct(mm)
correction is larger than this tolerance value,
Default value: 0.0mm
touchup is canceled, and the following warning is
generated: SVGN-237 Position error.
When the followign warning is genrated, the pulse

or this signal is output. The pulse width of this
signal is 500msec. When you use this signal, add
Position error DO[#] Default
it to PLC, and monitor it:
value: 0
SVGN-237 Position error
When this signal is turned on, it means calculated
position error is outside a tolerance value.
When the following warning is generated, the pulse

of this signal is output. The pulse width of this
signal is 500msec. When you use this signal, add
Thickness error DO[#] Default it to PLC, and monitor it:
value: 0 SVGN-239 Thickness error
When this signal is turned on, it means observed
thickness error exceeded the under thickness
tolerance or the over thickness tolerance.

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This item can change the max detection distance
Detection distance margin(mm) range. Refer to the chapter of the max detection
Default value: 0.0 mm distance range for more information about the max
detection distance range.
If the gun open distance at upper pane detection

exceeds the max detection distance range, the
Detection error DO[# ]Default followign warning is generated:
value: 0 SVGN-240 Panel Mis-Detect
Along with this warning, the DOUT index specified
here is pulsed for 500msec.
When the followign warning is generated, the robot

pauses automatically at the end distance if the
pause mode is specified to ENABLE:
Pause mode Default value:
SVGN-239 Thickness error
DISABLE
SVGN-240 Panel Mis-Detect
Remove the cause of above-mentioned warning
before restarting the program when the robot
pauses by the pause mode.
When the robot pauses at the end distance by the

Pause mode status DO[#]
pause mode, the DOUT index specified here is
Default value:0
pulsed for 500msec.
The program touchup incomplt output is asserted if

program touchup does not complete due to one of
the reasons below:
Program touchup incomplt
DO[#] Default value :0
SVGN-239 Thickness error
SVGN-240 Panel Mis-Detect
This item defines the index of the DOUT signal.
If the program touchup incomplete DO is assigned,

the operator requires a means to turn off the
Reset DI[#] Default value :0 program touchup incomplete DO externally. The
reset input is the input that provides this function.
This item defines the index of the reset input.
This item specifies whether thickness check is

performed during spot program touchup. Note: if
Thickness check mode Default
thickness check is false, touchup position is
value: ENABLE
determined based on the nominal thickness value,
and misdetect check is not performed.
The following items are set per equipment only, they cannot be set per gun.
• Max position err correct

• Min position err correct
• Position error DO
• Thickness error DO
• Detection distance margin
• Detection error DO
• Pause mode
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• Pause mode status DO
• Program touchup incomplt DO
• Reset DI
• Thickness check mode When thickness check mode is DISABLED, the following items cannot
be changed.
• Thickness error DO
• Detection error DO
Touchup Description
Maximum Detection Distance Range
If panel position shifts horizontally or if there is a foreign body such as a nut in the upper
panel, panel damage can occur during thickness check Detect distance check is performed to
prevent this. Warning (SVGN-240 Panel Mis-Detect) is generated if the position in which the
upper panel was detected exceeds the max detection distance range, and the spot program
touchup is canceled.

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Max Detection Distance
The max detection distance range is computed per the following items on the gun teach setup
screen.
• Over thickness tolerance

• Max position err correct
If one of the items mentioned above changes, the following prompt is displayed on the Teach
Pendant:
Detect Distance Prompt

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When the above-mentioned prompt message is displayed, the max detection distance range is
4.5mm. Therefore, from original taught position to 4.5mm is the max detection distance
range in the closing direction(Robot). And, warning(SVGN-240 Panel Mis-Detect) is
generated when the position in which the upper panel was detected exceeds the max
detection distance range. Spot program touchup is canceled when this occurs. Change the
detection distance margin to change the max detection distance range.
Detection Distance Range
5.4 Spot Program Touchup Status Screens

The current status of program touchup can be confirmed from the spot program touchup
status menu. To access the status screen

2. Press 0 NEXT and 3 STATUS.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of program touchup status and
press ENTER key. Spot program touchup status screen appears.
The following items are shown on this screen. The status of the latest executed program is
displayed at the first line. 50 sets of data can be displayed as the maximum.

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Table 26: Program Status Screen Descriptions
Item Description
Name of program where spot program touchup is /
Program Name
was performed.
Line number of program where the spot program
Lin
touchup was performed.
OK: Upper panel detection success
NG: Upper panel detection failure
** Attempted upper panel detection
Det
When the item is NG or **, thickness check and
touchup are skipped. Confirm the detection
distance margin in the setup screen.
The calculated position error correction is displayed.

When this value is positive, the direction of position
error correction is the robot close direction. When
this value is negative, the direction of position error
correction is the robot open direciton.
OK: The position error correction is within tolerance
Pos[mm] value.
NG: The position error correction is outside
tolerance value.
** Attempted positoin error correction calculation.
When this item is NG or **, touchup is not done.
Confirm max/min position err correct in the setup
screen.
More information is available for each line of the data can be displayed by pushing F3
[DETAIL].

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Table 27: Program Status Screen Description Details
Item Description
Name of program where spot program touchup is /
Program name
was performed.
Line number of program where the spot program
Lin
touchup was performed.
This item is max. detection distance range. Refer to
the chapter of the max. detection distance range for
Max detect dist range(mm)
more information about the max. detection distance
range.
This item is a result of the upper panel detection.

OK: Upper panel detection success
NG: Upper panel detection failure
Detection distance(mm) ** Attempted upper panel detection
When this item is NG or **, thickness check and
touchup are not done. Confirm the detection
distance margin in the setup screen.
This item is the expected (target) part thickness
Specified thickness(mm)
specified via pressure schedule.

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This item is the observed thickness.
OK: The error margin of the specified thickness
and the observed thickness is within tolerance
value.
NG: The error margin of the specified thickness
and the observed thickness is outside tolerance
Observed thickness(mm)
value.
** Attempted thickness check.
Confirm the specified thickness in the pressure
schedule and the under / over thickness tolerance
in the setup screen.
Max pos err correct(mm) This item is the max position error correction.
Min pos err correct(mm) This item is the min position error correction.
This item is the magnitude of the calcualted position

error correction.
OK: The position error correction is within tolerance
value.
NG: The position error correction is outside
Magnitude(mm)
tolerance value.
** Attempted position eror correction calculation.
Confirm the max / min position err correct in the
setup screen.
This item is the direction of the calculated position

error correction.
Robot Close: The direction of position error
Direction correction is the robot close direction.
Robot Open: The direcition of position error
correction is the robot open direction.
** Attempted position error correction calculation.
This item specifies date when spot program
Date
touchup was executed.
This item specifies time when spot program touchup
Time
was executed.
5.5 Spot Program Touchup Chart Feature

Program touchup logchart (henceforth referred to as logchart) is a sub-function of Spot
program touchup. Logchart provides a visual perspective of the automatic touchup process.
Summary blocks (symbols) at top of screen display overall touchup result and error
condition, if any. Charts beneath summary blocks show magnitude of thickness and position
change graphically. Trends over multiple points are exposed.
Launching the Touchup Chart
The touchup chart is accessed by selecting CHRT from the Serfogun Program touchup status
screen.

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NOTE: The Touchup chart is only available with the iPenant. If you select CHRT (F4)
without an iPendant the message “iPendant is required for this screen” is displayed.
A sample chart similar to the one shown is displayed:
Program Touchup Chart
This screen corresponds to the following touchup set of data.

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Table 28: Data Used for Sample Chart
Thickness Position
# Distance Detect Touchup Complete
Change Change
1 NG (overtol) ** ** No
2 Ok Overtol (NG) ** No
3 Ok Undertol (NG) ** No
Overtol (robot
4 Ok Ok No
close dir)
Undertol (robot
5 Ok Ok No
close dir)
Overto (robot
6 Ok Ok No
open dir)
Undertol (robot
7 Ok Ok No
open dir)
8 Ok Ok Ok Yes
9 Ok Ok Ok Yes
10 Ok Ok Ok Yes
** Status unknown — Check not performed due to failure off other criteria.
Screen Navigation Features
Table 29: Screen Navigation Features

Key Function
F2 or DN Arrow Display NEXT page
F3 or UP Arrow Display PREVIOUS page
Shift + (F2 or DN arrow) Display last (bottom) page
Shift _ (F3 or UP arrow) Display first (top) page
F4 Record select
F5 Filter select
F7 Configure eval tol settings
Enter Toggle chart tolerance line on/off
RT arrow Select next record right
LF arrow Select next record left
Shift + RT arrow Select rightmost record
Shirt _ LF arrow Select leftmost record
Screen summary:
• touchup result screen is displayed for 10 records (1page) at a time

• current record range is noted in upper right-hand corner
• most recent data (last / bottom page) displays at screen entry
• Records are shown in chronological order, from left to right.
• 10 blocks at top of screen summarize touchup result for 10records (line# noted within
block)
• Charts beneath blocks provide magnitude and direction of change for thickness and
position
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• additional info for selected record is shown on right side of screen
Text data storage
Data records used to generate the program touchup summary are available. The records are
stored in 2 files on fr. ~sgofset11.ls ~sgofset21.ls These are text files, with csv format. Users
can copy these files to pc and create macros with excel (for example) to create custom
graphics and macros.
Background
TP program position errors occur due to:
• offline teach error: differences between actual and expected panel location
• panel drift over time
• mis-teach by operator
Program touchup corrects position error in Z direction automatically. Executing a spot

program with program touchup input asserted, causes automatic search processes to execute
rather than spot process. Point is touched up, if 3 criteria are met: 1. detect distance, 2
thickness change, 3.position change.
• Detect distance criteria prevents damage from thickness check by ensuring that gun tip
is on panel.
• Thickness and position criteria ensure that thickness and location are consistent with
expected values
Logchart presents information relating to these 3 criteria via symbols, text and chart.
Detect distance criteria is shown below. See chart section for thickness and position criteria.
NOTE: A chart is not provided for detect distance due to insufficient screen space.
Detect Distance Criteria
Detect distance is gun open distance at initial panel detection.
• Detect error occurs if det.dist > det.dist.max

• det.dist = detdist.obs – detdist.max
• detdist.max = pos.err.max + thk.nom + thk.tol.upr + detdist.mgn
F5: FILTER SEL (data selection)
Filter SEL is used to select data subset. For example, only points that were NOT touched up
(SHOW BAD). Current filter selection is shown in upper left hand corner of screen. 6 filter
selections are available:

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Table 30: Filter Selections
# Filter Selection Description
1 SHOW ALL All points available
2 SHOW GOOD Points that were touched up
3 SHOW BAD Points NOT touched up
4 SHOW DETERR Points with detect distance overtol
5 SHOW THKERR Points with thick change over / under tolerance
Points with position chagne over / under
6 SHOW POSERR
tolerance
Info Panel
Info panel provides the following information:
1. Range of records currently displayed (page selection)

2. Total number of records available (with current filter setting)
3. Text summary for selected record number
The info panel is on the right hand side of the chart see below outlined in red.
Touchup Chart Info Panel Section

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Table 31: Info Panel Features
Template Description / Comment
Records: # -> # Page start record -> page end record
Page: # / # Current page number / number of pages available
Currently selected record number
^^Record: # NOTE: ^^ is displayed beneath summary block of

selected record and line is drawn below ^^ symbol
through selected record on chart.
Program: nameLine: # Program name and line number of point
Time: hh:mm:ss Touchup timestamp
Date: yyyy/mm/dd Touchup datestamp

DetDist: status Status of detect distance change.
# (Max: #) Observed detect distance ( Max detect distance )

Thickdiff: status Status of position change
# (Nom: #) Magnitude of position change (direction of poschg)
Min/Max: #/# Pos.tol.min / pos.tol.max
Posdiff: status Status of position change
# (Direction) Magnitude of position change (direction of poschg)
Min/Max: #/# Pos.tol.min / pos.tol.max
Outcome of touchup attempt - one of the following:

NOK (DetDist): detect distance criteria not
met.
NOK(thkDiff): thickness criteria not met.
Result NOK(PosDiff): Position criteria not met.
OK(RbtClos): Gap eliminated (point was
away from panel, prior to touchup).
OK(RbtOpn): Press elminated (point was into
panel, prior to touchup).
Touchup Chart Summary Blocks section
At the top of the summary chart, blocks are provided for additional summary information.

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Touchup Summary Blocks
Summary Block Symbol Meanings

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Chart Section
The area outlined in red is the chart section. Chart section shows result of thickness check
and position check. Enter key toggles tolerance lines on/off. Tolerance lines pertain to
selected record, but extend across entire chart (through other records).
Chart Section

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Thickness and Position Difference Criteria
NOTE: Max/min pos error criteria applies to both rbtclsdir(+) and rbtopndir(-). I.E. criteria
is: abs(pos.err) > pos.err.min && abs(pos.err) < pos.err.max Note: only tolerance lines with
same polarity as posdiff are displayed. Tolerance lines with opposite polarity of posdiff are
not shown, to make chart simpler.
Evaluation tolerance configuration screen
Eval tol is used with touchup diagnostic mode. In touchup diagnostic mode, thickness upper
tolerance is set to a large value (to avoid thickness error), and min pos error is set larger than
max pos error. This combination of settings leads to measurement of thickness and position
change (diff), without touchup. Eval tolerance is then set to an appropriate tolerance for
identification of bad points and applied to these measurements. Note: diagnostic mode can
also be used to confirm program touchup accuracy. Users would find the position error of a
given point and then confirm the result via direct manual measurement.
When evaluation tolerance is active:
• Touchup summary block is colorized per the measurement and eval tolerance, rather
than the tolerance that was present at measurement time
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• Tolerance lines on chart are displayed with a PINK line (tolerance line is normally red).
• “EvalTol active” is written to the bottom of chart
• Detect distance and touchup status boxes are blank
NOTE: ** displays when measurement data is unavailable due to:
1. Detect distance error: Thkness and PosDiff status = **

2. Thickness error: PosDiff status = **
Evaluation Tolerance

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Touchup Evaluation Tolerance
Table 32: Touchup Evaluation Tolerance Explanations

Parameter Comment
Evaluation tolerance Use eval tol, instead of org tol to evaluate criteria
Thickness tolerance upper Upper (over) thickness tolerance for evaluation
Thickness tolerance lower Lower (under) thickness tolerance for evaluation
Allowable position error in robot close direction for
Position tolerance upper
evaluation
Allowable position error in robot open direction for
Position tolerance lower
evaluation
5.5.1 Touchup Chart Screenshot
Ipendant does not provide direct support for screen snapshots. However, it is possible to
connect to the controller over Ethernet and capture a screenshot via a pc tool. The PCIF
option is required to do this.
Procedure for obtaining a Screenshot:
1. Connect to controller with internet explorer

2. Select to “Monitor iPendant ECHO”
3. Display desired chart on iPendant
4. Capture snapshot of screen with paint or another screen capture tool.
Controller Web Server

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5.6 Spot Program Touchup DISABLE Instruction
If a spot instruction is executed with the program touchup mode enabled, the spot program
touchup will execute. However, there may be some cases where automatic touchup is
undesirable. For example, if the robot or gun interfere with part of a workpiece or peripheral
devices, etc. when the robot or gun move to the upper panel detection start position in a
complicated environment. In such a case, program touchup mode needs to be kept enabled,
but it should be disabled only when a specific spot instruction is executed. The spot program
touchup disable instruction can be used to disable selected touchup at specific spot points in a
program. This is done by attaching this attaching the touchup disable instruction to the spot
instruction. This instruction is effective only to the spot instruction.
Sample program with the SpotProgTouch_Dsb instruction
To teach the spot program touchup disable instruction, place the cursor behind the spot
motion instruction and press the F4 CHOICE key to display the supplementary motion
instruction menu. Select a SpotProgTouchDsb from the menu.

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When the program above executes, the following sequence is executed by the 5th line.

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Spot Program Touchup Function Sequence: TP Enable
Spot Program Touchup Function Sequence: TP Disable
When this instruction is executed with the TP enabled, robot pauses at the start distance. Do
the touchup if necessary by manual. Moreover, when this instruction is executed, the prompt
message "Paused by Spot Prog Touch Dsb" is displayed for about one second.
NOTE: The spot program touchup disable should only be attached do spot instructions. Do
not attach it to other application instructions. The spot program touchup disable instruction is
useful only when the program touchup mode is enabled.

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5.7 Program Touchup Single Step Mode
When the spot program touchup is executed with single step enabled, the following sequence
is executed.
Program Touchup Single Step Mode
When the spot program touchup is executed with the single step enabled, robot pauses at the
taught position and the end distance . Do the touchup if necessary by manual.
Other specifications
BWD
The spot program touchup is not executed at BWD execution. Therefore, the robot and gun
do the same motion as motion of BWD execution of the spot instruction.
Pause / Jog
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The robot restarts the spot program touchup from the start distance at next restart when the
robot and the gun are jogged/paused while the spot program touchup is being executed.
Touchup
The spot program touchup is canceled on the way when the touchup is done by manual
operation/spot point touchup function while the spot program touchup is executing.
Therefore, the robot restarts from the end distance at next restart. Moreover, the spot point
touchup function cannot be used until the robot reaches the taught position while the spot
program touchup is being executed.
Skip
If user changes line execution line, program touchup is cancelled for that point, but will
continue at the next spot point.
Repower
If repower occurs, program touchup is automatically disabled.

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6 Style Sample Teach Pendant Programs
NOTE: USE ONLY ONE METHOD OF TIP WEAR MEASUREMENT FOR TIP WEAR
COMPENSATION (ONE-STEP OR TWO-STEP) . ONE-STEP IS USING TIP-TO-TIP
MEASURING AND THE AVERAGE OF THE TIP WEAR IS ASSUMED TO BE EQUALLY
DISTRIBUTED FROM EACH TIP. TWO-STEP WILL USE A CALIBRATION PLATE. IF
YOU ARE USING A CALIBRATION PLATE (TWO-STEP) FOR TIP WEAR MEASUREMENT,
DO NOT USE THE ROBOT’S ONE-STEP WEAR MEASUREMENT METHOD ELSEWHERE.
CONVERSLY, IF USING THE ONE STEP WEAR MEASUREMENT METHOD AT THE END OF
THE ROBOT’S PROGRAM, DON’T USE THE TWO-STEP METHOD . BUT IF YOU HAVE A
CALIBRATION PLATE BY DEFAULT USE THE TWO-STEP METHOD.
6.1 ASCII Upload

You can use the ASCII upload feature on the robot controllers to get these sample programs
into the robot. This saves the work of typing the instructions into the teach pendant manually.
The general procedure is:
1. Select the program lines from this document.
2. Copy to clipboard.
3. Open NotePad or similar editor.
4. Paste the lines into Notepad.
5. Check for Strikeout lines in the original listing from this document. If any are found,
delete those lines from the listing on Notepad.
6. Check the program header. If it is not complete, you will need to paste missing lines
into the header from another program. (You can get them from a saved .LS file from
the controller).
7. If you wish to add any logic to the program, do so now.
8. Save the file on Notepad as NAME.LS, where NAME is the name of the TP program.
9. This file can now be put on a memory card or USB Flash drive and inserted into the
controller. You can use the Files menu to load the NAME.LS file.
10. You can alternatively use FTP to copy the .LS file to the robot MD: device.
11. Check the alarm log for syntax errors while loading. If necessary, correct those errors
and try loading again.
NOTE: The SPOTTOOL+ manual discusses ASCII file operations
11.1 Saving Files as ASCII
11.2 ASCII UPLOAD

Page 138 of 305
6.2 PG21 – Carried Weld Operations Only
/PROG PG21
/ATTR
OWNER = MNEDITOR;
COMMENT = "Carried (2)SWG";
PROG_SIZE = 1768;
CREATE = DATE 10-06-07 TIME 17:29:34;
MODIFIED = DATE 10-06-07 TIME 17:29:34;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 83;
MEMORY_SIZE = 2200;
PROTECT = READ_WRITE;
TCD: STACK_SIZE = 0,
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
DEFAULT_GROUP = *,*,*,*,*;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
SPOT Welding Equipment Number : 1 ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
CYCLE_TARGET = 0.00 ;
/MN
1: !***************************** ;
2: ! CARRIED SPOTWELD PG21 ;
3: ! DUAL GUN;
4: ! NOTE: This program has NO ;
5: ! GP[1:robot] and ;
6: ! GP[2:servogun] motion ;
7: !***************************** ;
8: ;
9: !Verify Program ;
10: PROGRAM VERIFY(21) ;
11: ;
12: !Setup App Specific Outputs ;
13: ! Runs HOME_IO ;
14: SETUP OUTPUTS ;
15: ;
16: !Move to Home ;
17: GO TO HOME POS ;
18: ;
19: ! Move to pounce position ;
20: GO TO POUNCE ;
21: ;
22: !Clr to Adv Xfer ;
23: DO[954:CLRTOADVXFR]=ON ;
24: ;
25: !Clr to Ret Xfer ;
26: DO[955:CLRTORETXFR]=ON ;
27: ;
28: !Clr to Unclamp ;
29: DO[956:CLRTOUNCLMP]=OFF ;
30: ;
31: !-------------------------------- ;
32: LBL[33:Loop Back ] ;

Page 139 of 305
33: ;
34: ! Turn ON Robot in LOOP ;
35: DO[24:RBT IN LOOP]=ON ;
36: ;
37: !-------------------------------- ;
38: !Wait Continue from Pounce ;
39: !or Return to Home ;
40: WAIT DI[9:START CYCLE]=ON OR DI[13:RETURN TO HOME]=ON ;
41: ;
42: ! Turn OFF Robot in LOOP ;
43: DO[24:RBT IN LOOP]=OFF ;
44: ;
45: !If Return to Home ;
46: !jump to LB[13] ;
47: IF DI[13:RETURN TO HOME]=ON,JMP LBL[13] ;
48: ;
49: !If Continue from Pounce ;
50: !jump to LB[9]-Continue- ;
51: IF DI[9:START CYCLE]=ON,JMP LBL[9] ;
52: ;
53: JMP LBL[33] ;
54: ;
55: !-------------------------------- ;
56: !Continue from Pounce ;
57: LBL[9] ;
5: ;
8: ;
59: !Clr to Return Xfer ;
60: DO[955:CLRTORETXFR]=OFF ;
61: ;
63: DO[954:CLRTOADVXFR]=OFF ;
64: ;
67: ;
68: !Enter Zone1 ;
69: ENTER ZONE(1) ;
70: ;
71: !Calls Weld Routine ;
72: ! Contains Weld Points ;
73: CALL WELD01 ;
74: ;
77: ;
81: ;
83: DO[956:CLRTOUNCLMP]=ON ;
82: ;
85: !Exit Zone1 ;
86: EXIT ZONE(1) ;
87: ;
88: ;
89: !-------------------------------- ;
90: LBL[13] ;
Page 140 of 305
112: ;
113: !-------------------------------- ;
114: !Move to Home ;
116: ;
/POS
/END

Page 141 of 305
6.3 PG21 – Pedestal Weld Operation with Tip Dress Dump
The assumption for this program is the that the servo gun is group #2, axis 1 and 2
(simultaneous welds).
1) Remove ALL Spot Welding Positions (including the approach and depart
positions) in the main program (example PG21) and add them into it own
program called WELD01.tp (Gun#1 operation) with Group1 and Group2
enabled.
2) Create Tip Dress Macro Program with Group 2 enabled only (meaning servo gun
axis).
3) Configure Tip Dress Macro Program in the Macro table triggering off an DI[ ].
NOTE1: In PG21, Motion Group[1:Robot] only is defined.
NOTE2: CLR TO ADV XFR must be off (low) during the weld sequence in
order to trap a weld timer fault.
/PROG PG21
/ATTR
OWNER = MNEDITOR;
COMMENT = "Pedestal (2)SWG";
PROG_SIZE = 7488;
CREATE = DATE 10-06-07 TIME 17:29:34;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 372;
MEMORY_SIZE = 7932;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
DEFAULT_GROUP = 1,*,*,*,*;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! PEDESTAL SPOTWELD PG21 ;
3: ! with TIP Dress Dump ;
4: ! ;
5: ! NOTE: This program has ;
6: ! GP[1:robot] ;
7: !***************************** ;
8: ;
11: ;
12: !Set Robot UTOOL Number ;
Page 142 of 305
13: UTOOL_NUM=1 ;
14: ;
15: !Set Robot UFRAME Number ;
16: UFRAME_NUM=1 ;
17: ;
18: !If Part Present and Gripper ;
19: ! Closed, GO set Part Down ;
20: IF DI[67:PART PRESENT 1]=ON AND DI[74:CLMP 1 CLOSED]=ON AND
DI[76:CLMP 2 CLOSED]=ON,JMP LBL[10] ;
21: ;
22: ;
23: !-------------------------------- ;
24: !Set Robot Payload WITHOUT PART ;
25: PAYLOAD[2] ;
26: ;
28: ! Runs HOME_IO ;
29: SETUP OUTPUTS ;
30: ;
31: !Move to Home ;
33: ;
34: ! Move to pounce position ;
35: GO TO POUNCE ;
36: ;
39: ;
42: ;
45: ;
46: ;
47: !-------------------------------- ;
48: !Continue from JUMP ;
49: LBL[40] ;
50: ;
53: ;
54: !Wait Continue from Pounce ;
55: ! or Return to Home ;
56: WAIT DI[9:START CYCLE]=ON OR DI[13:RETURN TO HOME]=ON ;
57: ;
60: ;
62: ! jump to LB[13] ;
64: ;
65: !If Continue from Pounce ;
66: ! jump to LB[9] ;
67: IF DI[9:START CYCLE]=ON,JMP LBL[9] ;
68: ;
69: JMP LBL[40] ;
70: ;

Page 143 of 305
71: !-------------------------------- ;
72: !Continue from Pounce ;
73: LBL[9] ;
5: ;
8: ;
77: ;
80: ;
83: ;
84: ;
85: !******************************* ;
86: !PICKUP PATH ;
87: !******************************* ;
88: ;
91: ;
92: !Wait for Clear to Pickup ;
93: WAIT DI[94:CLR TO PICKUP]=ON ;
94: ;
97: ;
98: !Enter Zone1 ;
99: ENTER ZONE(1) ;
100: ;
101: !Check Clamps OPENED ;
102: WAIT DI[73:CLMP 1 OPENED]=ON ;
104: ;
105: ;
107: UFRAME_NUM=1 ;
108: ;
109: ! Move to Pickup Position ;
110: ;
111: ;
112: !At Pickup 1 ;
113: DO[49:RBT @ PKUP POS 1]=ON ;
114: ;
114: !Wait for part present or abort pickup ;
115: WAIT DI[67:PART PRESENT 1]=ON OR DI[93:ABORT PICKUP]=ON ;
116: IF DI[93:ABORT PICKUP]=ON,JMP LBL[500] ;
117: ;
118: !Close gripper 1,2 ;
119: CLOSE GRIPPER1 ;
120: CLOSE GRIPPER2 ;
121: ;
122: !Wait for Gripper 1 Close ;
123: WAIT ((DI[74:CLMP 1 CLOSED]=ON AND DI[76:CLMP 2 CLOSED]=ON)
: OR DI[93:ABORT PICKUP]=ON]) ;
132: ;
125: ;
Page 144 of 305
126: !Set Robot Payload WITH PART ;
127: PAYLOAD[3] ;
128: ;
129: ! Move above Pickup Position ;
130: ;
131: ;
132: !Wait for Pickup 1 Complete ;
133: WAIT DI[49:PICKUP COMP 1]=ON ;
133: ;
132: ;
123: JMP LBL[600] ;
123: ;
132: !-------------------------- ;
132: !If abort pickup is ON ;
132: LBL[500] ;
132: ;
123: !Open gripper 1,2 ;
123: OPEN GRIPPER1 ;
123: ;
123: !Wait for ALL Grippers ;
123: ! and Safety Clamps are ;
123: ! OPEN before continuing ;
123; WAIT DI[75:CLMP 2 OPENED]=ON ;
123: ;
123: !VACUUM 1 OFF ;
123: ! (if applicable) ;
123: CALL VAC1_OFF ;
123: ;
123: !Wait for ALL Grippers ;
123: ! and Safety Clamps are ;
123: ! OPEN before continuing ;
123; WAIT DI[75:CLMP 2 OPENED]=ON ;
123: ;
123: !Move above pickup Position ;
123: ! without the part. ;
123: !This need to be clear with ;
123: ! clamps open, otherwise use ;
123: ! a different position. ;
123:L P[3] 500 mm/sec CNT100 ;
123: ;
123: !Wait for no parts present ;
123: WAIT DI[66:NO PARTS PRESENT]=ON ;
123: ;
123: !If not Aborted or ;
123: ! Aborted with Clamp Open ;
123: LBL[600] ;
134: ;
135: !At Pickup 1 ;
136: DO[49:RBT @ PKUP POS 1]=OFF ;
137: ;
138: ! Move away from Pickup Pos ;
139: ;
140: ;
141: !Exit Zone1 ;
142: EXIT ZONE(1) ;
143: ;

Page 145 of 305
144: ;
145: !-------------------------------- ;
146: LBL[10:Skip Pickup ] ;
147: ;
150: ;
153: ;
156: ;
158: PAYLOAD[3] ;
159: ;
160: !If Skip Weld Routine ;
161: IF DI[123:WD SCMP/SKP1]=ON,JMP LBL[30] ;
162: ;
164: ! jump to LB[13] ;
166: ;
167: ;
168: !******************************* ;
169: !Pedestal weld Path ;
170: !******************************* ;
171: ;
172: !Tip Dress Clear ; 226: ;
173: WAIT DI[119:TD DUMP RET 1]=ON ;
174: ;
176: ;
177: ! Wait for Tip Dress Dump Macro t ;
178: WAIT DI[117:INIT TIP DRESS 1]=OFF ;
179: ;
182: ;
184: WAIT DO[972:TDDMP1INPROC]=OFF ;
185: ;
187: ;
187: ! Wait for Tip Wear Done Running ;
187: WAIT DO[974:RUNTWRCMP1]=OFF ;
187: ;
187: ! Wait for Tip Wear Done Running ;
187: ;
187: !Wait INDP MOTN ZNS Clear ;
187: WAIT DI[39:IND MOT ZN 1 CLR]=OFF AND
: DI[40:IND MOT ZN 2 CLR]=OFF AND DI[37:ZONE 13 CLR]=OFF AND
: DI[38:ZONE 14 CLR]=OFF ;
187: ;
187: !Wait until Tip Wear Measure FLAG is OFF ;

Page 146 of 305
187: WAIT (F[1:RunningTipWearR]=OFF AND F[2:RunningTipWearR2]=OFF)
;
188: ;
189: !OPEN GUN1 MACRO ;
190: OPEN GUN ;
191: ;
192: !OPEN GUN2 MACRO ;
193: OPEN GUN2 ;
194: ;
195: !Enter Zone3 w/Ped Welder ;
196: ENTER ZONE(3) ;
197: ;
198: !Calls Weld Routine ;
199: ! Contains Weld Points ;
200: CALL WELD01 ;
201: ;
202: !Exit Zone3 w/Ped Welder ;
203: EXIT ZONE(3) ;
204: ;
205: !-------------------------------- ;
206: !If pulled tip bypass, skip ;
207: !Calibration Routine ;
208: IF DO[141:AUTOPTBYPAS1]=ON OR DO[131:XFRMR OTEMP 1]=ON OR
: DO[113:PLDTIP BYPASS ]=ON OR DO[130:SG MTR OTEMP 1]=ON OR
: DO[121:AUTO TD1 ]=ON,JMP LBL[555] ;
209: ;
210: ! Wait for Tip Dress Dump Macro ;
212: ;
215: ;
215: !**************************** ;
215: !Add this logic if Tip Dress Dump ;
215: ! Process has to be Ran Independently ;
215: ! due to Dumps hitting ;
215: !Wait for Tip Dress Dump Return 1 ;
215: ;
215: !Wait for Independent ;
215: !Zone1 to be clear ;
215: WAIT DI[39:IND MOT ZN1 CLR]=OFF ;
215: !**************************** ;
215: ;
216: !**************************** ;
217: !Run TipWear 1 Compensation ;
218: ! Macro in the Background ;
219: !RUN TPWEARC1 BY TURNING ON DO[974] ;
220: ;
221: DO[974:RUNTWRCMP1]=ON ;
222: !**************************** ;
223: ;
224: !Label to jump to, skip calibrat ;
225: LBL[555] ;
226: ;
227: ;
228: !-------------------------------- ;

Page 147 of 305
: DO[113:PLDTIP BYPASS ]=ON OR DO[162:SG MTR OTEMP 2]=ON OR
: DO[153:AUTO TD2 ]=ON,JMP LBL[888] ;
232: ;
233: ! Wait for Tip Dress Dump Macro ;
235: ;
238: ;
238: !**************************** ;
238: !Add this logic if Tip Dress Dump ;
238: ! Process has to be Ran Independently ;
238: ! due to Dumps hitting ;
238: !Wait for Tip Dress Dump Return 1 ;
238: ;
238: !Wait for Independent ;
238: !Zone1 to be clear ;
238: WAIT DI[37:ZONE 13 CLR]=OFF ;
238: !**************************** ;
238: ;
239: !**************************** ;
240: !Run TipWear 2 Compensation ;
241: ! Macro in the Background ;
242: !RUN TPWEARC2 BY TURNING ON DO[976] ;
243: ;
244: DO[976:RUNTWRCMP2]=ON ;
245: !**************************** ;
246: ;
248: LBL[888] ;
249: ;
250: ;
251: !-------------------------------- ;
252: LBL[30:Skip Weld ] ;
253: ;
256: ;
259: ;
262: ;
264: PAYLOAD[3] ;
265: ;
266: !-------------------------------- ;
267: LBL[41:Loop Back] ;
268: ;
269: ;
272: ;
273: !Wait for Return2Home or Set Down ;
274: WAIT DI[96:CLR TO SET DOWN]=ON OR DI[13:RETURN TO HOME]=ON
;

Page 148 of 305
275: ;
278: ;
280: !jump to label ;
282: ;
283: !If Clear to Set Down ;
284: !jump to label ;
285: IF DI[96:CLR TO SET DOWN]=ON,JMP LBL[400] ;
286: ;
287: JMP LBL[41] ;
288: ;
289: LBL[400:GO to Set Down] ;
290: !******************************* ;
291: !DROPOFF PATH ;
292: !******************************* ;
293: ;
296: ;
299: ;
302: ;
303: !Enter Zone2 ;
304: ENTER ZONE(2) ;
305: ;
307: UFRAME_NUM=2 ;
308: ;
309: ! Move to Dropoff Position ;
310: ;
311: ;
312: !At Set Down ;
313: DO[59:RBT AT DRP OFF 1]=ON ;
314: ;
315: !Open Grippers 1,2 ;
318: ;
319: !Wait for Gripper 1,2 Open ;
322: ;
325: ;
326: !Wait for Set Down Complete ;
327: WAIT DI[59:SET DOWN COMP 1]=ON ;
328: ;
331: ;
333: PAYLOAD[2] ;

Page 149 of 305
334: ;
335: ! Move above Dropoff Position ;
336: ;
337: ;
338: !Wait for Part Release ;
339: WAIT DI[97:PART RELEASED]=ON ;
340: ;
341: !Robot Waiting in Loop ;
342: DO[59:RBT AT DRP OFF 1]=OFF ;
343: ;
344: ! Move away from Dropoff Pos ;
345: ;
346: ;
347: !Exit Zone2 ;
348: EXIT ZONE(2) ;
349: ;
352: ;
355: ;
358: ;
359: ;
360: LBL[13:Return to Home ] ;
361: ;
362: !-------------------------------- ;
365: ;
366: !FLAG to notify robot is running ;
367: ! TipWear Routine ;
368: !NOTE: Wait until FLAG is OFF ;
369: WAIT (F[1:RunningTipWearR]=OFF) ;
370: ;
371: ! F[2] is from TPWEARC2 Routine ;
372: WAIT (F[2]=OFF) ;
/POS
/END

Page 150 of 305
6.4 WELD01 for R-30iA Controllers
Enter ALL weld positions and weld commands in this teach pendant program.
NOTE1: In WELD01, Motion Groups[1:Robot] and Group[2:ServoGun] are
defined.
NOTE2: DUAL ServoGun will be Group2: Axis1 and Axis2.
/PROG WELD01
/ATTR
OWNER = MNEDITOR;
COMMENT = "Weld Gun1";
PROG_SIZE = 802;
CREATE = DATE 06-02-28 TIME 16:57:28;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 28;
MEMORY_SIZE = 1098;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
DEFAULT_GROUP = 1,1,*,*,*;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELD PATH ;
3: ! ;
7: !***************************** ;
8: ;
9: !Set Robot Payload ;
10: PAYLOAD[2] ;
11: ;
13: UTOOL_NUM=1 ;
14: ;
16: UFRAME_NUM=1 ;
17: ;
18: ! Approach Weld Position ;
19:J P[1] 100% FINE ;
20: ;
21: ! Weld Instructions ;
22:L P[2] 2000mm/sec CNT50
: SPOT[SD=1,1, EP=0,0, P=1,1, S=1,1, EP=0,0, ED=1,1] ;
Page 151 of 305
23: ;
24: ! Depart Weld Position ;
25:J P[1] 100% FINE ;
26: ;
27: !Set after Weld Paths ;
28: DO[111: WELDSEQCOMP2PLC1]=PULSE,1.0sec;
/POS
/END

Page 152 of 305
6.5 WELD01 for R-30iB Controllers
defined.
/PROG WELD01
/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 802;
CREATE = DATE 06-02-28 TIME 16:57:28;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 28;
MEMORY_SIZE = 1098;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELD PATH ;
3: ! ;
7: !***************************** ;
8: ;
10: PAYLOAD[2] ;
11: ;
13: UTOOL_NUM=1 ;
14: ;
16: UFRAME_NUM=1 ;
17: ;
19:J P[1] 100% FINE ;
20: ;
22:L P[2] 2000mm/sec CNT50

Page 153 of 305
: SPOT[SD=1,1, EP=0,0, P=1,1, t=0.0,0.0, S=1,1, EP=0,0, ED=1,1]
;
23: ;
25:J P[1] 100% FINE ;
26: ;
/POS
/END

Page 154 of 305
6.6 WELD02 for R-30iA Controllers
This program is called from program PG21.
defined.
/PROG WELD02
/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 802;
CREATE = DATE 06-02-28 TIME 16:57:28;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 28;
MEMORY_SIZE = 1098;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELD PATH ;
3: ! ;
7: !***************************** ;
8: ;
10: PAYLOAD[2] ;
11: ;
13: UTOOL_NUM=1 ;
14: ;
16: UFRAME_NUM=1 ;
17: ;
19:J P[1] 100% FINE ;
20: ;

Page 155 of 305
22:L P[2] 2000mm/sec CNT50
: SPOT[SD=1,1, EP=0,0, P=1,1, S=1,1, EP=0,0, ED=1,1] ;
23: ;
25:J P[1] 100% FINE ;
26: ;
27: ! ONLY DO[112:WELDSEQCOMP2PLC2] will be ;
27: ! pulsed ON if the second weld gun ;
27: ! has a unique weld sequence;
/POS
/END

Page 156 of 305
6.7 WELD02 for R-30iB Controllers
This program is called from program PG21.
defined.
/PROG WELD02
/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 802;
CREATE = DATE 06-02-28 TIME 16:57:28;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 28;
MEMORY_SIZE = 1098;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELD PATH ;
3: ! ;
7: !***************************** ;
8: ;
10: PAYLOAD[2] ;
11: ;
13: UTOOL_NUM=1 ;
14: ;
16: UFRAME_NUM=1 ;
17: ;
19:J P[1] 100% FINE ;
20: ;

Page 157 of 305
22:L P[2] 2000mm/sec CNT50
: SPOT[SD=1,1, EP=0,0, P=1,1, t=0.0,0.0, S=1,1, EP=0,0, ED=1,1]
;
23: ;
25:J P[1] 100% FINE ;
26: ;
27: ! ONLY DO[112:WELDSEQCOMP2PLC2] will be ;
27: ! pulsed ON if the second weld gun ;
27: ! has a unique weld sequence;
/POS
/END

Page 158 of 305
6.8 TPDRSMAC – Tip Dress Dump with Servo Tip Dresser
MACRO
This program will run automatically in the background, which is initiated by DI[966:
RUN TDDMP1] = ON.
NOTE1: In TPDRSMAC, NO Groups are define.
/PROG TPDRSMAC Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "TIP DRESS DUMP";
PROG_SIZE = 4500;
CREATE = DATE 10-06-01 TIME 13:33:26;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 182;
MEMORY_SIZE = 4952;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
/MN
1: !***************************** ;
2: !(1) Pedestal Tip Dress Dump ;
3: ! ;
7: !***************************** ;
8: ! ;
9: ! CONDITION TO START MACRO ;
10: ! DO[971:TipDrssAppl]=ON ;
11: ! DI[966:RunTipDrssDump1]+ ;
12: ! ROBOT AUTO ;
13: ! TP = OFF ;
14: ! NO FAULT ;
15: ! DO[972:TpDrsDump1InPrc]=OFF ;
16: ! ;
17: ! ;
18: ! CONDITION TO RE-START MACRO ;
19: ! SENERIO #1 ;
21: ! DO[972:TpDrsDump1InPrc]=ON ;
22: ! ROBOT AUTO ;
Page 159 of 305
23: ! TP = OFF ;
24: ! NO FAULT ;
25: ! DI[1:EXT RUN ENABLE]+ ;
26: ! ;
27: ! ;
29: ! SENERIO #2 ;
32: ! ROBOT AUTO ;
33: ! TP = OFF ;
34: ! NO FAULT ;
35: ! DI[1:EXT RUN ENABLE]=ON ;
36: ! SI[13:HoldReset]+ ;
37: ! ;
38: !In Tip Dress Dump Routine ;
39: ! Robot Internal Flag ;
40: DO[972:TDDMP1INPROC]=ON ;
41: ;
41: !Re-Runs Tip Wear Compensation ;
41: ! PROCESS ONLY ;
41: ! If robot is E-stopped ;
41: OPEN GUN ;
41: IF DO[122:TD COMPLETE 1]=ON,JMP LBL[1] ;
41: ;
42: !Runs Tip Wear Compensation ;
44: ! Skip Tip Dress Routine ;
45: IF DO[974:RUNTWRCMP1]=ON AND DI[117:INIT TIP DRESS 1]=OFF,JMP
LBL[1] ;
46: ! ;
47: !**************************** ;
48: !ENTER INDEPENDENT ZONE ;
49: !Let everyone know we are ;
50: ! in Independent ;
51: ! Motion Zone1 ;
52: DO[952:INDCLRMOTZONE1]=OFF ;
53: ;
54: ! Wait for Independent ;
55: ! Zone1 to be clear ;
56: WAIT DI[39:IND MOT ZN 1 CLR]=ON ;
57: !**************************** ;
58: ;
33: !Is this a New Tip? ;
34: !Jump if it isn’t a new tip ;
35: IF DI[669:NEW TIP]=OFF,JMP LBL[567] ;
36: ;
37: !-------------------------------- ;
38: ! Reset Wear Amount ;
39: ! ;
40: ! ;
41: ! This section is used ONLY ;
42: ! when New Tips (NTSR) is ;
43: ! set. This will reset the ;
44: ! tip wear amount from the ;
45: ! last master position w/o ;
46: ! the need to perform a ;
47: ! tip wear measurement ;
48: !-------------------------------- ;
Page 160 of 305
49: ;
26: !OPTIONALLY Run Open Gun Macro ;
26: ! Guarantee gun is inside stroke ;
26: ! limit before seating new caps ;
26: OPEN GUN ;
26: ;
26: !This seats the new caps ;
26: ! Set parameters in TW_PRS01 for ;
26: ! proper seating force and iterations ;
26: CALL TW_PRS01 ;
26: ;
92: !Let's PLC know to ADVANCE ;
93: !TIP DRESS DUMP ;
94: DO[440]=ON ;
95: ;
62: !IF NO New Tip 1 ;
63: LBL[567] ;
64: ;
59: !OPEN ServoGun ;
60: ! Use Grp#2 REF Pos 1 ;
61: ! Use PosReg PR[100] ;
62: !OPEN GUN ;
63: ;
64: !Wait Dump Advanced ;
65: WAIT DI[118:TD DUMP ADV 1]=ON ;
66: ;
67: !Turn OFF Flag to run Tip ;
68: ! Wear Compensation Routine ;
69: DO[974:RUNTWRCMP1]=OFF ;
70: ;
71: ;
72: DO[115:WELD/NO WELD MD]=ON ;
73: ;
74: ;
76: ! jump if it is ;
78: ;
79: !-------------------------------- ;
81: ! PEDESTAL ONLY ;
82: ! ;
90: !-------------------------------- ;
91: ;
92: ! The 1st parameter = 1 ;
93: ! that represents gun number ;
94: ! The 2nd parameter = 29 ;
95: ! that represents a place ;
96: ! holder for R[29] ;
97: CALL TWKRSMOV(1,29) ;
98: CALL TWKRSFIX(1,29) ;
99: ;
Page 161 of 305
100: ! The parameter = 29 ;
101: ! that uses R[29] ;
102: CALL TWKRSCLB(29) ;
103: ;
104: !IF NO New Tip ;
105: LBL[456] ;
106: ;
107: !Turn ON Equalization ;
108: ! *If Equalizer is Used (X=numbr) ;
109: !GO[X:Equal press ]=1 ;
110: ;
111: !Macro for Ped Tip Dress ;
112: CALL PEDTDMACS ;
113: ;
155: !Turn OFF Equalization ;
114: ;
118: !OPEN GUN ;
119: ;
120: ! Pulse ON Tip Dress Done to ;
121: ! return the dump ;
122: DO[122:TD COMPLETE 1]=ON ;
123: ;
124: !Reset Dress req ;
125: DO[936:STEPPERRST1]=ON ;
126: ;
127: ! Wait for Auto TipDress Position ;
128: WAIT DI[129:AUTOTPDRSPOSCLR1]=ON AND DI[670:DRESSED TIP]=ON
;
129: ;
130: ;
132: DO[936:STEPPERRST1]=OFF ;
133: ;
134: ;
135: ! Check ServoGun Open ;
136: WAIT DO[128:RTRCT/SRV OPN1]=ON ;
137: ;
138: !**************************** ;
139: !EXIT INDEPENDENT ZONE ;
141: ! out Independent ;
143: DO[952:INDCLRMOTZONE1]=ON ;
144: ;
147: WAIT DI[39:IND MOT ZN 1 CLR]=OFF ;
148: !**************************** ;
149: ;
150: ;
151: ! Wait Dump Retract ;

Page 162 of 305
153: ;
157: ;
158: !-------------------------------- ;
159: ! Label to jump to,Tip Wear Cmp ;
160: LBL[1:Run Tip Wear Com] ;
161: ;
162: ! If pulled tip bypass, jump ;
163: ! to the end of program ;
DO[113:PLDTIP BYPASS ]=ON OR DO[130:SG MTR OTEMP 1]=ON,JMP LBL[999]
;
165: ;
166: ;
167: !-------------------------------- ;
168: !Call Tip Wear Compensation ;
169: CALL TPWEARC1 ;
170: ;
171: ! Turn OFF Flag to run Tip ;
213: ;
215: DO[440]=OFF ;
216: ;
176: !-------------------------------- ;
177: !Label to jump to, finish routine ;
178: LBL[999:Done] ;
179: ;
181: DO[972:TDDMP1INPROC]=OFF ;
182: DO[115:WELD/NO WELD MD]=OFF ;
183: DO[122:TD COMPLETE 1]=OFF ;
184: ;
/POS
/END

Page 163 of 305
6.9 TPDRSMAC – Tip Dress Dump with Servo Tip Dresser for
Simultaneous Welders MACRO
RUN TDDMP1] = ON.
NOTE1: In TPDRSMAC, NO Groups are define.
/PROG TPDRSMAC Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "TIP DRESS DUMP";
PROG_SIZE = 4500;
CREATE = DATE 10-06-01 TIME 13:33:26;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 182;
MEMORY_SIZE = 4952;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
/MN
1: !***************************** ;
3: ! ;
7: !***************************** ;
8: ! ;
12: ! ROBOT AUTO ;
13: ! TP = OFF ;
14: ! NO FAULT ;
16: ! ;
17: ! ;
19: ! SENERIO #1 ;
22: ! ROBOT AUTO ;

Page 164 of 305
23: ! TP = OFF ;
24: ! NO FAULT ;
26: ! ;
27: ! ;
29: ! SENERIO #2 ;
32: ! ROBOT AUTO ;
33: ! TP = OFF ;
34: ! NO FAULT ;
37: ! ;
41: ;
110: !Wait for TipDresser 2 InActive ;
110: WAIT F[33:Tip Dress 2 in Progress]=OFF ;
41: ;
41: !Set Flag for Active TipDresser ;
41: F[32:Tip Dress 1 in Progress]=ON ;
41: ;
41: OPEN GUN ;
41: ;
LBL[1] ;
46: ! ;
47: !**************************** ;
48: !ENTER INDEPENDENT ZONE ;
53: ;
57: !**************************** ;
70: ;
71: !RESET TIPWEAR ;
72: !-------------------------------- ;

Page 165 of 305
80: !-------------------------------- ;
81: ;
85: OPEN GUN ;
86: ;
89: ! proper seating force and iterat ;
90: CALL TW_PRS01 ;
91: ;
94: DO[440]=ON ;
95: ;
97: LBL[567] ;
98: ;
62: !OPEN GUN ;
63: ;
66: ;
70: ;
71: ;
73: ;
74: ;
78: ;
79: !-------------------------------- ;
82: ! ;
90: !-------------------------------- ;
91: ;

Page 166 of 305
96: ;
96:
99: ;
101: ! that uses R[29] ;
103: ;
105: LBL[456] ;
106: ;
110: ;
110: !Make sure TipDress 2 is InActive ;
110: ;
112: CALL PEDTDMACS ;
113: ;
155: !Turn OFF Equalization ;
114: ;
118: OPEN GUN ;
119: ;
123: ;
126: ;
;
129: ;
130: ;
133: ;
134: ;
137: ;
138: !**************************** ;
139: !EXIT INDEPENDENT ZONE ;

Page 167 of 305
144: ;
148: !**************************** ;
149: ;
150: ;
153: ;
157: ;
158: !-------------------------------- ;
159: ! Label to jump to,Tip Wear Cmp ;
161: ;
;
165: ;
166: ;
167: !-------------------------------- ;
168: WAIT (F[1:RUNNINGTIPWEARR]=OFF AND F[2:RUNNINGTIPWEARR2]=OFF)
;

170: ;
174: ;
175: ;
215: DO[440]=OFF ;
216: ;
176: !-------------------------------- ;
178: LBL[999:Done] ;
179: ;
184: ;
185: !Set Flag for InActive TipDresser ;
186: F[32:Tip Dress 1 in Progress]=OFF ;
/POS
/END

Page 168 of 305
6.10 TPDRSMC2 - Tip Dress Dump with Servo Tip Dress MACRO
This program coordinates the tip wear and tip dressing operations for Servo Gun 2.
RUN TDDMP2] = ON.
NOTE1: In TPDRSMC2, NO Motion Groups are defined.
/PROG TPDRSMC2 Macro

/ATTR
OWNER = ASCBIN;
COMMENT = "TIP DRESS DUMP2";
PROG_SIZE = 4760;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = TPDRSMAC;
VERSION = 0;
LINE_COUNT = 188;
MEMORY_SIZE = 5188;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
7: !***************************** ;
8: ! ;
12: ! ROBOT AUTO ;
13: ! TP = OFF ;
14: ! NO FAULT ;
16: ! ;
17: ! ;
19: ! SENERIO #1 ;

Page 169 of 305
22: ! ROBOT AUTO ;
23: ! TP = OFF ;
24: ! NO FAULT ;
26: ! ;
27: ! ;
29: ! SENERIO #2 ;
32: ! ROBOT AUTO ;
33: ! TP = OFF ;
34: ! NO FAULT ;
37: ! ;
40: ;
41: OPEN GUN ;
41: ;
LBL[1] ;
46: ! ;
47: !**************************** ;
48: !ENTER ZONE ;
50: ! in Interference Zone ;
52: DO[912:CLROFZONE13]=OFF ;
53: ;
54: ! Wait for Interference ;
56: WAIT DI[37:ZONE 13 CLR]=ON ;
57: !**************************** ;
58: ;
65: !-------------------------------- ;
66: !Is this a New Tip 2? ;
67: !-------------------------------- ;
68: ! jump if it isn’t ;
69: IF DI[733:New Tip 2]=OFF,JMP LBL[569] ;
70: ;
72: !-------------------------------- ;
Page 170 of 305
80: !-------------------------------- ;
81: ;
26: OPEN GUN2 ;
26: ;
26: CALL TW_PRS02 ;
91: ;
94: DO[441]=ON ;
95: ;
85: !IF NO New Tip 2;
86: LBL[569] ;
87: ;
62: OPEN GUN2 ;
63: ;
66: ;
70: ;
71: ;
73: ;
74: ;
78: ;
79: !-------------------------------- ;
82: ! ;
90: !-------------------------------- ;
91: ;

Page 171 of 305
99: ;
101: ! that uses R[32] ;
103: ;
105: LBL[456] ;
106: ;
108: ! **If Equalizer is Used (X=numbe ;
109: !GO[2:Equal press ]=1 ;
110: ;
112: CALL PEDTDMC2S ;
113: ;
114: !Move Calibration ;
115: ! Plate in Position ;
116: ;
117: ;
118: !Run TipWear Routine ;
119: ! on Cal Plate ;
120: !CALL TW_UPD02 ;
121: ;
125: OPEN GUN2 ;
126: ;
130: ;
133: ;
;
136: ;
139: ;
140: ;
143: ! ;
144: !**************************** ;
145: !EXIT ZONE ;
149: DO[912:CLROFZONE13]=ON ;
150: ;

Page 172 of 305
154: !**************************** ;
155: ;
156: ;
159: ;
163: ;
164: !-------------------------------- ;
165: ! Label to jump to,Tip Wear Comp ;
167: ;
;
171: ;
172: ;
173: !-------------------------------- ;
;
176: ;
213: ;
215: DO[440]=OFF ;
216: ;
180: ;
181: ;
182: !-------------------------------- ;
184: LBL[999:Done] ;
185: ;
190: ;
/POS
/END

Page 173 of 305
6.11 TPDRSMC2 - Tip Dress Dump with Servo Tip Dress for
Simultaneous Welders MACRO
This program coordinates the tip wear and tip dressing operations for Servo Gun 2.
RUN TDDMP2] = ON.
NOTE1: In TPDRSMC2, NO Motion Groups are defined.
/PROG TPDRSMC2 Macro

/ATTR
OWNER = ASCBIN;
COMMENT = "TIP DRESS DUMP2";
PROG_SIZE = 4760;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = TPDRSMAC;
VERSION = 0;
LINE_COUNT = 188;
MEMORY_SIZE = 5188;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
7: !***************************** ;
8: ! ;
12: ! ROBOT AUTO ;
13: ! TP = OFF ;
14: ! NO FAULT ;
16: ! ;
17: ! ;
19: ! SENERIO #1 ;
Page 174 of 305
22: ! ROBOT AUTO ;
23: ! TP = OFF ;
24: ! NO FAULT ;
26: ! ;
27: ! ;
29: ! SENERIO #2 ;
32: ! ROBOT AUTO ;
33: ! TP = OFF ;
34: ! NO FAULT ;
37: ! ;
41: ;
110: !Wait for TipDresser 1 InActive ;
41: ;
41: !Set Flag for Active Tip Dresser ;
41: F[33:Tip Dress 2 in Progress]=ON ;
110: ;
41: OPEN GUN ;
41: ;
LBL[1] ;
46: ! ;
47: !**************************** ;
48: !ENTER ZONE ;
53: ;
57: !**************************** ;
70: ;
71: !RESET TIPWEAR ;
72: !-------------------------------- ;

Page 175 of 305
80: !-------------------------------- ;
81: ;
85: OPEN GUN2 ;
86: ;
89: ! proper seating force and iterat ;
90: CALL TW_PRS02 ;
91: ;
94: DO[441]=ON ;
95: ;
97: LBL[569] ;
98: ;
58: ;
62: OPEN GUN2 ;
63: ;
66: ;
70: ;
71: ;
73: ;
74: ;
78: ;
79: !-------------------------------- ;
82: ! ;

Page 176 of 305
90: !-------------------------------- ;
91: ;
99: ;
101: ! that uses R[32] ;
103: ;
105: LBL[456] ;
106: ;
108: ! **If Equalizer is Used (X=numbe ;
109: !GO[2:Equal press ]=1 ;
110: ;
110: !Make sure TipDress 1 is InActive ;
110: ;
112: CALL PEDTDMC2S ;
113: ;
114: !Move Calibration ;
115: ! Plate in Position ;
116: ;
117: ;
119: ! on Cal Plate ;
120: !CALL TW_UPD02 ;
121: ;
125: OPEN GUN2 ;
126: ;
130: ;
133: ;
;
136: ;
139: ;
140: ;

Page 177 of 305
143: ! ;
144: !**************************** ;
145: !EXIT ZONE ;
150: ;
154: !**************************** ;
155: ;
156: ;
159: ;
163: ;
164: !-------------------------------- ;
165: ! Label to jump to,Tip Wear Comp ;
167: ;
;
171: ;
172: ;
173: !-------------------------------- ;
;
176: ;
180: ;
213: ;
215: DO[441]=OFF ;
216: ;
181: ;
182: !-------------------------------- ;
184: LBL[999:Done] ;
185: ;
190: ;
185: !Set Flag for InActive TipDresser ;

Page 178 of 305
186: F[33:Tip Dress 2 in Progress]=OFF ;
/POS
/END

Page 179 of 305
6.12 PEDTDMACS - Pedestal Tip Dress Dump with Servo Tip
Dresser MACRO for R-30iA Controllers
BLOWOFF
 The location of the BLOWOFF TP program call will have to be
decided by the process.
 The BLOWOFF program needs to be called after the robot is
away from the dresser, DO[118] is turned OFF and RO[5] has
been turned OFF.
 RO[5] needs to be turned ON and OFF in this program for
normal operation as PMC no longer controls this output.
 PMC dated on or after 2013-04-15 includes the Blowoff
change.
/PROG PEDTDMACS Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "PED GUN SERVO TD MAC";
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
DEFAULT_GROUP = *,1,*,*,*;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO PED SERVO TIP DRESS ;
3: ! ;
4: ! Pedestal SERVO Tip Dress ;
5: ! ;
7: ! GP[2:servogun] ONLY ;
7: ! NOTE: Servo Tip Dresser will ;
7: ! not spin in step mode ;
8: !***************************** ;
9: ;
Page 180 of 305
13: OPEN GUN ;
14: ;
15: !------------------------------ ;
15: !Reset Signals ;
16: DO[118:WLD CTRL1 TD ENABLE]=OFF ;
16: RO[5:TIPDRSENB BLWFF1]=OFF ;
17: DO[876:SRVOTIPDRSSALERT]=OFF ;
18: DO[877:SRVOTIPDRSSFAULT]=OFF ;
19: DO[875:SRVOTIPDRSSOK]=OFF ;
21: ;
23: !CHECK FOR TD PERMISSIVES ;
DO[113:PLDTIP BYPASS ]=ON OR DO[130:SG MTR OTEMP 1]=ON OR DI[120:TD
BYPASSED 1]=ON,JMP LBL[99] ;
25: ;
26: !------------------------------ ;
28: ;
27: !TURN ON TIP DRESSER ON ;
28: DO[118:WLD CTRL1 TD ENABLE]=ON ;
16: RO[5:TIPDRSENB BLWFF1]=ON ;
29: WAIT .50(sec) ;
38: ;
34: !------------------------------ ;
37: ;
38: !Dont Dress if motor problem ;
39: IF ($IS_MOR.$SERVO_READY[1]=0),JMP LBL[788] ;
40: ;
41: ! Do Servo Tip Dress Using ;
42: ! TIPDRESS Instruction ;
43: ! Use TD=1 for new tip ;
44: ! Use correct P= for new tip ;
45: ;
46: ! Record the position with ;
47: ! fixed tip at cutting position ;
48: ! set SD/ED that'll clear dresser ;
49: ! ;
50: TIPDRESS[SD=2,EP=0,P=94,TD=1,ED=2] ;
51: ;
52: !Set Servo TD-OK if no alerts ;
53: IF (!DO[876:SRVOTIPDRSSALERT] AND
!DO[877:SRVOTIPDRSSFAULT]),DO[875:SRVOTIPDRSSOK]=(ON) ;
56: ;
57: JMP LBL[789] ;
58: ;
59: !------------------------------ ;
60: !IF OLD Tip ;
61: LBL[456] ;
62: ;
40: ;

Page 181 of 305
43: ! Use TD=2 for old tip ;
44: ! Use correct P= for old tip ;
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
101: !UALM for Servo TD Motor Fault ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN ;
49: ;
54: !END OF PROGRAM ;
55: LBL[99:END OF PROGRAM] ;
56: ;
116: ;
117: !Move away from the Dresser ;
118: !Position away from the Dresser ;
119: !Recorded Here ;
120: ;
121: !Call the BLOWOFF TP program ;
122: ! Prevents the BLOWOFF macro ;
122: ! from being executed if ;
122: ! tip dress enable is OFF ;
122: IF DO[10044]=OFF AND DO[4:RBT IN TEACH]=ON,JMP LBL[350] ;
122: CALL BLOWOFF ;
122: LBL[350] ;
123: ;
/POS
/END

Page 182 of 305
Dresser MACRO for Simultaneous Welders with R-30iA
Controllers
BLOWOFF
been turned OFF.
change.

/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
5: ! ;
8: !***************************** ;
9: ;

Page 183 of 305
13: OPEN GUN ;
14: ;
15: !------------------------------ ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
34: !------------------------------ ;
37: ;
40: ;
43: ! Use TD=(1,0) for new tip ;
45: ;
49: ! ;
50: TIPDRESS[SD=2,EP=0,P=94,TD=(1,0),ED=2] ;
51: ;
56: ;
57: JMP LBL[789] ;
58: ;
59: !------------------------------ ;
60: !IF OLD Tip ;
61: LBL[456] ;
62: ;
40: ;

Page 184 of 305
43: ! Use TD=(2,0) for old tip ;
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN ;
49: ;
56: ;
116: ;
120: ;
122: CALL BLOWOFF ;
122: LBL[350] ;
123: ;
/POS
/END

Page 185 of 305
Dresser MACRO for R-30iB Controllers
BLOWOFF
been turned OFF.
change.

/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
5: ! ;
8: !***************************** ;
9: ;
Page 186 of 305
13: OPEN GUN ;
14: ;
15: !------------------------------ ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
34: !------------------------------ ;
37: ;
40: ;
45: ;
49: ! ;
50: TIPDRESS[SD=2,EP=0,P=94,t=0.0,TD=1,ED=2] ;
51: ;
56: ;
57: JMP LBL[789] ;
58: ;
59: !------------------------------ ;
60: !IF OLD Tip ;
61: LBL[456] ;
62: ;
40: ;

Page 187 of 305
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN ;
49: ;
56: ;
116: ;
120: ;
122: CALL BLOWOFF ;
122: LBL[350] ;
123: ;
/POS
/END

Page 188 of 305
Dresser MACRO for Simultaneous Welders with R-30iB
Controllers
BLOWOFF
been turned OFF.
change.

/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
5: ! ;
8: !***************************** ;
9: ;

Page 189 of 305
13: OPEN GUN ;
14: ;
15: !------------------------------ ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
34: !------------------------------ ;
37: ;
40: ;
45: ;
49: ! ;
50: TIPDRESS[SD=2,EP=0,P=94,t=0.0,TD=(1,0),ED=2] ;
51: ;
56: ;
57: JMP LBL[789] ;
58: ;
59: !------------------------------ ;
60: !IF OLD Tip ;
61: LBL[456] ;
62: ;
40: ;

Page 190 of 305
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN ;
49: ;
56: ;
116: ;
120: ;
122: CALL BLOWOFF ;
122: LBL[350] ;
123: ;
/POS
/END

Page 191 of 305
6.16 PEDTDMC2S - Pedestal Tip Dress Dump with Servo Tip
Dress MACRO for R-30iA Controllers
BLOWOFF
been turned OFF.
change.
This macro turns on the tip dresser for gun 2. It is called by the TPDRSMC2 program
for pedestal tip dress dump for Gun 2.
/PROG PEDTDMC2S Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "PED GUN SERVO TD 2 MAC";
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO PED SERVO TIP DRESS 2 ;
3: ! ;
4: ! Pedestal SERVO Tip Dress 2;
5: ! ;
8: !***************************** ;
Page 192 of 305
9: ;
13: OPEN GUN2 ;
14: ;
15: !------------------------------ ;
17: DO[868:SRVOTIPDRSSALERT2]=OFF ;
18: DO[869:SRVOTIPDRSSFAULT2]=OFF ;
19: DO[867:SRVOTIPDRSSOK2]=OFF ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
42: !------------------------------ ;
56: ;
59: ;
66: ;
69: ! ;
70: TIPDRESS[SD=2,EP=0,P=94,TD=1,EP=0,ED=2] ;
71: ;
73: IF (!DO[868:STD Alert2] AND !DO[869:STD Fault2]),DO[867:STD-
OK2]=(ON) ;
74: DO[868:STD Alert2]=OFF ;
75: DO[869:STD Fault2]=OFF ;
76: ;
77: JMP LBL[789] ;
78: ;
79: !------------------------------ ;
80: !IF OLD Tip ;
81: LBL[456] ;
89: ;
Page 193 of 305
40: ;
45: ;
49: ! ;
51: ;
53: IF (!DO[868:SRVOTIPDRSSALERT2] AND
!DO[869:SRVOTIPDRSSFAULT2]),DO[867:SRVOTIPDRSSOK2]=(ON) ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN2 ;
49: ;
56: ;
116: ;
120: ;
122: ! tip dress enable 2 is OFF ;
122: CALL BLOWOFF2 ;
122: LBL[350] ;
123: ;
/POS
/END

Page 194 of 305
Dress MACRO for Simultaneous Welders with R-30iA
Controllers
BLOWOFF
been turned OFF.
change.

/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
5: ! ;

Page 195 of 305
8: !***************************** ;
9: ;
13: OPEN GUN2 ;
14: ;
15: !------------------------------ ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
42: !------------------------------ ;
56: ;
59: ;
66: ;
69: ! ;
70: TIPDRESS[SD=2,EP=0,P=94,TD=(0,1),EP=0,ED=2] ;
71: ;
OK2]=(ON) ;
76: ;
77: JMP LBL[789] ;
78: ;
79: !------------------------------ ;
80: !IF OLD Tip ;
81: LBL[456] ;
89: ;
Page 196 of 305
40: ;
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN2 ;
49: ;
56: ;
116: ;
120: ;
122: LBL[350] ;
123: ;
/POS
/END

Page 197 of 305
Dress MACRO for R-30iB Controllers
BLOWOFF
been turned OFF.
change.

/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
5: ! ;
8: !***************************** ;

Page 198 of 305
9: ;
13: OPEN GUN2 ;
14: ;
15: !------------------------------ ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
42: !------------------------------ ;
56: ;
59: ;
66: ;
69: ! ;
70: TIPDRESS[SD=2,EP=0,P=94,t=0.0,TD=1,EP=0,ED=2] ;
71: ;
OK2]=(ON) ;
76: ;
77: JMP LBL[789] ;
78: ;
79: !------------------------------ ;
80: !IF OLD Tip ;
81: LBL[456] ;
89: ;
Page 199 of 305
40: ;
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN2 ;
49: ;
56: ;
116: ;
120: ;
122: LBL[350] ;
123: ;
/POS
/END

Page 200 of 305
Dress MACRO for Simultaneous Welders with R-30iB
Controllers
BLOWOFF
been turned OFF.
change.

/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 1466;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = CGTDM;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 1850;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
5: ! ;

Page 201 of 305
8: !***************************** ;
9: ;
13: OPEN GUN2 ;
14: ;
15: !------------------------------ ;
21: ;
25: ;
26: !------------------------------ ;
28: ;
29: WAIT .50(sec) ;
38: ;
42: !------------------------------ ;
56: ;
59: ;
66: ;
69: ! ;
70: TIPDRESS[SD=2,EP=0,P=94,t=0.0,TD=(0,1),EP=0,ED=2] ;
71: ;
OK2]=(ON) ;
76: ;
77: JMP LBL[789] ;
78: ;
79: !------------------------------ ;
80: !IF OLD Tip ;
81: LBL[456] ;
89: ;
Page 202 of 305
40: ;
45: ;
49: ! ;
51: ;
44: ;
57: JMP LBL[789] ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;
105: LBL[789] ;
105: ;
48: OPEN GUN2 ;
49: ;
56: ;
116: ;
120: ;
122: LBL[350] ;
123: ;
/POS
/END

Page 203 of 305
6.20 TPWEARC1 - TIP WEAR COMPENSATION
For Pedestal Tip Dress Dump Application ONLY
WR_UPDAT(#,#) = 1 STEP METHOD
TW_UPDAT(#,#) = 2 STEP METHOD – CARRIED SWG APPLICATION ONLY
This program is a GROUP#2 ONLY and GROUP#3 (if (2) Pedestal Welders).
This program can run automatically in the background. This is run in background
from PG21 and called from TPDRSMAC.
/PROG TPWEARC1
/ATTR
OWNER = MNEDITOR;
COMMENT = "TIPWEAR MACRO";
PROG_SIZE = 2524;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 92;
MEMORY_SIZE = 2928;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
/MN
1: !******************************** ;
2: !TIPWEAR MACRO ;
3: ! ;
4: !Macro use everytime when robot ;
5: ! moves home ;
6: ! Runs in the background ;
8: ! GP[2:servogun] motion ONLY ;
9: !******************************** ;
10: ;
11: ;
12: !FLAG to tell robot that Tip Wear ;
Page 204 of 305
13: ! Routine is being run ;
14: !Don't end Main program until ;
15: ! Flag is OFF ;
16: F[1:RunningTipWearR]=(ON) ;
17: ;
18: !******************************** ;
19: ! ENTER INDEPENDENT ZONE ;
20: ! Let everyone know we are ;
24: ;
28: ;
29: !******************************** ;
33: ;
35: ! to the END of program ;
36: IF DI[958:PULLTIPBYPS1]=ON,JMP LBL[999] ;
37: ;
38: ;
39: !******************************** ;
40: !Run Tip Wear Update Routine ;
41: !******************************** ;
42: ;
45: IF DI[669:NEW TIP]=ON,JMP LBL[1] ;
46: ;
47: !Call Tip Wear Update with NO NEW ;
48: ! Program to update Tip ;
49: ! location ;
50: ! (1) represents Gun1 ;
51: ! (0) not a new tip installed ;
52: CALL WR_UPDAT(1,0) ;
53: ;
54: ! Jump to the END of program ;
55: JMP LBL[999] ;
56: ;
57: ;
58: !Label to jump to, if it is a new ;
59: ! tip ;
60: LBL[1:New Tip] ;
65: ;
66: !Call Tip Update with NEW TIP ;
68: ;
69: !Label to jump to when finished ;
70: ! tip calibration ;
71: LBL[999:Done] ;
72: ;
73: !**************************** ;
74: !NOTE: REMOVE INDEPENDENT ;
75: ! MOTION ZONE 2 LOGIC ;
76: ! WHEN CARRIED APP ON ;
77: ;
68: !******************************** ;

Page 205 of 305
69: ! EXIT INDEPENDENT ZONE ;
70: ! Let everyone know we are ;
74: ;
78: !******************************** ;
88: ;
89: ;
91: ! Routine has ended ;
92: F[1:RunningTipWearR]=(OFF) ;
/POS
/END

Page 206 of 305
6.21 TPWEARC2 - TIP WEAR COMPENSATION
For Pedestal Tip Dress Dump Application ONLY
WR_UPDAT(#,#) = 1 STEP METHOD
TW_UPDAT(#,#) = 2 STEP METHOD – CARRIED SWG APPLICATION ONLY
This program is a GROUP#2 ONLY and GROUP#3 (if (2) Pedestal Welders).
This program can run automatically in the background. This is run in background
from PG21 and called from TPDRSMC2.
/PROG TPWEARC2
/ATTR
OWNER = MNEDITOR;
COMMENT = "TIPWEAR 2 MACRO";
PROG_SIZE = 2410;
CREATE = DATE 09-07-25 TIME 13:37:02;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 92;
MEMORY_SIZE = 2814;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
/MN
1: !******************************** ;
2: !TIPWEAR MACRO ;
3: ! ;
4: !Macro use everytime when robot ;
5: ! moves home ;
6: ! Runs in the background ;
8: ! GP[2:servogun] motion ONLY ;
9: !******************************** ;
10: ;
11: ;
Page 207 of 305
13: ! Routine is being run ;
14: ! Don't end Main program until ;
15: ! this Flag is OFF ;
16: F[2]=(ON) ;
17: ;
18: !**************************** ;
23: !ENTER ZONE ;
26: !MOTION ZONE 14 ;
28: ;
29: ! Wait for ;
32: !**************************** ;
33: ;
35: ! to the END of program ;
36: IF DI[959:PULLTIPBYPS2]=ON,JMP LBL[999] ;
37: ;
38: ;
39: !******************************** ;
40: !Run Tip Wear Update Routine ;
41: !******************************** ;
42: ;
45: IF DI[733:New Tip2]=ON,JMP LBL[1] ;
46: ;
47: !Call Tip Wear Update with NO NEW ;
48: ! Program to update Tip ;
49: ! location ;
50: ! (2) represents Gun2 ;
51: ! (0) not a new tip installed ;
53: ;
54: ! Jump to the END of program ;
55: JMP LBL[999] ;
56: ;
57: ;
58: !Label to jump to, if it is a new ;
59: ! tip ;
60: LBL[1:New Tip] ;
65: ;
66: !Call Tip Update with NEW TIP ;
68: ;
69: !Label to jump to, finished tip c ;
70: ! calibration ;
71: LBL[999:Done] ;
72: ;
73: !**************************** ;
74: !NOTE: REMOVE INDEPENDENT ;
75: ! MOTION ZONE 2 LOGIC ;
76: ! WHEN CARRIED APP ONLY ;
77: ;
78: !ENTER ZONE ;

Page 208 of 305
81: !MOTION ZONE 14 ;
83: ;
84: ! Wait for ;
87: !**************************** ;
88: ;
89: ;
91: ! Routine has ended ;
92: F[2:RunningTipWearR2]=(OFF) ;
/POS
/END

Page 209 of 305
6.22 TW_UPD01 - TIP WEAR UPDATE GUN 1
For Carried Application ONLY
-USE Calibration Plate
Measure the tip wear using the 2-step method for gun 1 (uses a plate).
/PROG TW_UPD01
/ATTR
OWNER = MNEDITOR;
COMMENT = "Update TW on Gun1";
PROG_SIZE = 982;
CREATE = DATE 06-02-28 TIME 16:57:28;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 31;
MEMORY_SIZE = 1366;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
/MN
1: !***************************** ;
1: !Program description ;
2: ! Update wear measurement for ;
3: ! gun number 1 using fixture-. ;
4: ! based wear measurement ;
5: ;
6: ! Arguments to TW_UPDAT ;
8: !Parm2: new tips:1,used tips:0 ;
9: ;
10: !Note: Parm2 is used only ;
11: ! for measurement error checking ;
12: ! ( increased error function). ;
13: !Parm2 should be <>0 at cap ;
14: ! change only. ;
15: !If measurement error checkng ;
16: ! is NOT used, then Parm2 ;
17: ! should always be 0. ;
18: ;
19: !***************************** ;
23: ! New Tip Installed ;
26: ;
24: CALL TW_UPDAT(1,1) ;
25: END ;
26: ;
26: ;
27: !***************************** ;

Page 210 of 305
29: LBL[456] ;
30: ;
32: ;
/POS
/END

Page 211 of 305
6.23 TW_UPD02 - TIP WEAR UPDATE GUN 2
For Carried Application ONLY
-USE Calibration Plate
Measure the tip wear using the 2-step method for gun 2 (uses a plate).
/PROG TW_UPD02
/ATTR
OWNER = MNEDITOR;
COMMENT = "Updat TW on Gun2";
PROG_SIZE = 982;
CREATE = DATE 06-02-28 TIME 16:57:28;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 31;
MEMORY_SIZE = 1366;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
/MN
1: !***************************** ;
2: !Program description ;
3: ! Update wear measurement for ;
4: ! gun number 2 using fixture-. ;
5: ! based wear measurement ;
6: ;
7: ! Arguments to TW_UPDAT ;
9: !Parm2: new tips:1,used tips:0 ;
10: ;
11: !Note: Parm2 is used only ;
12: ! for measurement error checking ;
13: ! ( increased error function). ;
14: !Parm2 should be <>0 at cap ;
15: ! change only. ;
16: !If measurement error checkng ;
16: ! is NOT used, then Parm2 ;
18: ! should always be 0. ;
19: ;
20: !***************************** ;
24: ! New Tip Installed ;
26: ;
26: END ;
27: ;
28: !***************************** ;
30: LBL[456] ;

Page 212 of 305
31: ;
33: ;
/POS
/END

Page 213 of 305
6.24 TIP_MEAS1 – Gun 1 Tip Wear Cutter Warning
This program is called in PG10. The reason for recording this value was to give the
plant an idea as to how many dresses are occurring for a single tip and compare it
with the estimated number of dresses from the welding engineers. The program also
contains a check after 10 tip dresses to see if one tip is wearing faster than the other
tip by a specified amount. This program is used for Trend tracking only and does not
indicate or calculate the tip wear amounts; tip wear amounts are calculated in the
internal Fanuc Software.
*** DO[438:TipWearWarn] is pulsed to the PLC if a trend is detected indicating

that one tip is wearing faster than the other.
***DO[888:TipWearMovingWC#1] or DO[888:TipWearMovingWC#1] and

DO[139:TipChgReqWC#1] will be activated if Wear of one of the Tips exceeds
the Max Tip Wear setting
/PROG TIP_MEAS1 Macro
/ATTR
OWNER = MNEDITOR;
COMMENT = "CHK TIPWEAR MEAS";
PROG_SIZE = 1880;
CREATE = DATE 10-09-21 TIME 08:48:30;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 65;
MEMORY_SIZE = 2408;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !*************************** ;
2: !TIP CUTTER WARNING MACRO ;
3: !*************************** ;
4: ;
5: !REG.BELOW CAPTURE USER INPUT MAX ;
6: !WEAR DWN VALS(MENU/SETUP/SRVGUN) ;
7: R[45:MaxMoveableTipwr]=($SGGUN1.$SETUP.$MAXWDNTIP) ;
8: R[46:MaxFixedTipwr]=($SGGUN1.$SETUP.$MAXWDNRBT) ;
9: ;
10: ;
11: !REG.BELOW CAPTURE CURRENT TIP ;
12: !WEAR AMOUNT (STATUS/Servogun) ;
13: R[47:WRDWN_TIP]=($SGGUN1.$SETUP.$WRDWN_TIP) ;
14: R[48:ActualFiwedTipwr]=($SGGUN1.$SETUP.$WRDWN_RBT) ;
15: ;

Page 214 of 305
16: ;
17: !CHECK IF ACTUAL TIPWEAR AMOUNT ;
18: ! IS GREATER THAN MAX WEAR DWN ;
19: IF (R[47:WRDWN_TIP]>R[45:MaxMoveableTipwr]),JMP LBL[1] ;
20: IF (R[48:ActualFiwedTipwr]>R[46:MaxFixedTipwr]),JMP LBL[1] ;
21: ;
22: ;
23: !RECORD 1ST TIPWEAR MEASUREMENT ;
24: ! ON 1ST TIP DRESS ;
25: IF (R[49:Number of Tip dr]=1),R[44:Amt]=(R[47:WRDWN_TIP]) ;
26: ;
27: ;
28: !SET COUNTER TO 10 ON THE 11TH DR ;
29: IF (R[49:Number of Tip dr]=11),R[42:Tip Dress Counte]=10 ;
30: ;
31: !ADD TO COUNTER AFTER 11TH DRESS ;
32: IF (R[49:Number of Tip dr]>11),R[42:Tip Dress Counte]=R[42:Tip
Dress Counte]+1 ;
33: ;
30: !CHECK IF ONE TIP IS WEARING FASTER THAN ;
30: ! THE OTHER TIP AFTER 10 TIP DRESSES ;
30: ! IF IT IS, SET AN OUTPUT TO PLC ;
30: IF (R[49:Number of Tip dr]<10),JMP LBL[20] ;
30: ;
30: !CHECK TO SEE IF MOVEABLE TIP IS WEARING FASTER ;
30: ! THAN THE STATIONARY TIP ;
30: IF (R[47:WRDWN_TIP]-R[48:ActualFixedTipwr]>=R[83:Max Tip
Wear]),DO[438:TipWearWarn]=PULSE,2.0sec ;
30: ;
30: !CHECK TO SEE IF STATIONARY TIP IS WEARING FASTER ;
30: ! THAN MOVEABLE TIP ;
30: IF (R[48:AcutalFixedTipwr]-R[47:WRDWN_TIP]>=R[83:Max Tip
30: ;
30: LBL[20] ;
34: !CALCULATE AVG TIPWEAR ;
35: IF (R[49:Number of Tip dr]>=11),R[43:Avg
Wear]=((R[47:WRDWN_TIP]-R[44:Amt])/R[42:Tip Dress Counte]) ;
36: ;
37: !SET TIP CUTTER WARNING ;
38: IF (R[49:Number of Tip dr]>=11 AND R[43:Avg
Wear]<.02),DO[433:TIPCUTWARN#1]=PULSE,0.5sec ;
39: ;
39: !------------------------------;
39: !CHECK TIP WEAR ;
40: LBL[1] ;
40: ;
42: ! IS LESS THAN OR EQUAL TO MAX ;
43: ! WEAR ;
44: IF (R[47:WRDWN_TIP]<=R[45:MaxMoveableTipwr]),JMP LBL[35] ;
44: ;
44: !CHANGE REQUIRED ;
44: ! ON MOVEABLE TIP ;
44: DO[888:TipWearMovingWC#1]=ON ;
44: ;
44: LBL[35] ;
44: ;
45: IF (R[48:ActualFiwedTipwr]<=R[46:MaxFixedTipwr]),JMP LBL[36] ;
46: ;
44: ! ON FIXED TIP ;
47: DO[889:TipWearFixedWC#1]=ON ;
47: ;
47: LBL[36] ;
Page 215 of 305
48: ;
/POS
/END

Page 216 of 305
6.25 TIP_MEAS2 – Gun 2 Tip Wear Cutter Warning
This program is called in PG10. The reason for recording this value was to give the
plant an idea as to how many dresses are occurring for a single tip and compare it
with the estimated number of dresses from the welding engineers. The program also
contains a check after 10 tip dresses to see if one tip is wearing faster than the other
tip by a specified amount. This program is used for Trend tracking only and does not
indicate or calculate the tip wear amounts; tip wear amounts are calculated in the
internal Fanuc Software.
*** DO[439:TipWearWarn] is pulsed to the PLC if a trend is detected indicating

that one tip is wearing faster than the other.
***DO[898:TipWearMovingWC#2] or DO[899:TipWearMovingWC#2] and

DO[171:TipChgReqWC#2] will be activated if Wear of one of the Tips exceeds
the Max Tip Wear setting
/PROG TIP_MEAS2 Macro
/ATTR
OWNER = MNEDITOR;
COMMENT = "CHK TIPWEAR MEAS";
PROG_SIZE = 1810;
CREATE = DATE 10-09-21 TIME 08:48:30;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 61;
MEMORY_SIZE = 2226;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !*************************** ;
2: !TIP CUTTER WARNING MACRO ;
3: !SERVO GUN 2 ;
4: !*************************** ;
5: ;
6: !REG.BELOW CAPTURE USER INPUT MAX ;
7: !WEAR DWN VALS(MENU/SETUP/SRVGUN) ;
8: R[55:MaxMoveableTipwr]=($SGGUN2.$SETUP.$MAXWDNTIP) ;
9: R[56:MaxFixedTipwr]=($SGGUN2.$SETUP.$MAXWDNRBT) ;
10: ;
11: ;
12: !REG.BELOW CAPTURE CURRENT TIP ;
13: !WEAR AMOUNT (STATUS/Servogun) ;
14: R[57:WRDWN_TIP]=($SGGUN2.$SETUP.$WRDWN_TIP) ;
15: R[58:ActualFiwedTipwr]=($SGGUN2.$SETUP.$WRDWN_RBT) ;

Page 217 of 305
16: ;
17: ;
19: ! IS GREATER THAN MAX WEAR DWN ;
20: IF (R[57:WRDWN_TIP]>R[55:MaxMoveableTipwr]),JMP LBL[1] ;
21: IF (R[58:ActualFiwedTipwr]>R[56:MaxFixedTipwr]),JMP LBL[1] ;
22: ;
23: ;
24: !RECORD 1ST TIPWEAR MEASUREMENT ;
25: ! ON 1ST TIP DRESS ;
26: IF (R[59:Number of Tip dr]=1),R[54:Amt]=(R[57:WRDWN_TIP]) ;
27: ;
28: ;
29: !SET COUNTER TO 10 ON THE 11TH DR ;
30: IF (R[59:Number of Tip dr]=11),R[52:Tip Dress Counte]=10 ;
31: ;
32: !ADD TO COUNTER AFTER 11TH DRESS ;
33: IF (R[59:Number of Tip dr]>11),R[52:Tip Dress Counte]=R[52:Tip
Dress Counte]+1 ;
34: ;
30: !CHECK IF ONE TIP IS WEARING FASTER THAN ;
30: ! THE OTHER TIP AFTER 10 TIP DRESSES ;
30: ! IF IT IS, SET AN OUTPUT TO PLC ;
30: IF (R[59:Number of Tip dr]<10),JMP LBL[20] ;
30: ;
30: !CHECK TO SEE IF MOVEABLE TIP IS WEARING FASTER ;
30: ! THAN THE STATIONARY TIP ;
30: IF (R[57:WRDWN_TIP]-R[58:ActualFixedTipwr]>=R[84:Max Tip
30: ;
30: !CHECK TO SEE IF STATIONARY TIP IS WEARING FASTER ;
30: ! THAN MOVEABLE TIP ;
30: IF (R[58:AcutalFixedTipwr]-R[57:WRDWN_TIP]>=R[84:Max Tip
30: ;
30: LBL[20] ;
35: !CALCULATE AVG TIPWEAR ;
36: IF (R[59:Number of Tip dr]>=11),R[53:Avg
Wear]=((R[57:WRDWN_TIP]-R[54:Amt])/R[52:Tip Dress Counte]) ;
37: ;
38: !SET TIP CUTTER WARNING ;
39: IF (R[59:Number of Tip dr]>=11 AND R[53:Avg
Wear]<.02),DO[433]=PULSE,0.5sec ;
40: ;
39: !------------------------------;
39: !CHECK TIP WEAR ;
40: LBL[1] ;
40: ;
42: ! IS LESS THAN OR EQUAL TO MAX ;
43: ! WEAR ;
44: IF (R[57:WRDWN_TIP]<=R[55:MaxMoveableTipwr]),JMP LBL[35] ;
44: ;
44: ! ON MOVEABLE TIP ;
44: DO[898:TipWearMovingWC#2]=ON ;
44: ;
44: LBL[35] ;
44: ;
45: IF (R[58:ActualFiwedTipwr]<=R[56:MaxFixedTipwr]),JMP LBL[36] ;
46: ;
44: ! ON FIXED TIP ;
47: DO[899:TipWearFixedWC#2]=ON ;
47: ;
Page 218 of 305
47: LBL[36] ;
48: ;
/POS
/END

Page 219 of 305
6.26 WELD1ENB MACRO
This macro enables welding once, with no retries. This macro is called from another
TP program. (for example from PG08)
/PROG WELD1ENB Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "SET WELD RETRY 1";
PROG_SIZE = 858;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 21;
MEMORY_SIZE = 1174;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! Number of Retries ;
3: ! ;
4: ! 0 = Weld only ONCE ;
5: ! 1 = Weld + one retry ;
6: ! 3 = Weld + three retries ;
7: ! ;
11: !***************************** ;
12: ;
13: ! Set the number of weld retries ;
14: $SPOTADVFUNC.$NUM_RETRIES=0 ;
/POS
/END

Page 220 of 305
6.27 WELD1DIS MACRO
This macro re-enables welding with retries. This macro is called from another TP
program (for example from PG08).
/PROG WELD1DIS Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "SET WELD RETRY 3";
PROG_SIZE = 858;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 21;
MEMORY_SIZE = 1174;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! Number of Retries ;
3: ! ;
4: ! 0 = Weld only ONCE ;
5: ! 1 = Weld + one retry ;
6: ! 3 = Weld + three retries ;
7: ! ;
11: !***************************** ;
12: ;
14: $SPOTADVFUNC.$NUM_RETRIES=3 ;
/POS
/END

Page 221 of 305
6.28 WELDHOME MACRO for R-30iA Controllers
This macro executes when the robot is at HOME and the manual weld push button is
pressed, or the PLC remote manual weld button. Please make sure to enable only
group 2 (gun) motion on this macro.
The macro table should be set up with macro number 32 = WELDHOME, which
should be triggered by DI[902], which is an input defined as follows:
1. Robot at home
2. Program not running
3. Program not paused
4. DO[967: MANUALWELD1PB] or DI[REMOTE MANUALWELD1] pressed
Please set up a pressure 26 with any common pressure (i.e. 220 pounds) and a part
thickness of 0 (zero).
/PROG WELDHOME Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "WELDHOME";
PROG_SIZE = 870;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 23;
MEMORY_SIZE = 1146;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELDHOME MACRO ;
3: ! ;
4: ! Triggered by DI[902:WeldHome] ;
5: ! Manual Weld Button in ;
6: ! I/F Screen ;
7: ! ;
10: !***************************** ;
12: !Read current weld schedule ;
13: R[4:Weld Sched Num]=GO[7:MANUALWELDW1BITS] ;
14: ;
15: SPOT[SD=3,0, EP=0,0, P=1,0, S=R[4],0, EP=0,0, ED=3,0] ;
/POS
/END

Page 222 of 305
6.29 WELDHOME MACRO for R-30iB Controllers
The macro table should be set up with macro number 32 = WELDHOME, which
5. Robot at home
8. DO[967: MANUALWELD1PB] or DI[REMOTE MANUALWELD1] pressed
/PROG WELDHOME Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "WELDHOME";
PROG_SIZE = 870;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 23;
MEMORY_SIZE = 1146;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
6: ! I/F Screen ;
7: ! ;
10: !***************************** ;
11: ;
14: ;
15: SPOT[SD=3,0, EP=0,0, P=1,0, t=0.0,0.0, S=R[4],0, EP=0,0,
ED=3,0] ;

Page 223 of 305
/POS
/END

Page 224 of 305
6.30 WELDHOM2 MACRO for R-30iA Controllers
The macro table should be set up with macro number 42 = WELDHOM2, which
1. Robot at home
4. DO[968: MANUALWELD2PB] or DI[REMOTE MANUAL WELD2] pressed
/PROG WELDHOM2 Macro
/ATTR
OWNER = MNEDITOR;
COMMENT = "WELD HOME 2";
PROG_SIZE = 870;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 23;
MEMORY_SIZE = 1146;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
6: ! I/F Screen ;
7: ! ;
10: !***************************** ;
11: ;
13: R[6:Weld Sched Num2]=GO[9:MANUALWELDW2BITS] ;
14: ;
15: SPOT[SD=0,3, EP=0,0, P=0,1, S=0,R[6], EP=0,0, ED=0,3] ;
/POS
/END

Page 225 of 305
6.31 WELDHOM2 MACRO for R-30iB Controllers
The macro table should be set up with macro number 42 = WELDHOM2, which
5. Robot at home
8. DO[968: MANUALWELD2PB] or DI[REMOTE MANUAL WELD2] pressed
/PROG WELDHOM2 Macro
/ATTR
OWNER = MNEDITOR;
COMMENT = "WELD HOME 2";
PROG_SIZE = 870;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 23;
MEMORY_SIZE = 1146;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
6: ! I/F Screen ;
7: ! ;
10: !***************************** ;
11: ;
13: R[6:Weld Sched Num2]=GO[9:MANUALWELDW2BITS] ;
14: ;
15: SPOT[SD=0,3, EP=0,0, P=0,1, t=0.0,0.0, S=0,R[6], EP=0,0,
ED=0,3] ;
16: ;

Page 226 of 305
/POS
/END

Page 227 of 305
6.32 WELDONCE MACRO
This macro executes when a weld fault occurs (and thus DO7:Time Delay Exceeded
turns ON), and either the manual weld push button is pressed, or the PLC remote
weld button is pressed. This macro should be added in the macro table (31), which
should be set up to trigger this macro when DI[121: REM MAN WELD 1] is turned
ON.
/PROG WELDONCE Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "WELDONCE";
PROG_SIZE = 862;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 24;
MEMORY_SIZE = 1142;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELDONCE MACRO ;
3: ! ;
5: ! ;
6: ! Triggered by DI[121:RemManWeld] ;
7: ! Used After a Weld Fault ;
8: ! ;
12: !***************************** ;
13: ;
14: ! Update robot variable ;
15: CALL WELD1ENB ;
16: ;
17: ! Fault Reset ;
18: DO[959:FAULTRESET]=PULSE,0.5sec ;
19: ;
/POS
/END

Page 228 of 305
6.33 WELDONC2 MACRO
This macro executes when a weld fault occurs (and thus DO7:Time Delay Exceeded
turns ON), and either the manual weld push button is pressed, or the PLC remote
weld button is pressed. This macro should be added in the macro table (41), which
should be set up to trigger this macro when DI[153:Call WeldOnc2 Macro] is turned
ON.
/PROG WELDONCE Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "WELDONCE";
PROG_SIZE = 862;
CREATE = DATE 10-01-12 TIME 16:01:56;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 24;
MEMORY_SIZE = 1142;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: !WELDONCE MACRO ;
3: ! ;
5: ! ;
6: ! Triggered by DI[153:RemManWeld2] ;
7: ! Used After a Weld Fault ;
8: ! ;
12: !***************************** ;
13: ;
14: ! Update robot variable ;
15: CALL WELD1ENB ;
16: ;
17: ! Fault Reset ;
18: DO[959:FAULTRESET]=PULSE,0.5sec ;
19: ;
/POS
/END

Page 229 of 305
6.34 MANWELD1 MACRO for R-30iA Controllers
This Macro is called from PG08 and sends a weld schedule for gun 1 when the robot
controller is set up with SEPARATE gun motion groups.
/PROG MANWELD1 Macro
/ATTR
OWNER = MNEDITOR;
COMMENT = "";
PROG_SIZE = 272;
CREATE = DATE 13-04-23 TIME 08:31:34;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 0;
MEMORY_SIZE = 516;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! Manual Tip Dress ;
3: ! Dual SWG ;
4: ! Sends Manual Weld 1 ;
5: ! ;
9: !***************************** ;
10: ;
11: !Save the man. wld. schedule ;
13: ;
14: !Weld with part thickness 0 ;
15: !And manual weld schedule ;
16: SPOT[SD=2, EP=0, P=1, S=R[4], EP=0, ED=12] ;
17: ;
18: !Wait for the button release ;
19: WAIT DI[976:MANUALWELD1PB]=OFF ;
20: ;
/POS
/END

Page 230 of 305
6.35 MANWELD1 MACRO for R-30iB Controllers
/ATTR
OWNER = MNEDITOR;
COMMENT = "";
PROG_SIZE = 272;
CREATE = DATE 13-04-23 TIME 08:31:34;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 0;
MEMORY_SIZE = 516;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG ;
5: ! ;
9: !***************************** ;
10: ;
13: ;
16: SPOT[SD=2, EP=0, P=1, t=0.0, S=R[4], EP=0, ED=12] ;
17: ;
20: ;
/POS
/END

Page 231 of 305
6.36 MANWELD2 MACRO for R-30iA Controllers
/ATTR
OWNER = MNEDITOR;
COMMENT = "";
PROG_SIZE = 272;
CREATE = DATE 13-04-23 TIME 08:31:34;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 0;
MEMORY_SIZE = 516;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
DEFAULT_GROUP = *,*,1,*,*;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG ;
5: ! ;
9: !***************************** ;
10: ;
12: R[6:Weld Sched Num W]=GO[9:MANUALWELDW2BITS] ;
13: ;
16: SPOT[SD=2, EP=0, P=1, S=R[6], EP=0, ED=12] ;
17: ;
20: ;
/POS
/END

Page 232 of 305
6.37 MANWELD2 MACRO for R-30iB Controllers
/ATTR
OWNER = MNEDITOR;
COMMENT = "";
PROG_SIZE = 272;
CREATE = DATE 13-04-23 TIME 08:31:34;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 0;
MEMORY_SIZE = 516;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
DEFAULT_GROUP = *,*,1,*,*;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG ;
5: ! ;
9: !***************************** ;
10: ;
13: ;
16: SPOT[SD=2, EP=0, P=1, t=0.0, S=R[6], EP=0, ED=12] ;
17: ;
20: ;
/POS
/END

Page 233 of 305
6.38 PG08 – Manual Tip Dress for Carried Application for R-30iA
Controllers
NOTE1: Since the robot maybe in a confined area, make sure robot is Clear of
Transfer, when going to and from Home position.
NOTE2: Do NOT do a Manual Weld after changing tips. This will cause the
robot to do an Auto Tip Dress and stop at the tip dresser OR the robot may not
go to tip dress at all. If you find yourself in this situation, toggle NTSR to the
weld controller to clear the issue or do a Manual Weld and then initiate NTSR.
NOTE3: If there are SEPARATE gun motion groups, ONLY Group 1 is used.
Otherwise, Group 1 and Group 2 are used. See commented notes in the
program.
/PROG PG08
/ATTR
OWNER = MNEDITOR;
COMMENT = "Manual Tip Dress";
PROG_SIZE = 7291;
CREATE = DATE 10-05-10 TIME 14:50:46;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 338;
MEMORY_SIZE = 7735;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG - Carried ;
4: ! Moves robot to Maint Position ;
5: ! ;
Page 234 of 305
8: ! Separate motion is 1 group ;
8: ! Same motion is group 1 and 2 ;
9: !***************************** ;
10: ;
13: ;
14: !CLR TO ADV. TRANSFER ;
16: ;
18: PAYLOAD[2] ;
19: ;
21: UTOOL_NUM=1 ;
22: ;
24: UFRAME_NUM=1 ;
25: ;
27: SETUP OUTPUTS ;
28: ;
29: !Move to Home ;
31: ;
32: !Enable "number of retries=0" ;
33: WLD RETRY1 ENBLD ;
34: ;
35: ;
36: !------------------------------ ;
37: !Check for Inspect Request ;
38: IF DI[6:MAINT RQST PLC]=ON,JMP LBL[222] ;
39: ;
40: !Approach to Maint Pos ;
41:J P[1] 100% FINE ;
42:J P[2] 100% FINE ;
43: ;
44: !Maintenance Position ;
45:L P[3:Inspect Posn] 2000mm/sec FINE ;
46: ;
47: ! Wait for Tip Dress Dump 1 Macro ;
49: ;
52: ;
53: !OPEN GUN MACRO ;
54: OPEN GUN ;
55: ;
56: !OPEN GUN 2 MACRO ;
57: OPEN GUN2 ;
58: ;
59: ;
60: !Maint Position ON ;
61: DO[6:RBT AT MAINT]=ON ;
62: ;
62: !RESET Tip Change Required ;
62: ! DO[139] to PLC ;

Page 235 of 305
62: DO[888: Tip wear moving WC#1]=OFF ;
62: DO[889: Tip wear fixed WC#1]=OFF ;
62: ;
62: ! DO[139] to PLC ;
63: ;
64: !------------------------------ ;
65: !Label to jump after weld ;
66: LBL[1] ;
67: ;
71: !Wait for Maintenance Clear ;
72: ! Manual Weld PB or ;
73: ! Tip Alignment PB ;
74: WAIT (DI[7:MAINT POS CLR]=ON OR DO[967:MANUALWELD1PB]=ON OR
DO[968:MANUALWELD2PB]=ON OR DI[974:TIPALIGNCLOSED]=ON OR
DI[972]=ON OR RO[1:EQUALIZATION VALVE 1]=ON OR
RO[2:EQUALIZATION VALVE 2]=ON) ;
75: ;
79: !If maintenance clear, Jump Over ;
80: !the weld routine ;
81: IF DI[7:MAINT POS CLR]=ON,JMP LBL[8] ;
82: ;
83: !If TIP ALIGN was selected ;
84: IF DI[974:TIPALIGNCLOSED]=ON,JMP LBL[100] ;
85: ;
86: !If MANUAL WELD was selected ;
87: IF DO[967:MANUALWELD1PB]=ON,JMP LBL[101] ;
88: ;
90: IF DI[972]=ON,JMP LBL[110] ;
91: ;
94: ;
95: !ONLY If EQUALIZATION is Added to ;
96: !If EQUALIZATION was selected ;
97: IF RO[1:EQUALIZATION VALVE 1]=ON,JMP LBL[102] ;
98: ;
102: ;
103: ! jump back up ;
104: JMP LBL[1] ;
105: ;
106: ;
107: !------------------------------ ;
108: !TIP ALIGN ;
109: LBL[100] ;
110: ;
111: !CLOSE GUN MACRO ;
112: CLOSE GUN ;
113: ;
115: WAIT DI[974:TIPALIGNCLOSED]=OFF ;
116: ;
117: !Wait for the button press ;
118: WAIT DI[975:TIPALIGNOPEN]=ON ;
Page 236 of 305
119: ;
121: OPEN GUN ;
122: ;
123: !Wait for the buttons release ;
124: WAIT DI[975:TIPALIGNOPEN]=OFF ;
125: ;
128: ;
129: !Finished ALIGN Jump Back ;
130: JMP LBL[1] ;
131: ;
132: ;
133: !------------------------------ ;
134: !MANUAL WELD, ;
135: LBL[101] ;
136: ;
137: !Send manual weld schedule ;
137: !using MANWELD1 if using
137: ! SEPARATE gun motion groups ;
137: ! and then JMP LBL[1] ;
138: !CALL MANWELD1 ;
138: ;
138: !Done welding, Jump back ;
138: !JMP LBL[1] ;
139: ;
139: !If using SAME gun motion groups ;
139: ! then use the following- ;
139: ;
142: SPOT[SD=2,0, EP=0,0, P=1,0, S=(R[4],0), EP=0,0, ED=12,0] ;
143: ;
146: ;
148: JMP LBL[1] ;
149: ;
150: ;
151: !------------------------------ ;
152: !TIP ALIGN 2 ;
153: LBL[110] ;
154: ;
155: !CLOSE GUN 2 MACRO ;
156: CLOSE GUN2 ;
157: ;
159: WAIT DI[972]=OFF ;
160: ;
162: WAIT DI[973]=ON ;
163: ;
165: OPEN GUN2 ;

Page 237 of 305
166: ;
168: WAIT DI[973]=OFF ;
169: ;
171: WAIT DI[972]=OFF ;
172: ;
174: JMP LBL[1] ;
175: ;
176: ;
177: !------------------------------ ;
178: !MANUAL WELD2, ;
179: LBL[111] ;
180: ;
181: ;
181: !JMP LBL[1] ;
181: ;
183: ;
186: SPOT[SD=0,2, EP=0,0, P=0,1, S=(0,R[6]), EP=0,0, ED=0,12] ;
187: ;
190: ;
192: JMP LBL[1] ;
193: ;
194: !------------------------------ ;
195: !EQUALIZATION G1 ;
196: LBL[102] ;
197: ;
198: !Set GO[1] to pressure that will ;
199: !move the gun. This will ;
200: ! identify to the user that the ;
201: ! Equalization is working ;
202: GO[1:EQUALIZATION VALVE 1]=40 ;
203: ;
204: WAIT 1.00(sec) ;
205: ;
207: ;
208: WAIT 1.00(sec) ;
209: ;
211: ;
212: WAIT 1.00(sec) ;

Page 238 of 305
213: ;
215: ;
216: !Done, Jump back ;
217: JMP LBL[1] ;
218: ;
219: !------------------------------ ;
221: LBL[103] ;
222: ;
228: ;
229: WAIT 1.00(sec) ;
230: ;
232: ;
233: WAIT 1.00(sec) ;
234: ;
236: ;
237: WAIT 1.00(sec) ;
238: ;
240: ;
242: JMP LBL[1] ;
243: ;
244: !------------------------------ ;
245: LBL[7] ;
246: ;
247: DO[936:STEPPERRST1]=PULSE,1.0sec ;
248: ;
249: JMP LBL[9] ;
250: ;
251: ;
252: !------------------------------ ;
253: LBL[17] ;
254: ;
256: ;
257: JMP LBL[9] ;
258: ;
259: ;
260: !------------------------------ ;
261: !Maintenance clear ;
262: LBL[8] ;
263: ;
264: IF DI[120:TD BYPASSED 1]=ON,JMP LBL[7] ;
265: ;
267: ;
268: ;
269: !------------------------------ ;
270: LBL[9] ;
206: ;

Page 239 of 305
207: !Maint Position OFF ;
208: DO[6:RBT AT MAINT]=OFF ;
209: ;
203: !Depart pos. ;
204:J P[2] 100% FINE ;
205:J P[1] 100% FINE ;
206: ;
209: ;
301: !Set Number of retries ;
303: ;
304: JMP LBL[444] ;
305: ;
306: ;
307: !------------------------------ ;
308: LBL[222:INSPECT POS] ;
309: ;
310: !Approach to Inspect Pos ;
311:J P[1] 20% CNT100 ;
312:J P[2] 20% CNT100 ;
313: ;
314: !Inspect Position ;
315:L P[3:Inspect Posn] 200mm/sec CNT100 ;
316: ;
317: ;
320: ;
322: WAIT DI[7:MAINT POS CLR]=ON ;
323: ;
326: ;
327: LBL[444:WAIT FOR PLC] ;
328: ;
/POS
/END

Page 240 of 305
6.39 PG08 – Manual Tip Dress for Carried Application for R-30iB
Controllers
NOTE1: Since the robot maybe in a confined area, make sure robot is Clear of
program.
/PROG PG08
/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 7291;
CREATE = DATE 10-05-10 TIME 14:50:46;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 338;
MEMORY_SIZE = 7735;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG - Carried ;
5: ! ;

Page 241 of 305
9: !***************************** ;
10: ;
13: ;
16: ;
18: PAYLOAD[2] ;
19: ;
21: UTOOL_NUM=1 ;
22: ;
24: UFRAME_NUM=1 ;
25: ;
27: SETUP OUTPUTS ;
28: ;
29: !Move to Home ;
31: ;
34: ;
35: ;
36: !------------------------------ ;
39: ;
41:J P[1] 100% FINE ;
42:J P[2] 100% FINE ;
43: ;
45:L P[3:Inspect Posn] 2000mm/sec FINE ;
46: ;
49: ;
52: ;
54: OPEN GUN ;
55: ;
57: OPEN GUN2 ;
58: ;
59: ;
62: ;
Page 242 of 305
62: ! DO[139] to PLC ;
62: ;
62: ! DO[139] to PLC ;
63: ;
64: !------------------------------ ;
66: LBL[1] ;
67: ;
DI[972]=ON OR RO[1:EQUALIZATION VALVE 1]=ON OR
RO[2:EQUALIZATION VALVE 2]=ON) ;
75: ;
82: ;
85: ;
88: ;
90: IF DI[972]=ON,JMP LBL[110] ;
91: ;
92: !and a 2 gun on SEPARATE motion ;
92: ! group setup is being used ;
94: ;
98: ;
102: ;
104: JMP LBL[1] ;
105: ;
106: ;
107: !------------------------------ ;
108: !TIP ALIGN ;
109: LBL[100] ;
110: ;
112: CLOSE GUN ;
113: ;
Page 243 of 305
116: ;
119: ;
121: OPEN GUN ;
122: ;
125: ;
128: ;
130: JMP LBL[1] ;
131: ;
132: ;
133: !------------------------------ ;
135: LBL[101] ;
136: ;
138: ;
138: !JMP LBL[1] ;
138: ;
139: ;
142: SPOT[SD=2,0, EP=0,0, P=1,0, t=0.0,0.0, S=(R[4],0), EP=0,0,
ED=12,0] ;
143: ;
146: ;
148: JMP LBL[1] ;
149: ;
150: ;
151: !------------------------------ ;
152: !TIP ALIGN 2 ;
153: LBL[110] ;
154: ;
156: CLOSE GUN2 ;
157: ;
159: WAIT DI[972]=OFF ;
160: ;

Page 244 of 305
162: WAIT DI[973]=ON ;
163: ;
165: OPEN GUN2 ;
166: ;
168: WAIT DI[973]=OFF ;
169: ;
171: WAIT DI[972]=OFF ;
172: ;
174: JMP LBL[1] ;
175: ;
176: ;
177: !------------------------------ ;
179: LBL[111] ;
180: ;
181: ;
181: !JMP LBL[1] ;
181: ;
183: ;
186: SPOT[SD=0,2, EP=0,0, P=0,1, t=0.0,0.0, S=(0,R[6]), EP=0,0,
ED=0,12] ;
187: ;
190: ;
192: JMP LBL[1] ;
193: ;
194: !------------------------------ ;
196: LBL[102] ;
197: ;
203: ;
204: WAIT 1.00(sec) ;
205: ;
207: ;

Page 245 of 305
208: WAIT 1.00(sec) ;
209: ;
211: ;
212: WAIT 1.00(sec) ;
213: ;
215: ;
217: JMP LBL[1] ;
218: ;
219: !------------------------------ ;
221: LBL[103] ;
222: ;
228: ;
229: WAIT 1.00(sec) ;
230: ;
232: ;
233: WAIT 1.00(sec) ;
234: ;
236: ;
237: WAIT 1.00(sec) ;
238: ;
240: ;
242: JMP LBL[1] ;
243: ;
244: !------------------------------ ;
245: LBL[7] ;
246: ;
248: ;
249: JMP LBL[9] ;
250: ;
251: ;
252: !------------------------------ ;
253: LBL[17] ;
254: ;
256: ;
257: JMP LBL[9] ;
258: ;
259: ;
260: !------------------------------ ;
262: LBL[8] ;
263: ;
265: ;

Page 246 of 305
267: ;
268: ;
269: !------------------------------ ;
270: LBL[9] ;
206: ;
209: ;
203: !Depart pos. ;
204:J P[2] 100% FINE ;
205:J P[1] 100% FINE ;
206: ;
209: ;
303: ;
304: JMP LBL[444] ;
305: ;
306: ;
307: !------------------------------ ;
309: ;
311:J P[1] 20% CNT100 ;
312:J P[2] 20% CNT100 ;
313: ;
315:L P[3:Inspect Posn] 200mm/sec CNT100 ;
316: ;
317: ;
320: ;
323: ;
326: ;
328: ;
/POS
/END

Page 247 of 305
6.40 PG08 – Manual Tip Dress for Pedestal Dump Application for
R-30iA Controllers
NOTE1: DO[37: New Tip Dress Enable] = ON will enable a tip dress when a new
tip is selected, for use with offset caps.
NOTE3: Since the robot may be in a confined area, make sure robot is Clear of
program.
/PROG PG08
/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 7339;
CREATE = DATE 10-05-10 TIME 14:50:46;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 341;
MEMORY_SIZE = 7771;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG - Pedestal ;
5: ! ;

Page 248 of 305
9: !***************************** ;
10: ;
13: ;
16: ;
18: PAYLOAD[2] ;
19: ;
21: UTOOL_NUM=1 ;
22: ;
24: UFRAME_NUM=1 ;
25: ;
27: SETUP OUTPUTS ;
28: ;
29: !Move to Home ;
31: ;
34: ;
35: !------------------------------ ;
38: ;
40:J P[1] 100% FINE ;
41:J P[2] 100% FINE ;
42: ;
44:L P[3:Inspect pos] 2000mm/sec FINE ;
45: ;
48: ;
51: ;
53: OPEN GUN ;
54: ;
56: OPEN GUN2 ;
57: ;
58: ;
61: ;
61: ! DO[139] to PLC ;

Page 249 of 305
61: ;
61: ! DO[139] to PLC ;
62: ;
63: !------------------------------ ;
65: LBL[1] ;
66: ;
DI[972:TIPALIGNCLOSED2]=ON OR RO[1:EQUALIZATION VALVE 1]=ON
OR RO[2:EQUALIZATION VALVE 2]=ON) ;
74: ;
81: ;
84: ;
87: ;
89: IF DI[972]=ON,JMP LBL[110] ;
90: ;
93: ;
97: ;
101: ;
103: JMP LBL[1] ;
104: ;
105: ;
106: !------------------------------ ;
107: !TIP ALIGN ;
108: LBL[100] ;
109: ;
111: CLOSE GUN ;
112: ;
115: ;
118: ;
Page 250 of 305
120: OPEN GUN ;
121: ;
124: ;
127: ;
129: JMP LBL[1] ;
130: ;
131: ;
132: !------------------------------ ;
134: LBL[101] ;
135: ;
138: ;
138: !JMP LBL[1] ;
138: ;
139: ;
142: SPOT[SD=2,0, EP=0,0, P=1,0, S=(R[4],0), EP=0,0, ED=12,0] ;
143: ;
146: ;
148: JMP LBL[1] ;
149: ;
150: ;
151: !------------------------------ ;
152: !TIP ALIGN 2 ;
153: LBL[110] ;
154: ;
156: CLOSE GUN2 ;
157: ;
159: WAIT DI[972]=OFF ;
160: ;
162: WAIT DI[973]=ON ;
163: ;
165: OPEN GUN2 ;
166: ;

Page 251 of 305
168: WAIT DI[973]=OFF ;
169: ;
171: WAIT DI[972]=OFF ;
172: ;
174: JMP LBL[1] ;
175: ;
176: ;
177: !------------------------------ ;
179: LBL[111] ;
180: ;
181: ;
181: !JMP LBL[1] ;
181: ;
183: ;
186: SPOT[SD=0,2, EP=0,0, P=0,1, S=(0,R[6]), EP=0,0, ED=0,12] ;
187: ;
191: ;
193: JMP LBL[1] ;
194: ;
195: ;
196: !------------------------------ ;
198: LBL[102] ;
199: ;
200: !Set GO[1] to a pressure that wil ;
205: ;
206: WAIT 1.00(sec) ;
207: ;
209: ;
210: WAIT 1.00(sec) ;
211: ;
213: ;
214: WAIT 1.00(sec) ;
215: ;

Page 252 of 305
217: ;
219: JMP LBL[1] ;
220: ;
221: !------------------------------ ;
223: LBL[103] ;
224: ;
230: ;
231: WAIT 1.00(sec) ;
232: ;
234: ;
235: WAIT 1.00(sec) ;
236: ;
238: ;
239: WAIT 1.00(sec) ;
240: ;
242: ;
244: JMP LBL[1] ;
245: ;
246: !------------------------------ ;
247: LBL[7] ;
248: ;
250: ;
251: JMP LBL[9] ;
252: ;
253: ;
254: ;
255: !------------------------------ ;
256: LBL[17] ;
257: ;
259: ;
260: JMP LBL[9] ;
261: ;
262: ;
263: !------------------------------ ;
265: LBL[8] ;
266: ;
268: ;
270: ;
271: ;
272: !------------------------------ ;
273: LBL[9] ;
274: ;

Page 253 of 305
DO[113:PLDTIP BYPASS ]=ON OR DO[130:SG MTR OTEMP 1]=ON,JMP
LBL[555] ;
278: ;
279: !Run TipWear Routine in the ;
280: ! background ;
;
186: IF DO[972:TDDMP1INPROC]=ON OR DO[669:NSTR]=ON,JMP LBL[145] ;
281: RUN TPWEARC1 ;
282: ;
282: LBL[145] ;
284: LBL[555] ;
285: ;
LBL[888] ;
289: ;
290: !Run TipWear 2 Routine in the ;
291: ! background ;
;
186: IF DO[973:TDDMP2INPROC]=ON OR DO[733:New Tip 2]=ON,JMP
LBL[146] ;
292: RUN TPWEARC2 ;
293: ;
282: LBL[146] ;
295: LBL[888] ;
206: ;
209: ;
203: !Depart pos. ;
204:J P[2] 100% FINE ;
205:J P[1] 100% FINE ;
206: ;
209: ;
306: ;
307: JMP LBL[444] ;
308: ;
309: ;
310: !------------------------------ ;
312: ;
314:J P[1] 20% CNT100 ;
315:J P[2] 20% CNT100 ;
316: ;
318:L P[3:Inspect pos] 200mm/sec CNT100 ;
Page 254 of 305
319: ;
320: ;
323: ;
326: ;
329: ;
331: ;
334: ;
339: ;
341: WAIT (F[2]=OFF) ;
/POS
/END

Page 255 of 305
6.41 PG08 – Manual Tip Dress for Pedestal Dump Application for
R-30iB Controllers
NOTE1: DO[37: New Tip Dress Enable] = ON will enable a tip dress when a new
tip is selected, for use with offset caps.
NOTE3: Since the robot may be in a confined area, make sure robot is Clear of
program.
/PROG PG08
/ATTR
OWNER = MNEDITOR;
PROG_SIZE = 7339;
CREATE = DATE 10-05-10 TIME 14:50:46;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 341;
MEMORY_SIZE = 7771;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! Dual SWG - Pedestal ;
5: ! ;

Page 256 of 305
9: !***************************** ;
10: ;
13: ;
16: ;
18: PAYLOAD[2] ;
19: ;
21: UTOOL_NUM=1 ;
22: ;
24: UFRAME_NUM=1 ;
25: ;
27: SETUP OUTPUTS ;
28: ;
29: !Move to Home ;
31: ;
34: ;
35: !------------------------------ ;
38: ;
40:J P[1] 100% FINE ;
41:J P[2] 100% FINE ;
42: ;
44:L P[3:Inspect pos] 2000mm/sec FINE ;
45: ;
48: ;
51: ;
53: OPEN GUN ;
54: ;
56: OPEN GUN2 ;
57: ;
58: ;
61: ;
61: ! DO[139] to PLC ;

Page 257 of 305
61: ;
61: ! DO[139] to PLC ;
62: ;
63: !------------------------------ ;
65: LBL[1] ;
66: ;
DI[972:TIPALIGNCLOSED2]=ON OR RO[1:EQUALIZATION VALVE 1]=ON
OR RO[2:EQUALIZATION VALVE 2]=ON) ;
74: ;
81: ;
84: ;
87: ;
89: IF DI[972]=ON,JMP LBL[110] ;
90: ;
93: ;
97: ;
101: ;
103: JMP LBL[1] ;
104: ;
105: ;
106: !------------------------------ ;
107: !TIP ALIGN ;
108: LBL[100] ;
109: ;
111: CLOSE GUN ;
112: ;
115: ;
118: ;
Page 258 of 305
120: OPEN GUN ;
121: ;
124: ;
127: ;
129: JMP LBL[1] ;
130: ;
131: ;
132: !------------------------------ ;
134: LBL[101] ;
135: ;
138: ;
138: !JMP LBL[1] ;
138: ;
139: ;
142: SPOT[SD=2,0, EP=0,0, P=1,0, t=0.0,0.0, S=(R[4],0), EP=0,0,
ED=12,0] ;
143: ;
146: ;
148: JMP LBL[1] ;
149: ;
150: ;
151: !------------------------------ ;
152: !TIP ALIGN 2 ;
153: LBL[110] ;
154: ;
156: CLOSE GUN2 ;
157: ;
159: WAIT DI[972]=OFF ;
160: ;
162: WAIT DI[973]=ON ;
163: ;
165: OPEN GUN2 ;
166: ;

Page 259 of 305
168: WAIT DI[973]=OFF ;
169: ;
171: WAIT DI[972]=OFF ;
172: ;
174: JMP LBL[1] ;
175: ;
176: ;
177: !------------------------------ ;
179: LBL[111] ;
180: ;
181: ;
181: !JMP LBL[1] ;
181: ;
183: ;
186: SPOT[SD=0,2, EP=0,0, P=0,1, t=0.0,0.0, S=(0,R[6]), EP=0,0,
ED=0,12] ;
187: ;
191: ;
193: JMP LBL[1] ;
194: ;
195: ;
196: !------------------------------ ;
198: LBL[102] ;
199: ;
205: ;
206: WAIT 1.00(sec) ;
207: ;
209: ;
210: WAIT 1.00(sec) ;
211: ;
213: ;

Page 260 of 305
214: WAIT 1.00(sec) ;
215: ;
217: ;
219: JMP LBL[1] ;
220: ;
221: !------------------------------ ;
223: LBL[103] ;
224: ;
230: ;
231: WAIT 1.00(sec) ;
232: ;
234: ;
235: WAIT 1.00(sec) ;
236: ;
238: ;
239: WAIT 1.00(sec) ;
240: ;
242: ;
244: JMP LBL[1] ;
245: ;
246: !------------------------------ ;
247: LBL[7] ;
248: ;
250: ;
251: JMP LBL[9] ;
252: ;
253: ;
254: ;
255: !------------------------------ ;
256: LBL[17] ;
257: ;
259: ;
260: JMP LBL[9] ;
261: ;
262: ;
263: !------------------------------ ;
265: LBL[8] ;
266: ;
268: ;
270: ;
271: ;
272: !------------------------------ ;

Page 261 of 305
273: LBL[9] ;
274: ;
LBL[555] ;
278: ;
279: !Run TipWear Routine in the ;
280: ! background ;
;
186: IF DO[972:TDDMP1INPROC]=ON OR DO[669:NTSR]=ON,JMP LBL[145] ;
281: RUN TPWEARC1 ;
282: ;
186: LBL[145] ;
284: LBL[555] ;
285: ;
LBL[888] ;
289: ;
290: !Run TipWear 2 Routine in the ;
291: ! background ;
;
186: IF DO[973:TDDMP2INPROC]=ON OR DO[733:New Tip 2]=ON,JMP
LBL[146] ;
292: RUN TPWEARC2 ;
293: ;
293: LBL[146] ;
295: LBL[888] ;
206: ;
209: ;
203: !Depart pos. ;
204:J P[2] 100% FINE ;
205:J P[1] 100% FINE ;
206: ;
209: ;
306: ;
307: JMP LBL[444] ;
308: ;
309: ;
310: !------------------------------ ;
312: ;
314:J P[1] 20% CNT100 ;
315:J P[2] 20% CNT100 ;
316: ;
Page 262 of 305
318:L P[3:Inspect pos] 200mm/sec CNT100 ;
319: ;
320: ;
323: ;
326: ;
329: ;
331: ;
334: ;
339: ;
341: WAIT (F[2]=OFF) ;
/POS
/END

Page 263 of 305
6.42 PG09 – Minor Maintenance Positions
/PROG PG09
/ATTR
OWNER = MNEDITOR;
COMMENT = "Maintenance PRG";
PROG_SIZE = 1532;
CREATE = DATE 09-10-02 TIME 10:57:02;
FILE_NAME = ;
VERSION = 0;
LINE_COUNT = 54;
MEMORY_SIZE = 1816;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
3: ! ;
4: !***************************** ;
5: ;
8: ;
11: ;
12: PAYLOAD[2] ;
13: ;
15: UTOOL_NUM=1 ;
16: ;
18: UFRAME_NUM=1 ;
19: ;
21: SETUP OUTPUTS ;
22: ;
23: !Move to Home ;
25: ;
26: !------------------------------ ;
28:J P[1] 20% CNT10 ;
29: ;
31:J P[2] 10% FINE ;
32: ;
34: DO[587:RBT AT MIN MAINT]=ON ;
35: ;

Page 264 of 305
36: !Turn ON Robot in Loop ;
38: ;
41: ;
42: !Turn OFF Robot in Loop ;
48: ;
50: DO[587:RBT AT MIN MAINT]=OFF ;
51: ;
45: !------------------------------ ;
46: !Depart from Maint Pos ;
47:J P[1] 20% CNT10 ;
48: ;
50: DO[587:RBT AT MIN MAINT]=OFF ;
51: ;
52: !Move to Home ;
54: ;
/POS
/END

Page 265 of 305
6.43 PG10 or PG06 – Auto Tip Dress with Servo Tip Dresser for
Carried Application for R-30iA Controllers
NOTE1: PG06 is used for side-cut if needed use below as template replacing 10
for 06 in the title and Program Verify macro.
/PROG PG10
/ATTR
OWNER = MNEDITOR;
COMMENT = "Auto Tip Dress";
PROG_SIZE = 4152;
CREATE = DATE 09-07-30 TIME 08:19:50;
FILE_NAME = PG10;
VERSION = 0;
LINE_COUNT = 178;
MEMORY_SIZE = 4636;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO TIP DRESS ;
3: ! Carried Dual SWG ;
4: ! Moves robot to Tip Dress ;
5: ! ;
9: !***************************** ;
10: ;
13: ;

Page 266 of 305
16: ;
18: PAYLOAD[2] ;
19: ;
21: UTOOL_NUM=1 ;
22: ;
24: UFRAME_NUM=1 ;
25: ;
27: SETUP OUTPUTS ;
28: ;
29: !Move to Home ;
31: ;
32: ;
36: ;
37: !-------------------------------- ;
39: ! ;
40: ! ;
48: !-------------------------------- ;
49: ;
26: OPEN GUN ;
26: ;
26: CALL TW_PRS01 ;
26: ;
57: ;
59: ! that uses R[29] ;
61: ;
61: R[49:Number of Tip dr]=0 ;
61: ;
62: !Ensure that Tip Wear Warning is Off ;
62: ! After Tip Dress ;

Page 267 of 305
62: DO[438:TipWearWarn]=OFF ;
62: ;
63: LBL[456] ;
64: ;
65: !-------------------------------- ;
67: !-------------------------------- ;
70: ;
72: ;
26: OPEN GUN2 ;
26: ;
26: CALL TW_PRS02 ;
26: ;
80: ;
82: ! that uses R[32] ;
84: ;
84: ;
86: LBL[458] ;
87: ;
90: !------------------------------ ;
91: !Approach Position ;
91:L P[2] 2000mm/sec FINE ;
92: ;
94: OPEN GUN ;
95: ;
96: ;
97: !Turn OFF Weld Mode ;
99: ;
100: ;
101: !Move to Tip Dress ;
102: !Position 1 ;
103:L P[3] 2000mm/sec FINE ;
104: ;
105: ;
106: ;
107: !Macro for Tip Dress ;

Page 268 of 305
108: CALL CGTDMACS ;
109: ;
110: ;
113: ;
;
115: ;
116: ;
119: ;
120: !IF lost caps/water ;
121: IF DO[141:AUTOPTBYPAS1]=ON,JMP LBL[123] ;
122: ;
123: !!*** GUN 2 LOGIC *** ;
125: OPEN GUN2 ;
126: ;
127: ;
129: !Position 2 ;
130:L P[4] 2000mm/sec FINE ;
131: ;
132: ;
134: CALL CGTDMC2S ;
135: ;
136: ;
139: ;
141: WAIT DI[161:AUTOTPDRSPOSCLR2]=ON AND DI[734: DRESSTIPS2]=ON
;
142: ;
143: ;
146: ;
149: ;
150: !Move to Calibration ;
151: ! Plate ;
152:L P[5] 2000mm/sec FINE ;
153: ;
154: ;
156: ! on Cal Plate Gun 1 ;
157: CALL TW_UPD01 ;
158: ;
159: ;
163: ;

Page 269 of 305
165: LBL[123] ;
166: ;
167: !Turn ON Weld Mode ;
169: ;
170: ;
171: !Depart Position ;
172:L P[2] 2000mm/sec FINE ;
173:J P[6] 100% FINE ;
174: ;
121: !Tip Cutter Warning Checks ;
122: CALL TIP_MEAS1 ;
104: ;
104: !Don’t jump to label 475 if using Resistance check logic ;
104: JMP LBL[475] ;
105: !-------------------------------- ;
106: !TIP RESISTANCE CHK LOGIC ;
108: !-------------------------------- ;
109: ;
111: DO[115:WELD/NO WELD MD1]=OFF ;
112: ;
113: !Allow TipWear to Finish ;
114: WAIT 1.00(sec) ;
115: ;
116: !Set Tip Resistance Output ;
117: DO[946:TIPRESISTFLT1]=ON ;
118: ;
119: !Set Tip Resistance Weld Sch ;
120: SPOT[SD=1,EP=0,P=96,S=30,EP=0,ED=1] ;
121: ;
122: !Reset Tip Resistance Output ;
123: DO[946:TIPRESISTFLT1]=OFF ;
124: ;
125: !Pulse Stepper Reset Output ;
127: ;
128: !Wait 4 AutoTipDress Pos Clear ;
129: WAIT DI[129:AUTOTPDRSPOSCLR1]=ON ;
129: ;
175: !-------------------------------- ;
129: LBL[475] ;
129: ;
178: ;
/POS
/END

Page 270 of 305
6.44 PG10 or PG06 – Auto Tip Dress with Servo Tip Dresser for
Carried Application for R30iB Controllers
NOTE1: PG06 is used for side-cut if needed use below as template replacing 10
for 06 in the title and Program Verify macro.
/PROG PG10
/ATTR
OWNER = MNEDITOR;
COMMENT = "Auto Tip Dress";
PROG_SIZE = 4152;
CREATE = DATE 09-07-30 TIME 08:19:50;
FILE_NAME = PG10;
VERSION = 0;
LINE_COUNT = 178;
MEMORY_SIZE = 4636;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO TIP DRESS ;
3: ! Carried Dual SWG ;
4: ! Moves robot to Tip Dress ;
5: ! ;
9: !***************************** ;
10: ;
13: ;

Page 271 of 305
16: ;
18: PAYLOAD[2] ;
19: ;
21: UTOOL_NUM=1 ;
22: ;
24: UFRAME_NUM=1 ;
25: ;
27: SETUP OUTPUTS ;
28: ;
29: !Move to Home ;
31: ;
32: ;
36: ;
37: !-------------------------------- ;
39: ! ;
40: ! ;
48: !-------------------------------- ;
49: ;
26: OPEN GUN ;
26: ;
26: CALL TW_PRS01 ;
26: ;
57: ;
59: ! that uses R[29] ;
61: ;
61: ;
62: !Ensure that Tip Wear Warning is Off ;

Page 272 of 305
62: ! After Tip Dress ;
62: ;
63: LBL[456] ;
64: ;
65: !-------------------------------- ;
67: !-------------------------------- ;
70: ;
72: ;
26: OPEN GUN2 ;
26: ;
26: CALL TW_PRS02 ;
26: ;
80: ;
82: ! that uses R[32] ;
84: ;
84: ;
86: LBL[458] ;
87: ;
90: !------------------------------ ;
91: !Approach Position ;
92: ;
94: OPEN GUN ;
95: ;
96: ;
99: ;
100: ;
102: !Position 1 ;
103:L P[3] 2000mm/sec FINE ;
104: ;
105: ;
106: ;

Page 273 of 305
108: CALL CGTDMACS ;
109: ;
110: ;
113: ;
;
115: ;
116: ;
119: ;
122: ;
123: !!*** GUN 2 LOGIC *** ;
125: OPEN GUN2 ;
126: ;
127: ;
129: !Position 2 ;
130:L P[4] 2000mm/sec FINE ;
131: ;
132: ;
134: CALL CGTDMC2S ;
135: ;
136: ;
139: ;
141: WAIT DI[161:AUTOTPDRSPOSCLR2]=ON AND DI[734: DRESSTIPS2]=ON
;
142: ;
143: ;
146: ;
149: ;
150: !Move to Calibration ;
151: ! Plate ;
152:L P[5] 2000mm/sec FINE ;
153: ;
154: ;
158: ;
159: ;

Page 274 of 305
163: ;
165: LBL[123] ;
166: ;
167: !Turn ON Weld Mode ;
169: ;
170: ;
171: !Depart Position ;
172:L P[2] 2000mm/sec FINE ;
173:J P[6] 100% FINE ;
174: ;
121: !Tip Cutter Warning Checks ;
104: ;
104: !Don’t jump to label 475 if using Resistance check logic ;
104: JMP LBL[475] ;
105: !-------------------------------- ;
106: !TIP RESISTANCE CHK LOGIC ;
108: !-------------------------------- ;
109: ;
111: DO[115:WELD/NO WELD MD1]=OFF ;
112: ;
113: !Allow TipWear to Finish ;
114: WAIT 1.00(sec) ;
115: ;
116: !Set Tip Resistance Output ;
117: DO[946:TIPRESISTFLT1]=ON ;
118: ;
119: !Set Tip Resistance Weld Sch ;
120: SPOT[SD=1,EP=0,P=96,t=0.0,S=30,EP=0,ED=1] ;
121: ;
122: !Reset Tip Resistance Output ;
123: DO[946:TIPRESISTFLT1]=OFF ;
124: ;
125: !Pulse Stepper Reset Output ;
127: ;
128: !Wait 4 AutoTipDress Pos Clear ;
129: WAIT DI[129:AUTOTPDRSPOSCLR1]=ON ;
129: ;
175: !-------------------------------- ;
129: LBL[475] ;
129: ;
178: ;
/POS
/END

Page 275 of 305
6.45 CGTDMACS – Carried Servo Gun with Servo Tip Dresser
MACRO for R-30iA Controllers
In order for tip wear offsets to be applied during tip dress,
the tip dress TP program must contain group 1 and group 2
motion. Also, the TIPDRESS instruction must be in motion
option format. This means that the final position for tip
dress must be attached to the TIPDRESS instruction.
To optimize the tip dress, the final tip dress position should
be taught to have the fixed tip just below the cutting blade.
It is taught similar to how a weld location is taught.
BLOWOFF
been turned OFF.
change.
/PROG CGTDMACS Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "CAR GUN STD MAC";
PROG_SIZE = 3334;
CREATE = DATE 00-01-03 TIME 11:25:38;
FILE_NAME = CGTDMAC;
VERSION = 0;
LINE_COUNT = 115;
MEMORY_SIZE = 3794;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO SERVO TIP DRESS ;
3: ! Carried SWG ;
4: ! ;
Page 276 of 305
6: ! GP[1:robot] AND ;
8: !***************************** ;
9: ;
10: !Save robot gun open pos ;
11: PR[95:TipDrsGun1OpnPos]=LPOS ;
12: ;
13: !------------------------------ ;
14: ;
20: ;
23: WAIT 1.50(sec) ;
24: ;
25: !------------------------------ ;
26: ;
29: WAIT .50(sec) ;
30: ;
31: !Check for TD Motor ON ;
32: IF DO[873]=OFF,JMP LBL[250] ;
33: ;
34: !------------------------------ ;
37: ;
46: R[49:Number of Tip dr]=0;
46: ;
40: ;
45: ;
49: ! ;
50:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=94,TD=1,ED=2] ;
51: ;
Page 277 of 305
56: ;
57: JMP LBL[789] ;
58: ;
59: !------------------------------ ;
60: !IF OLD Tip ;
61: LBL[456] ;
62: ;
57: R[49:Number of Tip dr]=R[49:Number of Tip dr]+1;
58: ;
63: !Dont Servo Dress if motor problm ;
65: ;
73: ! ;
74:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=95,TD=2,ED=2] ;
75: ;
80: ;
81: JMP LBL[789] ;
82: ;
83: !------------------------------ ;
84: ;
85: !Jump here if TD MOTOR not enabld ;
86: ;
87: LBL[250] ;
88: ;
91:L P[1] 2000mm/sec FINE
: PRESS_MOTN[SD=94,P=94] ;
92: WAIT 1.00(sec) ;
93: ;
95: ! both tips open from dresser ;
97: ;
98: JMP LBL[789] ;
99: !------------------------------ ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;

Page 278 of 305
105: LBL[789] ;
106: ;
107: !Move Back to Orginal pos ;
108:L PR[95:TipDrsGun1OpnPos] 1000mm/sec FINE ;
109: ;
112: ;
116: ;
120: ;
122: CALL BLOWOFF ;
122: LBL[350] ;
/POS
/END

Page 279 of 305
6.46 CGTDMACS – Carried Servo Gun with Servo Tip Dresser
MACRO for R-30iB Controllers
BLOWOFF
been turned OFF.
change.
/PROG CGTDMACS Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "CAR GUN STD MAC";
PROG_SIZE = 3334;
CREATE = DATE 00-01-03 TIME 11:25:38;
VERSION = 0;
LINE_COUNT = 115;
MEMORY_SIZE = 3794;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO SERVO TIP DRESS ;
3: ! Carried SWG ;
4: ! ;
Page 280 of 305
8: !***************************** ;
9: ;
12: ;
13: !------------------------------ ;
14: ;
20: ;
23: WAIT 1.50(sec) ;
24: ;
25: !------------------------------ ;
26: ;
29: WAIT .50(sec) ;
30: ;
32: IF DO[873]=OFF,JMP LBL[250] ;
33: ;
34: !------------------------------ ;
37: ;
46: ;
40: ;
45: ;
49: ! ;
50:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=94,t=0.0,TD=1,ED=2] ;
51: ;
Page 281 of 305
56: ;
57: JMP LBL[789] ;
58: ;
59: !------------------------------ ;
60: !IF OLD Tip ;
61: LBL[456] ;
62: ;
58: ;
65: ;
73: ! ;
74:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=95,t=0.0,TD=2,ED=2] ;
75: ;
80: ;
81: JMP LBL[789] ;
82: ;
83: !------------------------------ ;
84: ;
86: ;
87: LBL[250] ;
88: ;
: PRESS_MOTN[SD=94,P=94,t=0.0] ;
92: WAIT 1.00(sec) ;
93: ;
97: ;
98: JMP LBL[789] ;
99: !------------------------------ ;
100: ;
102: LBL[788] ;
103: UALM[65] ;
104: ;

Page 282 of 305
105: LBL[789] ;
106: ;
109: ;
112: ;
116: ;
120: ;
122: CALL BLOWOFF ;
122: LBL[350] ;
/POS
/END

Page 283 of 305
6.47 CGTDMC2S – Carried Servo Gun #2 with Servo Tip Dresser
MACRO for R-30iA Controllers
BLOWOFF
been turned OFF.
change.
/PROG CGTDMC2S Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "CAR GUN STD 2 MAC";
PROG_SIZE = 4254;
CREATE = DATE 00-01-03 TIME 11:25:38;
VERSION = 0;
LINE_COUNT = 153;
MEMORY_SIZE = 4762;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO SERVO TIP DRESS 2;
3: ! Carried SWG2 ;
4: ! ;
Page 284 of 305
9: !***************************** ;
10: ;
13: ;
15: !------------------------------ ;
18: ;
21: DO[867:Servo TD OK2]=OFF ;
24: ;
29: WAIT 1.50(sec) ;
27: ;
28: !------------------------------ ;
33: ;
37: !WAIT .50(sec) ;
38: ;
40: IF DO[874:TIP DRESS MTR ENB2]=OFF,JMP LBL[250] ;
41: ;
42: !------------------------------ ;
56: ;
46: ;
59: ;
66: ;
69: ! ;
70:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=95,TD=1,EP=0,ED=2] ;
71: ;
Page 285 of 305
OK2]=(ON) ;
76: ;
77: JMP LBL[789] ;
78: ;
79: !------------------------------ ;
80: !IF OLD Tip ;
81: LBL[456] ;
89: ;
58: ;
93: ;
59: ;
69: ! ;
107:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=95,TD=2,EP=0,ED=2] ;
108: ;
OK2]=(ON) ;
113: ;
114: JMP LBL[789] ;
115: ;
116: !------------------------------ ;
117: ;
119: ;
120: LBL[250] ;
121: ;
: PRESS_MOTN[SD=94,P=94] ;
125: WAIT 1.00(sec) ;
126: ;
129:L P[2] 2000mm/sec FINE ;
130: ;
131: JMP LBL[789] ;
132: !------------------------------ ;
133: ;
132: !UALM for Servo TD Motor Fault;
134: LBL[788] ;
135: UALM[65] ;
136: ;
Page 286 of 305
137: LBL[789] ;
138: ;
144: ;
147: ;
116: ;
120: ;
122: LBL[350] ;
123: ;
/POS
/END

Page 287 of 305
6.48 CGTDMC2S – Carried Servo Gun #2 with Servo Tip Dresser
MACRO for R-30iB Controllers
BLOWOFF
been turned OFF.
change.
/PROG CGTDMC2S Macro

/ATTR
OWNER = MNEDITOR;
COMMENT = "CAR GUN STD 2 MAC";
PROG_SIZE = 4254;
CREATE = DATE 00-01-03 TIME 11:25:38;
VERSION = 0;
LINE_COUNT = 153;
MEMORY_SIZE = 4762;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! AUTO SERVO TIP DRESS 2;
3: ! Carried SWG2 ;
4: ! ;
Page 288 of 305
9: !***************************** ;
10: ;
13: ;
15: !------------------------------ ;
18: ;
21: DO[867:Servo TD OK2]=OFF ;
24: ;
29: WAIT 1.50(sec) ;
27: ;
28: !------------------------------ ;
33: ;
37: !WAIT .50(sec) ;
38: ;
40: IF DO[874:TIP DRESS MTR ENB2]=OFF,JMP LBL[250] ;
41: ;
42: !------------------------------ ;
56: ;
46: ;
59: ;
66: ;
69: ! ;
70:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=95,t=0.0,TD=1,EP=0,ED=2] ;
71: ;
Page 289 of 305
OK2]=(ON) ;
76: ;
77: JMP LBL[789] ;
78: ;
79: !------------------------------ ;
80: !IF OLD Tip ;
81: LBL[456] ;
89: ;
58: ;
93: ;
59: ;
69: ! ;
107:L P[1] 2000mm/sec CNT25
: TIPDRESS[SD=2,EP=0,P=95,t=0.0,TD=2,EP=0,ED=2] ;
108: ;
OK2]=(ON) ;
113: ;
114: JMP LBL[789] ;
115: ;
116: !------------------------------ ;
117: ;
119: ;
120: LBL[250] ;
121: ;
: PRESS_MOTN[SD=94,P=94,t=0.0] ;
125: WAIT 1.00(sec) ;
126: ;
129:L P[2] 2000mm/sec FINE ;
130: ;
131: JMP LBL[789] ;
132: !------------------------------ ;
133: ;
132: !UALM for Servo TD Motor Fault;
134: LBL[788] ;
135: UALM[65] ;
136: ;
Page 290 of 305
137: LBL[789] ;
138: ;
144: ;
147: ;
116: ;
120: ;
122: LBL[350] ;
123: ;
/POS
/END

Page 291 of 305
6.49 OPNGUN – Open Servo Gun Position MACRO
/PROG OPNGUN Macro
/ATTR
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !******************************** ;
2: ! OPEN GUN MACRO ;
3: ! ;
6: ! ;
7: ! Record GRP2 Ref Pos 1 ;
8: ! turns ON DO[128] ;
9: ! Record POS Reg PR[100] ;
10: !***************************** ;
11: ;
12: !RECORD OPEN SWG POSITION ;
13:J PR[100:SWG Full OPN Pos] 100% FINE ;
/POS
/END

Page 292 of 305
6.50 CLSGUN – Close Servo Gun Position MACRO
/PROG CLSGUN Macro
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !******************************** ;
2: ! CLOSE GUN MACRO ;
3: ! ;
6: ! ;
8: !***************************** ;
9: ;
10: !RECORD CLOSE SWG POSITION ;
11:J PR[101:SWG Close Pos] 100% FINE ;
/POS
/END

Page 293 of 305
6.51 OPNGUN2 – Open Servo Gun 2 Position MACRO
/PROG OPNGUN2 Macro
/ATTR
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !******************************** ;
2: ! OPEN GUN 2 MACRO ;
3: ! ;
6: ! ;
7: ! Record GRP2 Ref Pos 2 ;
8: ! turns ON DO[160] ;
10: !***************************** ;
11: ;
12: !RECORD OPEN SWG POSITION ;
13:J PR[102:SWG Full OPN Pos] 100% FINE ;
/POS
/END

Page 294 of 305
6.52 CLSGUN2 – Close Servo Gun 2 Position MACRO
/PROG CLSGUN2 Macro
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !******************************** ;
2: ! CLOSE GUN 2 MACRO ;
3: ! ;
6: ! ;
8: !***************************** ;
9: ;
10: !RECORD CLOSE SWG POSITION ;
11:J PR[103:SWG Close 2 Pos] 100% FINE ;
/POS
/END

Page 295 of 305
6.53 BLOWOFF – Tip Dress Spin and Blower Program
/PROG BLOWOFF
/ATTR
OWNER = MNEDITOR;
COMMENT = "BLOWOFF";
PROG_SIZE = 884;
CREATE = DATE 00-01-03 TIME 11:25:38;
FILE_NAME = BLOWOFF;
VERSION = 0;
LINE_COUNT = 21;
MEMORY_SIZE = 1180;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! BLOWOFF ;
3: ! Spin the Dresser ;
4: ! and Turn ON the Blower ;
5: ! ;
8: !***************************** ;
9: ;
10: !Turn ON the Dresser ;
11: !This will Spin the Dresser ;
12: !for a Specified Speed and Time ;
13: !3 Parameters are Required ;
14: !Param 1 = dresser number ;
15: !Param 2 = speed in rpm ;
16: !Param 3 = duration in ms ;
17: CALL TURNDRES(1,300,4000) ;
18: ;
19: !Pulse ON the Blower ;
20: RO[5:TIPDRSENB BLWFF1]=PULSE,4.0sec ;
21: ;
/POS
/END

Page 296 of 305
6.54 BLOWOFF2 – Tip Dress Spin and Blower Program 2
/PROG BLOWOFF2
/ATTR
OWNER = MNEDITOR;
COMMENT = "BLOWOFF2";
PROG_SIZE = 884;
CREATE = DATE 00-01-03 TIME 11:25:38;
FILE_NAME = BLOWOFF2;
VERSION = 0;
LINE_COUNT = 21;
MEMORY_SIZE = 1180;
TASK_PRIORITY = 50,
TIME_SLICE = 0,
BUSY_LAMP_OFF = 0,
ABORT_REQUEST = 0,
PAUSE_REQUEST = 0;
CONTROL_CODE = 00000000 00000000;
/APPL
SPOT : TRUE ;
CYCLE_REFERENCE = 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0;
/MN
1: !***************************** ;
2: ! BLOWOFF2 ;
3: ! Spin the Dresser ;
4: ! and Turn ON the Blower ;
5: ! ;
8: !***************************** ;
9: ;
10: !Turn ON the Dresser ;
11: !This will Spin the Dresser ;
12: !for a Specified Speed and Time ;
13: !3 Parameters are Required ;
14: !Param 1 = dresser number ;
15: !Param 2 = speed in rpm ;
16: !Param 3 = duration in ms ;
17: CALL TURNDRES(2,300,4000) ;
18: ;
19: !Pulse ON the Blower ;
20: RO[7:TIPDRSENB BLWFF2]=PULSE,4.0sec ;
21: ;
/POS
/END

Page 297 of 305
6.55 HOME_IO – Reset Input/Output MACRO
/PROG HOME_IO
COMMENT = "SET AT HOME I-O";
/APPL
/MN
1: !******************************** ;
2: !MACRO SET AT HOME I-O ;
3: ! ;
4: !Also runs Automatically when ;
5: ! robot goes from non-home pos ;
6: ! to home pos ;
7: ! ;
11: !***************************** ;
12: ;
15: ;
16: !CLR TO RET. TRANSFER ;
18: ;
19: !CLEAR TO UNCLAMP ;
21: ;
22: ;
23: !ROBOT USER DEFINE OFF ;
24: DO[41:UDEF RBT OUT 1]=OFF ;
32: ;
33: ;
34: !RESET FAULT RESET ;
35: DO[959:FAULTRESET]=OFF ;
36: ;
37: ;
38: !RESET ROBOT LOOP ;
40: DO[977:WTRSVRPULSRST]=OFF ;
41: DO[963:PRGRM FLT]=OFF ;
42: ;
43: !AT REPAIR OFF ;
44: DO[587:RBT AT MINMAINT]=OFF;
45: ;
46: ;
47: !RESET PICKUP POS ;

Page 298 of 305
56: ;
57: ;
58: !RESET WRK POS ;
59: DO[177:MDL WRK POS 1]=OFF ;
67: ;
69: !CLEAR EXIT ZONES ;
84: ;
85: !SET NUMBER RESET = ;
86: ! (3) RETRIES ;
87: CALL WELD1DIS ;
88: ;
43: !PEDESTAL APPLICATION ONLY ;
68: DO[971:PEDDMPAPP]=ON ;
88: ;
86: !Reset Tip Dress Dump 1 Advance ;
86: !When not in dress macro;
86: IF (!DO[972:TPDMP1INPRC]),DO[440:TD DUMP ADV]=OFF;
86: ;
86: !Reset Tip Dress Dump 2 Advance ;
86: !When not in dress macro;
86: IF (!DO[973:TPDMP2INPRC]),DO[441:TD DUMP ADV]=OFF;
91: ;
92: !RESET Weld Mode ONLY;
84: ;
85: ! Reset the register that holds ;
86: ! the program number to run ;
87: R[153:ProgSelNum]=0 ;
/POS
/END

Page 299 of 305
7 Software I/F Panels
The Software Interface Panels are located under MENU, using F1 – F5 buttons or by
pressing MENU, 0-Next, 8 Browser, F1-TYPE.
7.1 SPOT SWG Menu

Page 300 of 305
NOTE:
On a Servo Nut Weld Application – the MANUAL WELD PB is to RETRY to weld the Nut
again.
 On a Servo Nut Weld Application – the NUT WELD/REFEED PB is to REFFED the
nut with the lizard tongue and RETRY to weld the Nut again.
 On a Servo Nut Weld Application – on a Plunge Fault (the nut does NOT collapse per
the define tolerance setting in the robot servogun menu) - to recover you must set the
WELD/NOWELD SELECTOR SWITCH (SS) to NOWELD, press the MANUAL
WELD PB, the servo gun tries to weld in NO Weld mode, causing the weld complete
to be ON from the weld controller, then moves on to the next weld point, before the
next weld occurs you must set the WELD/NOWELD SS back to WELD.

Page 301 of 305
8 PMC Logic (S-Logic) (2) SWG with Servo Tip Dresser
for R-30iA Controllers

Page 302 of 305
[FORD_NEXTGEN_ENETSafe_(2)SWG_STD_2016_03_30]
Ladder Diagram 1
N00001 R0000.0 R0000.0

A 1 ALWAYS ON
ALWAYS ALWAYS
ON ON
R0000.0
B
ALWAYS
ON
N00002 R0000.0 G1000.0

C 4 NO IMMEDIATE STOP
ALWAYS NO IMSTP
ON
N00003 X0000.0 R0100.5 K0004.5 G1000.1

D 6 NO HOLD
DI 1 EXT BREAK A EQUALENB NO HOLD
RNENBL NO HOLD L 1&2 SS
N00004 X1026.4 R0100.5

E 10 S BREAK A NO HOLD
SI12 HOL BREAK A
DSW NO HOLD
N00005 X1026.5 R0100.5

F 12 R BREAK A NO HOLD
SI13 RES BREAK A
ETSW NO HOLD
X1026.4 X1025.6
G
SI12 HOL CYCLE
DSW START
X0000.1 X1026.4
H
DI 2 EX SI12 HOL
RNEN RST DSW
N00006 R0000.0 G1000.2

I 20 SAFE SPEED
ALWAYS SFSPD
ON
N00007 X1000.3 G1000.3

J 22
O
Ladder Diagram 2
N00008 X1025.1 G1000.4

A 24 FAULT RESET
FAULT RB FAULT
RESET RESET
X0000.1 X0001.2
B
DI 2 EX DI 11
RNEN RST PLC AUTO
X1026.5
C
SI13 RES
ETSW
X0000.3
D
DI 4 EXT
CY STRT
X0000.2
E
DI 3 EXT
MTR ON
Y0119.6
F
DO 959 F
LT RESET
R0223.0
G
DI 976 M
AN WELD1
R0220.4
H
DI 956 R
EFEDWLD1
R0223.1
I
DI 977 M
AN WELD2
N00009 X1000.6 G1000.6

J 36 GO HOME
HOME
N00010 R0000.0 G1000.7

K 38 ENABLE
ALWAYS ENABLE
ON
N00011 F1000.0 Y1000.0

L 40
COMMAND
ENABLE
N00012 F1000.1 Y1000.1

M 42
SYSTEM
READY
Y1025.5
N MOTORS ENABLE
MOTORS
ENABLE
N00013 F1000.2 Y1000.2

O 45
PROGRAM
RUNNING
Ladder Diagram 3
N00014 F1000.3 Y1000.3

A 47
PAUSED
N00015 F1000.4 Y1000.4

B 49
HELD
Y0000.0
C ROBOT RUN ENABLE INTERRUPT ACK
DO 1 RUN
ENB ACK
N00016 F1000.5 ACT R0338.0

D 52 SUB 3 0031 INTERNAL FAULT DELAY
FAULT TMR INT FLT
DELAY
N00017 F1000.5 G1000.4 R0397.0 R0338.0 Y1000.5

E 56
FAULT RB FAULT FILTERED INT FLT
RESET FAULT DELAY
Y0120.2 Y0000.4
F ROBOT CONTROLLER FAULT
DO 963 DO 5 RBT
PRG FLT CNT FLT
Y0001.6
G
DO 15 CO
LL DTCT
N00018 F1000.6 Y1000.6

H 64
AT HOME
Y0002.0 Y0000.1
I ROBOT AT HOME
DO 17 RB DO 2 RBT
T @ HM1 @ HOME
Y0002.1
J
DO 18 RB
T @ HM2
Y0002.2
K
DO 19 RB
T @ HM3
Y0002.3
L
DO 20 RB
T @ HM4
Y0002.4
M
DO 21 RB
T @ HM5
Y0002.5
N
DO 22 RB
T @ HM6
Y0002.6
O
DO 23 RB
T @ HM7
Ladder Diagram 4
N00019 F1000.7 Y1000.7

A 74
TPENABLE
Y0119.7 Y0000.3
B ROBOT IN TEACH
DO 960 DO 4 RBT
AUTO KEY IN TCH
N00020 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

C 78
ECO17 ECO18 ECO19 ECO20 ECO21 ECO22 ECO23
FC1 FC2 FC4 FC8 FC16 FC32 FC64
1 R1402.7 R1405.0
D S
ECO24 FACILITY
FC128 CODE 11
N00021 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 R1400.6 1

E 87
EC01 EC02 ECO3 ECO4 ECO5 ECO6 ECO7
1 R1400.7 R1401.1 R1401.2 R1401.3 R1401.5 R1401.6 2

F
ECO8 ECO10 ECO11 ECO12 ECO14 ECO15
2 R1401.7 R1405.1
G
ECO16 ERROR 4
N00022 R1405.0 R1405.1 G1000.4 R1405.2

H 102 FENCE FAULT
FACILITY ERROR 4 RB FAULT FENCE
CODE 11 RESET FAULT
R1405.2
I
FENCE
FAULT
N00023 R0000.1 F1000.5 R1466.0 F1000.0 F1000.1 K0010.3

J 107 POWER FAIL RECOVERY
INT EXT FAULT BRK PWR COMMAND SYSTEM PWR FAIL
MTR ON FL RCVRY ENABLE READY RECVRY
R0000.2
K
INT EXT
CYC STRT
K0010.3
L
PWR FAIL
RECVRY
N00024 K0010.3 ACT R1466.0

M 115 SUB 3 0027 BREAK POWER FAIL RECOVERY
PWR FAIL TMR BRK PWR
RECVRY FL RCVRY
O
Ladder Diagram 5
N00025 Y0000.3 F1000.0 Y0000.4 R0000.1 R0000.2 F1000.1 F1008.0 1

A 119
DO 4 RBT COMMAND DO 5 RBT INT EXT INT EXT SYSTEM STEP
IN TCH ENABLE CNT FLT MTR ON CYC STRT READY
R1404.5 Y0000.2
B
DRP AUTO DO 3 RBT
FAULT IN AUTO
1 F1008.2 X1025.0 R1405.2 K0010.0 Y0001.6 Y0000.2

C ROBOT IN AUTOMATIC
TP FANUC FENCE TEACH DO 15 CO DO 3 RBT
E-STOP E-STOP FAULT MEMORY LL DTCT IN AUTO
N00026 Y0119.5 Y0072.4

D 136 INPUT SIMULATED
DO 958 I DO 581 I
NPUTSIM NPUTSIM
N00027 R1404.4 R1456.0 R1404.2 F1000.5 G1000.4 R0330.2 R0386.1 R1404.5

E 138 S DROP AUTO FAULT
FC AVAIL APPL FC ZERO FAULT RB FAULT SERVOGUN SVGN320& DRP AUTO
ALARMS RESET ALARM 326 LTCH FAULT
N00028 F1000.5 R1404.5

F 146 R DROP AUTO FAULT
FAULT DRP AUTO
FAULT
G1000.4
G
RB FAULT
RESET
N00029 F1000.5 R1404.0 R1404.1 R1404.4

H 149
FAULT ECO33 ECO FC AVAIL
STROBE RETRIEVE
N00030 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 153
FC AVAIL ECO17 ECO18 ECO19 ECO20 ECO21 ECO22
FC1 FC2 FC4 FC8 FC16 FC32
1 R1402.6 R1402.7 R1404.3

J S
ECO23 ECO24 SPOT
FC64 FC128 ALARM
N00031 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

K 163
1 R1402.6 R1402.7 R0330.0

L S
ECO23 ECO24 ARC
FC64 FC128 ALARM
N00032 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

M 173
1 R1402.6 R1402.7 R0330.1

N S
ECO23 ECO24 SEALER
FC64 FC128 ALARM
O
Ladder Diagram 6
N00033 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

A 183
1 R1402.6 R1402.7 R0330.2

B S
ECO23 ECO24 SERVOGUN
FC64 FC128 ALARM
N00034 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

C 193
1 R1402.6 R1402.7 R0330.3

D S
ECO23 ECO24 TOOLCHNG
FC64 FC128 ALARM
N00035 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

E 203
1 R1402.6 R1402.7 R0330.4

F S
ECO23 ECO24 SYSTEM
FC64 FC128 ALARM
N00036 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

G 213
1 R1402.6 R1402.7 R1406.0

H S
ECO23 ECO24 FACILITY
FC64 FC128 CODE 15
N00037 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 223
1 R1402.6 R1402.7 R1404.2

J
ECO23 ECO24 FC ZERO
FC64 FC128
O
Ladder Diagram 7
N00038 R1404.1 ACT R1404.3

A 233 SUB57 0001 R
ECO DIFU SPOT
RETRIEVE ALARM
R0330.0
B R
ARC
ALARM
R0330.1
C R
SEALER
ALARM
R0330.2
D R
SERVOGUN
ALARM
R0330.3
E R
TOOLCHNG
ALARM
R0330.4
F R
SYSTEM
ALARM
R1405.0
G R
FACILITY
CODE 11
R1406.0
H R
FACILITY
CODE 15
N00039 R1404.4 ACT R1404.6

I 244 SUB 3 0006
FC AVAIL TMR RETRIEVE
DELAY
N00040 R1404.6 R1404.1

J 248 S
RETRIEVE ECO
DELAY RETRIEVE
N00041 R1404.1 ACT R1404.1

K 250 SUB 3 0007 R
ECO TMR ECO
RETRIEVE RETRIEVE
N00042 Y0015.5 Y0015.5

L 254 S WELD FAULT #1
DO 126 W DO 126 W
LD FLT 1 LD FLT 1
N00043 X0083.1 Y0015.5

M 256 R WELD FAULT #1
DI 666 W DO 126 W
ELD CMP1 LD FLT 1
N00044 Y0019.5 Y0019.5

N 258 S WELD FAULT #2
DO 158 W DO 158 W
LD FLT 2 LD FLT 2
N00045 X0091.1 Y0019.5

O 260 R WELD FAULT #2
DI 730 W DO 158 W
ELD CMP2 LD FLT 2
Ladder Diagram 8
N00046 K0010.1 K0010.0 Y1025.5 R0000.1

A 262 S
EXT MTR TEACH MOTORS INT EXT
ON MEMORY ENABLE MTR ON
N00047 Y1025.5 R0000.1

B 266 R
MOTORS INT EXT
ENABLE MTR ON
N00048 X0000.2 K0010.0 K0010.5 K0010.1

C 268 EXTERNAL MOTORS ON
DI 3 EXT TEACH MAINT ME EXT MTR
MTR ON MEMORY M ON
X1026.5 Y0000.4 F1000.5

D
SI13 RES DO 5 RBT FAULT
ETSW CNT FLT
X1025.1
E
FAULT
RESET
X0000.1 X0001.2
F
DI 2 EX DI 11
RNEN RST PLC AUTO
N00049 K0010.2 K0010.0 K0010.5 R0000.2

G 280
EXT CYC TEACH MAINT ME INT EXT
START MEMORY M CYC STRT
N00050 X0000.3 K0010.0 K0010.2

H 284 EXTERNAL CYCLE START
DI 4 EXT TEACH EXT CYC
CY STRT MEMORY START
X1026.5 Y0000.4 F1000.5

I
ETSW CNT FLT
X1025.1
J
FAULT
RESET
X0000.1 X0001.2
K
DI 2 EX DI 11
RNEN RST PLC AUTO
R0340.0
L
MANUAL
WELD
N00051 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 296
DI 17 PG DI 18 PG DI 19 PG DI 20 PG DI 21 PG DI 22 PG DI 23 PG
SLCT 1 SLCT 2 SLCT 4 SLCT 8 SLCT 16 SLCT 32 SLCT 64
1 X0002.7 R0507.0
N PROGRAM 1
DI 24 PG PROGRAM
SLCT128 1
O
Ladder Diagram 9
N00052 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 305
1 X0002.7 R0507.1
B PROGRAM 2
DI 24 PG PROGRAM
SLCT128 2
N00053 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 314
1 X0002.7 R0507.2
D PROGRAM 3
DI 24 PG PROGRAM
SLCT128 3
N00054 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 323
1 X0002.7 R0507.3
F PROGRAM 4
DI 24 PG PROGRAM
SLCT128 4
N00055 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 332
1 X0002.7 R0507.4
H PROGRAM 5
DI 24 PG PROGRAM
SLCT128 5
N00056 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 341
1 X0002.7 R0507.5
J PROGRAM 6
DI 24 PG PROGRAM
SLCT128 6
N00057 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 350
1 X0002.7 R0507.6
L PROGRAM 7
DI 24 PG PROGRAM
SLCT128 7
N00058 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 359
1 X0002.7 R0507.7
N PROGRAM 8
DI 24 PG PROGRAM
SLCT128 8
O
Ladder Diagram 10
N00059 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 368
1 X0002.7 R0508.0
B PROGRAM 9
DI 24 PG PROGRAM
SLCT128 9
N00060 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 377
1 X0002.7 R0508.1
D PROGRAM 10
DI 24 PG PROGRAM
SLCT128 10
N00061 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 386
1 X0002.7 R0508.2
F PROGRAM 11
DI 24 PG PROGRAM
SLCT128 11
N00062 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 395
1 X0002.7 R0508.3
H PROGRAM 12
DI 24 PG PROGRAM
SLCT128 12
N00063 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 404
1 X0002.7 R0508.4
J PROGRAM 13
DI 24 PG PROGRAM
SLCT128 13
N00064 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 413
1 X0002.7 R0508.5
L PROGRAM 14
DI 24 PG PROGRAM
SLCT128 14
N00065 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 422
1 X0002.7 R0508.6
N PROGRAM 15
DI 24 PG PROGRAM
SLCT128 15
O
Ladder Diagram 11
N00066 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 431
1 X0002.7 R0508.7
B PROGRAM 16
DI 24 PG PROGRAM
SLCT128 16
N00067 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 440
1 X0002.7 R0509.0
D PROGRAM 17
DI 24 PG PROGRAM
SLCT128 17
N00068 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 449
1 X0002.7 R0509.1
F PROGRAM 18
DI 24 PG PROGRAM
SLCT128 18
N00069 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 458
1 X0002.7 R0509.2
H PROGRAM 19
DI 24 PG PROGRAM
SLCT128 19
N00070 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 467
1 X0002.7 R0509.3
J PROGRAM 20
DI 24 PG PROGRAM
SLCT128 20
O
Ladder Diagram 12
N00071 X0000.4 Y0000.2 F1000.2 F1000.3 F1000.6 X0001.2 G1000.1 1

A 476
DI 5 MV DO 3 RBT PROGRAM PAUSED AT HOME DI 11 NO HOLD
TO POUNC IN AUTO RUNNING PLC AUTO
Y0000.2 F1000.3 F1000.2 X0001.2

B
DO 3 RBT PAUSED PROGRAM DI 11
IN AUTO RUNNING PLC AUTO
F1000.6 R0507.0 F1000.2 F1000.3

C
AT HOME PROGRAM PROGRAM PAUSED
1 RUNNING
R0507.1
D
PROGRAM
2
R0507.2
E
PROGRAM
3
R0507.3
F
PROGRAM
4
R0507.4
G
PROGRAM
5
R0507.5
H
PROGRAM
6
R0507.6
I
PROGRAM
7
R0507.7
J
PROGRAM
8
R0508.0
K
PROGRAM
9
R0508.1
L
PROGRAM
10
R0508.2
M
PROGRAM
11
R0508.3
N
PROGRAM
12
R0508.4
O
PROGRAM
13
Ladder Diagram 13
R0508.5
A
PROGRAM
14
R0508.6
B
PROGRAM
15
R0508.7
C
PROGRAM
16
R0509.0
D
PROGRAM
17
R0509.1
E
PROGRAM
18
R0509.2
F
PROGRAM
19
R0509.3
G
PROGRAM
20
Y0000.2 F1000.3 F1000.2 X0000.1 X0001.2

H
DO 3 RBT PAUSED PROGRAM DI 2 EX DI 11
IN AUTO RUNNING RNEN RST PLC AUTO
R0223.0
I
DI 976 M
AN WELD1
R0223.1
J
DI 977 M
AN WELD2
1 R0000.1 D0603.0 Y0000.4 R0100.5 F1000.5 G1000.5

K UOP CYCLE START
INT EXT CYCLE DO 5 RBT BREAK A FAULT UOP CYC
MTR ON STRT DLY CNT FLT NO HOLD START
N00072 G1000.5 F1000.2 ACT D0603.0

L 528 SUB 3 0008 S CYCLE START DELAY
UOP CYC PROGRAM TMR CYCLE
START RUNNING STRT DLY
N00073 D0603.0 ACT D0603.0

M 533 SUB 3 0009 R CYCLE START DELAY
CYCLE TMR CYCLE
STRT DLY STRT DLY
N00074 F1000.2 D0603.0

N 537 R CYCLE START DELAY
PROGRAM CYCLE
RUNNING STRT DLY
N00075
O 539 SUB 1
END1
Ladder Diagram 14
N00076 Y0119.7 ACT K0010.4

A 540 SUB 3 0011 TEACH MEMORY DELAY
DO 960 TMR TEACH ME
AUTO KEY M DELAY
N00077 Y0000.3 X1026.5 X1025.1 X1025.6 K0010.0

B 544 TEACH MEMORY
DO 4 RBT SI13 RES FAULT CYCLE TEACH
IN TCH ETSW RESET START MEMORY
K0010.4
C
TEACH ME
M DELAY
K0010.0
D
TEACH
MEMORY
N00078 K0008.0 R0350.0

E 551 MAINTENANCE MODE
AUTO/MAI IN MAINT
NT SS
N00079 R0350.0 ACT D0610.0

F 553 SUB 3 0012 MAINTENANCE MODE DELAY
IN MAINT TMR MAINT
DELAY
N00080 D0610.0 Y0000.2 Y0000.1 X1026.5 X1025.1 K0010.5

G 557 MAINTENANCE MEMORY
MAINT DO 3 RBT DO 2 RBT SI13 RES FAULT MAINT ME
DELAY IN AUTO @ HOME ETSW RESET M
K0010.5 X0000.6
H
MAINT ME DI 7 MAI
M NT PSCLR
N00081 X0000.2 X0000.3 Y0000.2 K0010.6

I 566 EXTERNAL START ANTI-TIE DOWN
DI 3 EXT DI 4 EXT DO 3 RBT EXT STRT
MTR ON CY STRT IN AUTO ANTI TD
K0010.6
J
EXT STRT
ANTI TD
N00082 X0002.0 G1001.0

K 571
DI 17 PG PNS 1
SLCT 1
N00083 X0002.1 G1001.1

L 573
DI 18 PG PNS 2
SLCT 2
N00084 X0002.2 G1001.2

M 575
DI 19 PG PNS 3
SLCT 4
N00085 X0002.3 G1001.3

N 577
DI 20 PG PNS 4
SLCT 8
N00086 X0002.4 G1001.4

O 579
DI 21 PG PNS 5
SLCT 16
Ladder Diagram 15
N00087 X0002.5 G1001.5

A 581
DI 22 PG PNS 6
SLCT 32
N00088 X0002.6 G1001.6

B 583
DI 23 PG PNS 7
SLCT 64
N00089 X0002.7 G1001.7

C 585
DI 24 PG PNS 8
SLCT128
N00090 X0000.6 K0008.0 Y0120.5

D 587 MAINTNANCE POS CLEAR
DI 7 MAI AUTO/MAI DO 966
NT PSCLR NT SS MAINTCLR
N00091 K0008.0 Y0001.4

E 590 SEND ROBOT TO MAINTENANCE
AUTO/MAI DO 13 SN
NT SS DRBT MNT
N00092 Y0112.3 Y0003.0

F 592 CLEAR OF ZONE #1
DO 900 DO 25 CL
CLR ZN 1 R ZON 1
N00093 Y0112.4 Y0003.1

G 594 CLEAR OF ZONE #2
DO 901 DO 26 CL
CLR ZN 2 R ZON 2
N00094 Y0112.5 Y0003.2

H 596 CLEAR OF ZONE #3
DO 902 DO 27 CL
CLR ZN 3 R ZON 3
N00095 Y0112.6 Y0003.3

I 598 CLEAR OF ZONE #4
DO 903 DO 28 CL
CLR ZN 4 R ZON 4
N00096 Y0112.7 Y0003.4

J 600 CLEAR OF ZONE #5
DO 904 DO 29 CL
CLR ZN 5 R ZON 5
N00097 Y0113.0 Y0003.5

K 602 CLEAR OF ZONE #6
DO 905 DO 30 CL
CLR ZN 6 R ZON 6
N00098 Y0113.1 Y0003.6

L 604 CLEAR OF ZONE #7
DO 906 DO 31 CL
CLR ZN 7 R ZON 7
N00099 Y0113.2 Y0003.7

M 606 CLEAR OF ZONE #8
DO 907 DO 32 CL
CLR ZN 8 R ZON 8
N00100 Y0113.3 Y0004.0

N 608 CLEAR OF ZONE #9
DO 908 DO 33 CL
CLR ZN 9 R ZON 9
N00101 Y0113.4 Y0004.1

O 610 CLEAR OF ZONE #10
DO 909 C DO 34 CL
LR ZN 10 R ZON 10
Ladder Diagram 16
N00102 Y0113.5 Y0004.2

A 612 CLEAR OF ZONE #11
DO 910 C DO 35 CL
LR ZN 11 R ZON 11
N00103 Y0113.6 Y0004.3

B 614 CLEAR OF ZONE #12
DO 911 C DO 36 CL
LR ZN 12 R ZON 12
N00104 Y0113.7 Y0004.4

C 616 CLEAR OF ZONE #13
DO 912 C DO 37 CL
LR ZN 13 R ZON 13
N00105 Y0116.4 Y0004.5

D 618 CLEAR OF ZONE #14
DO 933 C DO 38 CL
LR ZN 14 R ZON 14
N00106 Y0118.7 Y0004.6

E 620 CLR OF INDEPENDENT MOTION ZN1
DO952 CL DO 39 CL
RMOTZN1 R INDMOT
N00107 Y0119.0 Y0004.7

F 622 CLR OF INDEPENDENT MOTION ZN2
DO953 CL DO 40 CL
RMOTZN2 R INDMT2
N00108 Y0119.1 X0000.0 Y0000.6

G 624 CLEAR TO ADVANCE TRANSFER
DO 954 C DI 1 EXT DO 7 CLR
LRAV XFR RNENBL ADV
N00109 Y0119.2 X0000.0 Y0000.7

H 627 CLEAR TO RETURN TRANSFER
LRET XFR RNENBL RET XFR
N00110 Y0119.3 X0000.0 Y0001.0

I 630 CLEAR TO UNCLAMP
LR UNCLP RNENBL 2 UNCLP
N00111 Y0000.3 R1000.0 Y0073.0

J 633 PROMPT BOX
DO 4 RBT DO 19001 DO 585
IN TCH PRPTBX PRMPT BX
N00112 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

K 636
1 R1402.7 R1405.3
L SYSTEM FACILITY CODE (24)
ECO24 SYS FCLY
FC128 CODE
N00113 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 645
FACILITY EC01 EC02 ECO3 ECO4 ECO5 ECO6
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0365.0

O SRVO-001 OPERATOR PANEL E-STOP
ECO13 ECO14 ECO15 ECO16 SRVO-001
Ladder Diagram 17
N00114 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 663
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0366.0

C SRVO-002 TEACH PENDANT E-STOP
N00115 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 681
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0367.0

F SRVO-003 DEADMAN SWITCH RELEAS
N00116 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 699
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0368.0

I SRVO-005 ROBOT OVERTRAVELL
N00117 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 717
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.0

L SRVO-007 EXTERNAL EMERGENCY ST
N00118 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 735
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.1

O SRVO-408 DCS SSO EXT EMERGSTOP
Ladder Diagram 18
N00119 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 753
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.3

C SRVO-50 COLLISION DETECT
N00120 R1406.3 X1025.1 Y0001.6

D 771 COLLISION DETECT
SRVO-50 FAULT DO 15 CO
RESET LL DTCT
Y0001.6
E
DO 15 CO
LL DTCT
N00121 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

F 775
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

G
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.2

H SRVO-65 LOW BATTERY
LOW BATT
N00122 F1001.0 Y0001.1

I 793 ROBOT BATTERY LOW
BATALM DO 10 RB
T BAT LW
N00123 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 795
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0371.0

L SRVO-101 ROBOT OVERATRAVEL
N00124 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 813
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.1

O DISTURBANCE EXCESS(SRVO11)
ECO13 ECO14 ECO15 ECO16 DISTURBA
NCE EXCE
Ladder Diagram 19
N00125 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 831
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0373.0

C SRVO-199 CONTROL STOP
CONTROL
N00126 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 849
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0374.0

F SRVO-232 NTED INPUT
NTED IN
N00127 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 867
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0375.0

I SRVO-233 TP OFF IN T1,T2/DOOR
TP OFF
N00128 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 885
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0376.0

L SRVO-280 SVOFF INPUT
SVOFF I
N00129 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 903
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.0

O SRVO-378 OPSFTY11 STATUS ABNOR
OPSFT11
Ladder Diagram 20
N00130 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 921
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.1

C SRVO-379 OPSFTY12 STATUS ABNOR
OPSFT12
N00131 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 939
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.2

F SRVO-380 OPSFTY21 STATUS ABNOR
OPSFT21
N00132 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 957
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.3

I SRVO-381 OPSFTY22 STATUS ABNOR
OPSFT22
N00133 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 975
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.4

L SRVO-382 OPSFTY31 STATUS ABNOR
OPSFT31
N00134 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 993
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.5

OPSFT32
Ladder Diagram 21
N00135 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1011
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.6

OPSFT41
N00136 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1029
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.7

OPSFT42
N00137 R0387.0 R0388.0

G 1047 SRVO OPSFTY ABNORM FAULT LATCH
SRVO-378 OPSFTY F
OPSFT11 LT LATCH
R0387.1
H
SRVO-379
OPSFT12
R0387.2
I
SRVO-380
OPSFT21
R0387.3
J
SRVO-381
OPSFT22
R0387.4
K
SRVO-382
OPSFT31
R0387.5
L
SRVO-383
OPSFT32
R0387.6
M
SRVO-384
OPSFT41
R0387.7
N
SRVO-385
OPSFT42
R0388.0 F1000.5
O
OPSFTY F FAULT
LT LATCH
Ladder Diagram 22
N00138 R0388.0 Y0073.1

A 1059 SAFETY CHAIN FAULT
OPSFTY F DO 586 S
LT LATCH FTY CHN
N00139 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

B 1061
SYS FCLY EC01 EC02 ECO3 ECO4 ECO5 ECO6
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

C
2 R1401.4 R1401.5 R1401.6 R1401.7 R0377.0

D SYST-034 HOLD SIGNAL FROM SOP/
ECO13 ECO14 ECO15 ECO16 SYST-034
HOLD SI
N00140 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

E 1079
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

F
2 R1401.4 R1401.5 R1401.6 R1401.7 R0378.0

G SYST-038 OPERATION MODE T1 SEL
OPERATI
N00141 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

H 1097
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

I
2 R1401.4 R1401.5 R1401.6 R1401.7 R0379.0

J
N00142 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

K 1115
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

L
2 R1401.4 R1401.5 R1401.6 R1401.7 R0380.0

M SYST-040 OPERATION MODE AUTO S
OPERATI
O
Ladder Diagram 23
N00143 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1133
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0381.0

C SYST-042 DEADMAN DEFEATED
DEADMAN
N00144 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1151
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0382.0

F SYST-043 TP DISABLE IN T1/T2
TP DISA
N00145 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 1169
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0383.0

I SYST-045 TP ENABLE IN AUTO MO
TP ENAB
N00146 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 1187
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0384.0

L SYST-154 NO START IN ISOLATE/B
NO STAR
N00147 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 1205
SERVOGUN EC01 EC02 ECO3 ECO4 ECO5 ECO6
ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0385.0

O SVGN-320 THCKNESS1 ERR REQ RES
ECO13 ECO14 ECO15 ECO16 SVGN-320
THK1ERR
Ladder Diagram 24
N00148 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1223
ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0386.0

C SVGN-326 THKNESS2 ERR REQ RES
THK2ERR
N00149 R0385.0 R0386.1

D 1241 SVGN 320 & 326 LATCH
SVGN-320 SVGN320&
THK1ERR 326 LTCH
R0386.0
E
SVGN-326
THK2ERR
R0386.1 G1000.4
F
SVGN320& RB FAULT
326 LTCH RESET
N00150 R0397.0 F1000.0 R0397.0

G 1247 FILTERED FAULT
FILTERED COMMAND FILTERED
FAULT ENABLE FAULT
R0398.0
H
FILTER
FLT GRP1
R0399.0
I
FILTER
FLT GRP2
O
Ladder Diagram 25
N00151 R0365.0 R0398.0

A 1252 FILTER FAULTS GROUP1
SRVO-001 FILTER
FLT GRP1
R0366.0
B
SRVO-002
R0367.0
C
SRVO-003
R0368.0
D
SRVO-005
R0369.0
E
R369.0
RESERVED
R0370.0
F
SRVO-007
R0371.0
G
SRVO-101
R0372.0
H
R372.0
RESERVED
R0373.0
I
SRVO-199
CONTROL
R0374.0
J
SRVO-232
NTED IN
R0375.0
K
SRVO-233
TP OFF
R0376.0
L
SRVO-280
SVOFF I
R0385.0
M
SVGN-320
THK1ERR
R0386.0
N
SVGN-326
THK2ERR
R0370.1
O
SRVO-408
Ladder Diagram 26
R1456.0
A
APPL
ALARMS
N00152 R0377.0 R0399.0

B 1269 FILTER FAULTS GROUP2
SYST-034 FILTER
HOLD SI FLT GRP2
R0378.0
C
SYST-038
OPERATI
R0379.0
D
SYST-039
R0380.0
E
SYST-040
OPERATI
R0381.0
F
SYST-042
DEADMAN
R0382.0
G
SYST-043
TP DISA
R0383.0
H
SYST-045
TP ENAB
R0384.0
I
SYST-154
NO STAR
X1025.0
J
FANUC
E-STOP
F1008.2
K
TP
E-STOP
X1026.1
L
SI9
AUTOMDSW
Y0000.3
M
DO 4 RBT
IN TCH
K0010.0
N
TEACH
MEMORY
R1405.2
O
FENCE
FAULT
Ladder Diagram 27
N00153 R0330.0 F1000.5 R1456.0

A 1284
ARC FAULT APPL
ALARM ALARMS
R0330.1
B
SEALER
ALARM
R0330.3
C
TOOLCHNG
ALARM
R0330.4
D
SYSTEM
ALARM
R1404.3
E
SPOT
ALARM
R1456.0
F
APPL
ALARMS
N00154 D0001.0 Y0079.0

G 1292 S TOOL CHANGER LOCK
TOOL CHA DO 633 T
NGE APP C LOCK
Y0079.1
H R TOOL CHANGER UNLOCK
DO 634 T
C UNLOCK
N00155 D0001.0 ACT

I 1295 SUB10 0000
TOOL CHA JMP
NGE APP
N00156
J 1298 SUB66 P0001
CALLU TOOL CHANGING
N00157
K 1300 SUB30
JMPE
N00158
L 1301 SUB66 P0002
CALLU WELDCONTROL1
N00159
M 1303 SUB66 P0003
CALLU TIPDRESSER1
N00160
N 1305 SUB66 P0004
CALLU WATERVALVE1
N00161
O 1307 SUB66 P0005
CALLU OVRTMP/NOSTRK1
Ladder Diagram 28
N00162
A 1309 SUB66 P0006
CALLU UALM
N00163
B 1311 SUB66 P0007
CALLU INTERFACE
N00164
C 1313 SUB66 P0008
CALLU MH
N00165
D 1315 SUB66 P0009
CALLU APPLICATION
N00166
E 1317 SUB66 P0020
CALLU AIR
N00167
F 1319 SUB66 P0015
CALLU WELDCONTROL2
N00168
G 1321 SUB66 P0016
CALLU TIPDRESSER2
N00169
H 1323 SUB66 P0017
CALLU WATERVALVE2
N00170
I 1325 SUB66 P0018
N00171
J 1327 SUB66 P0025
CALLU TOUCHUP1
N00172
K 1329 SUB 2
END2
N00173 ### P0001 ###

L 1330 SUB71 P0001
SP TOOL CHANGING
O
Ladder Diagram 29
N00174 X0080.0 R0347.0

A 1332 GUN ID NOT 0
DI 641 GUN ID
TOOL ID1 NOT 0
X0080.1
B
DI 642
TOOL ID2
X0080.2
C
DI 643
TOOL ID4
X0080.3
D
DI 644
TOOL ID8
N00175 X0080.0 X0080.1 X0080.2 X0080.3 R0321.0

E 1337
DI 641 DI 642 DI 643 DI 644 GUN 1 ON
TOOL ID1 TOOL ID2 TOOL ID4 TOOL ID8 ARM
N00176 X0080.0 X0080.1 X0080.2 X0080.3 R0322.0

F 1342
DI 641 DI 642 DI 643 DI 644 GUN 2 ON
N00177 X0080.0 X0080.1 X0080.2 X0080.3 R0323.0

G 1347
DI 641 DI 642 DI 643 DI 644 GUN 3 ON
N00178 X0080.0 X0080.1 X0080.2 X0080.3 R0324.0

H 1352
DI 641 DI 642 DI 643 DI 644 GUN 4 ON
N00179 X0080.0 X0080.1 X0080.2 X0080.3 R0325.0

I 1357
DI 641 DI 642 DI 643 DI 644 GUN 5 ON
N00180 X0080.0 X0080.1 X0080.2 X0080.3 R0326.0

J 1362
DI 641 DI 642 DI 643 DI 644 GUN 6 ON
N00181 X0080.0 X0080.1 X0080.2 X0080.3 R0326.1

K 1367
DI 641 DI 642 DI 643 DI 644 GUN 7 ON
N00182 X0080.0 X0080.1 X0080.2 X0080.3 R0326.2

L 1372
DI 641 DI 642 DI 643 DI 644 GUN 8 ON
O
Ladder Diagram 30
N00183 R0321.0 R0328.6

A 1377 TOOL ON ROBOT
GUN 1 ON TOOLONRO
ARM BOT
R0322.0
B
GUN 2 ON
ARM
R0323.0
C
GUN 3 ON
ARM
R0324.0
D
GUN 4 ON
ARM
R0325.0
E
GUN 5 ON
ARM
R0326.0
F
GUN 6 ON
ARM
R0326.1
G
GUN 7 ON
ARM
R0326.2
H
GUN 8 ON
ARM
N00184 R0321.0 R0322.0 R0323.0 R0324.0 R0325.0 R0326.0 R0326.1 1

I 1386
GUN 1 ON GUN 2 ON GUN 3 ON GUN 4 ON GUN 5 ON GUN 6 ON GUN 7 ON
ARM ARM ARM ARM ARM ARM ARM
1 R0326.2 R0348.0
J ANY GEO TOOL PRESENT ON ROBOT
GUN 8 ON GEOTOOLP
ARM RSNT
N00185 X0080.0 Y0038.0

K 1395 STUD WLD BRACKET NOT PRESENT2
DI 641 DO 305
TOOL ID1 TOOL ID1
N00186 X0080.1 Y0038.1

L 1397
DI 642 DO 306
TOOL ID2 TOOL ID2
N00187 X0080.2 Y0038.2

M 1399
DI 643 DO 307
TOOL ID4 TOOL ID4
N00188 X0080.3 Y0038.3

N 1401
DI 644 DO 308
TOOL ID8 TOOL ID8
O
Ladder Diagram 31
N00189 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 X0038.6 1

A 1403
DI 305 DI 306 DI 307 DI 308 DI 309 DI 310 DI 311
TCSTND1 TCSTND2 TCSTND3 TCSTND4 TCSTND5 TCSTND6 TCSTND7
1 X0038.7 R0327.0
B GUN 1-8 (ALL TOOLS IN STAND)
DI 312 GUN 1-8
TCSTND8
N00190 Y0117.4 K0011.1

C 1412 TOOL CHANGER RELEASE
DO 941 TC RE
TC UNLCK LEASED
N00191 Y0117.3 Y0000.2 X0079.4 X0079.5 R0328.6 Y0079.0

D 1414 S TOOL CHANGER LOCK
DO 940 DO 3 RBT DI 637 DI 638 TOOLONRO DO 633 T
TC LOCK IN AUTO RDY2LCK1 RDY2LCK2 BOT C LOCK
F1000.7 Y0119.7 K0015.0 R0328.6

E
TPENABLE DO 960 TC LOCK TOOLONRO
AUTO KEY PB BOT
N00192 X0079.0 Y0040.6

F 1427
DI 633 DO 327 T
TC LOCKD CCOUPMON
N00193 Y0117.4 Y0117.3 Y0000.2 Y0079.0

G 1429 R TOOL CHANGER LOCK
DO 941 DO 940 DO 3 RBT DO 633 T
TC UNLCK TC LOCK IN AUTO C LOCK
F1000.7 Y0119.7 K0016.0

H
TPENABLE DO 960 TC UNLOC
AUTO KEY K PB
N00194 K0011.1 Y0079.0 Y0000.2 X0080.4 X0080.5 1

I 1438
TC RE DO 633 T DO 3 RBT DI 645 T DI 646 T
LEASED C LOCK IN AUTO SIV SRV
F1000.7 Y0119.7 K0016.0 R0328.6 2

J
TPENABLE DO 960 TC UNLOC TOOLONRO
AUTO KEY K PB BOT
1 R0328.6 Y0079.1
K TOOL CHANGER UNLOCK
TOOLONRO DO 634 T
BOT C UNLOCK
2
L
N00195 K0015.0 K0016.0 F1000.7 Y0119.7 K0015.0

M 1452 TC LOCK PUSH BUTTON
TC LOCK TC UNLOC TPENABLE DO 960 TC LOCK
PB K PB AUTO KEY PB
N00196 K0016.0 K0015.0 F1000.7 Y0119.7 K0016.0

N 1457 TC UNLOCK PUSH BUTTON
TC UNLOC TC LOCK TPENABLE DO 960 TC UNLOC
K PB PB AUTO KEY K PB
N00197 X0079.1 Y0040.7

O 1462
DI 634 DO 328 T
TC ULCKD CRELMON
Ladder Diagram 32
N00198 R0328.6 K0008.0 R0218.4

A 1464 TOOL CHANGER NO TOOL DETECTED
TOOLONRO AUTO/MAI DI 940 T
BOT NT SS C NOTOOL
N00199 Y0117.5 Y0117.6 Y0000.2 Y0038.5

B 1467 TOOL CHANGER OPEN COVERS
DO 942 DO 943 DO 3 RBT DO 310 T
TCOPNCVR TCCLSCVR IN AUTO C OPNCVR
K0011.4 K0011.5 Y0000.3

C
TC OPENG TC CLOS DO 4 RBT
UNCOVER GUNCOVER IN TCH
N00200 Y0117.5 Y0117.6 Y0000.2 Y0038.6

D 1475 TOOL CHANGER CLOSE COVERS
DO 942 DO 943 DO 3 RBT DO 311 T
TCOPNCVR TCCLSCVR IN AUTO C CLSCVR
K0011.5 K0011.4 Y0000.3

E
TC CLOS TC OPENG DO 4 RBT
GUNCOVER UNCOVER IN TCH
N00201 X0038.0 R0321.0 R0329.0

F 1483 GUN1 POSITION
DI 305 GUN 1 ON GUN1 POS
TCSTND1 ARM ITION
X0038.0 X0039.3
G
DI 305 DI 316 G
TCSTND1 EOTPDCK
N00202 X0038.1 R0322.0 R0329.1

H 1489 GUN2 POSITION
TCSTND2 ARM ITION
X0038.1 X0039.3
I
DI 306 DI 316 G
TCSTND2 EOTPDCK
N00203 X0038.2 R0323.0 R0329.2

J 1495 GUN3 POSITION
TCSTND3 ARM ITION
X0038.2 X0039.3
K
DI 307 DI 316 G
TCSTND3 EOTPDCK
N00204 X0038.3 R0324.0 R0329.3

L 1501 GUN4 POSITION
TCSTND4 ARM ITION
X0038.3 X0039.3
M
DI 308 DI 316 G
TCSTND4 EOTPDCK
N00205 X0038.4 R0325.0 R0329.4

N 1507 GUN5 POSITION
TCSTND5 ARM ITION
X0038.4 X0039.3
O
DI 309 DI 316 G
TCSTND5 EOTPDCK
Ladder Diagram 33
N00206 X0038.5 R0326.0 R0329.5

A 1513 GUN6 POSITION
TCSTND6 ARM ITION
X0038.5 X0039.3
B
DI 310 DI 316 G
TCSTND6 EOTPDCK
N00207 X0038.6 R0326.1 R0329.6

C 1519 GUN7 POSITION
TCSTND7 ARM ITION
X0038.6 X0039.3
D
DI 311 DI 316 G
TCSTND7 EOTPDCK
N00208 X0038.7 R0326.2 R0329.7

E 1525 GUN8 POSITION
TCSTND8 ARM ITION
X0038.7 X0039.3
F
DI 312 DI 316 G
TCSTND8 EOTPDCK
N00209 R0329.0 R0328.7

G 1531 ALL GUN1-8 POSITION
GUN1 POS GUN1-8 P
ITION OSITION
R0329.1
H
GUN2 POS
ITION
R0329.2
I
GUN3 POS
ITION
R0329.3
J
GUN4 POS
ITION
R0329.4
K
GUN5 POS
ITION
R0329.5
L
GUN6 POS
ITION
R0329.6
M
GUN7 POS
ITION
R0329.7
N
GUN8 POS
ITION
O
Ladder Diagram 34
N00210 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1540
DI 316 G DI 305 DI 306 DI 307 DI 308 DI 309 DI 310
EOTPDCK TCSTND1 TCSTND2 TCSTND3 TCSTND4 TCSTND5 TCSTND6
1 X0038.6 X0038.7 R0320.0

B TOOL 1 IN OPDOCK
DI 311 DI 312 TOOL1INO
TCSTND7 TCSTND8 PDOCK
N00211 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

C 1550
1 X0038.6 X0038.7 R0320.1

D TOOL 2 IN OPDOCK
N00212 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

E 1560
1 X0038.6 X0038.7 R0320.2

F TOOL 3 IN OPDOCK
N00213 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

G 1570
1 X0038.6 X0038.7 R0320.3

H TOOL 4 IN OPDOCK
N00214 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

I 1580
1 X0038.6 X0038.7 R0320.4

J TOOL 5 IN OPDOCK
N00215 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

K 1590
1 X0038.6 X0038.7 R0320.5

L TOOL 6 IN OPDOCK
N00216 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

M 1600
1 X0038.6 X0038.7 R0320.6

N TOOL 7 IN OPDOCK
O
Ladder Diagram 35
N00217 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1610
1 X0038.6 X0038.7 R0320.7

B TOOL 8 IN OPDOCK
N00218 R0320.0 R0319.0

C 1620 ALL TOOLS IN OPDOCK
TOOL1INO ALLTOOLS
PDOCK INOPDOCK
R0320.1
D
TOOL2INO
PDOCK
R0320.2
E
TOOL3INO
PDOCK
R0320.3
F
TOOL4INO
PDOCK
R0320.4
G
TOOL5INO
PDOCK
R0320.5
H
TOOL6INO
PDOCK
R0320.6
I
TOOL7INO
PDOCK
R0320.7
J
TOOL8INO
PDOCK
N00219 X0082.6 Y0038.7

K 1629
DI 663 T DO 312 T
CCOMMOK CCOMMOK
N00220 X0082.7 Y0039.2

L 1631
DI 664 T DO 315 T
CTLSLDPW LSLIDPWR
N00221 X0079.4 X0079.5 G1008.4

M 1633 RTL1&L2SWITCHMISMATCH
DI 637 DI 638 UALM 5
RDY2LCK1 RDY2LCK2
X0079.4 X0079.5
N
DI 637 DI 638
RDY2LCK1 RDY2LCK2
N00222 R0328.6 G1008.5

O 1639 NOTOOLONARM
TOOLONRO UALM 6
BOT
Ladder Diagram 36
N00223 K0013.1 R0000.7 Y0126.7

A 1641 NO TOOL ON EOAT SS
NOTOOLON PART PRE DO 1016
EOATSS SENT NOEOATSS
N00224 K0013.1 R0000.7 K0013.1

B 1644 R NO TOOL ON EOAT SS
NOTOOLON PART PRE NOTOOLON
EOATSS SENT EOATSS
N00225 Y0039.3 Y0039.3

C 1647 S WRONG TOOL IN STAND
DO 316 W DO 316 W
RNGTLSTD RNGTLSTD
N00226 Y0039.3 X1025.1 Y0000.1 Y0039.3

D 1649 R WRONG TOOL IN STAND
DO 316 W FAULT DO 2 RBT DO 316 W
RNGTLSTD RESET @ HOME RNGTLSTD
N00227
E 1653 SUB72
SPE
N00228 ### P0002 ###

F 1654 SUB71 P0002
SP WELDCONTROL1
N00229 X0000.0 Y0083.0

G 1656 WELD CONTROLLER #1 ENABLE
DI 1 EXT DO 665 W
RNENBL C1 ENBLE
N00230 X0087.6 Y0014.4

H 1658 WELD CONTROLLER COMM OK #1
DI 703 W DO 117 W
1 COMMOK C1COM OK
N00231 Y0000.3 Y0083.1

I 1660 ROBOT IN TEACH TO WC #1
DO 4 RBT DO 666 R
IN TCH BTCH WC1
N00232 K0004.7 Y0014.1

J 1662 WELD/ NO WELD 1 SS
WELD / N DO 114 W
O WELD1 D/NWD1SS
N00233 K0006.4 Y0018.1

K 1664 WELD/ NO WELD 2 SS
WELD / N DO 146 W
O WELD2 D/NWD2SS
N00234 Y0014.1 Y0018.1 R0221.0

L 1666 REMOTE WELD / NO WELD MODE
DO 114 W DO 146 W DI 960 R
D/NWD1SS D/NWD2SS EM WELD
N00235 X0086.1 Y0015.6

M 1669 I AVAILABLE WARNING #1
DI 690 I DO 127 I
HI/LO AVL WRN1
N00236 X0087.5 Y0017.3

N 1671 ADAPTIVE MODE ENABLE
DI 702 A DO 140 A
DP MODE DP MODE
N00237 X0083.0 Y0015.3

O 1673 IN WELD CYCLE #1
DI 665 I DO 124 I
NWLDCYC1 NWD CY 1
Ladder Diagram 37
N00238 X0083.1 Y0015.4

A 1675 HAS WELDED #1
DI 666 W DO 125 H
ELD CMP1 AS WLD 1
N00239 X0083.3 Y0014.3

B 1677 NO WELD TIMER FAULT #1
DI 668 W DO 116 N
ELD FLT1 OWLDFLT1
N00240 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

C 1679
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0306.0
D ROBOT WELD SCHEDULE WELD CTRL1
DO 686 ROBOT WS
BP 128 WC#1
N00241 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

E 1688
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0307.0
F
DO 686 WLD SCH
BP 128 39 WC1
N00242 Y0014.1 Y0014.2 Y0083.4

G 1697 WELD / NO WELD
DO 114 W DO 115 W DO 669 W
D/NWD1SS D/NWD1MD LD/NOWLD
N00243 X1020.2 X1020.0 X1020.1 D0004.0

H 1700 ALL WELD PARAMETER OK WC1
RI 3 WTR RI 1 XF RI 2 SRV LETSWELD
FL SW1 RMR OT1 OMTR OT1 WC1
O
Ladder Diagram 38
N00244 Y0109.7 D0004.0 K0000.0 ACT R0363.0

A 1704 SUB 3 0035 WELD BINARY WC1 TIMER
DO 880 LETSWELD DEBUG TMR BINARYTI
BP1 1 WC1 MER1
Y0110.0
B
DO 881
BP2 1
Y0110.1
C
DO 882
BP4 1
Y0110.2
D
DO 883
BP8 1
Y0110.3
E
DO 884
BP16 1
Y0110.4
F
DO 885
BP32 1
Y0110.5
G
DO 886
BP64 1
Y0110.6
H
DO 887
BP128 1
N00245 Y0109.7 D0004.0 R0363.0 Y0084.6

I 1717 BINARY PILOT 1 WC#1
DO 880 LETSWELD BINARYTI DO 679
BP1 1 WC1 MER1 BP 1
N00246 Y0110.0 D0004.0 R0363.0 Y0084.7

J 1721 BINARY PILOT 2 WC#1
BP2 1 WC1 MER1 BP 2
N00247 Y0110.1 D0004.0 R0363.0 Y0085.0

K 1725 BINARY PILOT 4 WC#1
BP4 1 WC1 MER1 BP 4
N00248 Y0110.2 D0004.0 R0363.0 Y0085.1

L 1729 BINARY PILOT 8 WC#1
BP8 1 WC1 MER1 BP 8
N00249 Y0110.3 D0004.0 R0363.0 Y0085.2

M 1733 BINARY PILOT 16 WC#1
BP16 1 WC1 MER1 BP 16
N00250 Y0110.4 D0004.0 R0363.0 Y0085.3

N 1737 BINARY PILOT 32 WC#1
N00251 Y0110.5 D0004.0 R0363.0 Y0085.4

O 1741 BINARY PILOT 64 WC#1
Ladder Diagram 39
N00252 Y0110.6 D0004.0 R0363.0 Y0085.5

A 1745 BINARY PILOT 128 WC#1
BP128 1 WC1 MER1 BP 128
N00253 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

B 1749
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0360.0
C NO WELD SCHEDULE WC1
DO 686 NOWLDSCH
BP 128 WC1
N00254 R0360.0 X0087.6 K0000.0 Y0083.5

D 1758 PRESSURE SWITCH INPUT
NOWLDSCH DI 703 W DEBUG DO 670
WC1 1 COMMOK PS INPUT
K0000.0 Y0116.5
E
DEBUG DO 934
RD SCHD1
N00255 Y0120.6 F1000.3 Y0000.1 R0223.0

F 1765
DO 967 M PAUSED DO 2 RBT DI 976 M
AN WELD1 @ HOME AN WELD1
X0015.0 K0008.0 Y0000.5 F1000.3 F1000.2

G
DI 121 R AUTO/MAI DO 6 RBT PAUSED PROGRAM
M MAN W1 NT SS @ MAINT RUNNING
Y0000.1 F1000.2 F1000.3

H
DO 2 RBT PROGRAM PAUSED
@ HOME RUNNING
N00256 Y0120.6 Y0000.1 F1000.2 F1000.3 R0213.6

I 1781 WELD AT HOME1
DO 967 M DO 2 RBT PROGRAM PAUSED DI 902 W
AN WELD1 @ HOME RUNNING ELDHOME1
X0015.0 K0008.0
J
DI 121 R AUTO/MAI
M MAN W1 NT SS
N00257 Y0048.3 Y0121.0 F1000.3 Y0000.1 R0220.4

K 1789 SWGNUT REFFED REWELD 1
DO 388 N DO 969 F PAUSED DO 2 RBT DI 956 R
UTFD APP EDWLD1PB @ HOME EFEDWLD1
N00258 K0008.6 D0612.0 K0008.6

L 1794 S DRESS TIP RESET PB 1
DTSR PB IF PB TO DTSR PB
1 1
N00259 K0008.6 D0612.0 K0008.6

M 1797 R DRESS TIP RESET PB 1
1 1
N00260 K0005.1 D0612.0 K0005.1

N 1800 S NEW TIP PUSH BUTTON1
NEW TIP IF PB TO NEW TIP
PB1 PB1
N00261 K0005.1 D0612.0 K0005.1

O 1803 R NEW TIP PUSH BUTTON1
PB1 PB1
Ladder Diagram 40
N00262 K0005.2 D0612.0 K0005.2

A 1806 S INITIATE AUTO TIP DRESS PB1
INIT AUT IF PB TO INIT AUT
O TD PB1 O TD PB1
N00263 K0005.2 D0612.0 K0005.2

B 1809 R INITIATE AUTO TIP DRESS PB1
O TD PB1 O TD PB1
N00264 K0005.5 D0612.0 K0005.5

C 1812 S TIP ALIGN CLOSE PB1
TIP ALGN IF PB TO TIP ALGN
CLS PB1 CLS PB1
N00265 K0005.5 D0612.0 K0005.5

D 1815 R TIP ALIGN CLOSE PB1
CLS PB1 CLS PB1
N00266 K0005.6 D0612.0 K0005.6

E 1818 S TIP ALIGNMENT OPEN PB1
OPN PB1 OPN PB1
N00267 K0005.6 D0612.0 K0005.6

F 1821 R TIP ALIGNMENT OPEN PB1
OPN PB1 OPN PB1
N00268 K0005.7 D0612.0 K0005.7

G 1824 S INITIATE AUTO TIP CHANGE PB1
INITAUTO IF PB TO INITAUTO
TCPB1 TCPB1
N00269 K0005.7 D0612.0 K0005.7

H 1827 R INITIATE AUTO TIP CHANGE PB1
TCPB1 TCPB1
N00270 K0006.0 D0612.0 K0006.0

I 1830 S AUTO TIP CHANGE FAULT ACK PB1
ATC FLT IF PB TO ATC FLT
ACK PB1 ACK PB1
N00271 K0006.0 D0612.0 K0006.0

J 1833 R AUTO TIP CHANGE FAULT ACK PB1
ACK PB1 ACK PB1
N00272 Y0120.6 D0612.0 Y0120.6

K 1836 S MANUAL WELD1
DO 967 M IF PB TO DO 967 M
AN WELD1 AN WELD1
N00273 Y0120.6 D0612.0 Y0120.6

L 1839 R MANUAL WELD1
AN WELD1 AN WELD1
N00274 Y0121.0 D0612.0 Y0121.0

M 1842 S SWGNUT WELD REFEED REWELD1 PB
DO 969 F IF PB TO DO 969 F
EDWLD1PB EDWLD1PB
N00275 Y0121.0 D0612.0 Y0121.0

N 1845 R SWGNUT WELD REFEED REWELD1 PB
EDWLD1PB EDWLD1PB
O
Ladder Diagram 41
N00276 Y1020.0 Y1020.0

A 1848 S RDO 1 EQUALIZATION VALVE 1
RO 1 RO 1
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
B
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00277 Y1020.0 Y1020.0

C 1853 R RDO 1 EQUALIZATION VALVE 1
RO 1 RO 1
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
D
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00278 K0004.5 K0006.2

E 1858 R EQUALIZER 1 SS
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00279 K0004.5 X1026.1 G1000.1 ACT K0004.5

F 1860 SUB 3 0033 R EQUALIZATION ENABLE 1&2 SS
EQUALENB SI9 NO HOLD TMR EQUALENB
L 1&2 SS AUTOMDSW L 1&2 SS
N00280 K0000.0 Y0083.3 D0612.0 X1025.1 Y0083.3

G 1866 RESET WELDER
DEBUG DO 668 R IF PB TO FAULT DO 668 R
ST WLD RESET ST WLD
X1025.1
H
FAULT
RESET
N00281 K0015.1 D0612.0 K0015.1

I 1872 S ADVANCE TIP DRESS DUMP 1
ADVTIPDR IF PB TO ADVTIPDR
SSDUMP1 SSDUMP1
N00282 K0015.1 D0612.0 K0015.1

J 1875 R ADVANCE TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00283 K0015.2 D0612.0 K0015.2

K 1878 S RETRACT TIP DRESS DUMP 1
RETTIPDR IF PB TO RETTIPDR
SSDUMP1 SSDUMP1
N00284 K0015.2 D0612.0 K0015.2

L 1881 R RETRACT TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00285 K0015.1 Y0000.2 X1026.1 K0015.2 Y0017.5

M 1884
ADVTIPDR DO 3 RBT SI9 RETTIPDR DO 142 A
SSDUMP1 IN AUTO AUTOMDSW SSDUMP1 DVDUMP1
N00286 K0015.2 Y0000.2 X1026.1 K0015.1 Y0017.6

N 1889
RETTIPDR DO 3 RBT SI9 ADVTIPDR DO 143 R
SSDUMP1 IN AUTO AUTOMDSW SSDUMP1 ETDUMP1
O
Ladder Diagram 42
N00287 Y0120.6 K0000.3 D0610.1

A 1894 S CONSTANT CURRENT WELD TIMER 1
DO 967 M CCWLDMDE CCWELDMO
AN WELD1 NB1 DETIMR1
X0015.0 K0008.0 K0000.3

B
DI 121 R AUTO/MAI CCWLDMDE
M MAN W1 NT SS NB1
N00288 D0610.1 ACT D0610.1

C 1901 SUB 3 0037 R CONSTANT CURRENT WELD TIMER 1
CCWELDMO TMR CCWELDMO
DETIMR1 DETIMR1
N00289 X0054.5 Y0087.1

D 1905 CONSTANT CURRENT WELD MODE 1
DI 438 C DO 698 C
CWELDMOD CWELDMOD
D0610.1
E
CCWELDMO
DETIMR1
N00290
F 1908 SUB72
SPE
N00291 ### P0003 ###

G 1909 SUB71 P0003
SP TIPDRESSER1
N00292 X0087.1 Y0017.2

H 1911 TIP CHANGE REQUIRED #1
DI 698 T DO 139 T
PCHNGRQW PCHG RQ1
X0087.0
I
DI 697 T
PCHNGRQ
Y0110.7
J
DO 888 T
PWRMOV1
Y0111.0
K
DO 889 T
PWRFIX1
N00293 K0005.5 Y0000.5 R0222.6

L 1916 TIP ALIGNMENT CLOSED 1
TIP ALGN DO 6 RBT DI 974 T
CLS PB1 @ MAINT IP CLS1
N00294 K0005.6 Y0000.5 R0222.7

M 1919 TIP ALIGNMENT OPENED 1
OPN PB1 @ MAINT IP OPN1
N00295 X0083.4 Y0016.3

N 1922 NEW TIPS RESET #1
DI 669 N DO 132 N
EW TIP WTP RST1
O
Ladder Diagram 43
N00296 R0345.0 Y0084.5 X0001.2 K0008.0 R0345.0

A 1924 INITIATE AUTO TIP MEMORY 1
TIP MEM DO 678 D DI 11 AUTO/MAI TIP MEM
1 TSR PLC AUTO NT SS 1
Y0119.1 K0005.2
B
DO 954 C INIT AUT
LRAV XFR O TD PB1
N00297 R0334.0 Y0109.0 Y0000.5 X0083.1 R0333.0

C 1932 TIP DRESS MEMORY WC #1
DRESS CA DO 873 T DO 6 RBT DI 666 W TD MEM W
P TC1 D1 ENB @ MAINT ELD CMP1 C #1
R0333.0
D
TD MEM W
C #1
N00298 X0083.4 K0008.0 Y0000.5 X0014.7 R0333.0 R0334.0

E 1938 DRESS CAPS AFTER TIP CHNGE1
DI 669 N AUTO/MAI DO 6 RBT DI 120 T TD MEM W DRESS CA
EW TIP NT SS @ MAINT D BYPSS1 C #1 P TC1
R0334.0
F
DRESS CA
P TC1
N00299 X0083.2 Y0015.0

G 1945 AUTO TIP DRESS #1
DI 667 M DO 121 A
AINT REQ UTOTD 1
R0334.0 Y0048.3
H
DRESS CA DO 388 N
P TC1 UTFD APP
R0345.0
I
TIP MEM
1
N00300 K0005.0 Y0014.0

J 1951 PULLED TIP BYPASS SS ON I/F
PULLED T DO 113 P
IP BYPS1 LTPBY SS
K0006.5
K
PULLED T
IP BYPS2
N00301 Y0085.7 R0351.0

L 1954 PULLED TIP SEAL WC #1
DO 688 PULLDTIP
TIP WTR1 SEAL 1
N00302 R0351.0 ACT D0611.0

M 1956 SUB 3 0014 PULLED TIMER WC #1
PULLDTIP TMR PULLEDTI
SEAL 1 P TIMER
N00303 R0220.6 Y0017.4

N 1960 AUTO PULLED TIP BYPASS 1
DI 958 P DO 141 A
LDTIP 1 PTB 1
R0220.7
O
DI 959 P
LDTIP 2
Ladder Diagram 44
N00304 Y0014.5 X0001.2 Y0109.0

A 1963 TIP DRESSER #1 ENABLE
DO 118 D DI 11 DO 873 T
RSR ON 1 PLC AUTO D1 ENB
K0005.3 Y0000.3
B
TEACH TD DO 4 RBT
ENABLE1 IN TCH
N00305 R0000.0 Y0014.5 X0001.2 Y0086.6

C 1970 TIP DRESS MOTOR ON 1
ALWAYS DO 118 D DI 11 DO 695 T
ON RSR ON 1 PLC AUTO D MTR ON
K0005.3 Y0000.3
D
TEACH TD DO 4 RBT
ENABLE1 IN TCH
N00306 X1020.2 X0000.0 X0013.6 R0220.6

E 1978 PULLED TIP BYPASS 1
RI 3 WTR DI 1 EXT DI 111 A DI 958 P
FL SW1 RNENBL UTOTIPCH LDTIP 1
R0220.6 D0611.0
F
DI 958 P PULLEDTI
LDTIP 1 P TIMER
N00307 K0004.6 Y0014.7

G 1985 TIP DRESS MOTOR FLT BYPASS #1
TD MTR F DO 120 T
LT BYPS1 DMFL BY1
N00308 D0605.0 R0411.0 R0412.0

H 1987 TD FAULT1
TDMTROFF TDCURREN TDFAULT1
1TIM1 TOK1
N00309 Y0014.5 X0086.2 Y0109.2 K0004.6 Y0083.3 R0411.0

I 1990 TD CURRENT OK FROM WC1
DO 118 D DI 691 T DO 875 S TD MTR F DO 668 R TDCURREN
RSR ON 1 IP DR OK RVTPDROK LT BYPS1 ST WLD TOK1
R0411.0
J
TDCURREN
TOK1
N00310 R0412.0 ACT D0606.0

K 1997 SUB 3 0019 TD MOTOR OFF 2 FAULT TIMER 1
TDFAULT1 TMR TDMTROFF
2TIM1
N00311 Y0014.5 ACT D0605.0

L 2001 SUB 3 0020 TD MOTOR OFF 1 FAULT TIMER 1
DO 118 D TMR TDMTROFF
RSR ON 1 1TIM1
N00312 Y0083.3 R0411.0 D0606.0 R0415.0

M 2005 TD MOTOR FAULT 1
DO 668 R TDCURREN TDMTROFF TDMTRFLT
ST WLD TOK1 2TIM1 1
R0408.0
N
TPRESFLT
1
R0415.0
O
TDMTRFLT
1
Ladder Diagram 45
N00313 R0415.0 Y0014.6

A 2012 TIP DRESS MOTOR FLT #1
TDMTRFLT DO 119 T
1 DM FLT 1
N00314 Y0118.1 ACT D0604.0

B 2014 SUB 3 0021 TIP RESISTANCE FAULT TIMER 1
DO 946 R TMR TPRESFLT
ESCHKMD1 TIM1
N00315 D0604.0 R0409.0 R0408.0

C 2018 TIP RESISTANCE FAULT1
TPRESFLT TPRESFLT TPRESFLT
TIM1 LAT1 1
N00316 Y0118.1 X0086.3 K0005.4 Y0083.3 R0409.0

D 2021 TIP RESISTANCE FAULT LATCH1
DO 946 R DI 692 T TIP RESI DO 668 R TPRESFLT
ESCHKMD1 PDRRSOK1 ST BYPS1 ST WLD LAT1
R0409.0
E
TPRESFLT
LAT1
N00317 X0014.4 Y0121.2 Y0118.7 F1000.5 R0221.6

F 2027 RUNTIP DRESS DUMP MACRO1
DI 117 I DO 971 P DO952 CL FAULT DI 966 R
NIT TD 1 EDDMPAPP RMOTZN1 NTDDMP1
X0014.6 X0083.2 Y0015.0 Y0121.5

G
DI 119 T DI 667 M DO 121 A DO 974
D DMP R1 AINT REQ UTOTD 1 TPWRCMP1
N00318 K0008.5 K0008.5

H 2037 S NTSR ENABLE 1 SS
NTSR ENB NTSR ENB
1SS 1SS
N00319 K0008.5 X1025.1 K0008.5

I 2039 R NTSR ENABLE 1 SS
NTSR ENB FAULT NTSR ENB
1SS RESET 1SS
K0008.5 X0083.4
J
NTSR ENB DI 669 N
1SS EW TIP
N00320 K0015.6 K0015.6

K 2045 S DTSR ENABLE 1 SS
DTSRENB1 DTSRENB1
SS SS
N00321 K0015.6 X1025.1 K0015.6

L 2047 R DTSR ENABLE 1 SS
DTSRENB1 FAULT DTSRENB1
SS RESET SS
K0015.6 X0083.5
M
DTSRENB1 DI 670 D
SS RSSTIP1
N00322 K0008.5 K0005.1 Y0084.4

N 2053 NEW TIP STEPPER RESET
NTSR ENB NEW TIP DO 677 N
1SS PB1 TSR
X0015.3
O
DI 124 N
EWTPRST1
Ladder Diagram 46
N00323 K0015.6 K0008.6 Y0084.5

A 2057 DRESS TIP STEPPER RESET
DTSRENB1 DTSR PB DO 678 D
SS 1 TSR
Y0116.7 Y0054.2
B DRSSTIPSTPRST1
DO 936 DO 435 D
STP RST1 TSR1
N00324
C 2062 SUB72
SPE
N00325 ### P0004 ###

D 2063 SUB71 P0004
SP WATERVALVE1
N00326 X1020.2 X0001.6 Y0085.7

E 2065 TIP WATER FLOW 1
RI 3 WTR DI 15 SY DO 688
FL SW1 S WTR ON TIP WTR1
N00327 X0014.0 R0000.5 Y1020.3

F 2068 WATER RESET 1
DI 113 R WTR RST RO 4 WTR
ST WTRSV PULSE OP RESET1
Y1020.3 X1020.2
G
RO 4 WTR RI 3 WTR
RESET1 FL SW1
X1025.1
H
FAULT
RESET
N00328 Y1020.3 Y0122.0 ACT R0000.5

I 2075 SUB 3 0039 WATER RESET PULSE OPTION
RO 4 WTR DO 977 TMR WTR RST
RESET1 WS PLSOP PULSE OP
Y1020.5
J
RO 6 WTR
RESET2
N00329
K 2081 SUB72
SPE
N00330 ### P0005 ###

L 2082 SUB71 P0005
SP OVRTMP/NOSTRK1
N00331 X1020.0 Y0086.4

M 2084 TRANSFORMER OVERTEMP1
RI 1 XF DO 693 X
RMR OT1 FMR OT
N00332 X1020.1 Y0086.5

N 2086 SERVO MOTOR OVERTEMP1
RI 2 SRV DO 694 S
OMTR OT1 RVMTR OT
O
Ladder Diagram 47
N00333 X1020.0 X1025.1 R0500.0

A 2088 TRANSFORMER OVERTEMP SEAL1
RI 1 XF FAULT XFRMR OT
RMR OT1 RESET MP SEAL1
R0500.0
B
XFRMR OT
MP SEAL1
N00334 X1020.1 X1025.1 R0500.1

C 2092 SERVO MOTOR OVERTEMP SEAL1
RI 2 SRV FAULT SRVO MTR
OMTR OT1 RESET OTSEAL1
R0500.1
D
SRVO MTR
OTSEAL1
N00335 R0500.0 Y0016.2

E 2096 TRANSFORMER OVERTEMP FAULT #1
XFRMR OT DO 131 X
MP SEAL1 FMR OTF1
N00336 R0500.1 Y0016.1

F 2098 SG MOTOR OVERTEMP FAULT #1
SRVO MTR DO 130 S
OTSEAL1 GM OTF1
N00337 R0500.0 K0005.0 R0220.6 R0500.1 D0004.1

G 2100 REMOTE NO STROKE OK WC1
XFRMR OT PULLED T DI 958 P SRVO MTR REMSTROK
MP SEAL1 IP BYPS1 LDTIP 1 OTSEAL1 EOK1
Y0048.3 Y0048.2
H
DO 388 N DO 387 W
UTFD APP LD2 APP
Y0048.2 Y0050.5
I
DO 387 W DO 406 N
LD2 APP TFD 2APP
N00338 R0501.0 K0006.5 R0220.7 R0501.1 D0004.2

J 2112 REMOTE NO STROKE OK WC2
XFRMR OT PULLED T DI 959 P SRVOMTR REMSTROK
MP SEAL2 IP BYPS2 LDTIP 2 OT SEAL2 EOK2
Y0050.5
K
DO 406 N
TFD 2APP
Y0048.2
L
DO 387 W
LD2 APP
Y0048.1 Y0048.3 Y0048.2 Y0050.5

M
DO 386 DO 388 N DO 387 W DO 406 N
WLD1 APP UTFD APP LD2 APP TFD 2APP
N00339 D0004.1 D0004.2 R0221.1

N 2124 REMOTE STROKE
REMSTROK REMSTROK DI 961 R
EOK1 EOK2 EM STRK
N00340
O 2127 SUB72
SPE
Ladder Diagram 48
N00341 ### UALM ###

A 2128 SUB71 P0006
SP UALM
N00342 Y0120.2 X1025.1 Y0120.2

B 2130 PROGRAM FAULT
DO 963 FAULT DO 963
PRG FLT RESET PRG FLT
N00343 Y0120.2 G1008.0

C 2133 PROGRAM VERIFY FAULT
DO 963 UALM1
PRG FLT
N00344 X0083.2 G1008.1

D 2135 MAINTENANCE REQUIRED
DI 667 M UALM2
AINT REQ
N00345 X0083.2 X0087.0 G1008.2

E 2137 TIP CHANGE REQUESTED
DI 667 M DI 697 T UALM 3
AINT REQ PCHNGRQ
X0091.2 X0087.1
F
DI 731 M DI 698 T
ANT REQ2 PCHNGRQW
N00346 X0014.1 G1008.7

G 2143 PLCWELDTIMERFLT-PRSSWLDPB
DI 114 R UALM 8
STW TMR
N00347 Y0021.2 G1009.0

DO 171 T UALM 9
PCHG RQ2
N00348 X0083.3 G1009.1

I 2147 WELD FAULT WC#1
DI 668 W UALM 10
ELD FLT1
N00349 X0091.3 G1009.2

J 2149 WELD FAULT WC#2
DI 732 W UALM 11
ELD FLT2
N00350 Y0039.3 G1009.7

K 2151 TC PRESS FAULT RESET
DO 316 W UALM 16
RNGTLSTD
N00351 X0001.6 G1010.3

L 2153 SYSTEM WATER FLOW OFF
DI 15 SY UALM 20
S WTR ON
N00352 Y0014.7 G1010.4

M 2155 TIP DRESS MOTOR 1 FLT BYPASSED
DO 120 T UALM 21
DMFL BY1
N00353 Y0014.6 G1010.5

N 2157 TIP DRESS MOTOR 1 FAULT
DO 119 T UALM 22
DM FLT 1
N00354 K0010.0 Y0119.7 Y0000.3 G1010.6

O 2159 TEACH MEMORY ON
TEACH DO 960 DO 4 RBT UALM23
MEMORY AUTO KEY IN TCH
Ladder Diagram 49
N00355 R0220.6 G1010.7

A 2163 PULLED TIP MEMORY
DI 958 P UALM 24
LDTIP 1
N00356 R0000.0 G1011.0

B 2165 GUN DISABLED SELECTOR SWITCH
ALWAYS UALM 25
ON
N00357 K0004.5 G1011.1

C 2167 EQUALIZER ENABLED
EQUALENB UALM 26
L 1&2 SS
N00358 Y0120.6 G1011.2

D 2169 PLC/ MANUAL WELD PB DEPRESSED
DO 967 M UALM 27
AN WELD1
X0015.0
E
DI 121 R
M MAN W1
N00359 Y0017.2 G1011.3

F 2172 TIP CHANGE REQUIRED
DO 139 T UALM 28
PCHG RQ1
N00360 Y0002.7 G1011.4

G 2174 IN PROGRAM LOOP
DO 24 RB UALM 29
T LOOP
N00361 X1020.1 G1011.5

H 2176 SERVO MOTOR OVERTEMP FOR SG
RI 2 SRV UALM 30
OMTR OT1
N00362 X1020.0 G1011.6

I 2178 TRANSFORMER OVERTEMP
RI 1 XF UALM 31
RMR OT1
N00363 X0087.6 G1011.7

J 2180 WELD CONTROLLER 1 COMM LOST
DI 703 W UALM 32
1 COMMOK
N00364
K 2182 SUB72
SPE
N00365 ### INTERFACE ###

L 2183 SUB71 P0007
SP INTERFACE
O
Ladder Diagram 50
N00366 D0612.1 ACT D0612.0

A 2185 SUB 3 0040 INTERFACE PB TIMEOUT
MH IF PB TMR IF PB TO
TO
D0612.2
B
SEAL IF
PB TO
D0612.3
C
STUD IF
PB TO
D0612.4
D
SWG1 IF
PB TO
D0612.5
E
SWG2 IF
PB TO
O
Ladder Diagram 51
N00367 K0002.0 D0612.1

A 2193 MH IF PB TO
CLMP1CLS MH IF PB
TO
K0002.1
B
CLMP1OPN
K0002.2
C
CLMP2CLS
K0002.3
D
CLMP2OPN
K0002.4
E
CLMP3CLS
K0002.5
F
CLMP3OPN
K0002.6
G
CLMP4CLS
K0002.7
H
CLMP4OPN
K0003.0
I
CLMP5CLS
K0003.1
J
CLMP5OPN
K0003.2
K
CLMP6CLS
K0003.3
L
CLMP6OPN
K0003.4
M
CLMP7CLS
K0003.5
N
CLMP7OPN
K0003.6
O
CLMP8CLS
Ladder Diagram 52
K0003.7
A
CLMP8OPN
K0004.0
B
CLMP9CLS
K0004.1
C
CLMP9OPN
K0004.2
D
CLP10CLS
K0004.3
E
CLP10OPN
K0014.2
F
VAC 1 ON
PB
K0014.3
G
VAC 2 ON
PB
K0014.4
H
VAC 3 ON
PB
K0014.5
I
BLOWOFF
1 ON PB
K0014.6
J
BLOWOFF
2 ON PB
K0014.7
K
BLOWOFF
3 ON PB
K0000.4
L
RERUNPRC
PB
K0000.5
M
ACCPTPRC
PB
K0000.6
N
REJCTPRC
PB
K0000.7
O
INSPCTSE
LPB
Ladder Diagram 53
K0011.4
A
TC OPENG
UNCOVER
K0011.5
B
TC CLOS
GUNCOVER
K0016.1
C
VAC 4 ON
PB
K0016.2
D
BLOWOFF
4 ON PB
O
Ladder Diagram 54
N00368 Y0121.0 D0612.4

A 2228 SWG1 IF PB TO
DO 969 F SWG1 IF
EDWLD1PB PB TO
Y0120.6
B
DO 967 M
AN WELD1
Y0083.3
C
DO 668 R
ST WLD
K0005.1
D
NEW TIP
PB1
K0008.6
E
DTSR PB
1
K0005.2
F
INIT AUT
O TD PB1
K0005.5
G
TIP ALGN
CLS PB1
K0005.6
H
TIP ALGN
OPN PB1
K0005.7
I
INITAUTO
TCPB1
K0006.0
J
ATC FLT
ACK PB1
K0015.1
K
ADVTIPDR
SSDUMP1
K0015.2
L
RETTIPDR
SSDUMP1
O
Ladder Diagram 55
N00369 Y0121.1 D0612.5

DO 970 F SWG2 IF
EDWLD2PB PB TO
Y0120.7
B
DO 968 M
AN WELD2
Y0091.3
C
DO 732 R
ST WLD2
K0006.6
D
NEW TIP
PB2
K0009.2
E
DTSR PB
2
K0006.7
F
INIT AUT
O TD PB2
K0007.2
G
TIP ALGN
CLS PB2
K0007.3
H
TIP ALGN
OPN PB2
K0007.4
I
INITAUTO
TCPB2
K0007.5
J
ATC FLT
ACK PB2
K0015.3
K
ADVTIPDR
SSDUMP2
K0015.4
L
RETTIPDR
SSDUMP2
N00370
M 2254 SUB72
SPE
N00371 ### MH ###

N 2255 SUB71 P0008
SP MH
N00372 Y0000.3 K0004.4 R1410.0

O 2257 MANUAL GRIP ENABLE
DO 4 RBT MAN GRP MAN GRP
IN TCH ENBLE SS ENABLE
Ladder Diagram 56
N00373 R1410.0 ACT

A 2260 SUB10 0000
MAN GRP JMP
ENABLE
N00374 R0000.0 Y0114.0

B 2263 OPEN CLAMP 1
ALWAYS DO 913
ON OPNCLMP1
N00375 R0000.0 Y0114.1

C 2265 CLOSE CLAMP 1
ALWAYS DO 914
ON CLSCLMP1
N00376 R0000.0 Y0114.2

D 2267 OPEN CLAMP 2
ALWAYS DO 915
ON OPNCLMP2
N00377 R0000.0 Y0114.3

E 2269 CLOSE CLAMP 2
ALWAYS DO 916
ON CLSCLMP2
N00378 R0000.0 Y0114.4

F 2271 OPEN CLAMP 3
ALWAYS DO 917
ON OPNCLMP3
N00379 R0000.0 Y0114.5

G 2273 CLOSE CLAMP 3
ALWAYS DO 918
ON CLSCLMP3
N00380 R0000.0 Y0114.6

H 2275 OPEN CLAMP 4
ALWAYS DO 919
ON OPNCLMP4
N00381 R0000.0 Y0114.7

I 2277 CLOSE CLAMP 4
ALWAYS DO 920
ON CLSCLMP4
N00382 R0000.0 Y0115.0

J 2279 OPEN CLAMP 5
ALWAYS DO 921
ON OPNCLMP5
N00383 R0000.0 Y0115.1

K 2281 CLOSE CLAMP 5
ALWAYS DO 922
ON CLSCLMP5
N00384 R0000.0 Y0115.2

L 2283 OPEN CLAMP 6
ALWAYS DO 923
ON OPNCLMP6
N00385 R0000.0 Y0115.3

M 2285 CLOSE CLAMP 6
ALWAYS DO 924
ON CLSCLMP6
N00386 R0000.0 Y0115.4

N 2287 OPEN CLAMP 7
ALWAYS DO 925
ON OPNCLMP7
N00387 R0000.0 Y0115.5

O 2289 CLOSE CLAMP 7
ALWAYS DO 926
ON CLSCLMP7
Ladder Diagram 57
N00388 R0000.0 Y0115.6

A 2291 OPEN CLAMP 8
ALWAYS DO 927
ON OPNCLMP8
N00389 R0000.0 Y0115.7

B 2293 CLOSE CLAMP 8
ALWAYS DO 928
ON CLSCLMP8
N00390 R0000.0 Y0116.0

C 2295 OPEN CLAMP 9
ALWAYS DO 929
ON OPNCLMP9
N00391 R0000.0 Y0116.1

D 2297 CLOSE CLAMP 9
ALWAYS DO 930
ON CLSCLMP9
N00392 R0000.0 Y0116.2

E 2299 OPEN CLAMP 10
ALWAYS DO 931
ON OPNCLP10
N00393 R0000.0 Y0116.3

F 2301 CLOSE CLAMP 10
ALWAYS DO 932
ON CLSCLP10
N00394 R0000.0 Y0127.2

G 2303 VACUUM 1 ON
ALWAYS DO1019 V
ON AC1ON
N00395 R0000.0 Y0127.3

H 2305 BLOWOFF 1 ON
ALWAYS DO1020 B
ON LWOF1ON
N00396 R0000.0 Y0127.4

I 2307 VACUUM 2 ON
ALWAYS DO1021 V
ON AC2ON
N00397 R0000.0 Y0127.5

J 2309 BLOWOFF 2 ON
ALWAYS DO1022 B
ON LWOF2ON
N00398 R0000.0 Y0127.6

K 2311 VACUUM 3 ON
ALWAYS DO1023 V
ON AC3ON
N00399 R0000.0 Y0127.7

L 2313 BLOWOFF 3 ON
ALWAYS DO1024 B
ON LWOF3ON
N00400 R0000.0 Y0118.5

M 2315 VACUUM 4 ON
ALWAYS DO 950 V
ON AC4ON
N00401 R0000.0 Y0118.6

N 2317 BLOWOFF 4 ON
ALWAYS DO 951 B
ON LWOF4ON
N00402
O 2319 SUB30
JMPE
Ladder Diagram 58
N00403 R1410.0 ACT R0001.1

A 2320 SUB 3 0038
MAN GRP TMR MAN GRP
ENABLE TO
N00404 R0001.1 ACT

B 2324 SUB10 0000
MAN GRP JMP
TO
N00405 K0002.1 X1026.1 Y0114.0

C 2327 OPEN CLAMP 1
CLMP1OPN SI9 DO 913
AUTOMDSW OPNCLMP1
N00406 Y0114.0 Y0009.0

D 2330 OPEN CLAMP #1
DO 913 DO 73 OP
OPNCLMP1 N CLMP1
N00407 K0002.0 X1026.1 Y0114.1

CLMP1CLS SI9 DO 914
AUTOMDSW CLSCLMP1
N00408 Y0114.1 Y0009.1

F 2335 CLOSE CLAMP #1
DO 914 DO 74 CL
CLSCLMP1 S CLMP1
N00409 K0002.3 X1026.1 Y0114.2

G 2337 OPEN CLAMP 2
CLMP2OPN SI9 DO 915
AUTOMDSW OPNCLMP2
N00410 Y0114.2 Y0009.2

H 2340 OPEN CLAMP #2
DO 915 DO 75 OP
OPNCLMP2 N CLMP2
N00411 K0002.2 X1026.1 Y0114.3

CLMP2CLS SI9 DO 916
AUTOMDSW CLSCLMP2
N00412 Y0114.3 Y0009.3

J 2345 CLOSE CLAMP #2
DO 916 DO 76 CL
CLSCLMP2 S CLMP2
N00413 K0002.5 X1026.1 Y0114.4

K 2347 OPEN CLAMP 3
CLMP3OPN SI9 DO 917
AUTOMDSW OPNCLMP3
N00414 Y0114.4 Y0009.4

L 2350 OPEN CLAMP #3
DO 917 DO 77 OP
OPNCLMP3 N CLMP 3
N00415 K0002.4 X1026.1 Y0114.5

CLMP3CLS SI9 DO 918
AUTOMDSW CLSCLMP3
N00416 Y0114.5 Y0009.5

N 2355 CLOSE CLAMP #3
DO 918 DO 78 CL
CLSCLMP3 S CLMP3
N00417 K0002.7 X1026.1 Y0114.6

O 2357 OPEN CLAMP 4
CLMP4OPN SI9 DO 919
AUTOMDSW OPNCLMP4
Ladder Diagram 59
N00418 Y0114.6 Y0009.6

A 2360 OPEN CLAMP #4
DO 919 DO 79 OP
OPNCLMP4 N CLMP4
N00419 K0002.6 X1026.1 Y0114.7

CLMP4CLS SI9 DO 920
AUTOMDSW CLSCLMP4
N00420 Y0114.7 Y0009.7

C 2365 CLOSE CLAMP #4
DO 920 DO 80 CL
CLSCLMP4 S CLMP4
N00421 K0003.1 X1026.1 Y0115.0

D 2367 OPEN CLAMP 5
CLMP5OPN SI9 DO 921
AUTOMDSW OPNCLMP5
N00422 Y0115.0 Y0010.0

E 2370 OPEN CLAMP #5
DO 921 DO 81 OP
OPNCLMP5 N CLMP5
N00423 K0003.0 X1026.1 Y0115.1

CLMP5CLS SI9 DO 922
AUTOMDSW CLSCLMP5
N00424 Y0115.1 Y0010.1

G 2375 CLOSE CLAMP #5
DO 922 DO 82 CL
CLSCLMP5 S CLMP5
N00425 K0003.3 X1026.1 Y0115.2

H 2377 OPEN CLAMP 6
CLMP6OPN SI9 DO 923
AUTOMDSW OPNCLMP6
N00426 Y0115.2 Y0010.2

I 2380 OPEN CLAMP #6
DO 923 DO 83 OP
OPNCLMP6 N CLMP6
N00427 K0003.2 X1026.1 Y0115.3

J 2382 CLOSE CLAMP 6
CLMP6CLS SI9 DO 924
AUTOMDSW CLSCLMP6
N00428 Y0115.3 Y0010.3

K 2385 CLOSE CLAMP #6
DO 924 DO 84 CL
CLSCLMP6 S CLMP 6
N00429 K0003.5 X1026.1 Y0115.4

L 2387 OPEN CLAMP 7
CLMP7OPN SI9 DO 925
AUTOMDSW OPNCLMP7
N00430 Y0115.4 Y0010.4

M 2390 OPEN CLAMP #7
DO 925 DO 85 OP
OPNCLMP7 N CLMP 7
N00431 K0003.4 X1026.1 Y0115.5

N 2392 CLOSE CLAMP 7
CLMP7CLS SI9 DO 926
AUTOMDSW CLSCLMP7
N00432 Y0115.5 Y0010.5

O 2395 CLOSE CLAMP #7
DO 926 DO 86 CL
CLSCLMP7 S CLAMP7
Ladder Diagram 60
N00433 K0003.7 X1026.1 Y0115.6

A 2397 OPEN CLAMP 8
CLMP8OPN SI9 DO 927
AUTOMDSW OPNCLMP8
N00434 Y0115.6 Y0010.6

B 2400 OPEN CLAMP #8
DO 927 DO 87 OP
OPNCLMP8 N CLMP8
N00435 K0003.6 X1026.1 Y0115.7

CLMP8CLS SI9 DO 928
AUTOMDSW CLSCLMP8
N00436 Y0115.7 Y0010.7

D 2405 CLOSE CLAMP #8
DO 928 DO 88 CL
CLSCLMP8 S CLAMP8
N00437 K0004.1 X1026.1 Y0116.0

E 2407 OPEN CLAMP 9
CLMP9OPN SI9 DO 929
AUTOMDSW OPNCLMP9
N00438 Y0116.0 Y0011.0

F 2410 OPEN CLAMP #9
DO 929 DO 89 OP
OPNCLMP9 N CLMP9
N00439 K0004.0 X1026.1 Y0116.1

CLMP9CLS SI9 DO 930
AUTOMDSW CLSCLMP9
N00440 Y0116.1 Y0011.1

H 2415 CLOSE CLAMP #9
DO 930 DO 90 CL
CLSCLMP9 S CLMP9
N00441 K0004.3 X1026.1 Y0116.2

I 2417 OPEN CLAMP 10
CLP10OPN SI9 DO 931
AUTOMDSW OPNCLP10
N00442 Y0116.2 Y0011.2

J 2420 OPEN CLAMP #10
DO 931 DO 91 OP
OPNCLP10 N CLMP10
N00443 K0004.2 X1026.1 Y0116.3

CLP10CLS SI9 DO 932
AUTOMDSW CLSCLP10
N00444 Y0116.3 Y0011.3

L 2425 CLOSE CLAMP #10
DO 932 DO 92 CL
CLSCLP10 S CLMP10
N00445 K0014.2 X1026.1 K0014.1 Y0127.2

M 2427 VACUUM 1 ON
VAC 1 ON SI9 VAC/BLOW DO1019 V
PB AUTOMDSW OFFTIMER AC1ON
N00446 Y0127.2 Y0008.0

N 2431
DO1019 V DO 65 VA
AC1ON C 1 ON
N00447 K0014.5 X1026.1 K0014.1 Y0127.3

O 2433 BLOWOFF 1 ON
BLOWOFF SI9 VAC/BLOW DO1020 B
1 ON PB AUTOMDSW OFFTIMER LWOF1ON
Ladder Diagram 61
N00448 Y0127.3 Y0008.1

A 2437
DO1020 B DO 66 BL
LWOF1ON WOFF1ON
N00449 K0014.3 X1026.1 K0014.1 Y0127.4

B 2439 VACUUM 2 ON
N00450 Y0127.4 Y0008.2

C 2443
DO1021 V DO 67 VA
AC2ON C 2 ON
N00451 K0014.6 X1026.1 K0014.1 Y0127.5

D 2445 BLOWOFF 2 ON
N00452 Y0127.5 Y0008.3

E 2449
DO1022 B DO 68 BL
LWOF2ON WOFF2ON
N00453 K0014.4 X1026.1 K0014.1 Y0127.6

F 2451 VACUUM 3 ON
N00454 Y0127.6 Y0008.4

G 2455
DO1023 V DO 69 VA
AC3ON C 3 ON
N00455 K0014.7 X1026.1 K0014.1 Y0127.7

H 2457 BLOWOFF 3 ON
N00456 Y0127.7 Y0008.5

I 2461
DO1024 B DO 70 BL
LWOF3ON WOFF3ON
N00457 K0016.1 X1026.1 K0014.1 Y0118.5

J 2463 VACUUM 4 ON
VAC 4 ON SI9 VAC/BLOW DO 950 V
N00458 Y0118.5 Y0008.6

K 2467
DO 950 V DO 71 VA
AC4ON C 4 ON
N00459 K0016.2 X1026.1 K0014.1 Y0118.6

L 2469 BLOWOFF 4 ON
BLOWOFF SI9 VAC/BLOW DO 951 B
N00460 Y0118.6 Y0008.7

M 2473
DO 951 B DO 72 BL
LWOF4ON WOFF4ON
N00461
N 2475 SUB30
JMPE
O
Ladder Diagram 62
N00462 Y0008.0 ACT K0014.1

A 2476 SUB 3 0032 VACUUM / BLOWOFF TIMER
DO 65 VA TMR VAC/BLOW
C 1 ON OFFTIMER
Y0008.1
B
DO 66 BL
WOFF1ON
Y0008.2
C
DO 67 VA
C 2 ON
Y0008.3
D
DO 68 BL
WOFF2ON
Y0008.4
E
DO 69 VA
C 3 ON
Y0008.5
F
DO 70 BL
WOFF3ON
Y0008.6
G
DO 71 VA
C 4 ON
Y0008.7
H
DO 72 BL
WOFF4ON
N00463 K0002.0 D0612.0 K0002.0

I 2487 CLMP1 CLOSE
CLMP1CLS IF PB TO CLMP1CLS
N00464 K0002.1 D0612.0 K0002.1

J 2490 CLMP1 OPEN
CLMP1OPN IF PB TO CLMP1OPN
N00465 K0002.2 D0612.0 K0002.2

K 2493 CLMP2 CLOSE
N00466 K0002.3 D0612.0 K0002.3

L 2496 CLMP2 OPEN
N00467 K0002.4 D0612.0 K0002.4

M 2499 CLMP3 CLOSE
N00468 K0002.5 D0612.0 K0002.5

N 2502 CLMP3 OPEN
N00469 K0002.6 D0612.0 K0002.6

O 2505 CLMP4 CLOSE
Ladder Diagram 63
N00470 K0002.7 D0612.0 K0002.7

A 2508 CLMP4 OPEN
N00471 K0003.0 D0612.0 K0003.0

B 2511 CLMP5 CLOSE
N00472 K0003.1 D0612.0 K0003.1

C 2514 CLMP5 OPEN
N00473 K0003.2 D0612.0 K0003.2

D 2517 CLMP6 CLOSE
N00474 K0003.3 D0612.0 K0003.3

E 2520 CLMP6 OPEN
N00475 K0003.4 D0612.0 K0003.4

F 2523 CLMP7 CLOSE
N00476 K0003.5 D0612.0 K0003.5

G 2526 CLMP7 OPEN
N00477 K0003.6 D0612.0 K0003.6

H 2529 CLMP8 CLOSE
N00478 K0003.7 D0612.0 K0003.7

I 2532 CLMP8 OPEN
N00479 K0004.0 D0612.0 K0004.0

J 2535 CLMP9 CLOSE
N00480 K0004.1 D0612.0 K0004.1

K 2538 CLMP9 OPEN
N00481 K0004.2 D0612.0 K0004.2

L 2541 CLMP10 CLOSE
CLP10CLS IF PB TO CLP10CLS
N00482 K0004.3 D0612.0 K0004.3

M 2544 CLMP10 OPEN
CLP10OPN IF PB TO CLP10OPN
N00483 K0014.2 D0612.0 K0014.2

N 2547
VAC 1 ON IF PB TO VAC 1 ON
PB PB
N00484 K0014.3 D0612.0 K0014.3

O 2550
PB PB
Ladder Diagram 64
N00485 K0014.4 D0612.0 K0014.4

A 2553
PB PB
N00486 K0016.1 D0612.0 K0016.1

B 2556
PB PB
N00487 K0014.5 D0612.0 K0014.5

C 2559
BLOWOFF IF PB TO BLOWOFF
1 ON PB 1 ON PB
N00488 K0014.6 D0612.0 K0014.6

D 2562
2 ON PB 2 ON PB
N00489 K0014.7 D0612.0 K0014.7

E 2565
3 ON PB 3 ON PB
N00490 K0016.2 D0612.0 K0016.2

F 2568
4 ON PB 4 ON PB
N00491 K0000.4 Y0012.6

G 2571 RERUN PROCESS
RERUNPRC DO 103 R
PB ERUNPRC
N00492 K0000.5 Y0012.7

H 2573 ACCEPT PROCESS
ACCPTPRC DO 104 A
PB CCPTPRC
N00493 K0000.6 Y0013.0

I 2575 REJECT PROCESS
REJCTPRC DO 105 R
PB EJCTPRC
N00494 K0000.7 Y0013.1

J 2577 INSPECTION SELECTED
INSPCTSE DO 106 I
LPB NSP SEL
K0001.3 K0001.5
K
VISIONIN ABORTPRO
TERVENSS CESS
N00495 K0000.4 D0612.0 K0000.4

L 2582 S RERUN PROCESS PB
RERUNPRC IF PB TO RERUNPRC
PB PB
N00496 K0000.4 D0612.0 K0000.4

M 2585 R RERUN PROCESS PB
PB PB
N00497 K0000.5 D0612.0 K0000.5

N 2588 S ACCEPT PROCESS PB
ACCPTPRC IF PB TO ACCPTPRC
PB PB
N00498 K0000.5 D0612.0 K0000.5

O 2591 R ACCEPT PROCESS PB
PB PB
Ladder Diagram 65
N00499 K0000.6 D0612.0 K0000.6

A 2594 S REJECT PROCESS PB
REJCTPRC IF PB TO REJCTPRC
PB PB
N00500 K0000.6 D0612.0 K0000.6

B 2597 R REJECT PROCESS PB
PB PB
N00501 K0000.7 D0612.0 K0000.7

C 2600 S INSPECTION SELECTED PB
INSPCTSE IF PB TO INSPCTSE
LPB LPB
N00502 K0000.7 D0612.0 K0000.7

D 2603 R INSPECTION SELECTED PB
LPB LPB
N00503 K0011.4 D0612.0 K0011.4

E 2606 TOOL CHANGER OPEN GUN COVER
TC OPENG IF PB TO TC OPENG
UNCOVER UNCOVER
N00504 K0011.5 D0612.0 K0011.5

F 2609 TOOL CHANGER CLOSE GUN COVER
TC CLOS IF PB TO TC CLOS
GUNCOVER GUNCOVER
N00505 X0008.2 R0000.7

G 2612 PART PRESENT ON EOAT
DI 67 PR PART PRE
T PRES1 SENT
X0008.3
H
DI 68 PR
T PRES2
X0008.4
I
DI 69 PR
T PRES3
X0008.5
J
DI 70 PR
T PRES4
X0008.6
K
DI 71 PR
T PRES5
X0008.7
L
DI 72 PR
T PRES6
N00506
M 2619 SUB72
SPE
N00507 ### APPLICATION ###

N 2620 SUB71 P0009
SP APPLICATION
N00508 D0000.0 Y0048.0

O 2622 MATERIAL HANLDING APPLICATION
MH APP DO 385 M
H APP
Ladder Diagram 66
N00509 D0000.1 Y0048.1

A 2624 WELD 1 APPLICATION
WELD 1 A DO 386
PP WLD1 APP
N00510 D0000.2 Y0048.2

B 2626 WELD 2 APPLICATION
WELD 2 A DO 387 W
PP LD2 APP
N00511 D0000.3 Y0048.3

C 2628 NUT FEED APPLICATION
NUT FEED DO 388 N
APP UTFD APP
N00512 D0000.4 Y0048.4

D 2630 SEALER 1 APPLICATION
SEAL 1 A DO 389 S
PP LR 1 APP
N00513 D0000.5 Y0048.5

E 2632 SEALER 2 APPLICATION
SEAL 2 DO 390 S
APP LR 2 APP
N00514 D0000.6 Y0048.6

F 2634 STUD WELD 1 APPLICATION
STUD 1 A DO 391 S
PP TDW 1APP
N00515 D0000.7 Y0048.7

G 2636 STUD WELD 2 APPLICATION
STUD 2 A DO 392 S
PP TDW 2APP
N00516 D0001.0 Y0049.0

H 2638 TOOL CHANGE APPLICATION
TOOL CHA DO 393 T
NGE APP C APP
N00517 D0001.1 Y0049.1

I 2640 RIVET 1 APPLICAYION
RIVET 1 DO 394 R
APP VT 1 APP
N00518 D0001.2 Y0049.2

J 2642 RIVET 2 APPLICATION
RIVET 2 DO 395 R
APP VT 2 APP
N00519 D0001.3 Y0049.3

K 2644 NUT RUNNER APPLICATION
NUT RUNN DO 396 N
ER APP UTR APP
N00520 D0001.4 Y0049.4

L 2646 MIG WELD APPLICATION
MIG WELD DO 397 M
APP IGW APP
N00521 D0001.5 Y0049.5

M 2648 ROLL HEMMER APPLICATION
ROLLER H DO 398 R
EMM APP LLHEM AP
N00522 D0001.6 Y0049.6

N 2650 LASER CUT APPLICATION
LASER CU DO 399 L
T APP SRCT APP
N00523 D0001.7 Y0049.7

O 2652 PLASMA CUT APPLICATION
PLASMA C DO 400 P
UT APP LSMA APP
Ladder Diagram 67
N00524 D0002.0 Y0050.0

A 2654 LASER WELD APPLICATION
LASER WE DO 401 L
LD APP SRWLDAPP
N00525 D0002.1 Y0050.1

B 2656 OPERATOR LOAD APPLICATION
OPER LOA DO 402 O
D APP P LD APP
N00526 D0002.2 Y0050.2

C 2658 VISION APPLICATION
VISION A DO 403 V
PP IS APP
N00527 D0002.3 Y0050.3

D 2660 PROGRAM LOCATOR APPLICATION
PROG LOC DO 404 P
APP RG LCAPP
N00528 D0002.4 Y0050.4

E 2662 INTERFACE DEFINITION BIT 21
IF DEF DO 405
21 INDEFB21
N00529 D0002.5 Y0050.5

F 2664 NUT FEEDER 2 APPLICATION
NUT FEED DO 406 N
ER 2 APP TFD 2APP
N00530 D0002.6 Y0050.6

G 2666 INTERFACE DEFINITION BIT 23
IF DEF DO 407 I
23 NDEF B23
N00531 D0002.7 Y0050.7

H 2668 INTERFACE DEFINITION BIT 24
IF DEF DO 408 I
24 NDEF B24
N00532 D0003.0 Y0051.0

I 2670 INTERFACE DEFINITION BIT 25
IF DEF DO 409 I
25 NDEF B25
N00533 D0003.1 Y0051.1

J 2672 INTERFACE DEFINITION BIT 26
IF DEF DO 410 I
26 NDEF B26
N00534 D0003.2 Y0051.2

K 2674 INTERFACE DEFINITION BIT 27
IF DEF DO 411 I
27 NDEF B27
N00535 D0003.3 Y0051.3

L 2676 INTERFACE DEFINITION BIT 28
IF DEF DO 412 I
28 NDEF B28
N00536 D0003.4 Y0051.4

M 2678 INTERFACE DEFINITION BIT 29
IF DEF DO 413 I
29 NDEF B29
N00537 D0003.5 Y0051.5

N 2680 INTERFACE DEFINITION BIT 30
IF DEF DO 414 I
30 NDEF B30
N00538 D0003.6 Y0051.6

O 2682 INTERFACE DEFINITION BIT 31
IF DEF DO 415 I
31 NDEF B31
Ladder Diagram 68
N00539 D0003.7 Y0051.7

A 2684 INTERFACE DEFINITION BIT 32
IF DEF DO 416 I
32 NDEF B32
N00540
B 2686 SUB72
SPE
N00541 ### P0015 ###

C 2687 SUB71 P0015
SP WELDCONTROL2
N00542 X0000.0 Y0091.0

D 2689 WELD CONTROLLER #2 ENABLE
DI 1 EXT DO 729 W
RNENBL C2 ENBL
N00543 X0095.6 Y0018.4

E 2691 WELD CONTROLLER COMM OK #2
DI 767 W DO 149 W
2 COMMOK C2COM OK
N00544 Y0000.3 Y0091.1

F 2693 ROBOT IN TEACH TO WC #2
DO 4 RBT DO 730 R
IN TCH BTCH WC2
N00545 X0094.1 Y0019.6

G 2695 I AVAILABLE WARNING #2
DI 754 I DO 159 I
-HI/LO 2 AVL WRN2
N00546 X0095.5 Y0021.3

H 2697
DI 766 A DO 172 A
DP MODE2 DPMODEN2
N00547 X0091.0 Y0019.3

I 2699 IN WELD CYCLE #2
DI 729 I DO 156 I
NWLDCYC2 NWD CY 2
N00548 X0091.1 Y0019.4

J 2701 HAS WELDED #2
DI 730 W DO 157 H
ELD CMP2 AS WLD 2
N00549 X0091.3 Y0018.3

K 2703 NO WELD TIMER FAULT #2
DI 732 W DO 148 N
ELD FLT2 OWLDFLT2
N00550 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

L 2705
DO 743 DO 744 DO 745 DO 746 DO 747 DO 748 DO 749
BP2 1 BP2 2 BP2 4 BP2 8 BP2 16 BP2 32 BP2 64
1 Y0093.5 R0306.1
M ROBOT WELD SCHEDULE WELD CTRL2
DO 750 ROBOT WS
BP2 128 WC#2
N00551 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

N 2714
DO 743 DO 744 DO 745 DO 746 DO 747 DO 748 DO 749
BP2 1 BP2 2 BP2 4 BP2 8 BP2 16 BP2 32 BP2 64
1 Y0093.5 R0362.0
O
DO 750 WLD SCH
BP2 128 39 WC2
Ladder Diagram 69
N00552 Y0018.1 Y0018.2 Y0091.4

A 2723 WELD / NO WELD#2
DO 146 W DO 147 W DO 733 W
D/NWD2SS D/NWD2MD LD/NWLD2
N00553 X1020.5 X1020.3 X1020.4 D0004.5

B 2726 ALL WELD PARAMETER OK WC2
N00554 Y0111.1 D0004.5 K0000.0 ACT R0364.0

C 2730 SUB 3 0036 WELD BINARY WC2 TIMER
BP1 2 WC2 MER2
Y0111.2
D
DO 891
BP2 2
Y0111.3
E
DO 892
BP4 2
Y0111.4
F
DO 893
BP8 2
Y0111.5
G
DO 894
BP16 2
Y0111.6
H
DO 895
BP32 2
Y0111.7
I
DO 896
BP64 2
Y0112.0
J
DO 897
BP128 2
N00555 Y0111.1 D0004.5 R0364.0 Y0092.6

BP1 2 WC2 MER2 BP2 1
N00556 Y0111.2 D0004.5 R0364.0 Y0092.7

N00557 Y0111.3 D0004.5 R0364.0 Y0093.0

N00558 Y0111.4 D0004.5 R0364.0 Y0093.1

N00559 Y0111.5 D0004.5 R0364.0 Y0093.2

Ladder Diagram 70
N00560 Y0111.6 D0004.5 R0364.0 Y0093.3

N00561 Y0111.7 D0004.5 R0364.0 Y0093.4

B 2767 BINARY PILOT 64 WC#2
N00562 Y0112.0 D0004.5 R0364.0 Y0093.5

C 2771 BINARY PILOT 128 WC#2
BP128 2 WC2 MER2 BP2 128
N00563 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

D 2775
DO 743 DO 744 DO 745 DO 746 DO 747 DO 748 DO 749
BP2 1 BP2 2 BP2 4 BP2 8 BP2 16 BP2 32 BP2 64
1 Y0093.5 R0361.0
E NO WELD SCHEDULE WC2
DO 750 NOWLDSCH
BP2 128 WC2
N00564 R0361.0 X0095.6 K0000.0 Y0091.5

F 2784 PRESSURE SWITCH INPUT#2
K0000.0 Y0116.6
G
DEBUG DO 935
RD SCHD2
N00565 Y0120.7 F1000.3 Y0000.1 R0223.1

H 2791
X0019.0 K0008.0 Y0000.5 F1000.3 F1000.2

I
Y0000.1 F1000.2 F1000.3

J
@ HOME RUNNING
N00566 Y0120.7 Y0000.1 F1000.2 F1000.3 R0213.7

K 2807 WELD AT HOME2
X0019.0 K0008.0
L
DI 153 R AUTO/MAI
M MAN W2 NT SS
N00567 Y0050.5 Y0121.1 F1000.3 Y0000.1 R0220.5

M 2815 SWGNUT REFFED REWELD 2
TFD 2APP EDWLD2PB @ HOME EFEDWLD2
N00568 K0009.2 D0612.0 K0009.2

N 2820 S DRESS TIP RESET PB 2
2 2
N00569 K0009.2 D0612.0 K0009.2

O 2823 R DRESS TIP RESET PB 2
2 2
Ladder Diagram 71
N00570 K0006.6 D0612.0 K0006.6

A 2826 S NEW TIP PUSH BUTTON2
PB2 PB2
N00571 K0006.6 D0612.0 K0006.6

B 2829 R NEW TIP PUSH BUTTON2
PB2 PB2
N00572 K0006.7 D0612.0 K0006.7

C 2832 S INITIATE AUTO TIP DRESS PB2
O TD PB2 O TD PB2
N00573 K0006.7 D0612.0 K0006.7

D 2835 R INITIATE AUTO TIP DRESS PB2
O TD PB2 O TD PB2
N00574 K0007.2 D0612.0 K0007.2

E 2838 S TIP ALIGN CLOSE PB2
CLS PB2 CLS PB2
N00575 K0007.2 D0612.0 K0007.2

F 2841 R TIP ALIGN CLOSE PB2
CLS PB2 CLS PB2
N00576 K0007.3 D0612.0 K0007.3

G 2844 S TIP ALIGNMENT OPEN PB2
OPN PB2 OPN PB2
N00577 K0007.3 D0612.0 K0007.3

H 2847 R TIP ALIGNMENT OPEN PB2
OPN PB2 OPN PB2
N00578 K0007.4 D0612.0 K0007.4

I 2850 S INITIATE AUTO TIP CHANGE PB2
TCPB2 TCPB2
N00579 K0007.4 D0612.0 K0007.4

J 2853 R INITIATE AUTO TIP CHANGE PB2
TCPB2 TCPB2
N00580 K0007.5 D0612.0 K0007.5

K 2856 S AUTO TIP CHANGE FAULT ACK PB2
ACK PB2 ACK PB2
N00581 K0007.5 D0612.0 K0007.5

L 2859 R AUTO TIP CHANGE FAULT ACK PB2
ACK PB2 ACK PB2
N00582 Y0120.7 D0612.0 Y0120.7

M 2862 S MANUAL WELD2
AN WELD2 AN WELD2
N00583 Y0120.7 D0612.0 Y0120.7

N 2865 R MANUAL WELD2
AN WELD2 AN WELD2
N00584 Y0121.1 D0612.0 Y0121.1

O 2868 S SWGNUT WELD REFEED REWELD2 PB
EDWLD2PB EDWLD2PB
Ladder Diagram 72
N00585 Y0121.1 D0612.0 Y0121.1

A 2871 R SWGNUT WELD REFEED REWELD2 PB
EDWLD2PB EDWLD2PB
N00586 Y1020.1 Y1020.1

B 2874 S RDO2 EQUALIZATION VALVE 2
RO 2 RO 2
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
C
EQUALENB EQUALIZE
L 1&2 SS R 2 SS
N00587 Y1020.1 Y1020.1

D 2879 R RDO2 EQUALIZATION VALVE 2
RO 2 RO 2
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
E
EQUALENB EQUALIZE
L 1&2 SS R 2 SS
N00588 K0004.5 K0007.7

F 2884 R EQUALIZER 2 SS
EQUALENB EQUALIZE
L 1&2 SS R 2 SS
N00589 K0000.0 Y0091.3 D0612.0 X1025.1 Y0091.3

G 2886 RESET WELDER#2
ST WLD2 RESET ST WLD2
X1025.1
H
FAULT
RESET
N00590 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00591 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00592 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00593 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00594 K0015.3 Y0000.2 X1026.1 K0015.4 Y0021.5

M 2904
N00595 K0015.4 Y0000.2 X1026.1 K0015.3 Y0021.6

N 2909
O
Ladder Diagram 73
N00596 Y0120.7 K0014.0 D0610.2

X0019.0 K0008.0 K0014.0

B
M MAN W2 NT SS NB2
N00597 D0610.2 ACT D0610.2

DETIMR2 DETIMR2
N00598 X0054.5 Y0095.1

DI 438 C DO 762 C
CWELDMOD CWELDMD2
D0610.2
E
CCWELDMO
DETIMR2
N00599
F 2928 SUB72
SPE
N00600 ### P0016 ###

G 2929 SUB71 P0016
SP TIPDRESSER2
N00601 X0095.1 Y0021.2

DI 762 T DO 171 T
PCHNGRQ2 PCHG RQ2
X0095.0
I
DI 761 T
PCNGREQ2
Y0112.1
J
DO 898 T
PWRMOV2
Y0112.2
K
DO 899 T
PWRFIX2
N00602 K0007.2 Y0000.5 R0222.4

N00603 K0007.3 Y0000.5 R0222.5

N00604 X0091.4 Y0020.3

DI 733 N DO 164 N
EW TIP2 WTP RST2
O
Ladder Diagram 74
N00605 R0346.0 Y0092.5 X0001.2 K0008.0 R0346.0

2 TSR2 PLC AUTO NT SS 2
Y0119.1 K0006.7
B
DO 954 C INIT AUT
LRAV XFR O TD PB2
N00606 R0335.0 Y0109.1 Y0000.5 X0091.1 R0332.0

R0332.0
D
TD MEM W
C #2
N00607 X0091.4 K0008.0 Y0000.5 X0018.7 R0332.0 R0335.0

EW TIP2 NT SS @ MAINT D BYPSS2 C #2 P TC2
R0335.0
F
DRESS CA
P TC2
N00608 X0091.2 Y0019.0

DI 731 M DO 153 A
ANT REQ2 UTO TD 2
R0335.0 Y0050.5
H
DRESS CA DO 406 N
P TC2 TFD 2APP
R0346.0
I
TIP MEM
2
N00609 Y0093.7 Y0119.1 R0352.0

J 2971 PULLED TIP SEAL WC #2
DO 752 T DO 954 C PULLDTIP
IP WTR2 LRAV XFR SEAL 2
N00610 R0352.0 ACT D0613.0

K 2974 SUB 3 0015 PULLED TIMER WC #2
SEAL 2 P TIMER2
N00611 Y0018.5 X0001.2 Y0109.1

L 2978 TIP DRESSER #2 ENABLE
DO 150 D DI 11 DO 874 T
K0007.0 Y0000.3
M
TEACH TD DO 4 RBT
ENABLE2 IN TCH
N00612 R0000.0 Y0018.5 X0001.2 Y0094.6

N 2985 TIP DRESS MOTOR ON #2
ON RSR ON 2 PLC AUTO D MTRON2
K0007.0 Y0000.3
O
TEACH TD DO 4 RBT
ENABLE2 IN TCH
Ladder Diagram 75
N00613 X1020.5 X0000.0 X0013.6 R0220.7

A 2993 PULLED TIP BYPASS 2
RI 6 WTR DI 1 EXT DI 111 A DI 959 P
FL SW2 RNENBL UTOTIPCH LDTIP 2
R0220.7 D0613.0
B
DI 959 P PULLEDTI
LDTIP 2 P TIMER2
N00614 K0006.3 Y0018.7

C 3000 TIP DRESS MTR FLT BYPASS #2
TD MTR F DO 152 T
LT BYPS2 DMFL BY2
N00615 D0608.0 R0410.0 R0413.0

D 3002 TD FAULT2
1TIM2 TOK2
N00616 Y0018.5 X0094.2 Y0108.2 K0006.3 Y0091.3 R0410.0

E 3005 TD CURRENT OK FROM WC2
RSR ON 2 IP DR OK RVTDOK2 LT BYPS2 ST WLD2 TOK2
R0410.0
F
TDCURREN
TOK2
N00617 R0413.0 ACT D0609.0

G 3012 SUB 3 0017 TD MOTOR OFF 2 FAULT TIMER 2
2TIM2
N00618 Y0018.5 ACT D0608.0

H 3016 SUB 3 0018 TD MOTOR OFF 1 FAULT TIMER 2
RSR ON 2 1TIM2
N00619 Y0091.3 R0410.0 D0609.0 R0416.0

I 3020 TD MOTOR FAULT 2
ST WLD2 TOK2 2TIM2 2
R0406.0
J
TPRESFLT
2
R0416.0
K
TDMTRFLT
2
N00620 R0416.0 Y0018.6

L 3027 TIP DRESS MOTOR FAULT #2
TDMTRFLT DO 151 T
2 DM FLT 2
N00621 Y0118.2 ACT D0607.0

M 3029 SUB 3 0022 TIP RESISTANCE FAULT TIMER 2
ESCHKMD2 TIM2
N00622 D0607.0 R0407.0 R0406.0

N 3033 TIP RESISTANCE FAULT2
TIM2 LAT2 2
O
Ladder Diagram 76
N00623 Y0118.2 X0094.3 K0007.1 Y0091.3 R0407.0

A 3036 TIP RESISTANCE FAULT LATCH2
ESCHKMD2 PDRRSOK2 ST BYPS2 ST WLD2 LAT2
R0407.0
B
TPRESFLT
LAT2
N00624 X0018.4 Y0121.2 Y0113.7 F1000.5 R0221.7

C 3042 RUNTIP DRESS DUMP MACRO2
DI 149 I DO 971 P DO 912 C FAULT DI 967 R
NITTPDR2 EDDMPAPP LR ZN 13 NTDDMP2
X0018.6 X0091.2 Y0019.0 Y0121.7

D
DI 151 T DI 731 M DO 153 A DO 976
D DMP R2 ANT REQ2 UTO TD 2 TPWRCMP2
N00625 K0009.1 K0009.1

E 3052 S NTSR ENABLE 2 SS
NTSR ENB NTSR ENB
2SS 2SS
N00626 K0009.1 X1025.1 K0009.1

F 3054 R NTSR ENABLE 2 SS
2SS RESET 2SS
K0009.1 X0091.4
G
NTSR ENB DI 733 N
2SS EW TIP2
N00627 K0015.7 K0015.7

H 3060 S DTSR ENABLE 2 SS
DTSRENB2 DTSRENB2
SS SS
N00628 K0015.7 X1025.1 K0015.7

I 3062 R DTSR ENABLE 2 SS
SS RESET SS
K0015.7 X0091.5
J
DTSRENB2 DI 734 D
SS RSSTIP2
N00629 K0009.1 K0006.6 Y0092.4

K 3068 NEW TIP STEPPER RESET#2
2SS PB2 TSR2
X0019.3
L
DI 156 N
EWTPRST2
N00630 K0015.7 K0009.2 Y0092.5

M 3072 DRESS TIP STEPPER RESET#2
SS 2 TSR2
Y0117.0 Y0054.3
N DRSSTIPSTPRST2
DO 937 DO 436 D
STP RST2 TSR2
N00631
O 3077 SUB72
SPE
Ladder Diagram 77
N00632 ### P0017 ###

A 3078 SUB71 P0017
SP WATERVALVE2
N00633 X1020.5 X0001.6 Y0093.7

B 3080 TIP WATER FLOW #2
RI 6 WTR DI 15 SY DO 752 T
FL SW2 S WTR ON IP WTR2
N00634 X0014.0 R0000.5 Y1020.5

C 3083 WATER RESET 2
Y1020.5 X1020.5
D
RO 6 WTR RI 6 WTR
RESET2 FL SW2
X1025.1
E
FAULT
RESET
N00635
F 3090 SUB72
SPE
N00636 ### P0018 ###

G 3091 SUB71 P0018
SP OVRTMP/NOSTRK2
N00637 X1020.3 Y0094.4

H 3093 TRANSFORMER OVERTEMP#2
RI 4 XF DO 757 X
RMR OT2 FMR OT2
N00638 X1020.4 Y0094.5

I 3095 SERVO MOTOR OVERTEMP#2
RI 5 SRV DO 758 S
OMTR OT2 RVMTROT2
N00639 X1020.3 X1025.1 R0501.0

J 3097 TRANSFORMER OVERTEMP SEAL2
R0501.0
K
XFRMR OT
MP SEAL2
N00640 X1020.4 X1025.1 R0501.1

L 3101 SERVO MOTOR OVERTEMP SEAL2
RI 5 SRV FAULT SRVOMTR
OMTR OT2 RESET OT SEAL2
R0501.1
M
SRVOMTR
OT SEAL2
N00641 R0501.0 Y0020.2

N 3105 TRANSFORMER OVERTEMP FAULT #2
XFRMR OT DO 131 X
MP SEAL2 FMR OTF2
N00642 R0501.1 Y0020.1

O 3107 SG MOTOR OTEMP FAULT#2
SRVOMTR DO 162 S
OT SEAL2 GM OTF2
Ladder Diagram 78
N00643
A 3109 SUB72
SPE
N00644 ### P0020 ###

B 3110 SUB71 P0020
SP AIR
N00645 X1020.6 Y0001.5

C 3112 END OF ARM AIR ON
RI 7 AIR DO 14 EO
FL SW A AIR ON
N00646
D 3114 SUB72
SPE
N00647 ### P0025 ###

E 3115 SUB71 P0025
SP TOUCHUP1
N00648 K0000.1 Y0054.4

F 3117 PROGRAM TOUCHUP REQUEST
TOUCHUP1 DO 437 P
ENB RGTCHREQ
N00649
G 3119 SUB72
SPE
O
9 PMC Logic (S-Logic) (2) SWG with Servo Tip Dresser
for R-30iB Controllers

Page 303 of 305
[f3l1swg2] Ladder Diagram 1
N00001 R0000.0 R0000.0

A 1 ALWAYS ON
ALWAYS__ ALWAYS__
ON ON
R0000.0
B
ALWAYS__
ON
N00002 R0000.0 G1000.0

ALWAYS__ NO_IMSTP
ON
N00003 X0000.0 R0100.5 K0004.5 G1000.1

D 6 NO HOLD
DI_1_EXT BREAK_A_ EQUALENB NO_HOLD
_RNENBL NO_HOLD L_1_2_SS
N00004 X1026.4 R0100.5

SI12_HOL BREAK_A_
DSW NO_HOLD
N00005 X1026.5 R0100.5

SI13_RES BREAK_A_
ETSW NO_HOLD
X1026.4 X1025.6
G
SI12_HOL CYCLE___
DSW START
X0000.1 X1026.4
H
DI_2_EX_ SI12_HOL
RNEN_RST DSW
N00006 R0000.0 G1000.2

I 20 SAFE SPEED
ALWAYS__ SFSPD
ON
N00007 X1000.3 G1000.3

J 22
O
N00008 X1025.1 G1000.4

A 24 FAULT RESET
FAULT___ RB_FAULT
RESET _RESET
X0000.1 X0001.2
B
DI_2_EX_ DI_11___
RNEN_RST PLC_AUTO
X1026.5
C
SI13_RES
ETSW
X0000.3
D
DI_4_EXT
_CY_STRT
X0000.2
E
DI_3_EXT
MTR_ON
Y0119.6
F
DO_959_F
LT_RESET
R0223.0
G
DI_976_M
AN_WELD1
R0220.4
H
DI_956_R
EFEDWLD1
R0223.1
I
DI_977_M
AN_WELD2
N00009 X1000.6 G1000.6

J 36 GO HOME
HOME
N00010 R0000.0 G1000.7

K 38 ENABLE
ALWAYS__ ENABLE
ON
N00011 F1000.0 Y1000.0

L 40
COMMAND_
ENABLE
N00012 F1000.1 Y1000.1

M 42
SYSTEM__
READY
Y1025.5
N MOTORS ENABLE
MOTORS__
ENABLE
N00013 F1000.2 Y1000.2

O 45
PROGRAM_
RUNNING
N00014 F1000.3 Y1000.3

A 47
PAUSED
N00015 F1000.4 Y1000.4

B 49
HELD
Y0000.0
DO_1_RUN
_ENB_ACK
N00016 F1000.5 ACT R0338.0

FAULT TMR INT_FLT_
__DELAY
N00017 F1000.5 G1000.4 R0397.0 R0338.0 Y1000.5

E 56
FAULT RB_FAULT FILTERED INT_FLT_
_RESET _FAULT __DELAY
Y0120.2 Y0000.4
DO_963__ DO_5_RBT
PRG_FLT _CNT_FLT
Y0001.6
G
DO_15_CO
LL_DTCT
N00018 F1000.6 Y1000.6

H 64
AT_HOME
Y0002.0 Y0000.1
I ROBOT AT HOME
DO_17_RB DO_2_RBT
T_@_HM1 _@_HOME
Y0002.1
J
DO_18_RB
T_@_HM2
Y0002.2
K
DO_19_RB
T_@_HM3
Y0002.3
L
DO_20_RB
T_@_HM4
Y0002.4
M
DO_21_RB
T_@_HM5
Y0002.5
N
DO_22_RB
T_@_HM6
Y0002.6
O
DO_23_RB
T_@_HM7
N00019 F1000.7 Y1000.7

A 74
TPENABLE
Y0119.7 Y0000.3
B ROBOT IN TEACH
DO_960__ DO_4_RBT
AUTO_KEY _IN_TCH
N00020 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

C 78
ECO17___ ECO18___ ECO19___ ECO20___ ECO21___ ECO22___ ECO23___
1 R1402.7 R1405.0
D S
ECO24___ FACILITY
FC128 _CODE_11
N00021 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 R1400.6 1

E 87
1 R1400.7 R1401.1 R1401.2 R1401.3 R1401.5 R1401.6 2

F
2 R1401.7 R1405.1
G
ECO16 ERROR_4
N00022 R1405.0 R1405.1 G1000.4 R1405.2

H 102 FENCE FAULT
FACILITY ERROR_4 RB_FAULT FENCE___
_CODE_11 _RESET FAULT
R1405.2
I
FENCE___
FAULT
N00023 R0000.1 F1000.5 R1466.0 F1000.0 F1000.1 K0010.3

INT_EXT_ FAULT BRK_PWR_ COMMAND_ SYSTEM__ PWR_FAIL
MTR_ON FL_RCVRY ENABLE READY _RECVRY
R0000.2
K
INT_EXT_
CYC_STRT
K0010.3
L
PWR_FAIL
_RECVRY
N00024 K0010.3 ACT R1466.0

PWR_FAIL TMR BRK_PWR_
_RECVRY FL_RCVRY
O
N00025 Y0000.3 F1000.0 Y0000.4 R0000.1 R0000.2 F1000.1 F1008.0 1

A 119
DO_4_RBT COMMAND_ DO_5_RBT INT_EXT_ INT_EXT_ SYSTEM__ STEP
_IN_TCH ENABLE _CNT_FLT MTR_ON CYC_STRT READY
R1404.5 Y0000.2
B
DRP_AUTO DO_3_RBT
_FAULT _IN_AUTO
1 F1008.2 X1025.0 R1405.2 K0010.0 Y0001.6 Y0000.2

TP______ FANUC___ FENCE___ TEACH___ DO_15_CO DO_3_RBT
E-STOP E-STOP FAULT MEMORY LL_DTCT _IN_AUTO
N00026 Y0119.5 Y0072.4

DO_958_I DO_581_I
NPUTSIM NPUTSIM
N00027 R1404.4 R1456.0 R1404.2 F1000.5 G1000.4 R0330.2 R0386.1 R1404.5

FC_AVAIL APPL____ FC_ZERO FAULT RB_FAULT SERVOGUN SVGN320_ DRP_AUTO
ALARMS _RESET _ALARM 326_LTCH _FAULT
N00028 F1000.5 R1404.5

FAULT DRP_AUTO
_FAULT
G1000.4
G
RB_FAULT
_RESET
N00029 F1000.5 R1404.0 R1404.1 R1404.4

H 149
FAULT ECO33___ ECO_____ FC_AVAIL
STROBE RETRIEVE
N00030 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 153
FC_AVAIL ECO17___ ECO18___ ECO19___ ECO20___ ECO21___ ECO22___
1 R1402.6 R1402.7 R1404.3

J S
ECO23___ ECO24___ SPOT____
FC64 FC128 ALARM
N00031 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

K 163
1 R1402.6 R1402.7 R0330.0

L S
ECO23___ ECO24___ ARC_____
FC64 FC128 ALARM
N00032 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

M 173
1 R1402.6 R1402.7 R0330.1

N S
ECO23___ ECO24___ SEALER__
FC64 FC128 ALARM
O
N00033 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

A 183
1 R1402.6 R1402.7 R0330.2

B S
ECO23___ ECO24___ SERVOGUN
FC64 FC128 _ALARM
N00034 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

C 193
1 R1402.6 R1402.7 R0330.3

D S
ECO23___ ECO24___ TOOLCHNG
FC64 FC128 __ALARM
N00035 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

E 203
1 R1402.6 R1402.7 R0330.4

F S
ECO23___ ECO24___ SYSTEM__
FC64 FC128 _ALARM
N00036 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

G 213
1 R1402.6 R1402.7 R1406.0

H S
ECO23___ ECO24___ FACILITY
FC64 FC128 _CODE_15
N00037 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 223
1 R1402.6 R1402.7 R1404.2

J
ECO23___ ECO24___ FC_ZERO
FC64 FC128
O
N00038 R1404.1 ACT R1404.3

A 233 SUB57 0001 R
ECO_____ DIFU SPOT____
RETRIEVE ALARM
R0330.0
B R
ARC_____
ALARM
R0330.1
C R
SEALER__
ALARM
R0330.2
D R
SERVOGUN
_ALARM
R0330.3
E R
TOOLCHNG
__ALARM
R0330.4
F R
SYSTEM__
_ALARM
R1405.0
G R
FACILITY
_CODE_11
R1406.0
H R
FACILITY
_CODE_15
N00039 R1404.4 ACT R1404.6

I 244 SUB 3 0006
FC_AVAIL TMR RETRIEVE
_DELAY
N00040 R1404.6 R1404.1

J 248 S
RETRIEVE ECO_____
_DELAY RETRIEVE
N00041 R1404.1 ACT R1404.1

K 250 SUB 3 0007 R
ECO_____ TMR ECO_____
RETRIEVE RETRIEVE
N00042 Y0015.5 Y0015.5

DO_126_W DO_126_W
LD_FLT_1 LD_FLT_1
N00043 X0083.1 Y0015.5

DI_666_W DO_126_W
ELD_CMP1 LD_FLT_1
N00044 Y0019.5 Y0019.5

DO_158_W DO_158_W
LD_FLT_2 LD_FLT_2
N00045 X0091.1 Y0019.5

DI_730_W DO_158_W
ELD_CMP2 LD_FLT_2
N00046 K0010.1 K0010.0 Y1025.5 R0000.1

A 262 S
EXT_MTR_ TEACH___ MOTORS__ INT_EXT_
ON MEMORY ENABLE MTR_ON
N00047 Y1025.5 R0000.1

B 266 R
MOTORS__ INT_EXT_
ENABLE MTR_ON
N00048 X0000.2 K0010.0 K0010.5 K0010.1

DI_3_EXT TEACH___ MAINT_ME EXT_MTR_
MTR_ON MEMORY M ON
X1026.5 Y0000.4 F1000.5

D
SI13_RES DO_5_RBT FAULT
ETSW _CNT_FLT
X1025.1
E
FAULT___
RESET
X0000.1 X0001.2
F
DI_2_EX_ DI_11___
RNEN_RST PLC_AUTO
N00049 K0010.2 K0010.0 K0010.5 R0000.2

G 280
EXT_CYC_ TEACH___ MAINT_ME INT_EXT_
START MEMORY M CYC_STRT
N00050 X0000.3 K0010.0 K0010.2

DI_4_EXT TEACH___ EXT_CYC_
_CY_STRT MEMORY START
X1026.5 Y0000.4 F1000.5

I
ETSW _CNT_FLT
X1025.1
J
FAULT___
RESET
X0000.1 X0001.2
K
DI_2_EX_ DI_11___
RNEN_RST PLC_AUTO
R0340.0
L
MANUAL__
WELD
N00051 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 296
DI_17_PG DI_18_PG DI_19_PG DI_20_PG DI_21_PG DI_22_PG DI_23_PG
_SLCT_1 _SLCT_2 _SLCT_4 _SLCT_8 _SLCT_16 _SLCT_32 _SLCT_64
1 X0002.7 R0507.0
N PROGRAM 1
DI_24_PG PROGRAM_
_SLCT128 1
O
N00052 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 305
1 X0002.7 R0507.1
B PROGRAM 2
DI_24_PG PROGRAM_
_SLCT128 2
N00053 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 314
1 X0002.7 R0507.2
D PROGRAM 3
DI_24_PG PROGRAM_
_SLCT128 3
N00054 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 323
1 X0002.7 R0507.3
F PROGRAM 4
DI_24_PG PROGRAM_
_SLCT128 4
N00055 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 332
1 X0002.7 R0507.4
H PROGRAM 5
DI_24_PG PROGRAM_
_SLCT128 5
N00056 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 341
1 X0002.7 R0507.5
J PROGRAM 6
DI_24_PG PROGRAM_
_SLCT128 6
N00057 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 350
1 X0002.7 R0507.6
L PROGRAM 7
DI_24_PG PROGRAM_
_SLCT128 7
N00058 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 359
1 X0002.7 R0507.7
N PROGRAM 8
DI_24_PG PROGRAM_
_SLCT128 8
O
N00059 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 368
1 X0002.7 R0508.0
B PROGRAM 9
DI_24_PG PROGRAM_
_SLCT128 9
N00060 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 377
1 X0002.7 R0508.1
D PROGRAM 10
DI_24_PG PROGRAM_
_SLCT128 10
N00061 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 386
1 X0002.7 R0508.2
F PROGRAM 11
DI_24_PG PROGRAM_
_SLCT128 11
N00062 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 395
1 X0002.7 R0508.3
H PROGRAM 12
DI_24_PG PROGRAM_
_SLCT128 12
N00063 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 404
1 X0002.7 R0508.4
J PROGRAM 13
DI_24_PG PROGRAM_
_SLCT128 13
N00064 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 413
1 X0002.7 R0508.5
L PROGRAM 14
DI_24_PG PROGRAM_
_SLCT128 14
N00065 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 422
1 X0002.7 R0508.6
N PROGRAM 15
DI_24_PG PROGRAM_
_SLCT128 15
O
N00066 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 431
1 X0002.7 R0508.7
B PROGRAM 16
DI_24_PG PROGRAM_
_SLCT128 16
N00067 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 440
1 X0002.7 R0509.0
D PROGRAM 17
DI_24_PG PROGRAM_
_SLCT128 17
N00068 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 449
1 X0002.7 R0509.1
F PROGRAM 18
DI_24_PG PROGRAM_
_SLCT128 18
N00069 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 458
1 X0002.7 R0509.2
H PROGRAM 19
DI_24_PG PROGRAM_
_SLCT128 19
N00070 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 467
1 X0002.7 R0509.3
J PROGRAM 20
DI_24_PG PROGRAM_
_SLCT128 20
O
N00071 X0000.4 Y0000.2 F1000.2 F1000.3 F1000.6 X0001.2 G1000.1 1

A 476
DI_5_MV_ DO_3_RBT PROGRAM_ PAUSED AT_HOME DI_11___ NO_HOLD
TO_POUNC _IN_AUTO RUNNING PLC_AUTO
Y0000.2 F1000.3 F1000.2 X0001.2

B
DO_3_RBT PAUSED PROGRAM_ DI_11___
_IN_AUTO RUNNING PLC_AUTO
F1000.6 R0507.0 F1000.2 F1000.3

C
AT_HOME PROGRAM_ PROGRAM_ PAUSED
1 RUNNING
R0507.1
D
PROGRAM_
2
R0507.2
E
PROGRAM_
3
R0507.3
F
PROGRAM_
4
R0507.4
G
PROGRAM_
5
R0507.5
H
PROGRAM_
6
R0507.6
I
PROGRAM_
7
R0507.7
J
PROGRAM_
8
R0508.0
K
PROGRAM_
9
R0508.1
L
PROGRAM_
10
R0508.2
M
PROGRAM_
11
R0508.3
N
PROGRAM_
12
R0508.4
O
PROGRAM_
13
R0508.5
A
PROGRAM_
14
R0508.6
B
PROGRAM_
15
R0508.7
C
PROGRAM_
16
R0509.0
D
PROGRAM_
17
R0509.1
E
PROGRAM_
18
R0509.2
F
PROGRAM_
19
R0509.3
G
PROGRAM_
20
Y0000.2 F1000.3 F1000.2 X0000.1 X0001.2

H
DO_3_RBT PAUSED PROGRAM_ DI_2_EX_ DI_11___
_IN_AUTO RUNNING RNEN_RST PLC_AUTO
R0223.0
I
DI_976_M
AN_WELD1
R0223.1
J
DI_977_M
AN_WELD2
1 R0000.1 D0603.0 Y0000.4 R0100.5 F1000.5 G1000.5

K UOP CYCLE START
INT_EXT_ CYCLE___ DO_5_RBT BREAK_A_ FAULT UOP_CYC_
MTR_ON STRT_DLY _CNT_FLT NO_HOLD START
N00072 G1000.5 F1000.2 ACT D0603.0

UOP_CYC_ PROGRAM_ TMR CYCLE___
START RUNNING STRT_DLY
N00073 D0603.0 ACT D0603.0

CYCLE___ TMR CYCLE___
STRT_DLY STRT_DLY
N00074 F1000.2 D0603.0

PROGRAM_ CYCLE___
RUNNING STRT_DLY
N00075
O 539 SUB 1
END1
N00076 Y0119.7 ACT K0010.4

DO_960__ TMR TEACH_ME
AUTO_KEY M_DELAY
N00077 Y0000.3 X1026.5 X1025.1 X1025.6 K0010.0

B 544 TEACH MEMORY
DO_4_RBT SI13_RES FAULT___ CYCLE___ TEACH___
_IN_TCH ETSW RESET START MEMORY
K0010.4
C
TEACH_ME
M_DELAY
K0010.0
D
TEACH___
MEMORY
N00078 K0008.0 R0350.0

AUTO/MAI IN_MAINT
NT_SS
N00079 R0350.0 ACT D0610.0

IN_MAINT TMR MAINT___
DELAY
N00080 D0610.0 Y0000.2 Y0000.1 X1026.5 X1025.1 K0010.5

MAINT___ DO_3_RBT DO_2_RBT SI13_RES FAULT___ MAINT_ME
DELAY _IN_AUTO _@_HOME ETSW RESET M
K0010.5 X0000.6
H
MAINT_ME DI_7_MAI
M NT_PSCLR
N00081 X0000.2 X0000.3 Y0000.2 K0010.6

DI_3_EXT DI_4_EXT DO_3_RBT EXT_STRT
MTR_ON _CY_STRT _IN_AUTO _ANTI_TD
K0010.6
J
EXT_STRT
_ANTI_TD
N00082 X0002.0 G1001.0

K 571
DI_17_PG PNS_1
_SLCT_1
N00083 X0002.1 G1001.1

L 573
DI_18_PG PNS_2
_SLCT_2
N00084 X0002.2 G1001.2

M 575
DI_19_PG PNS_3
_SLCT_4
N00085 X0002.3 G1001.3

N 577
DI_20_PG PNS_4
_SLCT_8
N00086 X0002.4 G1001.4

O 579
DI_21_PG PNS_5
_SLCT_16
N00087 X0002.5 G1001.5

A 581
DI_22_PG PNS_6
_SLCT_32
N00088 X0002.6 G1001.6

B 583
DI_23_PG PNS_7
_SLCT_64
N00089 X0002.7 G1001.7

C 585
DI_24_PG PNS_8
_SLCT128
N00090 X0000.6 K0008.0 Y0120.5

DI_7_MAI AUTO/MAI DO_966__
NT_PSCLR NT_SS MAINTCLR
N00091 K0008.0 Y0001.4

AUTO/MAI DO_13_SN
NT_SS DRBT_MNT
N00092 Y0112.3 Y0003.0

DO_900__ DO_25_CL
CLR_ZN_1 R_ZON_1
N00093 Y0112.4 Y0003.1

DO_901__ DO_26_CL
CLR_ZN_2 R_ZON_2
N00094 Y0112.5 Y0003.2

DO_902__ DO_27_CL
CLR_ZN_3 R_ZON_3
N00095 Y0112.6 Y0003.3

DO_903__ DO_28_CL
CLR_ZN_4 R_ZON_4
N00096 Y0112.7 Y0003.4

DO_904__ DO_29_CL
CLR_ZN_5 R_ZON_5
N00097 Y0113.0 Y0003.5

DO_905__ DO_30_CL
CLR_ZN_6 R_ZON_6
N00098 Y0113.1 Y0003.6

DO_906__ DO_31_CL
CLR_ZN_7 R_ZON_7
N00099 Y0113.2 Y0003.7

DO_907__ DO_32_CL
CLR_ZN_8 R_ZON_8
N00100 Y0113.3 Y0004.0

DO_908__ DO_33_CL
CLR_ZN_9 R_ZON_9
N00101 Y0113.4 Y0004.1

DO_909_C DO_34_CL
LR_ZN_10 R_ZON_10
N00102 Y0113.5 Y0004.2

DO_910_C DO_35_CL
LR_ZN_11 R_ZON_11
N00103 Y0113.6 Y0004.3

DO_911_C DO_36_CL
LR_ZN_12 R_ZON_12
N00104 Y0113.7 Y0004.4

DO_912_C DO_37_CL
LR_ZN_13 R_ZON_13
N00105 Y0116.4 Y0004.5

DO_933_C DO_38_CL
LR_ZN_14 R_ZON_14
N00106 Y0118.7 Y0004.6

DO952_CL DO_39_CL
RMOTZN1 R_INDMOT
N00107 Y0119.0 Y0004.7

DO953_CL DO_40_CL
RMOTZN2 R_INDMT2
N00108 Y0119.1 X0000.0 Y0000.6

DO_954_C DI_1_EXT DO_7_CLR
LRAV_XFR _RNENBL _ADV
N00109 Y0119.2 X0000.0 Y0000.7

LRET_XFR _RNENBL _RET_XFR
N00110 Y0119.3 X0000.0 Y0001.0

LR_UNCLP _RNENBL _2_UNCLP
N00111 Y0000.3 R1000.0 Y0073.0

J 633 PROMPT BOX
DO_4_RBT DO_19001 DO_585__
_IN_TCH _PRPTBX PRMPT_BX
N00112 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

K 636
1 R1402.7 R1405.3
ECO24___ SYS_FCLY
FC128 CODE
N00113 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 645
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0365.0

N00114 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 663
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0366.0

N00115 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 681
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0367.0

N00116 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 699
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0368.0

N00117 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 717
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.0

N00118 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 735
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.1

N00119 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 753
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.3

N00120 R1406.3 X1025.1 Y0001.6

SRVO-50 FAULT___ DO_15_CO
RESET LL_DTCT
Y0001.6
E
DO_15_CO
LL_DTCT
N00121 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

F 775
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

G
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.2

ECO13 ECO14 ECO15 ECO16 SRVO-65_
LOW_BATT
N00122 F1001.0 Y0001.1

BATALM DO_10_RB
T_BAT_LW
N00123 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 795
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0371.0

N00124 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 813
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.1

NCE_EXCE
N00125 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 831
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0373.0

_CONTROL
N00126 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 849
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0374.0

_NTED_IN
N00127 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 867
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0375.0

_TP_OFF
N00128 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 885
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0376.0

_SVOFF_I
N00129 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 903
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.0

O SRVO-378 SFDIxx STATUS ABNOR
_SFDIxx
N00130 F1008.1 ACT R0388.1

A 921 SUB24 0001 F1008.1 SYSRST DELAY ON
SYSRST TMRB F1008.1_
DELAY ON
B 0000000124
N00131 R0387.0 R0388.1 R0388.0

C 926 SRVO OPSFTY ABNORM FAULT LATCH
SRVO-378 F1008.1_ OPSFTY_F
_SFDIxx DELAY ON LT_LATCH
R0388.0 F1000.5
D
OPSFTY_F FAULT
LT_LATCH
N00132 R0388.0 Y0073.1

E 932 SAFETY CHAIN FAULT
OPSFTY_F DO_586_S
LT_LATCH FTY_CHN
N00133 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

F 934
SYS_FCLY EC01 EC02 ECO3 ECO4 ECO5 ECO6
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

G
2 R1401.4 R1401.5 R1401.6 R1401.7 R0377.0

H SYST-034 HOLD SIGNAL FROM SOP/
_HOLD_SI
N00134 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

I 952
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

J
2 R1401.4 R1401.5 R1401.6 R1401.7 R0378.0

K SYST-038 OPERATION MODE T1 SEL
_OPERATI
N00135 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

L 970
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

M
2 R1401.4 R1401.5 R1401.6 R1401.7 R0379.0

N
O
N00136 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 988
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0380.0

C SYST-040 OPERATION MODE AUTO S
_OPERATI
N00137 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1006
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0381.0

F SYST-042 DEADMAN DEFEATED
_DEADMAN
N00138 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 1024
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0382.0

I SYST-043 TP DISABLE IN T1/T2
_TP_DISA
N00139 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 1042
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0383.0

L SYST-045 TP ENABLE IN AUTO MO
_TP_ENAB
N00140 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 1060
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0384.0

O SYST-154 NO START IN ISOLATE/B
_NO_STAR
N00141 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1078
_ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0385.0

C SVGN-320 THCKNESS1 ERR REQ RES
_THK1ERR
N00142 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1096
_ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0386.0

F SVGN-326 THKNESS2 ERR REQ RES
_THK2ERR
N00143 R0385.0 R0386.1

G 1114 SVGN 320 AND 326 LATCH
SVGN-320 SVGN320_
_THK1ERR 326_LTCH
R0386.0
H
SVGN-326
_THK2ERR
R0386.1 G1000.4
I
SVGN320_ RB_FAULT
326_LTCH _RESET
N00144 R0397.0 F1000.0 R0397.0

J 1120 FILTERED FAULT
FILTERED COMMAND_ FILTERED
_FAULT ENABLE _FAULT
R0398.0
K
FILTER__
FLT_GRP1
R0399.0
L
FILTER__
FLT_GRP2
O
N00145 R0365.0 R0398.0

SRVO-001 FILTER__
FLT_GRP1
R0366.0
B
SRVO-002
R0367.0
C
SRVO-003
R0368.0
D
SRVO-005
R0369.0
E
R369.0__
RESERVED
R0370.0
F
SRVO-007
R0371.0
G
SRVO-101
R0372.0
H
R372.0__
RESERVED
R0373.0
I
SRVO-199
_CONTROL
R0374.0
J
SRVO-232
_NTED_IN
R0375.0
K
SRVO-233
_TP_OFF
R0376.0
L
SRVO-280
_SVOFF_I
R0385.0
M
SVGN-320
_THK1ERR
R0386.0
N
SVGN-326
_THK2ERR
R0370.1
O
SRVO-408
R1456.0
A
APPL____
ALARMS
N00146 R0377.0 R0399.0

SYST-034 FILTER__
_HOLD_SI FLT_GRP2
R0378.0
C
SYST-038
_OPERATI
R0379.0
D
SYST-039
R0380.0
E
SYST-040
_OPERATI
R0381.0
F
SYST-042
_DEADMAN
R0382.0
G
SYST-043
_TP_DISA
R0383.0
H
SYST-045
_TP_ENAB
R0384.0
I
SYST-154
_NO_STAR
X1025.0
J
FANUC___
E-STOP
F1008.2
K
TP______
E-STOP
X1026.1
L
SI9_____
AUTOMDSW
Y0000.3
M
DO_4_RBT
_IN_TCH
K0010.0
N
TEACH___
MEMORY
R1405.2
O
FENCE___
FAULT
N00147 R0330.0 F1000.5 R1456.0

A 1157
ARC_____ FAULT APPL____
ALARM ALARMS
R0330.1
B
SEALER__
ALARM
R0330.3
C
TOOLCHNG
__ALARM
R0330.4
D
SYSTEM__
_ALARM
R1404.3
E
SPOT____
ALARM
R1456.0
F
APPL____
ALARMS
N00148 D0001.0 Y0079.0

TOOL_CHA DO_633_T
NGE_APP C_LOCK
Y0079.1
DO_634_T
C_UNLOCK
N00149 D0001.0 ACT

I 1168 SUB10 0000
TOOL_CHA JMP
NGE_APP
N00150
J 1171 SUB66 P0001
CALLU TOOL_CHANGING
N00151
K 1173 SUB30
JMPE
N00152
L 1174 SUB66 P0002
CALLU WELDCONTROL1
N00153
M 1176 SUB66 P0003
CALLU TIPDRESSER1
N00154
N 1178 SUB66 P0004
CALLU WATERVALVE1
N00155
O 1180 SUB66 P0005
N00156
A 1182 SUB66 P0006
CALLU UALM
N00157
B 1184 SUB66 P0007
CALLU INTERFACE
N00158
C 1186 SUB66 P0008
CALLU MH
N00159
D 1188 SUB66 P0009
CALLU APPLICATION
N00160
E 1190 SUB66 P0020
CALLU AIR
N00161
F 1192 SUB66 P0015
CALLU WELDCONTROL2
N00162
G 1194 SUB66 P0016
CALLU TIPDRESSER2
N00163
H 1196 SUB66 P0017
CALLU WATERVALVE2
N00164
I 1198 SUB66 P0018
N00165
J 1200 SUB66 P0025
CALLU TOUCHUP1
N00166
K 1202 SUB 2
END2
N00167 ### TOOL_CHANGING ###

L 1203 SUB71 P0001
SP TOOL_CHANGING
O
N00168 X0080.0 R0347.0

A 1205 GUN ID NOT 0
DI_641__ GUN_ID__
TOOL_ID1 NOT_0
X0080.1
B
DI_642__
TOOL_ID2
X0080.2
C
DI_643__
TOOL_ID4
X0080.3
D
DI_644__
TOOL_ID8
N00169 X0080.0 X0080.1 X0080.2 X0080.3 R0321.0

E 1210
DI_641__ DI_642__ DI_643__ DI_644__ GUN_1_ON
TOOL_ID1 TOOL_ID2 TOOL_ID4 TOOL_ID8 _ARM
N00170 X0080.0 X0080.1 X0080.2 X0080.3 R0322.0

F 1215
DI_641__ DI_642__ DI_643__ DI_644__ GUN_2_ON
N00171 X0080.0 X0080.1 X0080.2 X0080.3 R0323.0

G 1220
DI_641__ DI_642__ DI_643__ DI_644__ GUN_3_ON
N00172 X0080.0 X0080.1 X0080.2 X0080.3 R0324.0

H 1225
DI_641__ DI_642__ DI_643__ DI_644__ GUN_4_ON
N00173 X0080.0 X0080.1 X0080.2 X0080.3 R0325.0

I 1230
DI_641__ DI_642__ DI_643__ DI_644__ GUN_5_ON
N00174 X0080.0 X0080.1 X0080.2 X0080.3 R0326.0

J 1235
DI_641__ DI_642__ DI_643__ DI_644__ GUN_6_ON
N00175 X0080.0 X0080.1 X0080.2 X0080.3 R0326.1

K 1240
DI_641__ DI_642__ DI_643__ DI_644__ GUN_7_ON
N00176 X0080.0 X0080.1 X0080.2 X0080.3 R0326.2

L 1245
DI_641__ DI_642__ DI_643__ DI_644__ GUN_8_ON
O
N00177 R0321.0 R0328.6

GUN_1_ON TOOLONRO
_ARM BOT
R0322.0
B
GUN_2_ON
_ARM
R0323.0
C
GUN_3_ON
_ARM
R0324.0
D
GUN_4_ON
_ARM
R0325.0
E
GUN_5_ON
_ARM
R0326.0
F
GUN_6_ON
_ARM
R0326.1
G
GUN_7_ON
_ARM
R0326.2
H
GUN_8_ON
_ARM
N00178 R0321.0 R0322.0 R0323.0 R0324.0 R0325.0 R0326.0 R0326.1 1

I 1259
GUN_1_ON GUN_2_ON GUN_3_ON GUN_4_ON GUN_5_ON GUN_6_ON GUN_7_ON
_ARM _ARM _ARM _ARM _ARM _ARM _ARM
1 R0326.2 R0348.0
GUN_8_ON GEOTOOLP
_ARM RSNT
N00179 X0080.0 Y0038.0

DI_641__ DO_305__
TOOL_ID1 TOOL_ID1
N00180 X0080.1 Y0038.1

L 1270
DI_642__ DO_306__
TOOL_ID2 TOOL_ID2
N00181 X0080.2 Y0038.2

M 1272
DI_643__ DO_307__
TOOL_ID4 TOOL_ID4
N00182 X0080.3 Y0038.3

N 1274
DI_644__ DO_308__
TOOL_ID8 TOOL_ID8
O
N00183 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 X0038.6 1

A 1276
DI_305__ DI_306__ DI_307__ DI_308__ DI_309__ DI_310__ DI_311__
1 X0038.7 R0327.0
DI_312__ GUN_1-8
TCSTND8
N00184 Y0117.4 K0011.1

DO_941__ TC____RE
TC_UNLCK LEASED
N00185 Y0117.3 Y0000.2 X0079.4 X0079.5 R0328.6 Y0079.0

DO_940__ DO_3_RBT DI_637__ DI_638__ TOOLONRO DO_633_T
TC_LOCK _IN_AUTO RDY2LCK1 RDY2LCK2 BOT C_LOCK
F1000.7 Y0119.7 K0015.0 R0328.6

E
TPENABLE DO_960__ TC_LOCK_ TOOLONRO
AUTO_KEY PB BOT
N00186 Y0117.4 Y0117.3 Y0000.2 Y0079.0

F 1300 R TOOL CHANGER LOCK
DO_941__ DO_940__ DO_3_RBT DO_633_T
TC_UNLCK TC_LOCK _IN_AUTO C_LOCK
F1000.7 Y0119.7 K0016.0

G
TPENABLE DO_960__ TC_UNLOC
AUTO_KEY K_PB
N00187 X0079.0 Y0040.6

H 1309
DI_633__ DO_327_T
TC_LOCKD CCOUPMON
N00188 K0011.1 Y0079.0 Y0000.2 X0080.4 X0080.5 1

I 1311
TC____RE DO_633_T DO_3_RBT DI_645_T DI_646_T
LEASED C_LOCK _IN_AUTO SIV SRV
F1000.7 Y0119.7 K0016.0 R0328.6 2

J
TPENABLE DO_960__ TC_UNLOC TOOLONRO
AUTO_KEY K_PB BOT
1 R0328.6 Y0079.1
TOOLONRO DO_634_T
BOT C_UNLOCK
2
L
N00189 K0015.0 K0016.0 F1000.7 Y0119.7 K0015.0

TC_LOCK_ TC_UNLOC TPENABLE DO_960__ TC_LOCK_
PB K_PB AUTO_KEY PB
N00190 K0016.0 K0015.0 F1000.7 Y0119.7 K0016.0

TC_UNLOC TC_LOCK_ TPENABLE DO_960__ TC_UNLOC
K_PB PB AUTO_KEY K_PB
N00191 X0079.1 Y0040.7

O 1335
DI_634__ DO_328_T
TC_ULCKD CRELMON
N00192 R0328.6 K0008.0 R0218.4

TOOLONRO AUTO/MAI DI_940_T
BOT NT_SS C_NOTOOL
N00193 Y0117.5 Y0117.6 Y0000.2 Y0038.5

DO_942__ DO_943__ DO_3_RBT DO_310_T
TCOPNCVR TCCLSCVR _IN_AUTO C_OPNCVR
K0011.4 K0011.5 Y0000.3

C
TC_OPENG TC__CLOS DO_4_RBT
UNCOVER GUNCOVER _IN_TCH
N00194 Y0117.5 Y0117.6 Y0000.2 Y0038.6

DO_942__ DO_943__ DO_3_RBT DO_311_T
TCOPNCVR TCCLSCVR _IN_AUTO C_CLSCVR
K0011.5 K0011.4 Y0000.3

E
TC__CLOS TC_OPENG DO_4_RBT
GUNCOVER UNCOVER _IN_TCH
N00195 X0038.0 R0321.0 R0329.0

DI_305__ GUN_1_ON GUN1_POS
TCSTND1 _ARM ITION
X0038.0 X0039.3
G
DI_305__ DI_316_G
TCSTND1 EOTPDCK
N00196 X0038.1 R0322.0 R0329.1

TCSTND2 _ARM ITION
X0038.1 X0039.3
I
DI_306__ DI_316_G
TCSTND2 EOTPDCK
N00197 X0038.2 R0323.0 R0329.2

TCSTND3 _ARM ITION
X0038.2 X0039.3
K
DI_307__ DI_316_G
TCSTND3 EOTPDCK
N00198 X0038.3 R0324.0 R0329.3

TCSTND4 _ARM ITION
X0038.3 X0039.3
M
DI_308__ DI_316_G
TCSTND4 EOTPDCK
N00199 X0038.4 R0325.0 R0329.4

TCSTND5 _ARM ITION
X0038.4 X0039.3
O
DI_309__ DI_316_G
TCSTND5 EOTPDCK
N00200 X0038.5 R0326.0 R0329.5

TCSTND6 _ARM ITION
X0038.5 X0039.3
B
DI_310__ DI_316_G
TCSTND6 EOTPDCK
N00201 X0038.6 R0326.1 R0329.6

TCSTND7 _ARM ITION
X0038.6 X0039.3
D
DI_311__ DI_316_G
TCSTND7 EOTPDCK
N00202 X0038.7 R0326.2 R0329.7

TCSTND8 _ARM ITION
X0038.7 X0039.3
F
DI_312__ DI_316_G
TCSTND8 EOTPDCK
N00203 R0329.0 R0328.7

GUN1_POS GUN1-8_P
ITION OSITION
R0329.1
H
GUN2_POS
ITION
R0329.2
I
GUN3_POS
ITION
R0329.3
J
GUN4_POS
ITION
R0329.4
K
GUN5_POS
ITION
R0329.5
L
GUN6_POS
ITION
R0329.6
M
GUN7_POS
ITION
R0329.7
N
GUN8_POS
ITION
O
N00204 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1413
DI_316_G DI_305__ DI_306__ DI_307__ DI_308__ DI_309__ DI_310__
1 X0038.6 X0038.7 R0320.0

B TOOL 1 IN OPDOCK
DI_311__ DI_312__ TOOL1INO
N00205 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

C 1423
1 X0038.6 X0038.7 R0320.1

D TOOL 2 IN OPDOCK
N00206 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

E 1433
1 X0038.6 X0038.7 R0320.2

F TOOL 3 IN OPDOCK
N00207 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

G 1443
1 X0038.6 X0038.7 R0320.3

H TOOL 4 IN OPDOCK
N00208 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

I 1453
1 X0038.6 X0038.7 R0320.4

J TOOL 5 IN OPDOCK
N00209 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

K 1463
1 X0038.6 X0038.7 R0320.5

L TOOL 6 IN OPDOCK
N00210 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

M 1473
1 X0038.6 X0038.7 R0320.6

N TOOL 7 IN OPDOCK
O
N00211 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1483
1 X0038.6 X0038.7 R0320.7

B TOOL 8 IN OPDOCK
N00212 R0320.0 R0319.0

TOOL1INO ALLTOOLS
PDOCK INOPDOCK
R0320.1
D
TOOL2INO
PDOCK
R0320.2
E
TOOL3INO
PDOCK
R0320.3
F
TOOL4INO
PDOCK
R0320.4
G
TOOL5INO
PDOCK
R0320.5
H
TOOL6INO
PDOCK
R0320.6
I
TOOL7INO
PDOCK
R0320.7
J
TOOL8INO
PDOCK
N00213 X0082.6 Y0038.7

K 1502
DI_663_T DO_312_T
CCOMMOK CCOMMOK
N00214 X0082.7 Y0039.2

L 1504
DI_664_T DO_315_T
CTLSLDPW LSLIDPWR
N00215 X0079.4 X0079.5 G1008.4

M 1506 RTL1ANDL2SWITCHMISMATCH
DI_637__ DI_638__ UALM_5
RDY2LCK1 RDY2LCK2
X0079.4 X0079.5
N
DI_637__ DI_638__
RDY2LCK1 RDY2LCK2
N00216 R0328.6 G1008.5

O 1512 NOTOOLONARM
TOOLONRO UALM_6
BOT
N00217 K0013.1 R0000.7 Y0126.7

NOTOOLON PART_PRE DO_1016_
N00218 K0013.1 R0000.7 K0013.1

NOTOOLON PART_PRE NOTOOLON
EOATSS SENT EOATSS
N00219 Y0039.3 Y0039.3

DO_316_W DO_316_W
RNGTLSTD RNGTLSTD
N00220 Y0039.3 X1025.1 Y0000.1 Y0039.3

DO_316_W FAULT___ DO_2_RBT DO_316_W
RNGTLSTD RESET _@_HOME RNGTLSTD
N00221
E 1526 SUB72
SPE
N00222 ### WELDCONTROL1 ###

F 1527 SUB71 P0002
SP WELDCONTROL1
N00223 X0000.0 Y0083.0

DI_1_EXT DO_665_W
_RNENBL C1_ENBLE
N00224 X0087.6 Y0014.4

DI_703_W DO_117_W
1_COMMOK C1COM_OK
N00225 Y0000.3 Y0083.1

DO_4_RBT DO_666_R
_IN_TCH BTCH_WC1
N00226 K0004.7 Y0014.1

WELD_/_N DO_114_W
O_WELD1 D/NWD1SS
N00227 K0006.4 Y0018.1

WELD_/_N DO_146_W
O_WELD2 D/NWD2SS
N00228 Y0014.1 Y0018.1 R0221.0

DO_114_W DO_146_W DI_960_R
D/NWD1SS D/NWD2SS EM_WELD
N00229 X0086.1 Y0015.6

DI_690_I DO_127_I
_HI/LO AVL_WRN1
N00230 X0087.5 Y0017.3

DI_702_A DO_140_A
DP_MODE DP_MODE
N00231 X0083.0 Y0015.3

DI_665_I DO_124_I
NWLDCYC1 NWD_CY_1
N00232 X0083.1 Y0015.4

DI_666_W DO_125_H
ELD_CMP1 AS_WLD_1
N00233 X0083.3 Y0014.3

DI_668_W DO_116_N
ELD_FLT1 OWLDFLT1
N00234 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

C 1552
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0306.0
DO_686__ ROBOT_WS
BP_128 _WC#1
N00235 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

E 1561
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0307.0
F
DO_686__ WLD_SCH_
BP_128 39_WC1
N00236 Y0014.1 Y0014.2 Y0083.4

DO_114_W DO_115_W DO_669_W
N00237 X1020.2 X1020.0 X1020.1 D0004.0

RI_3_WTR RI_1__XF RI_2_SRV LETSWELD
_FL_SW1 RMR_OT1 OMTR_OT1 WC1
O
N00238 Y0109.7 D0004.0 K0000.0 ACT R0363.0

DO_880__ LETSWELD DEBUG TMR BINARYTI
BP1_1 WC1 MER1
Y0110.0
B
DO_881__
BP2_1
Y0110.1
C
DO_882__
BP4_1
Y0110.2
D
DO_883__
BP8_1
Y0110.3
E
DO_884__
BP16_1
Y0110.4
F
DO_885__
BP32_1
Y0110.5
G
DO_886__
BP64_1
Y0110.6
H
DO_887__
BP128_1
N00239 Y0109.7 D0004.0 R0363.0 Y0084.6

DO_880__ LETSWELD BINARYTI DO_679__
BP1_1 WC1 MER1 BP_1
N00240 Y0110.0 D0004.0 R0363.0 Y0084.7

BP2_1 WC1 MER1 BP_2
N00241 Y0110.1 D0004.0 R0363.0 Y0085.0

BP4_1 WC1 MER1 BP_4
N00242 Y0110.2 D0004.0 R0363.0 Y0085.1

BP8_1 WC1 MER1 BP_8
N00243 Y0110.3 D0004.0 R0363.0 Y0085.2

BP16_1 WC1 MER1 BP_16
N00244 Y0110.4 D0004.0 R0363.0 Y0085.3

N00245 Y0110.5 D0004.0 R0363.0 Y0085.4

N00246 Y0110.6 D0004.0 R0363.0 Y0085.5

BP128_1 WC1 MER1 BP_128
N00247 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

B 1622
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0360.0
DO_686__ NOWLDSCH
BP_128 WC1
N00248 R0360.0 X0087.6 K0000.0 Y0083.5

NOWLDSCH DI_703_W DEBUG DO_670__
WC1 1_COMMOK PS_INPUT
K0000.0 Y0116.5
E
DEBUG DO_934__
RD_SCHD1
N00249 Y0120.6 F1000.3 Y0000.1 R0223.0

F 1638
DO_967_M PAUSED DO_2_RBT DI_976_M
AN_WELD1 _@_HOME AN_WELD1
X0015.0 K0008.0 Y0000.5 F1000.3 F1000.2

G
DI_121_R AUTO/MAI DO_6_RBT PAUSED PROGRAM_
M_MAN_W1 NT_SS _@_MAINT RUNNING
Y0000.1 F1000.2 F1000.3

H
DO_2_RBT PROGRAM_ PAUSED
_@_HOME RUNNING
N00250 Y0120.6 Y0000.1 F1000.2 F1000.3 R0213.6

DO_967_M DO_2_RBT PROGRAM_ PAUSED DI_902_W
AN_WELD1 _@_HOME RUNNING ELDHOME1
X0015.0 K0008.0
J
DI_121_R AUTO/MAI
M_MAN_W1 NT_SS
N00251 Y0048.3 Y0121.0 F1000.3 Y0000.1 R0220.4

DO_388_N DO_969_F PAUSED DO_2_RBT DI_956_R
UTFD_APP EDWLD1PB _@_HOME EFEDWLD1
N00252 K0008.6 D0612.0 K0008.6

DTSR_PB_ IF_PB_TO DTSR_PB_
1 1
N00253 K0008.6 D0612.0 K0008.6

1 1
N00254 K0005.1 D0612.0 K0005.1

NEW_TIP_ IF_PB_TO NEW_TIP_
PB1 PB1
N00255 K0005.1 D0612.0 K0005.1

PB1 PB1
N00256 K0005.2 D0612.0 K0005.2

INIT_AUT IF_PB_TO INIT_AUT
O_TD_PB1 O_TD_PB1
N00257 K0005.2 D0612.0 K0005.2

O_TD_PB1 O_TD_PB1
N00258 K0005.5 D0612.0 K0005.5

TIP_ALGN IF_PB_TO TIP_ALGN
_CLS_PB1 _CLS_PB1
N00259 K0005.5 D0612.0 K0005.5

_CLS_PB1 _CLS_PB1
N00260 K0005.6 D0612.0 K0005.6

_OPN_PB1 _OPN_PB1
N00261 K0005.6 D0612.0 K0005.6

_OPN_PB1 _OPN_PB1
N00262 K0005.7 D0612.0 K0005.7

INITAUTO IF_PB_TO INITAUTO
TCPB1 TCPB1
N00263 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00264 K0006.0 D0612.0 K0006.0

ATC_FLT_ IF_PB_TO ATC_FLT_
ACK_PB1 ACK_PB1
N00265 K0006.0 D0612.0 K0006.0

ACK_PB1 ACK_PB1
N00266 Y0120.6 D0612.0 Y0120.6

DO_967_M IF_PB_TO DO_967_M
AN_WELD1 AN_WELD1
N00267 Y0120.6 D0612.0 Y0120.6

AN_WELD1 AN_WELD1
N00268 Y0121.0 D0612.0 Y0121.0

DO_969_F IF_PB_TO DO_969_F
EDWLD1PB EDWLD1PB
N00269 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
O
N00270 Y1020.0 Y1020.0

RO__1___ RO__1___
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
B
EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00271 Y1020.0 Y1020.0

RO__1___ RO__1___
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
D
EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00272 K0004.5 K0006.2

EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00273 K0004.5 X1026.1 G1000.1 ACT K0004.5

F 1733 SUB 3 0033 R EQUALIZATION ENABLE 1AND2 SS
EQUALENB SI9_____ NO_HOLD TMR EQUALENB
L_1_2_SS AUTOMDSW L_1_2_SS
N00274 K0000.0 Y0083.3 D0612.0 X1025.1 Y0083.3

G 1739 RESET WELDER
DEBUG DO_668_R IF_PB_TO FAULT___ DO_668_R
ST_WLD RESET ST_WLD
X1025.1
H
FAULT___
RESET
N00275 K0015.1 D0612.0 K0015.1

ADVTIPDR IF_PB_TO ADVTIPDR
SSDUMP1 SSDUMP1
N00276 K0015.1 D0612.0 K0015.1

SSDUMP1 SSDUMP1
N00277 K0015.2 D0612.0 K0015.2

RETTIPDR IF_PB_TO RETTIPDR
SSDUMP1 SSDUMP1
N00278 K0015.2 D0612.0 K0015.2

SSDUMP1 SSDUMP1
N00279 K0015.1 Y0000.2 X1026.1 K0015.2 Y0017.5

M 1757
ADVTIPDR DO_3_RBT SI9_____ RETTIPDR DO_142_A
SSDUMP1 _IN_AUTO AUTOMDSW SSDUMP1 DVDUMP1
N00280 K0015.2 Y0000.2 X1026.1 K0015.1 Y0017.6

N 1762
RETTIPDR DO_3_RBT SI9_____ ADVTIPDR DO_143_R
SSDUMP1 _IN_AUTO AUTOMDSW SSDUMP1 ETDUMP1
O
N00281 Y0120.6 K0000.3 D0610.1

DO_967_M CCWLDMDE CCWELDMO
AN_WELD1 NB1 DETIMR1
X0015.0 K0008.0 K0000.3

B
DI_121_R AUTO/MAI CCWLDMDE
M_MAN_W1 NT_SS NB1
N00282 D0610.1 ACT D0610.1

DETIMR1 DETIMR1
N00283 X0054.5 Y0087.1

DI_438_C DO_698_C
CWELDMOD CWELDMOD
D0610.1
E
CCWELDMO
DETIMR1
N00284
F 1781 SUB72
SPE
N00285 ### TIPDRESSER1 ###

G 1782 SUB71 P0003
SP TIPDRESSER1
N00286 X0087.1 Y0017.2

DI_698_T DO_139_T
PCHNGRQW PCHG_RQ1
X0087.0
I
DI_697_T
PCHNGRQ
Y0110.7
J
DO_888_T
PWRMOV1
Y0111.0
K
DO_889_T
PWRFIX1
N00287 K0005.5 Y0000.5 R0222.6

TIP_ALGN DO_6_RBT DI_974_T
_CLS_PB1 _@_MAINT IP_CLS1
N00288 K0005.6 Y0000.5 R0222.7

_OPN_PB1 _@_MAINT IP_OPN1
N00289 X0083.4 Y0016.3

DI_669_N DO_132_N
EW_TIP WTP_RST1
O
N00290 R0345.0 Y0084.5 X0001.2 K0008.0 R0345.0

TIP_MEM_ DO_678_D DI_11___ AUTO/MAI TIP_MEM_
___1 TSR PLC_AUTO NT_SS ___1
Y0119.1 K0005.2
B
DO_954_C INIT_AUT
LRAV_XFR O_TD_PB1
N00291 R0334.0 Y0109.0 Y0000.5 X0083.1 R0333.0

DRESS_CA DO_873_T DO_6_RBT DI_666_W TD_MEM_W
P_TC1 D1_ENB _@_MAINT ELD_CMP1 C_#1
R0333.0
D
TD_MEM_W
C_#1
N00292 X0083.4 K0008.0 Y0000.5 X0014.7 R0333.0 R0334.0

DI_669_N AUTO/MAI DO_6_RBT DI_120_T TD_MEM_W DRESS_CA
EW_TIP NT_SS _@_MAINT D_BYPSS1 C_#1 P_TC1
R0334.0
F
DRESS_CA
P_TC1
N00293 X0083.2 Y0015.0

DI_667_M DO_121_A
AINT_REQ UTOTD_1
R0334.0 Y0048.3
H
DRESS_CA DO_388_N
P_TC1 UTFD_APP
R0345.0
I
TIP_MEM_
___1
N00294 K0005.0 Y0014.0

PULLED_T DO_113_P
IP_BYPS1 LTPBY_SS
K0006.5
K
PULLED_T
IP_BYPS2
N00295 Y0085.7 R0351.0

DO_688__ PULLDTIP
TIP_WTR1 _SEAL_1
N00296 R0351.0 ACT D0611.0

_SEAL_1 P_TIMER
N00297 R0220.6 Y0017.4

DI_958_P DO_141_A
LDTIP_1 PTB_1
R0220.7
O
DI_959_P
LDTIP_2
N00298 Y0014.5 X0001.2 Y0109.0

DO_118_D DI_11___ DO_873_T
RSR_ON_1 PLC_AUTO D1_ENB
K0005.3 Y0000.3
B
TEACH_TD DO_4_RBT
_ENABLE1 _IN_TCH
N00299 R0000.0 Y0014.5 X0001.2 Y0086.6

ALWAYS__ DO_118_D DI_11___ DO_695_T
ON RSR_ON_1 PLC_AUTO D_MTR_ON
K0005.3 Y0000.3
D
TEACH_TD DO_4_RBT
_ENABLE1 _IN_TCH
N00300 X1020.2 X0000.0 X0013.6 R0220.6

RI_3_WTR DI_1_EXT DI 111 A DI_958_P
_FL_SW1 _RNENBL UTOTIPCH LDTIP_1
R0220.6 D0611.0
F
DI_958_P PULLEDTI
LDTIP_1 P_TIMER
N00301 K0004.6 Y0014.7

TD_MTR_F DO_120_T
LT_BYPS1 DMFL_BY1
N00302 D0605.0 R0411.0 R0412.0

H 1860 TD FAULT1
1TIM1 TOK1
N00303 Y0014.5 X0086.2 Y0109.2 K0004.6 Y0083.3 R0411.0

DO_118_D DI_691_T DO_875_S TD_MTR_F DO_668_R TDCURREN
RSR_ON_1 IP_DR_OK RVTPDROK LT_BYPS1 ST_WLD TOK1
R0411.0
J
TDCURREN
TOK1
N00304 R0412.0 ACT D0606.0

2TIM1
N00305 Y0014.5 ACT D0605.0

DO_118_D TMR TDMTROFF
RSR_ON_1 1TIM1
N00306 Y0083.3 R0411.0 D0606.0 R0415.0

DO_668_R TDCURREN TDMTROFF TDMTRFLT
ST_WLD TOK1 2TIM1 1
R0408.0
N
TPRESFLT
1
R0415.0
O
TDMTRFLT
1
N00307 R0415.0 Y0014.6

TDMTRFLT DO_119_T
1 DM_FLT_1
N00308 Y0118.1 ACT D0604.0

DO_946_R TMR TPRESFLT
ESCHKMD1 TIM1
N00309 D0604.0 R0409.0 R0408.0

TIM1 LAT1 1
N00310 Y0118.1 X0086.3 K0005.4 Y0083.3 R0409.0

DO_946_R DI_692_T TIP_RESI DO_668_R TPRESFLT
ESCHKMD1 PDRRSOK1 ST_BYPS1 ST_WLD LAT1
R0409.0
E
TPRESFLT
LAT1
N00311 X0014.4 Y0121.2 Y0118.7 F1000.5 R0221.6

DI_117_I DO_971_P DO952_CL FAULT DI_966_R
NIT_TD_1 EDDMPAPP RMOTZN1 NTDDMP1
X0014.6 X0083.2 Y0015.0 Y0121.5

G
DI_119_T DI_667_M DO_121_A DO_974__
D_DMP_R1 AINT_REQ UTOTD_1 TPWRCMP1
N00312 K0008.5 K0008.5

NTSR_ENB NTSR_ENB
1SS 1SS
N00313 K0008.5 X1025.1 K0008.5

NTSR_ENB FAULT___ NTSR_ENB
1SS RESET 1SS
K0008.5 X0083.4
J
NTSR_ENB DI_669_N
1SS EW_TIP
N00314 K0015.6 K0015.6

DTSRENB1 DTSRENB1
SS SS
N00315 K0015.6 X1025.1 K0015.6

DTSRENB1 FAULT___ DTSRENB1
SS RESET SS
K0015.6 X0083.5
M
DTSRENB1 DI_670_D
SS RSSTIP1
N00316 K0008.5 K0005.1 Y0084.4

NTSR_ENB NEW_TIP_ DO_677_N
1SS PB1 TSR
X0015.3
O
DI_124_N
EWTPRST1
N00317 K0015.6 K0008.6 Y0084.5

DTSRENB1 DTSR_PB_ DO_678_D
SS 1 TSR
Y0116.7 Y0054.2
B DRSSTIPSTPRST1
DO_936__ DO_435_D
STP_RST1 TSR1
N00318
C 1935 SUB72
SPE
N00319 ### WATERVALVE1 ###

D 1936 SUB71 P0004
SP WATERVALVE1
N00320 X1020.2 X0001.6 Y0085.7

RI_3_WTR DI_15_SY DO_688__
_FL_SW1 S_WTR_ON TIP_WTR1
N00321 X0014.0 R0000.5 Y1020.3

DI_113_R WTR_RST_ RO_4_WTR
ST_WTRSV PULSE_OP _RESET1
Y1020.3 X1020.2
G
RO_4_WTR RI_3_WTR
_RESET1 _FL_SW1
X1025.1
H
FAULT___
RESET
N00322 Y1020.3 Y0122.0 ACT R0000.5

RO_4_WTR DO_977__ TMR WTR_RST_
_RESET1 WS_PLSOP PULSE_OP
Y1020.5
J
RO_6_WTR
_RESET2
N00323
K 1954 SUB72
SPE
N00324 ### OVRTMP/NOSTRK1 ###

L 1955 SUB71 P0005
SP OVRTMP/NOSTRK1
N00325 X1020.0 Y0086.4

RI_1__XF DO_693_X
RMR_OT1 FMR_OT
N00326 X1020.1 Y0086.5

RI_2_SRV DO_694_S
OMTR_OT1 RVMTR_OT
O
N00327 X1020.0 X1025.1 R0500.0

RI_1__XF FAULT___ XFRMR_OT
RMR_OT1 RESET MP_SEAL1
R0500.0
B
XFRMR_OT
MP_SEAL1
N00328 X1020.1 X1025.1 R0500.1

RI_2_SRV FAULT___ SRVO_MTR
OMTR_OT1 RESET _OTSEAL1
R0500.1
D
SRVO_MTR
_OTSEAL1
N00329 R0500.0 Y0016.2

XFRMR_OT DO_131_X
MP_SEAL1 FMR_OTF1
N00330 R0500.1 Y0016.1

SRVO_MTR DO_130_S
_OTSEAL1 GM_OTF1
N00331 R0500.0 K0005.0 R0220.6 R0500.1 D0004.1

XFRMR_OT PULLED_T DI_958_P SRVO_MTR REMSTROK
MP_SEAL1 IP_BYPS1 LDTIP_1 _OTSEAL1 EOK1
Y0048.3 Y0048.2
H
DO_388_N DO_387_W
UTFD_APP LD2_APP
Y0048.2 Y0050.5
I
DO_387_W DO_406_N
LD2_APP TFD_2APP
N00332 R0501.0 K0006.5 R0220.7 R0501.1 D0004.2

J 1985 REMOTE NO STROKE OK WC2
XFRMR_OT PULLED_T DI_959_P SRVOMTR_ REMSTROK
MP_SEAL2 IP_BYPS2 LDTIP_2 OT_SEAL2 EOK2
Y0050.5
K
DO_406_N
TFD_2APP
Y0048.2
L
DO_387_W
LD2_APP
Y0048.1 Y0048.3 Y0048.2 Y0050.5

M
DO_386__ DO_388_N DO_387_W DO_406_N
WLD1_APP UTFD_APP LD2_APP TFD_2APP
N00333 D0004.1 D0004.2 R0221.1

REMSTROK REMSTROK DI_961_R
EOK1 EOK2 EM_STRK
N00334
O 2000 SUB72
SPE
N00335 ### UALM ###

A 2001 SUB71 P0006
SP UALM
N00336 Y0120.2 X1025.1 Y0120.2

DO_963__ FAULT___ DO_963__
PRG_FLT RESET PRG_FLT
N00337 Y0120.2 G1008.0

DO_963__ UALM1
PRG_FLT
N00338 X0083.2 G1008.1

DI_667_M UALM2
AINT_REQ
N00339 X0083.2 X0087.0 G1008.2

DI_667_M DI_697_T UALM_3
AINT_REQ PCHNGRQ
X0091.2 X0087.1
F
DI_731_M DI_698_T
ANT_REQ2 PCHNGRQW
N00340 X0014.1 G1008.7

DI_114_R UALM_8
STW_TMR
N00341 Y0021.2 G1009.0

DO_171_T UALM_9
PCHG_RQ2
N00342 X0083.3 G1009.1

DI_668_W UALM_10
ELD_FLT1
N00343 X0091.3 G1009.2

DI_732_W UALM_11
ELD_FLT2
N00344 Y0039.3 G1009.7

DO_316_W UALM_16
RNGTLSTD
N00345 X0001.6 G1010.3

DI_15_SY UALM_20
S_WTR_ON
N00346 Y0014.7 G1010.4

DO_120_T UALM_21
DMFL_BY1
N00347 Y0014.6 G1010.5

DO_119_T UALM_22
DM_FLT_1
N00348 K0010.0 Y0119.7 Y0000.3 G1010.6

TEACH___ DO_960__ DO_4_RBT UALM23
MEMORY AUTO_KEY _IN_TCH
N00349 R0220.6 G1010.7

DI_958_P UALM_24
LDTIP_1
N00350 R0000.0 G1011.0

ALWAYS__ UALM_25
ON
N00351 K0004.5 G1011.1

EQUALENB UALM_26
L_1_2_SS
N00352 Y0120.6 G1011.2

DO_967_M UALM_27
AN_WELD1
X0015.0
E
DI_121_R
M_MAN_W1
N00353 Y0017.2 G1011.3

DO_139_T UALM_28
PCHG_RQ1
N00354 Y0002.7 G1011.4

DO_24_RB UALM_29
T_LOOP
N00355 X1020.1 G1011.5

RI_2_SRV UALM_30
OMTR_OT1
N00356 X1020.0 G1011.6

RI_1__XF UALM_31
RMR_OT1
N00357 X0087.6 G1011.7

DI_703_W UALM_32
1_COMMOK
N00358
K 2055 SUB72
SPE

L 2056 SUB71 P0007
SP INTERFACE
O
N00360 D0612.1 ACT D0612.0

MH_IF_PB TMR IF_PB_TO
_TO
D0612.2
B
SEAL_IF_
PB_TO
D0612.3
C
STUD_IF_
PB_TO
D0612.4
D
SWG1_IF_
PB_TO
D0612.5
E
SWG2_IF_
PB_TO
O
N00361 K0002.0 D0612.1

A 2066 MH IF PB TO
CLMP1CLS MH_IF_PB
_TO
K0002.1
B
CLMP1OPN
K0002.2
C
CLMP2CLS
K0002.3
D
CLMP2OPN
K0002.4
E
CLMP3CLS
K0002.5
F
CLMP3OPN
K0002.6
G
CLMP4CLS
K0002.7
H
CLMP4OPN
K0003.0
I
CLMP5CLS
K0003.1
J
CLMP5OPN
K0003.2
K
CLMP6CLS
K0003.3
L
CLMP6OPN
K0003.4
M
CLMP7CLS
K0003.5
N
CLMP7OPN
K0003.6
O
CLMP8CLS
K0003.7
A
CLMP8OPN
K0004.0
B
CLMP9CLS
K0004.1
C
CLMP9OPN
K0004.2
D
CLP10CLS
K0004.3
E
CLP10OPN
K0014.2
F
VAC_1_ON
_PB
K0014.3
G
VAC_2_ON
_PB
K0014.4
H
VAC_3_ON
_PB
K0014.5
I
BLOWOFF_
1_ON_PB
K0014.6
J
BLOWOFF_
2_ON_PB
K0014.7
K
BLOWOFF_
3_ON_PB
K0000.4
L
RERUNPRC
PB
K0000.5
M
ACCPTPRC
PB
K0000.6
N
REJCTPRC
PB
K0000.7
O
INSPCTSE
LPB
K0011.4
A
TC_OPENG
UNCOVER
K0011.5
B
TC__CLOS
GUNCOVER
K0016.1
C
VAC_4_ON
_PB
K0016.2
D
BLOWOFF_
4_ON_PB
O
N00362 Y0121.0 D0612.4

DO_969_F SWG1_IF_
EDWLD1PB PB_TO
Y0120.6
B
DO_967_M
AN_WELD1
Y0083.3
C
DO_668_R
ST_WLD
K0005.1
D
NEW_TIP_
PB1
K0008.6
E
DTSR_PB_
1
K0005.2
F
INIT_AUT
O_TD_PB1
K0005.5
G
TIP_ALGN
_CLS_PB1
K0005.6
H
TIP_ALGN
_OPN_PB1
K0005.7
I
INITAUTO
TCPB1
K0006.0
J
ATC_FLT_
ACK_PB1
K0015.1
K
ADVTIPDR
SSDUMP1
K0015.2
L
RETTIPDR
SSDUMP1
O
N00363 Y0121.1 D0612.5

DO_970_F SWG2_IF_
EDWLD2PB PB_TO
Y0120.7
B
DO_968_M
AN_WELD2
Y0091.3
C
DO_732_R
ST_WLD2
K0006.6
D
NEW_TIP_
PB2
K0009.2
E
DTSR_PB_
2
K0006.7
F
INIT_AUT
O_TD_PB2
K0007.2
G
TIP_ALGN
_CLS_PB2
K0007.3
H
TIP_ALGN
_OPN_PB2
K0007.4
I
INITAUTO
TCPB2
K0007.5
J
ATC_FLT_
ACK_PB2
K0015.3
K
ADVTIPDR
SSDUMP2
K0015.4
L
RETTIPDR
SSDUMP2
N00364
M 2127 SUB72
SPE
N00365 ### MH ###

N 2128 SUB71 P0008
SP MH
N00366 Y0000.3 K0004.4 R1410.0

DO_4_RBT MAN_GRP_ MAN_GRP_
_IN_TCH ENBLE_SS ENABLE
N00367 R1410.0 ACT

A 2133 SUB10 0000
MAN_GRP_ JMP
ENABLE
N00368 R0000.0 Y0114.0

B 2136 OPEN CLAMP 1
ALWAYS__ DO_913__
ON OPNCLMP1
N00369 R0000.0 Y0114.1

ALWAYS__ DO_914__
ON CLSCLMP1
N00370 R0000.0 Y0114.2

D 2140 OPEN CLAMP 2
ALWAYS__ DO_915__
ON OPNCLMP2
N00371 R0000.0 Y0114.3

ALWAYS__ DO_916__
ON CLSCLMP2
N00372 R0000.0 Y0114.4

F 2144 OPEN CLAMP 3
ALWAYS__ DO_917__
ON OPNCLMP3
N00373 R0000.0 Y0114.5

ALWAYS__ DO_918__
ON CLSCLMP3
N00374 R0000.0 Y0114.6

H 2148 OPEN CLAMP 4
ALWAYS__ DO_919__
ON OPNCLMP4
N00375 R0000.0 Y0114.7

ALWAYS__ DO_920__
ON CLSCLMP4
N00376 R0000.0 Y0115.0

J 2152 OPEN CLAMP 5
ALWAYS__ DO_921__
ON OPNCLMP5
N00377 R0000.0 Y0115.1

ALWAYS__ DO_922__
ON CLSCLMP5
N00378 R0000.0 Y0115.2

L 2156 OPEN CLAMP 6
ALWAYS__ DO_923__
ON OPNCLMP6
N00379 R0000.0 Y0115.3

ALWAYS__ DO_924__
ON CLSCLMP6
N00380 R0000.0 Y0115.4

N 2160 OPEN CLAMP 7
ALWAYS__ DO_925__
ON OPNCLMP7
N00381 R0000.0 Y0115.5

ALWAYS__ DO_926__
ON CLSCLMP7
N00382 R0000.0 Y0115.6

A 2164 OPEN CLAMP 8
ALWAYS__ DO_927__
ON OPNCLMP8
N00383 R0000.0 Y0115.7

ALWAYS__ DO_928__
ON CLSCLMP8
N00384 R0000.0 Y0116.0

C 2168 OPEN CLAMP 9
ALWAYS__ DO_929__
ON OPNCLMP9
N00385 R0000.0 Y0116.1

ALWAYS__ DO_930__
ON CLSCLMP9
N00386 R0000.0 Y0116.2

ALWAYS__ DO_931__
ON OPNCLP10
N00387 R0000.0 Y0116.3

ALWAYS__ DO_932__
ON CLSCLP10
N00388 R0000.0 Y0127.2

G 2176 VACUUM 1 ON
ALWAYS__ DO1019_V
ON AC1ON
N00389 R0000.0 Y0127.3

H 2178 BLOWOFF 1 ON
ALWAYS__ DO1020_B
ON LWOF1ON
N00390 R0000.0 Y0127.4

I 2180 VACUUM 2 ON
ALWAYS__ DO1021_V
ON AC2ON
N00391 R0000.0 Y0127.5

J 2182 BLOWOFF 2 ON
ALWAYS__ DO1022_B
ON LWOF2ON
N00392 R0000.0 Y0127.6

K 2184 VACUUM 3 ON
ALWAYS__ DO1023_V
ON AC3ON
N00393 R0000.0 Y0127.7

L 2186 BLOWOFF 3 ON
ALWAYS__ DO1024_B
ON LWOF3ON
N00394 R0000.0 Y0118.5

M 2188 VACUUM 4 ON
ALWAYS__ DO_950_V
ON AC4ON
N00395 R0000.0 Y0118.6

N 2190 BLOWOFF 4 ON
ALWAYS__ DO_951_B
ON LWOF4ON
N00396
O 2192 SUB30
JMPE
N00397 R1410.0 ACT R0001.1

A 2193 SUB 3 0038
MAN_GRP_ TMR MAN_GRP_
ENABLE TO
N00398 R0001.1 ACT

B 2197 SUB10 0000
MAN_GRP_ JMP
TO
N00399 K0002.1 X1026.1 Y0114.0

C 2200 OPEN CLAMP 1
CLMP1OPN SI9_____ DO_913__
AUTOMDSW OPNCLMP1
N00400 Y0114.0 Y0009.0

DO_913__ DO_73_OP
OPNCLMP1 N_CLMP1
N00401 K0002.0 X1026.1 Y0114.1

CLMP1CLS SI9_____ DO_914__
AUTOMDSW CLSCLMP1
N00402 Y0114.1 Y0009.1

DO_914__ DO_74_CL
CLSCLMP1 S_CLMP1
N00403 K0002.3 X1026.1 Y0114.2

G 2210 OPEN CLAMP 2
AUTOMDSW OPNCLMP2
N00404 Y0114.2 Y0009.2

DO_915__ DO_75_OP
OPNCLMP2 N_CLMP2
N00405 K0002.2 X1026.1 Y0114.3

AUTOMDSW CLSCLMP2
N00406 Y0114.3 Y0009.3

DO_916__ DO_76_CL
CLSCLMP2 S_CLMP2
N00407 K0002.5 X1026.1 Y0114.4

K 2220 OPEN CLAMP 3
AUTOMDSW OPNCLMP3
N00408 Y0114.4 Y0009.4

DO_917__ DO_77_OP
OPNCLMP3 N_CLMP_3
N00409 K0002.4 X1026.1 Y0114.5

AUTOMDSW CLSCLMP3
N00410 Y0114.5 Y0009.5

DO_918__ DO_78_CL
CLSCLMP3 S_CLMP3
N00411 K0002.7 X1026.1 Y0114.6

O 2230 OPEN CLAMP 4
AUTOMDSW OPNCLMP4
N00412 Y0114.6 Y0009.6

DO_919__ DO_79_OP
OPNCLMP4 N_CLMP4
N00413 K0002.6 X1026.1 Y0114.7

AUTOMDSW CLSCLMP4
N00414 Y0114.7 Y0009.7

DO_920__ DO_80_CL
CLSCLMP4 S_CLMP4
N00415 K0003.1 X1026.1 Y0115.0

D 2240 OPEN CLAMP 5
AUTOMDSW OPNCLMP5
N00416 Y0115.0 Y0010.0

DO_921__ DO_81_OP
OPNCLMP5 N_CLMP5
N00417 K0003.0 X1026.1 Y0115.1

AUTOMDSW CLSCLMP5
N00418 Y0115.1 Y0010.1

DO_922__ DO_82_CL
CLSCLMP5 S_CLMP5
N00419 K0003.3 X1026.1 Y0115.2

H 2250 OPEN CLAMP 6
AUTOMDSW OPNCLMP6
N00420 Y0115.2 Y0010.2

DO_923__ DO_83_OP
OPNCLMP6 N_CLMP6
N00421 K0003.2 X1026.1 Y0115.3

AUTOMDSW CLSCLMP6
N00422 Y0115.3 Y0010.3

DO_924__ DO_84_CL
CLSCLMP6 S_CLMP_6
N00423 K0003.5 X1026.1 Y0115.4

L 2260 OPEN CLAMP 7
AUTOMDSW OPNCLMP7
N00424 Y0115.4 Y0010.4

DO_925__ DO_85_OP
OPNCLMP7 N_CLMP_7
N00425 K0003.4 X1026.1 Y0115.5

AUTOMDSW CLSCLMP7
N00426 Y0115.5 Y0010.5

DO_926__ DO_86_CL
CLSCLMP7 S_CLAMP7
N00427 K0003.7 X1026.1 Y0115.6

A 2270 OPEN CLAMP 8
AUTOMDSW OPNCLMP8
N00428 Y0115.6 Y0010.6

DO_927__ DO_87_OP
OPNCLMP8 N_CLMP8
N00429 K0003.6 X1026.1 Y0115.7

AUTOMDSW CLSCLMP8
N00430 Y0115.7 Y0010.7

DO_928__ DO_88_CL
CLSCLMP8 S_CLAMP8
N00431 K0004.1 X1026.1 Y0116.0

E 2280 OPEN CLAMP 9
AUTOMDSW OPNCLMP9
N00432 Y0116.0 Y0011.0

DO_929__ DO_89_OP
OPNCLMP9 N_CLMP9
N00433 K0004.0 X1026.1 Y0116.1

AUTOMDSW CLSCLMP9
N00434 Y0116.1 Y0011.1

DO_930__ DO_90_CL
CLSCLMP9 S_CLMP9
N00435 K0004.3 X1026.1 Y0116.2

CLP10OPN SI9_____ DO_931__
AUTOMDSW OPNCLP10
N00436 Y0116.2 Y0011.2

DO_931__ DO_91_OP
OPNCLP10 N_CLMP10
N00437 K0004.2 X1026.1 Y0116.3

CLP10CLS SI9_____ DO_932__
AUTOMDSW CLSCLP10
N00438 Y0116.3 Y0011.3

DO_932__ DO_92_CL
CLSCLP10 S_CLMP10
N00439 K0014.2 X1026.1 K0014.1 Y0127.2

M 2300 VACUUM 1 ON
VAC_1_ON SI9_____ VAC/BLOW DO1019_V
_PB AUTOMDSW OFFTIMER AC1ON
N00440 Y0127.2 Y0008.0

N 2304
DO1019_V DO_65_VA
AC1ON C_1_ON
N00441 K0014.5 X1026.1 K0014.1 Y0127.3

O 2306 BLOWOFF 1 ON
BLOWOFF_ SI9_____ VAC/BLOW DO1020_B
1_ON_PB AUTOMDSW OFFTIMER LWOF1ON
N00442 Y0127.3 Y0008.1

A 2310
DO1020_B DO_66_BL
LWOF1ON WOFF1ON
N00443 K0014.3 X1026.1 K0014.1 Y0127.4

B 2312 VACUUM 2 ON
N00444 Y0127.4 Y0008.2

C 2316
DO1021_V DO_67_VA
AC2ON C_2_ON
N00445 K0014.6 X1026.1 K0014.1 Y0127.5

D 2318 BLOWOFF 2 ON
N00446 Y0127.5 Y0008.3

E 2322
DO1022_B DO_68_BL
LWOF2ON WOFF2ON
N00447 K0014.4 X1026.1 K0014.1 Y0127.6

F 2324 VACUUM 3 ON
N00448 Y0127.6 Y0008.4

G 2328
DO1023_V DO_69_VA
AC3ON C_3_ON
N00449 K0014.7 X1026.1 K0014.1 Y0127.7

H 2330 BLOWOFF 3 ON
N00450 Y0127.7 Y0008.5

I 2334
DO1024_B DO_70_BL
LWOF3ON WOFF3ON
N00451 K0016.1 X1026.1 K0014.1 Y0118.5

J 2336 VACUUM 4 ON
VAC_4_ON SI9_____ VAC/BLOW DO_950_V
N00452 Y0118.5 Y0008.6

K 2340
DO_950_V DO_71_VA
AC4ON C_4_ON
N00453 K0016.2 X1026.1 K0014.1 Y0118.6

L 2342 BLOWOFF 4 ON
BLOWOFF_ SI9_____ VAC/BLOW DO_951_B
N00454 Y0118.6 Y0008.7

M 2346
DO_951_B DO_72_BL
LWOF4ON WOFF4ON
N00455
N 2348 SUB30
JMPE
O
N00456 Y0008.0 ACT K0014.1

DO_65_VA TMR VAC/BLOW
C_1_ON OFFTIMER
Y0008.1
B
DO_66_BL
WOFF1ON
Y0008.2
C
DO_67_VA
C_2_ON
Y0008.3
D
DO_68_BL
WOFF2ON
Y0008.4
E
DO_69_VA
C_3_ON
Y0008.5
F
DO_70_BL
WOFF3ON
Y0008.6
G
DO_71_VA
C_4_ON
Y0008.7
H
DO_72_BL
WOFF4ON
N00457 K0002.0 D0612.0 K0002.0

I 2360 CLMP1 CLOSE
CLMP1CLS IF_PB_TO CLMP1CLS
N00458 K0002.1 D0612.0 K0002.1

J 2363 CLMP1 OPEN
CLMP1OPN IF_PB_TO CLMP1OPN
N00459 K0002.2 D0612.0 K0002.2

K 2366 CLMP2 CLOSE
N00460 K0002.3 D0612.0 K0002.3

L 2369 CLMP2 OPEN
N00461 K0002.4 D0612.0 K0002.4

M 2372 CLMP3 CLOSE
N00462 K0002.5 D0612.0 K0002.5

N 2375 CLMP3 OPEN
N00463 K0002.6 D0612.0 K0002.6

O 2378 CLMP4 CLOSE
N00464 K0002.7 D0612.0 K0002.7

A 2381 CLMP4 OPEN
N00465 K0003.0 D0612.0 K0003.0

B 2384 CLMP5 CLOSE
N00466 K0003.1 D0612.0 K0003.1

C 2387 CLMP5 OPEN
N00467 K0003.2 D0612.0 K0003.2

D 2390 CLMP6 CLOSE
N00468 K0003.3 D0612.0 K0003.3

E 2393 CLMP6 OPEN
N00469 K0003.4 D0612.0 K0003.4

F 2396 CLMP7 CLOSE
N00470 K0003.5 D0612.0 K0003.5

G 2399 CLMP7 OPEN
N00471 K0003.6 D0612.0 K0003.6

H 2402 CLMP8 CLOSE
N00472 K0003.7 D0612.0 K0003.7

I 2405 CLMP8 OPEN
N00473 K0004.0 D0612.0 K0004.0

J 2408 CLMP9 CLOSE
N00474 K0004.1 D0612.0 K0004.1

K 2411 CLMP9 OPEN
N00475 K0004.2 D0612.0 K0004.2

L 2414 CLMP10 CLOSE
CLP10CLS IF_PB_TO CLP10CLS
N00476 K0004.3 D0612.0 K0004.3

M 2417 CLMP10 OPEN
CLP10OPN IF_PB_TO CLP10OPN
N00477 K0014.2 D0612.0 K0014.2

N 2420
VAC_1_ON IF_PB_TO VAC_1_ON
_PB _PB
N00478 K0014.3 D0612.0 K0014.3

O 2423
_PB _PB
N00479 K0014.4 D0612.0 K0014.4

A 2426
_PB _PB
N00480 K0016.1 D0612.0 K0016.1

B 2429
_PB _PB
N00481 K0014.5 D0612.0 K0014.5

C 2432
BLOWOFF_ IF_PB_TO BLOWOFF_
1_ON_PB 1_ON_PB
N00482 K0014.6 D0612.0 K0014.6

D 2435
2_ON_PB 2_ON_PB
N00483 K0014.7 D0612.0 K0014.7

E 2438
3_ON_PB 3_ON_PB
N00484 K0016.2 D0612.0 K0016.2

F 2441
4_ON_PB 4_ON_PB
N00485 K0000.4 Y0012.6

RERUNPRC DO_103_R
PB ERUNPRC
N00486 K0000.5 Y0012.7

ACCPTPRC DO_104_A
PB CCPTPRC
N00487 K0000.6 Y0013.0

REJCTPRC DO_105_R
PB EJCTPRC
N00488 K0000.7 Y0013.1

INSPCTSE DO_106_I
LPB NSP_SEL
K0001.3 K0001.5
K
VISIONIN ABORTPRO
TERVENSS CESS
N00489 K0000.4 D0612.0 K0000.4

RERUNPRC IF_PB_TO RERUNPRC
PB PB
N00490 K0000.4 D0612.0 K0000.4

PB PB
N00491 K0000.5 D0612.0 K0000.5

ACCPTPRC IF_PB_TO ACCPTPRC
PB PB
N00492 K0000.5 D0612.0 K0000.5

PB PB
N00493 K0000.6 D0612.0 K0000.6

REJCTPRC IF_PB_TO REJCTPRC
PB PB
N00494 K0000.6 D0612.0 K0000.6

PB PB
N00495 K0000.7 D0612.0 K0000.7

INSPCTSE IF_PB_TO INSPCTSE
LPB LPB
N00496 K0000.7 D0612.0 K0000.7

LPB LPB
N00497 K0011.4 D0612.0 K0011.4

TC_OPENG IF_PB_TO TC_OPENG
UNCOVER UNCOVER
N00498 K0011.5 D0612.0 K0011.5

TC__CLOS IF_PB_TO TC__CLOS
GUNCOVER GUNCOVER
N00499 X0008.2 R0000.7

DI_67_PR PART_PRE
T_PRES1 SENT
X0008.3
H
DI_68_PR
T_PRES2
X0008.4
I
DI_69_PR
T_PRES3
X0008.5
J
DI_70_PR
T_PRES4
X0008.6
K
DI_71_PR
T_PRES5
X0008.7
L
DI_72_PR
T_PRES6
N00500
M 2492 SUB72
SPE

N 2493 SUB71 P0009
SP APPLICATION
N00502 D0000.0 Y0048.0

MH_APP DO_385_M
H_APP
N00503 D0000.1 Y0048.1

WELD_1_A DO_386__
PP WLD1_APP
N00504 D0000.2 Y0048.2

WELD_2_A DO_387_W
PP LD2_APP
N00505 D0000.3 Y0048.3

NUT_FEED DO_388_N
_APP UTFD_APP
N00506 D0000.4 Y0048.4

SEAL_1_A DO_389_S
PP LR_1_APP
N00507 D0000.5 Y0048.5

SEAL_2__ DO_390_S
APP LR_2_APP
N00508 D0000.6 Y0048.6

STUD_1_A DO_391_S
PP TDW_1APP
N00509 D0000.7 Y0048.7

STUD_2_A DO_392_S
PP TDW_2APP
N00510 D0001.0 Y0049.0

TOOL_CHA DO_393_T
NGE_APP C_APP
N00511 D0001.1 Y0049.1

RIVET_1_ DO_394_R
APP VT_1_APP
N00512 D0001.2 Y0049.2

RIVET_2_ DO_395_R
APP VT_2_APP
N00513 D0001.3 Y0049.3

NUT_RUNN DO_396_N
ER_APP UTR_APP
N00514 D0001.4 Y0049.4

MIG_WELD DO_397_M
_APP IGW_APP
N00515 D0001.5 Y0049.5

ROLLER_H DO_398_R
EMM_APP LLHEM_AP
N00516 D0001.6 Y0049.6

LASER_CU DO_399_L
T_APP SRCT_APP
N00517 D0001.7 Y0049.7

PLASMA_C DO_400_P
UT_APP LSMA_APP
N00518 D0002.0 Y0050.0

LASER_WE DO_401_L
LD_APP SRWLDAPP
N00519 D0002.1 Y0050.1

OPER_LOA DO_402_O
D_APP P_LD_APP
N00520 D0002.2 Y0050.2

VISION_A DO_403_V
PP IS_APP
N00521 D0002.3 Y0050.3

PROG_LOC DO_404_P
_APP RG_LCAPP
N00522 D0002.4 Y0050.4

IF_DEF__ DO_405__
21 INDEFB21
N00523 D0002.5 Y0050.5

NUT_FEED DO_406_N
ER_2_APP TFD_2APP
N00524 D0002.6 Y0050.6

IF_DEF__ DO_407_I
23 NDEF_B23
N00525 D0002.7 Y0050.7

H 2541 INTERFACE DEFINITION BIT 24
IF_DEF__ DO_408_I
24 NDEF_B24
N00526 D0003.0 Y0051.0

IF_DEF__ DO_409_I
25 NDEF_B25
N00527 D0003.1 Y0051.1

IF_DEF__ DO_410_I
26 NDEF_B26
N00528 D0003.2 Y0051.2

IF_DEF__ DO_411_I
27 NDEF_B27
N00529 D0003.3 Y0051.3

IF_DEF__ DO_412_I
28 NDEF_B28
N00530 D0003.4 Y0051.4

IF_DEF__ DO_413_I
29 NDEF_B29
N00531 D0003.5 Y0051.5

IF_DEF__ DO_414_I
30 NDEF_B30
N00532 D0003.6 Y0051.6

IF_DEF__ DO_415_I
31 NDEF_B31
N00533 D0003.7 Y0051.7

IF_DEF__ DO_416_I
32 NDEF_B32
N00534
B 2559 SUB72
SPE

C 2560 SUB71 P0015
SP WELDCONTROL2
N00536 X0000.0 Y0091.0

DI_1_EXT DO_729_W
_RNENBL C2_ENBL
N00537 X0095.6 Y0018.4

DI_767_W DO_149_W
2_COMMOK C2COM_OK
N00538 Y0000.3 Y0091.1

DO_4_RBT DO_730_R
_IN_TCH BTCH_WC2
N00539 X0094.1 Y0019.6

DI_754_I DO_159_I
-HI/LO_2 AVL_WRN2
N00540 X0095.5 Y0021.3

H 2570
DI_766_A DO_172_A
DP_MODE2 DPMODEN2
N00541 X0091.0 Y0019.3

DI_729_I DO_156_I
NWLDCYC2 NWD_CY_2
N00542 X0091.1 Y0019.4

DI_730_W DO_157_H
ELD_CMP2 AS_WLD_2
N00543 X0091.3 Y0018.3

DI_732_W DO_148_N
ELD_FLT2 OWLDFLT2
N00544 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

L 2578
DO_743__ DO_744__ DO_745__ DO_746__ DO_747__ DO_748__ DO_749__
BP2_1 BP2_2 BP2_4 BP2_8 BP2_16 BP2_32 BP2_64
1 Y0093.5 R0306.1
DO_750__ ROBOT_WS
BP2_128 _WC#2
N00545 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

N 2587
DO_743__ DO_744__ DO_745__ DO_746__ DO_747__ DO_748__ DO_749__
BP2_1 BP2_2 BP2_4 BP2_8 BP2_16 BP2_32 BP2_64
1 Y0093.5 R0362.0
O
DO_750__ WLD_SCH_
BP2_128 39_WC2
N00546 Y0018.1 Y0018.2 Y0091.4

DO_146_W DO_147_W DO_733_W
N00547 X1020.5 X1020.3 X1020.4 D0004.5

N00548 Y0111.1 D0004.5 K0000.0 ACT R0364.0

BP1_2 WC2 MER2
Y0111.2
D
DO_891__
BP2_2
Y0111.3
E
DO_892__
BP4_2
Y0111.4
F
DO_893__
BP8_2
Y0111.5
G
DO_894__
BP16_2
Y0111.6
H
DO_895__
BP32_2
Y0111.7
I
DO_896__
BP64_2
Y0112.0
J
DO_897__
BP128_2
N00549 Y0111.1 D0004.5 R0364.0 Y0092.6

BP1_2 WC2 MER2 BP2_1
N00550 Y0111.2 D0004.5 R0364.0 Y0092.7

N00551 Y0111.3 D0004.5 R0364.0 Y0093.0

N00552 Y0111.4 D0004.5 R0364.0 Y0093.1

N00553 Y0111.5 D0004.5 R0364.0 Y0093.2

N00554 Y0111.6 D0004.5 R0364.0 Y0093.3

N00555 Y0111.7 D0004.5 R0364.0 Y0093.4

N00556 Y0112.0 D0004.5 R0364.0 Y0093.5

BP128_2 WC2 MER2 BP2_128
N00557 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

D 2648
DO_743__ DO_744__ DO_745__ DO_746__ DO_747__ DO_748__ DO_749__
BP2_1 BP2_2 BP2_4 BP2_8 BP2_16 BP2_32 BP2_64
1 Y0093.5 R0361.0
DO_750__ NOWLDSCH
BP2_128 WC2
N00558 R0361.0 X0095.6 K0000.0 Y0091.5

K0000.0 Y0116.6
G
DEBUG DO_935__
RD_SCHD2
N00559 Y0120.7 F1000.3 Y0000.1 R0223.1

H 2664
X0019.0 K0008.0 Y0000.5 F1000.3 F1000.2

I
Y0000.1 F1000.2 F1000.3

J
_@_HOME RUNNING
N00560 Y0120.7 Y0000.1 F1000.2 F1000.3 R0213.7

X0019.0 K0008.0
L
DI_153_R AUTO/MAI
M_MAN_W2 NT_SS
N00561 Y0050.5 Y0121.1 F1000.3 Y0000.1 R0220.5

TFD_2APP EDWLD2PB _@_HOME EFEDWLD2
N00562 K0009.2 D0612.0 K0009.2

2 2
N00563 K0009.2 D0612.0 K0009.2

2 2
N00564 K0006.6 D0612.0 K0006.6

PB2 PB2
N00565 K0006.6 D0612.0 K0006.6

PB2 PB2
N00566 K0006.7 D0612.0 K0006.7

O_TD_PB2 O_TD_PB2
N00567 K0006.7 D0612.0 K0006.7

O_TD_PB2 O_TD_PB2
N00568 K0007.2 D0612.0 K0007.2

_CLS_PB2 _CLS_PB2
N00569 K0007.2 D0612.0 K0007.2

_CLS_PB2 _CLS_PB2
N00570 K0007.3 D0612.0 K0007.3

_OPN_PB2 _OPN_PB2
N00571 K0007.3 D0612.0 K0007.3

_OPN_PB2 _OPN_PB2
N00572 K0007.4 D0612.0 K0007.4

TCPB2 TCPB2
N00573 K0007.4 D0612.0 K0007.4

TCPB2 TCPB2
N00574 K0007.5 D0612.0 K0007.5

ACK_PB2 ACK_PB2
N00575 K0007.5 D0612.0 K0007.5

ACK_PB2 ACK_PB2
N00576 Y0120.7 D0612.0 Y0120.7

AN_WELD2 AN_WELD2
N00577 Y0120.7 D0612.0 Y0120.7

AN_WELD2 AN_WELD2
N00578 Y0121.1 D0612.0 Y0121.1

EDWLD2PB EDWLD2PB
N00579 Y0121.1 D0612.0 Y0121.1

EDWLD2PB EDWLD2PB
N00580 Y1020.1 Y1020.1

RO__2___ RO__2___
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
C
EQUALENB EQUALIZE
L_1_2_SS R_2_SS
N00581 Y1020.1 Y1020.1

RO__2___ RO__2___
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
E
EQUALENB EQUALIZE
L_1_2_SS R_2_SS
N00582 K0004.5 K0007.7

EQUALENB EQUALIZE
L_1_2_SS R_2_SS
N00583 K0000.0 Y0091.3 D0612.0 X1025.1 Y0091.3

ST_WLD2 RESET ST_WLD2
X1025.1
H
FAULT___
RESET
N00584 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00585 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00586 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00587 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00588 K0015.3 Y0000.2 X1026.1 K0015.4 Y0021.5

M 2777
N00589 K0015.4 Y0000.2 X1026.1 K0015.3 Y0021.6

N 2782
O
N00590 Y0120.7 K0014.0 D0610.2

X0019.0 K0008.0 K0014.0

B
M_MAN_W2 NT_SS NB2
N00591 D0610.2 ACT D0610.2

DETIMR2 DETIMR2
N00592 X0054.5 Y0095.1

DI_438_C DO_762_C
CWELDMOD CWELDMD2
D0610.2
E
CCWELDMO
DETIMR2
N00593
F 2801 SUB72
SPE

G 2802 SUB71 P0016
SP TIPDRESSER2
N00595 X0095.1 Y0021.2

DI_762_T DO_171_T
PCHNGRQ2 PCHG_RQ2
X0095.0
I
DI_761_T
PCNGREQ2
Y0112.1
J
DO_898_T
PWRMOV2
Y0112.2
K
DO_899_T
PWRFIX2
N00596 K0007.2 Y0000.5 R0222.4

N00597 K0007.3 Y0000.5 R0222.5

N00598 X0091.4 Y0020.3

DI_733_N DO_164_N
EW_TIP2 WTP_RST2
O
N00599 R0346.0 Y0092.5 X0001.2 K0008.0 R0346.0

___2 TSR2 PLC_AUTO NT_SS ___2
Y0119.1 K0006.7
B
DO_954_C INIT_AUT
LRAV_XFR O_TD_PB2
N00600 R0335.0 Y0109.1 Y0000.5 X0091.1 R0332.0

R0332.0
D
TD_MEM_W
C_#2
N00601 X0091.4 K0008.0 Y0000.5 X0018.7 R0332.0 R0335.0

EW_TIP2 NT_SS _@_MAINT D_BYPSS2 C_#2 P_TC2
R0335.0
F
DRESS_CA
P_TC2
N00602 X0091.2 Y0019.0

DI_731_M DO_153_A
ANT_REQ2 UTO_TD_2
R0335.0 Y0050.5
H
DRESS_CA DO_406_N
P_TC2 TFD_2APP
R0346.0
I
TIP_MEM_
___2
N00603 Y0093.7 Y0119.1 R0352.0

DO_752_T DO_954_C PULLDTIP
IP_WTR2 LRAV_XFR _SEAL_2
N00604 R0352.0 ACT D0613.0

_SEAL_2 P_TIMER2
N00605 Y0018.5 X0001.2 Y0109.1

DO_150_D DI_11___ DO_874_T
K0007.0 Y0000.3
M
TEACH_TD DO_4_RBT
_ENABLE2 _IN_TCH
N00606 R0000.0 Y0018.5 X0001.2 Y0094.6

ON RSR_ON_2 PLC_AUTO D_MTRON2
K0007.0 Y0000.3
O
TEACH_TD DO_4_RBT
_ENABLE2 _IN_TCH
N00607 X1020.5 X0000.0 X0013.6 R0220.7

RI_6_WTR DI_1_EXT DI 111 A DI_959_P
_FL_SW2 _RNENBL UTOTIPCH LDTIP_2
R0220.7 D0613.0
B
DI_959_P PULLEDTI
LDTIP_2 P_TIMER2
N00608 K0006.3 Y0018.7

TD_MTR_F DO_152_T
LT_BYPS2 DMFL_BY2
N00609 D0608.0 R0410.0 R0413.0

D 2875 TD FAULT2
1TIM2 TOK2
N00610 Y0018.5 X0094.2 Y0108.2 K0006.3 Y0091.3 R0410.0

RSR_ON_2 IP_DR_OK RVTDOK2 LT_BYPS2 ST_WLD2 TOK2
R0410.0
F
TDCURREN
TOK2
N00611 R0413.0 ACT D0609.0

2TIM2
N00612 Y0018.5 ACT D0608.0

RSR_ON_2 1TIM2
N00613 Y0091.3 R0410.0 D0609.0 R0416.0

ST_WLD2 TOK2 2TIM2 2
R0406.0
J
TPRESFLT
2
R0416.0
K
TDMTRFLT
2
N00614 R0416.0 Y0018.6

TDMTRFLT DO_151_T
2 DM_FLT_2
N00615 Y0118.2 ACT D0607.0

ESCHKMD2 TIM2
N00616 D0607.0 R0407.0 R0406.0

TIM2 LAT2 2
O
N00617 Y0118.2 X0094.3 K0007.1 Y0091.3 R0407.0

ESCHKMD2 PDRRSOK2 ST_BYPS2 ST_WLD2 LAT2
R0407.0
B
TPRESFLT
LAT2
N00618 X0018.4 Y0121.2 Y0113.7 F1000.5 R0221.7

DI_149_I DO_971_P DO_912_C FAULT DI_967_R
NITTPDR2 EDDMPAPP LR_ZN_13 NTDDMP2
X0018.6 X0091.2 Y0019.0 Y0121.7

D
DI_151_T DI_731_M DO_153_A DO_976__
D_DMP_R2 ANT_REQ2 UTO_TD_2 TPWRCMP2
N00619 K0009.1 K0009.1

NTSR_ENB NTSR_ENB
2SS 2SS
N00620 K0009.1 X1025.1 K0009.1

2SS RESET 2SS
K0009.1 X0091.4
G
NTSR_ENB DI_733_N
2SS EW_TIP2
N00621 K0015.7 K0015.7

DTSRENB2 DTSRENB2
SS SS
N00622 K0015.7 X1025.1 K0015.7

SS RESET SS
K0015.7 X0091.5
J
DTSRENB2 DI_734_D
SS RSSTIP2
N00623 K0009.1 K0006.6 Y0092.4

2SS PB2 TSR2
X0019.3
L
DI_156_N
EWTPRST2
N00624 K0015.7 K0009.2 Y0092.5

SS 2 TSR2
Y0117.0 Y0054.3
N DRSSTIPSTPRST2
DO_937__ DO_436_D
STP_RST2 TSR2
N00625
O 2950 SUB72
SPE

A 2951 SUB71 P0017
SP WATERVALVE2
N00627 X1020.5 X0001.6 Y0093.7

RI_6_WTR DI_15_SY DO_752_T
_FL_SW2 S_WTR_ON IP_WTR2
N00628 X0014.0 R0000.5 Y1020.5

Y1020.5 X1020.5
D
RO_6_WTR RI_6_WTR
_RESET2 _FL_SW2
X1025.1
E
FAULT___
RESET
N00629
F 2963 SUB72
SPE

G 2964 SUB71 P0018
SP OVRTMP/NOSTRK2
N00631 X1020.3 Y0094.4

RI_4__XF DO_757_X
RMR_OT2 FMR_OT2
N00632 X1020.4 Y0094.5

RI_5_SRV DO_758_S
OMTR_OT2 RVMTROT2
N00633 X1020.3 X1025.1 R0501.0

R0501.0
K
XFRMR_OT
MP_SEAL2
N00634 X1020.4 X1025.1 R0501.1

RI_5_SRV FAULT___ SRVOMTR_
OMTR_OT2 RESET OT_SEAL2
R0501.1
M
SRVOMTR_
OT_SEAL2
N00635 R0501.0 Y0020.2

XFRMR_OT DO_131_X
MP_SEAL2 FMR_OTF2
N00636 R0501.1 Y0020.1

SRVOMTR_ DO_162_S
OT_SEAL2 GM_OTF2
N00637
A 2982 SUB72
SPE
N00638 ### AIR ###

B 2983 SUB71 P0020
SP AIR
N00639 X1020.6 Y0001.5

RI_7_AIR DO_14_EO
_FL_SW A_AIR_ON
N00640
D 2987 SUB72
SPE
N00641 ### TOUCHUP1 ###

E 2988 SUB71 P0025
SP TOUCHUP1
N00642 K0000.1 Y0054.4

F 2990 PROGRAM TOUCHUP REQUEST
TOUCHUP1 DO_437_P
ENB RGTCHREQ
N00643
G 2992 SUB72
SPE
O
10 PMC Logic (S-Logic) SWGBolt + SWGNut for R-30iA
Controllers

Page 304 of 305
[FORD_NEXTGEN_ENETSafe_SWGBolt_SWGNut_2015_10_30]
Ladder Diagram 1
N00001 R0000.0 R0000.0

A 1 ALWAYS ON
ALWAYS ALWAYS
ON ON
R0000.0
B
ALWAYS
ON
N00002 R0000.0 G1000.0

ALWAYS NO IMSTP
ON
N00003 X0000.0 R0100.5 K0004.5 G1000.1

D 6 NO HOLD
DI 1 EXT BREAK A EQUALENB NO HOLD
RNENBL NO HOLD L 1&2 SS
N00004 X1026.4 R0100.5

SI12 HOL BREAK A
DSW NO HOLD
N00005 X1026.5 R0100.5

SI13 RES BREAK A
ETSW NO HOLD
X1026.4 X1025.6
G
SI12 HOL CYCLE
DSW START
X0000.1 X1026.4
H
DI 2 EX SI12 HOL
RNEN RST DSW
N00006 R0000.0 G1000.2

I 20 SAFE SPEED
ALWAYS SFSPD
ON
N00007 X1000.3 G1000.3

J 22
O
Ladder Diagram 2
N00008 X1025.1 G1000.4

A 24 FAULT RESET
FAULT RB FAULT
RESET RESET
X0000.1 X0001.2
B
DI 2 EX DI 11
RNEN RST PLC AUTO
X1026.5
C
SI13 RES
ETSW
X0000.3
D
DI 4 EXT
CY STRT
X0000.2
E
DI 3 EXT
MTR ON
Y0119.6
F
DO 959 F
LT RESET
R0223.0
G
DI 976 M
AN WELD1
R0220.4
H
DI 956 R
EFEDWLD1
R0223.1
I
DI 977 M
AN WELD2
N00009 X1000.6 G1000.6

J 36 GO HOME
HOME
N00010 R0000.0 G1000.7

K 38 ENABLE
ALWAYS ENABLE
ON
N00011 F1000.0 Y1000.0

L 40
COMMAND
ENABLE
N00012 F1000.1 Y1000.1

M 42
SYSTEM
READY
Y1025.5
N MOTORS ENABLE
MOTORS
ENABLE
N00013 F1000.2 Y1000.2

O 45
PROGRAM
RUNNING
Ladder Diagram 3
N00014 F1000.3 Y1000.3

A 47
PAUSED
N00015 F1000.4 Y1000.4

B 49
HELD
Y0000.0
DO 1 RUN
ENB ACK
N00016 F1000.5 ACT R0338.0

FAULT TMR INT FLT
DELAY
N00017 F1000.5 G1000.4 R0397.0 R0338.0 Y1000.5

E 56
FAULT RB FAULT FILTERED INT FLT
RESET FAULT DELAY
Y0120.2 Y0000.4
DO 963 DO 5 RBT
PRG FLT CNT FLT
Y0001.6
G
DO 15 CO
LL DTCT
N00018 F1000.6 Y1000.6

H 64
AT HOME
Y0002.0 Y0000.1
I ROBOT AT HOME
DO 17 RB DO 2 RBT
T @ HM1 @ HOME
Y0002.1
J
DO 18 RB
T @ HM2
Y0002.2
K
DO 19 RB
T @ HM3
Y0002.3
L
DO 20 RB
T @ HM4
Y0002.4
M
DO 21 RB
T @ HM5
Y0002.5
N
DO 22 RB
T @ HM6
Y0002.6
O
DO 23 RB
T @ HM7
Ladder Diagram 4
N00019 F1000.7 Y1000.7

A 74
TPENABLE
Y0119.7 Y0000.3
B ROBOT IN TEACH
DO 960 DO 4 RBT
AUTO KEY IN TCH
N00020 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

C 78
1 R1402.7 R1405.0
D S
ECO24 FACILITY
FC128 CODE 11
N00021 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 R1400.6 1

E 87
1 R1400.7 R1401.1 R1401.2 R1401.3 R1401.5 R1401.6 2

F
2 R1401.7 R1405.1
G
ECO16 ERROR 4
N00022 R1405.0 R1405.1 G1000.4 R1405.2

H 102 FENCE FAULT
FACILITY ERROR 4 RB FAULT FENCE
CODE 11 RESET FAULT
R1405.2
I
FENCE
FAULT
N00023 R0000.1 F1000.5 R1466.0 F1000.0 F1000.1 K0010.3

INT EXT FAULT BRK PWR COMMAND SYSTEM PWR FAIL
MTR ON FL RCVRY ENABLE READY RECVRY
R0000.2
K
INT EXT
CYC STRT
K0010.3
L
PWR FAIL
RECVRY
N00024 K0010.3 ACT R1466.0

PWR FAIL TMR BRK PWR
RECVRY FL RCVRY
O
Ladder Diagram 5
N00025 Y0000.3 F1000.0 Y0000.4 R0000.1 R0000.2 F1000.1 F1008.0 1

A 119
DO 4 RBT COMMAND DO 5 RBT INT EXT INT EXT SYSTEM STEP
IN TCH ENABLE CNT FLT MTR ON CYC STRT READY
R1404.5 Y0000.2
B
DRP AUTO DO 3 RBT
FAULT IN AUTO
1 F1008.2 X1025.0 R1405.2 K0010.0 Y0001.6 Y0000.2

TP FANUC FENCE TEACH DO 15 CO DO 3 RBT
E-STOP E-STOP FAULT MEMORY LL DTCT IN AUTO
N00026 Y0119.5 Y0072.4

DO 958 I DO 581 I
NPUTSIM NPUTSIM
N00027 R1404.4 R1456.0 R1404.2 F1000.5 G1000.4 R0330.2 R0386.1 R1404.5

FC AVAIL APPL FC ZERO FAULT RB FAULT SERVOGUN SVGN320& DRP AUTO
ALARMS RESET ALARM 326 LTCH FAULT
N00028 F1000.5 R1404.5

FAULT DRP AUTO
FAULT
G1000.4
G
RB FAULT
RESET
N00029 F1000.5 R1404.0 R1404.1 R1404.4

H 149
FAULT ECO33 ECO FC AVAIL
STROBE RETRIEVE
N00030 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 153
1 R1402.6 R1402.7 R1404.3

J S
ECO23 ECO24 SPOT
FC64 FC128 ALARM
N00031 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

K 163
1 R1402.6 R1402.7 R0330.0

L S
ECO23 ECO24 ARC
FC64 FC128 ALARM
N00032 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

M 173
1 R1402.6 R1402.7 R0330.1

N S
ECO23 ECO24 SEALER
FC64 FC128 ALARM
O
Ladder Diagram 6
N00033 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

A 183
1 R1402.6 R1402.7 R0330.2

B S
ECO23 ECO24 SERVOGUN
FC64 FC128 ALARM
N00034 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

C 193
1 R1402.6 R1402.7 R0330.3

D S
ECO23 ECO24 TOOLCHNG
FC64 FC128 ALARM
N00035 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

E 203
1 R1402.6 R1402.7 R0330.4

F S
ECO23 ECO24 SYSTEM
FC64 FC128 ALARM
N00036 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

G 213
1 R1402.6 R1402.7 R1406.0

H S
ECO23 ECO24 FACILITY
FC64 FC128 CODE 15
N00037 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 223
1 R1402.6 R1402.7 R1404.2

J
ECO23 ECO24 FC ZERO
FC64 FC128
O
Ladder Diagram 7
N00038 R1404.1 ACT R1404.3

A 233 SUB57 0001 R
ECO DIFU SPOT
RETRIEVE ALARM
R0330.0
B R
ARC
ALARM
R0330.1
C R
SEALER
ALARM
R0330.2
D R
SERVOGUN
ALARM
R0330.3
E R
TOOLCHNG
ALARM
R0330.4
F R
SYSTEM
ALARM
R1405.0
G R
FACILITY
CODE 11
R1406.0
H R
FACILITY
CODE 15
N00039 R1404.4 ACT R1404.6

I 244 SUB 3 0006
FC AVAIL TMR RETRIEVE
DELAY
N00040 R1404.6 R1404.1

J 248 S
RETRIEVE ECO
DELAY RETRIEVE
N00041 R1404.1 ACT R1404.1

K 250 SUB 3 0007 R
ECO TMR ECO
RETRIEVE RETRIEVE
N00042 Y0015.5 Y0015.5

DO 126 W DO 126 W
LD FLT 1 LD FLT 1
N00043 X0083.1 Y0015.5

DI 666 W DO 126 W
ELD CMP1 LD FLT 1
N00044 Y0019.5 Y0019.5

DO 158 W DO 158 W
LD FLT 2 LD FLT 2
N00045 X0091.1 Y0019.5

DI 730 W DO 158 W
ELD CMP2 LD FLT 2
Ladder Diagram 8
N00046 K0010.1 K0010.0 Y1025.5 R0000.1

A 262 S
EXT MTR TEACH MOTORS INT EXT
ON MEMORY ENABLE MTR ON
N00047 Y1025.5 R0000.1

B 266 R
MOTORS INT EXT
ENABLE MTR ON
N00048 X0000.2 K0010.0 K0010.5 K0010.1

DI 3 EXT TEACH MAINT ME EXT MTR
MTR ON MEMORY M ON
X1026.5 Y0000.4 F1000.5

D
ETSW CNT FLT
X1025.1
E
FAULT
RESET
X0000.1 X0001.2
F
DI 2 EX DI 11
RNEN RST PLC AUTO
N00049 K0010.2 K0010.0 K0010.5 R0000.2

G 280
EXT CYC TEACH MAINT ME INT EXT
START MEMORY M CYC STRT
N00050 X0000.3 K0010.0 K0010.2

DI 4 EXT TEACH EXT CYC
CY STRT MEMORY START
X1026.5 Y0000.4 F1000.5

I
ETSW CNT FLT
X1025.1
J
FAULT
RESET
X0000.1 X0001.2
K
DI 2 EX DI 11
RNEN RST PLC AUTO
R0340.0
L
MANUAL
WELD
N00051 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 296
1 X0002.7 R0507.0
N PROGRAM 1
DI 24 PG PROGRAM
SLCT128 1
O
Ladder Diagram 9
N00052 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 305
1 X0002.7 R0507.1
B PROGRAM 2
DI 24 PG PROGRAM
SLCT128 2
N00053 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 314
1 X0002.7 R0507.2
D PROGRAM 3
DI 24 PG PROGRAM
SLCT128 3
N00054 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 323
1 X0002.7 R0507.3
F PROGRAM 4
DI 24 PG PROGRAM
SLCT128 4
N00055 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 332
1 X0002.7 R0507.4
H PROGRAM 5
DI 24 PG PROGRAM
SLCT128 5
N00056 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 341
1 X0002.7 R0507.5
J PROGRAM 6
DI 24 PG PROGRAM
SLCT128 6
N00057 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 350
1 X0002.7 R0507.6
L PROGRAM 7
DI 24 PG PROGRAM
SLCT128 7
N00058 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 359
1 X0002.7 R0507.7
N PROGRAM 8
DI 24 PG PROGRAM
SLCT128 8
O
Ladder Diagram 10
N00059 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 368
1 X0002.7 R0508.0
B PROGRAM 9
DI 24 PG PROGRAM
SLCT128 9
N00060 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 377
1 X0002.7 R0508.1
D PROGRAM 10
DI 24 PG PROGRAM
SLCT128 10
N00061 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 386
1 X0002.7 R0508.2
F PROGRAM 11
DI 24 PG PROGRAM
SLCT128 11
N00062 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 395
1 X0002.7 R0508.3
H PROGRAM 12
DI 24 PG PROGRAM
SLCT128 12
N00063 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 404
1 X0002.7 R0508.4
J PROGRAM 13
DI 24 PG PROGRAM
SLCT128 13
N00064 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 413
1 X0002.7 R0508.5
L PROGRAM 14
DI 24 PG PROGRAM
SLCT128 14
N00065 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 422
1 X0002.7 R0508.6
N PROGRAM 15
DI 24 PG PROGRAM
SLCT128 15
O
Ladder Diagram 11
N00066 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 431
1 X0002.7 R0508.7
B PROGRAM 16
DI 24 PG PROGRAM
SLCT128 16
N00067 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 440
1 X0002.7 R0509.0
D PROGRAM 17
DI 24 PG PROGRAM
SLCT128 17
N00068 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 449
1 X0002.7 R0509.1
F PROGRAM 18
DI 24 PG PROGRAM
SLCT128 18
N00069 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 458
1 X0002.7 R0509.2
H PROGRAM 19
DI 24 PG PROGRAM
SLCT128 19
N00070 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 467
1 X0002.7 R0509.3
J PROGRAM 20
DI 24 PG PROGRAM
SLCT128 20
O
Ladder Diagram 12
N00071 X0000.4 Y0000.2 F1000.2 F1000.3 F1000.6 X0001.2 G1000.1 1

A 476
DI 5 MV DO 3 RBT PROGRAM PAUSED AT HOME DI 11 NO HOLD
TO POUNC IN AUTO RUNNING PLC AUTO
Y0000.2 F1000.3 F1000.2 X0001.2

B
DO 3 RBT PAUSED PROGRAM DI 11
IN AUTO RUNNING PLC AUTO
F1000.6 R0507.0 F1000.2 F1000.3

C
AT HOME PROGRAM PROGRAM PAUSED
1 RUNNING
R0507.1
D
PROGRAM
2
R0507.2
E
PROGRAM
3
R0507.3
F
PROGRAM
4
R0507.4
G
PROGRAM
5
R0507.5
H
PROGRAM
6
R0507.6
I
PROGRAM
7
R0507.7
J
PROGRAM
8
R0508.0
K
PROGRAM
9
R0508.1
L
PROGRAM
10
R0508.2
M
PROGRAM
11
R0508.3
N
PROGRAM
12
R0508.4
O
PROGRAM
13
Ladder Diagram 13
R0508.5
A
PROGRAM
14
R0508.6
B
PROGRAM
15
R0508.7
C
PROGRAM
16
R0509.0
D
PROGRAM
17
R0509.1
E
PROGRAM
18
R0509.2
F
PROGRAM
19
R0509.3
G
PROGRAM
20
Y0000.2 F1000.3 F1000.2 X0000.1 X0001.2

H
DO 3 RBT PAUSED PROGRAM DI 2 EX DI 11
IN AUTO RUNNING RNEN RST PLC AUTO
R0223.0
I
DI 976 M
AN WELD1
R0223.1
J
DI 977 M
AN WELD2
1 R0000.1 D0603.0 Y0000.4 R0100.5 F1000.5 G1000.5

K UOP CYCLE START
INT EXT CYCLE DO 5 RBT BREAK A FAULT UOP CYC
MTR ON STRT DLY CNT FLT NO HOLD START
N00072 G1000.5 F1000.2 ACT D0603.0

UOP CYC PROGRAM TMR CYCLE
START RUNNING STRT DLY
N00073 D0603.0 ACT D0603.0

CYCLE TMR CYCLE
STRT DLY STRT DLY
N00074 F1000.2 D0603.0

PROGRAM CYCLE
RUNNING STRT DLY
N00075
O 539 SUB 1
END1
Ladder Diagram 14
N00076 Y0119.7 ACT K0010.4

DO 960 TMR TEACH ME
AUTO KEY M DELAY
N00077 Y0000.3 X1026.5 X1025.1 X1025.6 K0010.0

B 544 TEACH MEMORY
DO 4 RBT SI13 RES FAULT CYCLE TEACH
IN TCH ETSW RESET START MEMORY
K0010.4
C
TEACH ME
M DELAY
K0010.0
D
TEACH
MEMORY
N00078 K0008.0 R0350.0

AUTO/MAI IN MAINT
NT SS
N00079 R0350.0 ACT D0610.0

IN MAINT TMR MAINT
DELAY
N00080 D0610.0 Y0000.2 Y0000.1 X1026.5 X1025.1 K0010.5

MAINT DO 3 RBT DO 2 RBT SI13 RES FAULT MAINT ME
DELAY IN AUTO @ HOME ETSW RESET M
K0010.5 X0000.6
H
MAINT ME DI 7 MAI
M NT PSCLR
N00081 X0000.2 X0000.3 Y0000.2 K0010.6

DI 3 EXT DI 4 EXT DO 3 RBT EXT STRT
MTR ON CY STRT IN AUTO ANTI TD
K0010.6
J
EXT STRT
ANTI TD
N00082 X0002.0 G1001.0

K 571
DI 17 PG PNS 1
SLCT 1
N00083 X0002.1 G1001.1

L 573
DI 18 PG PNS 2
SLCT 2
N00084 X0002.2 G1001.2

M 575
DI 19 PG PNS 3
SLCT 4
N00085 X0002.3 G1001.3

N 577
DI 20 PG PNS 4
SLCT 8
N00086 X0002.4 G1001.4

O 579
DI 21 PG PNS 5
SLCT 16
Ladder Diagram 15
N00087 X0002.5 G1001.5

A 581
DI 22 PG PNS 6
SLCT 32
N00088 X0002.6 G1001.6

B 583
DI 23 PG PNS 7
SLCT 64
N00089 X0002.7 G1001.7

C 585
DI 24 PG PNS 8
SLCT128
N00090 X0000.6 K0008.0 Y0120.5

DI 7 MAI AUTO/MAI DO 966
NT PSCLR NT SS MAINTCLR
N00091 K0008.0 Y0001.4

AUTO/MAI DO 13 SN
NT SS DRBT MNT
N00092 Y0112.3 Y0003.0

DO 900 DO 25 CL
CLR ZN 1 R ZON 1
N00093 Y0112.4 Y0003.1

DO 901 DO 26 CL
CLR ZN 2 R ZON 2
N00094 Y0112.5 Y0003.2

DO 902 DO 27 CL
CLR ZN 3 R ZON 3
N00095 Y0112.6 Y0003.3

DO 903 DO 28 CL
CLR ZN 4 R ZON 4
N00096 Y0112.7 Y0003.4

DO 904 DO 29 CL
CLR ZN 5 R ZON 5
N00097 Y0113.0 Y0003.5

DO 905 DO 30 CL
CLR ZN 6 R ZON 6
N00098 Y0113.1 Y0003.6

DO 906 DO 31 CL
CLR ZN 7 R ZON 7
N00099 Y0113.2 Y0003.7

DO 907 DO 32 CL
CLR ZN 8 R ZON 8
N00100 Y0113.3 Y0004.0

DO 908 DO 33 CL
CLR ZN 9 R ZON 9
N00101 Y0113.4 Y0004.1

DO 909 C DO 34 CL
LR ZN 10 R ZON 10
Ladder Diagram 16
N00102 Y0113.5 Y0004.2

DO 910 C DO 35 CL
LR ZN 11 R ZON 11
N00103 Y0113.6 Y0004.3

DO 911 C DO 36 CL
LR ZN 12 R ZON 12
N00104 Y0113.7 Y0004.4

DO 912 C DO 37 CL
LR ZN 13 R ZON 13
N00105 Y0116.4 Y0004.5

DO 933 C DO 38 CL
LR ZN 14 R ZON 14
N00106 Y0118.7 Y0004.6

DO952 CL DO 39 CL
RMOTZN1 R INDMOT
N00107 Y0119.0 Y0004.7

DO953 CL DO 40 CL
RMOTZN2 R INDMT2
N00108 Y0119.1 X0000.0 Y0000.6

LRAV XFR RNENBL ADV
N00109 Y0119.2 X0000.0 Y0000.7

LRET XFR RNENBL RET XFR
N00110 Y0119.3 X0000.0 Y0001.0

LR UNCLP RNENBL 2 UNCLP
N00111 Y0000.3 R1000.0 Y0073.0

J 633 PROMPT BOX
DO 4 RBT DO 19001 DO 585
IN TCH PRPTBX PRMPT BX
N00112 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

K 636
1 R1402.7 R1405.3
ECO24 SYS FCLY
FC128 CODE
N00113 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 645
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0365.0

Ladder Diagram 17
N00114 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 663
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0366.0

N00115 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 681
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0367.0

N00116 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 699
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0368.0

N00117 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 717
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.0

N00118 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 735
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.1

Ladder Diagram 18
N00119 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 753
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.3

N00120 R1406.3 X1025.1 Y0001.6

SRVO-50 FAULT DO 15 CO
RESET LL DTCT
Y0001.6
E
DO 15 CO
LL DTCT
N00121 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

F 775
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

G
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.2

LOW BATT
N00122 F1001.0 Y0001.1

BATALM DO 10 RB
T BAT LW
N00123 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 795
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0371.0

N00124 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 813
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.1

NCE EXCE
Ladder Diagram 19
N00125 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 831
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0373.0

CONTROL
N00126 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 849
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0374.0

NTED IN
N00127 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 867
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0375.0

TP OFF
N00128 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 885
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0376.0

SVOFF I
N00129 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 903
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.0

OPSFT11
Ladder Diagram 20
N00130 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 921
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.1

OPSFT12
N00131 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 939
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.2

OPSFT21
N00132 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 957
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.3

I SRVO-381 OPSFTY22 STATUS ABNOR
OPSFT22
N00133 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 975
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.4

L SRVO-382 OPSFTY31 STATUS ABNOR
OPSFT31
N00134 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 993
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.5

OPSFT32
Ladder Diagram 21
N00135 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1011
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.6

OPSFT41
N00136 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1029
CODE 11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.7

OPSFT42
N00137 R0387.0 R0388.0

G 1047 SRVO OPSFTY ABNORM FAULT LATCH
SRVO-378 OPSFTY F
OPSFT11 LT LATCH
R0387.1
H
SRVO-379
OPSFT12
R0387.2
I
SRVO-380
OPSFT21
R0387.3
J
SRVO-381
OPSFT22
R0387.4
K
SRVO-382
OPSFT31
R0387.5
L
SRVO-383
OPSFT32
R0387.6
M
SRVO-384
OPSFT41
R0387.7
N
SRVO-385
OPSFT42
R0388.0 F1000.5
O
OPSFTY F FAULT
LT LATCH
Ladder Diagram 22
N00138 R0388.0 Y0073.1

A 1059 SAFETY CHAIN FAULT
OPSFTY F DO 586 S
LT LATCH FTY CHN
N00139 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

B 1061
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

C
2 R1401.4 R1401.5 R1401.6 R1401.7 R0377.0

D SYST-034 HOLD SIGNAL FROM SOP/
HOLD SI
N00140 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

E 1079
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

F
2 R1401.4 R1401.5 R1401.6 R1401.7 R0378.0

G SYST-038 OPERATION MODE T1 SEL
OPERATI
N00141 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

H 1097
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

I
2 R1401.4 R1401.5 R1401.6 R1401.7 R0379.0

J
N00142 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

K 1115
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

L
2 R1401.4 R1401.5 R1401.6 R1401.7 R0380.0

M SYST-040 OPERATION MODE AUTO S
OPERATI
O
Ladder Diagram 23
N00143 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1133
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0381.0

C SYST-042 DEADMAN DEFEATED
DEADMAN
N00144 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1151
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0382.0

F SYST-043 TP DISABLE IN T1/T2
TP DISA
N00145 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 1169
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0383.0

I SYST-045 TP ENABLE IN AUTO MO
TP ENAB
N00146 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 1187
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0384.0

L SYST-154 NO START IN ISOLATE/B
NO STAR
N00147 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 1205
ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0385.0

O SVGN-320 THCKNESS1 ERR REQ RES
THK1ERR
Ladder Diagram 24
N00148 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1223
ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0386.0

C SVGN-326 THKNESS2 ERR REQ RES
THK2ERR
N00149 R0385.0 R0386.1

D 1241 SVGN 320 & 326 LATCH
SVGN-320 SVGN320&
THK1ERR 326 LTCH
R0386.0
E
SVGN-326
THK2ERR
R0386.1 G1000.4
F
SVGN320& RB FAULT
326 LTCH RESET
N00150 R0397.0 F1000.0 R0397.0

G 1247 FILTERED FAULT
FILTERED COMMAND FILTERED
FAULT ENABLE FAULT
R0398.0
H
FILTER
FLT GRP1
R0399.0
I
FILTER
FLT GRP2
O
Ladder Diagram 25
N00151 R0365.0 R0398.0

SRVO-001 FILTER
FLT GRP1
R0366.0
B
SRVO-002
R0367.0
C
SRVO-003
R0368.0
D
SRVO-005
R0369.0
E
R369.0
RESERVED
R0370.0
F
SRVO-007
R0371.0
G
SRVO-101
R0372.0
H
R372.0
RESERVED
R0373.0
I
SRVO-199
CONTROL
R0374.0
J
SRVO-232
NTED IN
R0375.0
K
SRVO-233
TP OFF
R0376.0
L
SRVO-280
SVOFF I
R0385.0
M
SVGN-320
THK1ERR
R0386.0
N
SVGN-326
THK2ERR
R0370.1
O
SRVO-408
Ladder Diagram 26
R1456.0
A
APPL
ALARMS
N00152 R0377.0 R0399.0

SYST-034 FILTER
HOLD SI FLT GRP2
R0378.0
C
SYST-038
OPERATI
R0379.0
D
SYST-039
R0380.0
E
SYST-040
OPERATI
R0381.0
F
SYST-042
DEADMAN
R0382.0
G
SYST-043
TP DISA
R0383.0
H
SYST-045
TP ENAB
R0384.0
I
SYST-154
NO STAR
X1025.0
J
FANUC
E-STOP
F1008.2
K
TP
E-STOP
X1026.1
L
SI9
AUTOMDSW
Y0000.3
M
DO 4 RBT
IN TCH
K0010.0
N
TEACH
MEMORY
R1405.2
O
FENCE
FAULT
Ladder Diagram 27
N00153 R0330.0 F1000.5 R1456.0

A 1284
ARC FAULT APPL
ALARM ALARMS
R0330.1
B
SEALER
ALARM
R0330.3
C
TOOLCHNG
ALARM
R0330.4
D
SYSTEM
ALARM
R1404.3
E
SPOT
ALARM
R1456.0
F
APPL
ALARMS
N00154 D0001.0 Y0079.0

TOOL CHA DO 633 T
NGE APP C LOCK
Y0079.1
H S TOOL CHANGER UNLOCK
DO 634 T
C UNLOCK
N00155 D0001.0 ACT

I 1295 SUB10 0000
TOOL CHA JMP
NGE APP
N00156
J 1298 SUB66 P0001
CALLU TOOL CHANGING
N00157
K 1300 SUB30
JMPE
N00158
L 1301 SUB66 P0022
CALLU SWGBOLT
N00159
M 1303 SUB66 P0003
CALLU TIPDRESSER1
N00160
N 1305 SUB66 P0004
CALLU WATERVALVE1
N00161
O 1307 SUB66 P0005
Ladder Diagram 28
N00162
A 1309 SUB66 P0006
CALLU UALM
N00163
B 1311 SUB66 P0007
CALLU INTERFACE
N00164
C 1313 SUB66 P0008
CALLU MH
N00165
D 1315 SUB66 P0009
CALLU APPLICATION
N00166
E 1317 SUB66 P0020
CALLU AIR
N00167
F 1319 SUB66 P0015
CALLU WELDCONTROL2
N00168
G 1321 SUB66 P0016
CALLU TIPDRESSER2
N00169
H 1323 SUB66 P0017
CALLU WATERVALVE2
N00170
I 1325 SUB66 P0018
N00171
J 1327 SUB66 P0025
CALLU TOUCHUP1
N00172
K 1329 SUB 2
END2
N00173 ### P0001 ###

L 1330 SUB71 P0001
SP TOOL CHANGING
O
Ladder Diagram 29
N00174 X0080.0 R0347.0

A 1332 GUN ID NOT 0
DI 641 GUN ID
TOOL ID1 NOT 0
X0080.1
B
DI 642
TOOL ID2
X0080.2
C
DI 643
TOOL ID4
X0080.3
D
DI 644
TOOL ID8
N00175 X0080.0 X0080.1 X0080.2 X0080.3 R0321.0

E 1337
DI 641 DI 642 DI 643 DI 644 GUN 1 ON
N00176 X0080.0 X0080.1 X0080.2 X0080.3 R0322.0

F 1342
DI 641 DI 642 DI 643 DI 644 GUN 2 ON
N00177 X0080.0 X0080.1 X0080.2 X0080.3 R0323.0

G 1347
DI 641 DI 642 DI 643 DI 644 GUN 3 ON
N00178 X0080.0 X0080.1 X0080.2 X0080.3 R0324.0

H 1352
DI 641 DI 642 DI 643 DI 644 GUN 4 ON
N00179 X0080.0 X0080.1 X0080.2 X0080.3 R0325.0

I 1357
DI 641 DI 642 DI 643 DI 644 GUN 5 ON
N00180 X0080.0 X0080.1 X0080.2 X0080.3 R0326.0

J 1362
DI 641 DI 642 DI 643 DI 644 GUN 6 ON
N00181 X0080.0 X0080.1 X0080.2 X0080.3 R0326.1

K 1367
DI 641 DI 642 DI 643 DI 644 GUN 7 ON
N00182 X0080.0 X0080.1 X0080.2 X0080.3 R0326.2

L 1372
DI 641 DI 642 DI 643 DI 644 GUN 8 ON
O
Ladder Diagram 30
N00183 R0321.0 R0328.6

GUN 1 ON TOOLONRO
ARM BOT
R0322.0
B
GUN 2 ON
ARM
R0323.0
C
GUN 3 ON
ARM
R0324.0
D
GUN 4 ON
ARM
R0325.0
E
GUN 5 ON
ARM
R0326.0
F
GUN 6 ON
ARM
R0326.1
G
GUN 7 ON
ARM
R0326.2
H
GUN 8 ON
ARM
N00184 R0321.0 R0322.0 R0323.0 R0324.0 R0325.0 R0326.0 R0326.1 1

I 1386
GUN 1 ON GUN 2 ON GUN 3 ON GUN 4 ON GUN 5 ON GUN 6 ON GUN 7 ON
ARM ARM ARM ARM ARM ARM ARM
1 R0326.2 R0348.0
GUN 8 ON GEOTOOLP
ARM RSNT
N00185 X0080.0 Y0038.0

DI 641 DO 305
TOOL ID1 TOOL ID1
N00186 X0080.1 Y0038.1

L 1397
DI 642 DO 306
TOOL ID2 TOOL ID2
N00187 X0080.2 Y0038.2

M 1399
DI 643 DO 307
TOOL ID4 TOOL ID4
N00188 X0080.3 Y0038.3

N 1401
DI 644 DO 308
TOOL ID8 TOOL ID8
O
Ladder Diagram 31
N00189 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 X0038.6 1

A 1403
DI 305 DI 306 DI 307 DI 308 DI 309 DI 310 DI 311
1 X0038.7 R0327.0
DI 312 GUN 1-8
TCSTND8
N00190 Y0117.4 K0011.1

DO 941 TC RE
TC UNLCK LEASED
N00191 Y0117.3 Y0000.2 X0079.4 X0079.5 R0328.6 Y0079.0

DO 940 DO 3 RBT DI 637 DI 638 TOOLONRO DO 633 T
TC LOCK IN AUTO RDY2LCK1 RDY2LCK2 BOT C LOCK
F1000.7 Y0119.7 K0015.0 R0328.6

E
TPENABLE DO 960 TC LOCK TOOLONRO
AUTO KEY PB BOT
N00192 X0079.0 Y0040.6

F 1427
DI 633 DO 327 T
TC LOCKD CCOUPMON
N00193 Y0117.4 Y0117.3 Y0000.2 Y0079.0

G 1429 R TOOL CHANGER LOCK
DO 941 DO 940 DO 3 RBT DO 633 T
TC UNLCK TC LOCK IN AUTO C LOCK
F1000.7 Y0119.7 K0016.0

H
TPENABLE DO 960 TC UNLOC
AUTO KEY K PB
N00194 K0011.1 Y0079.0 Y0000.2 X0080.4 X0080.5 1

I 1438
TC RE DO 633 T DO 3 RBT DI 645 T DI 646 T
LEASED C LOCK IN AUTO SIV SRV
F1000.7 Y0119.7 K0016.0 R0328.6 2

J
TPENABLE DO 960 TC UNLOC TOOLONRO
AUTO KEY K PB BOT
1 R0328.6 Y0079.1
TOOLONRO DO 634 T
BOT C UNLOCK
2
L
N00195 K0015.0 K0016.0 F1000.7 Y0119.7 K0015.0

TC LOCK TC UNLOC TPENABLE DO 960 TC LOCK
PB K PB AUTO KEY PB
N00196 K0016.0 K0015.0 F1000.7 Y0119.7 K0016.0

TC UNLOC TC LOCK TPENABLE DO 960 TC UNLOC
K PB PB AUTO KEY K PB
N00197 X0079.1 Y0040.7

O 1462
DI 634 DO 328 T
TC ULCKD CRELMON
Ladder Diagram 32
N00198 R0328.6 K0008.0 R0218.4

TOOLONRO AUTO/MAI DI 940 T
BOT NT SS C NOTOOL
N00199 Y0117.5 Y0117.6 Y0000.2 Y0038.5

DO 942 DO 943 DO 3 RBT DO 310 T
TCOPNCVR TCCLSCVR IN AUTO C OPNCVR
K0011.4 K0011.5 Y0000.3

C
TC OPENG TC CLOS DO 4 RBT
UNCOVER GUNCOVER IN TCH
N00200 Y0117.5 Y0117.6 Y0000.2 Y0038.6

DO 942 DO 943 DO 3 RBT DO 311 T
TCOPNCVR TCCLSCVR IN AUTO C CLSCVR
K0011.5 K0011.4 Y0000.3

E
TC CLOS TC OPENG DO 4 RBT
GUNCOVER UNCOVER IN TCH
N00201 X0038.0 R0321.0 R0329.0

TCSTND1 ARM ITION
X0038.0 X0039.3
G
DI 305 DI 316 G
TCSTND1 EOTPDCK
N00202 X0038.1 R0322.0 R0329.1

TCSTND2 ARM ITION
X0038.1 X0039.3
I
DI 306 DI 316 G
TCSTND2 EOTPDCK
N00203 X0038.2 R0323.0 R0329.2

TCSTND3 ARM ITION
X0038.2 X0039.3
K
DI 307 DI 316 G
TCSTND3 EOTPDCK
N00204 X0038.3 R0324.0 R0329.3

TCSTND4 ARM ITION
X0038.3 X0039.3
M
DI 308 DI 316 G
TCSTND4 EOTPDCK
N00205 X0038.4 R0325.0 R0329.4

TCSTND5 ARM ITION
X0038.4 X0039.3
O
DI 309 DI 316 G
TCSTND5 EOTPDCK
Ladder Diagram 33
N00206 X0038.5 R0326.0 R0329.5

TCSTND6 ARM ITION
X0038.5 X0039.3
B
DI 310 DI 316 G
TCSTND6 EOTPDCK
N00207 X0038.6 R0326.1 R0329.6

TCSTND7 ARM ITION
X0038.6 X0039.3
D
DI 311 DI 316 G
TCSTND7 EOTPDCK
N00208 X0038.7 R0326.2 R0329.7

TCSTND8 ARM ITION
X0038.7 X0039.3
F
DI 312 DI 316 G
TCSTND8 EOTPDCK
N00209 R0329.0 R0328.7

GUN1 POS GUN1-8 P
ITION OSITION
R0329.1
H
GUN2 POS
ITION
R0329.2
I
GUN3 POS
ITION
R0329.3
J
GUN4 POS
ITION
R0329.4
K
GUN5 POS
ITION
R0329.5
L
GUN6 POS
ITION
R0329.6
M
GUN7 POS
ITION
R0329.7
N
GUN8 POS
ITION
O
Ladder Diagram 34
N00210 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1540
1 X0038.6 X0038.7 R0320.0

B TOOL 1 IN OPDOCK
N00211 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

C 1550
1 X0038.6 X0038.7 R0320.1

D TOOL 2 IN OPDOCK
N00212 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

E 1560
1 X0038.6 X0038.7 R0320.2

F TOOL 3 IN OPDOCK
N00213 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

G 1570
1 X0038.6 X0038.7 R0320.3

H TOOL 4 IN OPDOCK
N00214 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

I 1580
1 X0038.6 X0038.7 R0320.4

J TOOL 5 IN OPDOCK
N00215 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

K 1590
1 X0038.6 X0038.7 R0320.5

L TOOL 6 IN OPDOCK
N00216 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

M 1600
1 X0038.6 X0038.7 R0320.6

N TOOL 7 IN OPDOCK
O
Ladder Diagram 35
N00217 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1610
1 X0038.6 X0038.7 R0320.7

B TOOL 8 IN OPDOCK
N00218 R0320.0 R0319.0

TOOL1INO ALLTOOLS
PDOCK INOPDOCK
R0320.1
D
TOOL2INO
PDOCK
R0320.2
E
TOOL3INO
PDOCK
R0320.3
F
TOOL4INO
PDOCK
R0320.4
G
TOOL5INO
PDOCK
R0320.5
H
TOOL6INO
PDOCK
R0320.6
I
TOOL7INO
PDOCK
R0320.7
J
TOOL8INO
PDOCK
N00219 X0082.6 Y0038.7

K 1629
DI 663 T DO 312 T
CCOMMOK CCOMMOK
N00220 X0082.7 Y0039.2

L 1631
DI 664 T DO 315 T
CTLSLDPW LSLIDPWR
N00221 X0079.4 X0079.5 G1008.4

DI 637 DI 638 UALM 5
RDY2LCK1 RDY2LCK2
X0079.4 X0079.5
N
DI 637 DI 638
RDY2LCK1 RDY2LCK2
N00222 R0328.6 G1008.5

O 1639 NOTOOLONARM
TOOLONRO UALM 6
BOT
Ladder Diagram 36
N00223 K0013.1 R0000.7 Y0126.7

NOTOOLON PART PRE DO 1016
N00224 K0013.1 R0000.7 K0013.1

NOTOOLON PART PRE NOTOOLON
EOATSS SENT EOATSS
N00225 Y0039.3 Y0039.3

DO 316 W DO 316 W
RNGTLSTD RNGTLSTD
N00226 Y0039.3 X1025.1 Y0000.1 Y0039.3

DO 316 W FAULT DO 2 RBT DO 316 W
RNGTLSTD RESET @ HOME RNGTLSTD
N00227
E 1653 SUB72
SPE
N00228 ### P0002 ###

F 1654 SUB71 P0002
SP WELDCONTROL1
N00229 X0000.0 Y0083.0

DI 1 EXT DO 665 W
RNENBL C1 ENBLE
N00230 X0087.6 Y0014.4

DI 703 W DO 117 W
1 COMMOK C1COM OK
N00231 Y0000.3 Y0083.1

DO 4 RBT DO 666 R
IN TCH BTCH WC1
N00232 K0004.7 Y0014.1

WELD / N DO 114 W
O WELD1 D/NWD1SS
N00233 K0006.4 Y0018.1

WELD / N DO 146 W
O WELD2 D/NWD2SS
N00234 Y0014.1 Y0018.1 R0221.0

DO 114 W DO 146 W DI 960 R
D/NWD1SS D/NWD2SS EM WELD
N00235 X0086.1 Y0015.6

DI 690 I DO 127 I
HI/LO AVL WRN1
N00236 X0087.5 Y0017.3

DI 702 A DO 140 A
DP MODE DP MODE
N00237 X0083.0 Y0015.3

DI 665 I DO 124 I
NWLDCYC1 NWD CY 1
Ladder Diagram 37
N00238 X0083.1 Y0015.4

DI 666 W DO 125 H
ELD CMP1 AS WLD 1
N00239 X0083.3 Y0014.3

DI 668 W DO 116 N
ELD FLT1 OWLDFLT1
N00240 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

C 1679
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0306.0
DO 686 ROBOT WS
BP 128 WC#1
N00241 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

E 1688
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0307.0
F
DO 686 WLD SCH
BP 128 39 WC1
N00242 Y0014.1 Y0014.2 Y0083.4

DO 114 W DO 115 W DO 669 W
N00243 X1020.2 X1020.0 X1020.1 D0004.0

O
Ladder Diagram 38
N00244 Y0109.7 D0004.0 K0000.0 ACT R0363.0

BP1 1 WC1 MER1
Y0110.0
B
DO 881
BP2 1
Y0110.1
C
DO 882
BP4 1
Y0110.2
D
DO 883
BP8 1
Y0110.3
E
DO 884
BP16 1
Y0110.4
F
DO 885
BP32 1
Y0110.5
G
DO 886
BP64 1
Y0110.6
H
DO 887
BP128 1
N00245 Y0109.7 D0004.0 R0363.0 Y0084.6

BP1 1 WC1 MER1 BP 1
N00246 Y0110.0 D0004.0 R0363.0 Y0084.7

BP2 1 WC1 MER1 BP 2
N00247 Y0110.1 D0004.0 R0363.0 Y0085.0

BP4 1 WC1 MER1 BP 4
N00248 Y0110.2 D0004.0 R0363.0 Y0085.1

BP8 1 WC1 MER1 BP 8
N00249 Y0110.3 D0004.0 R0363.0 Y0085.2

N00250 Y0110.4 D0004.0 R0363.0 Y0085.3

N00251 Y0110.5 D0004.0 R0363.0 Y0085.4

Ladder Diagram 39
N00252 Y0110.6 D0004.0 R0363.0 Y0085.5

BP128 1 WC1 MER1 BP 128
N00253 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

B 1749
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0360.0
DO 686 NOWLDSCH
BP 128 WC1
N00254 R0360.0 X0087.6 K0000.0 Y0083.5

K0000.0 Y0116.5
E
DEBUG DO 934
RD SCHD1
N00255 Y0120.6 F1000.3 Y0000.1 R0223.0

F 1765
X0015.0 K0008.0 Y0000.5 F1000.3 F1000.2

G
Y0000.1 F1000.2 F1000.3

H
@ HOME RUNNING
N00256 Y0120.6 Y0000.1 F1000.2 F1000.3 R0213.6

X0015.0 K0008.0
J
DI 121 R AUTO/MAI
M MAN W1 NT SS
N00257 Y0048.3 Y0121.0 F1000.3 Y0000.1 R0220.4

UTFD APP EDWLD1PB @ HOME EFEDWLD1
N00258 K0008.6 D0612.0 K0008.6

1 1
N00259 K0008.6 D0612.0 K0008.6

1 1
N00260 K0005.1 D0612.0 K0005.1

PB1 PB1
N00261 K0005.1 D0612.0 K0005.1

PB1 PB1
Ladder Diagram 40
N00262 K0005.2 D0612.0 K0005.2

O TD PB1 O TD PB1
N00263 K0005.2 D0612.0 K0005.2

O TD PB1 O TD PB1
N00264 K0005.5 D0612.0 K0005.5

CLS PB1 CLS PB1
N00265 K0005.5 D0612.0 K0005.5

CLS PB1 CLS PB1
N00266 K0005.6 D0612.0 K0005.6

OPN PB1 OPN PB1
N00267 K0005.6 D0612.0 K0005.6

OPN PB1 OPN PB1
N00268 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00269 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00270 K0006.0 D0612.0 K0006.0

ACK PB1 ACK PB1
N00271 K0006.0 D0612.0 K0006.0

ACK PB1 ACK PB1
N00272 Y0120.6 D0612.0 Y0120.6

AN WELD1 AN WELD1
N00273 Y0120.6 D0612.0 Y0120.6

AN WELD1 AN WELD1
N00274 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
N00275 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
O
Ladder Diagram 41
N00276 Y1020.0 Y1020.0

RO 1 RO 1
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
B
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00277 Y1020.0 Y1020.0

RO 1 RO 1
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
D
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00278 K0004.5 K0006.2

EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00279 K0004.5 X1026.1 G1000.1 ACT K0004.5

F 1860 SUB 3 0033 R EQUALIZATION ENABLE 1&2 SS
N00280 K0000.0 Y0083.3 D0612.0 X1025.1 Y0083.3

G 1866 RESET WELDER
ST WLD RESET ST WLD
X1025.1
H
FAULT
RESET
N00281 K0015.1 D0612.0 K0015.1

SSDUMP1 SSDUMP1
N00282 K0015.1 D0612.0 K0015.1

SSDUMP1 SSDUMP1
N00283 K0015.2 D0612.0 K0015.2

SSDUMP1 SSDUMP1
N00284 K0015.2 D0612.0 K0015.2

SSDUMP1 SSDUMP1
N00285 K0015.1 Y0000.2 X1026.1 K0015.2 Y0017.5

M 1884
N00286 K0015.2 Y0000.2 X1026.1 K0015.1 Y0017.6

N 1889
O
Ladder Diagram 42
N00287 Y0120.6 K0000.3 D0610.1

X0015.0 K0008.0 K0000.3

B
M MAN W1 NT SS NB1
N00288 D0610.1 ACT D0610.1

DETIMR1 DETIMR1
N00289 X0054.5 Y0087.1

DI 438 C DO 698 C
CWELDMOD CWELDMOD
D0610.1
E
CCWELDMO
DETIMR1
N00290
F 1908 SUB72
SPE
N00291 ### P0003 ###

G 1909 SUB71 P0003
SP TIPDRESSER1
N00292 X0087.1 Y0017.2

DI 698 T DO 139 T
PCHNGRQW PCHG RQ1
X0087.0
I
DI 697 T
PCHNGRQ
Y0110.7
J
DO 888 T
PWRMOV1
Y0111.0
K
DO 889 T
PWRFIX1
N00293 K0005.5 Y0000.5 R0222.6

N00294 K0005.6 Y0000.5 R0222.7

N00295 X0083.4 Y0016.3

DI 669 N DO 132 N
EW TIP WTP RST1
O
Ladder Diagram 43
N00296 R0345.0 Y0084.5 X0001.2 K0008.0 R0345.0

1 TSR PLC AUTO NT SS 1
Y0119.1 K0005.2
B
DO 954 C INIT AUT
LRAV XFR O TD PB1
N00297 R0334.0 Y0109.0 Y0000.5 X0083.1 R0333.0

R0333.0
D
TD MEM W
C #1
N00298 X0083.4 K0008.0 Y0000.5 X0014.7 R0333.0 R0334.0

EW TIP NT SS @ MAINT D BYPSS1 C #1 P TC1
R0334.0
F
DRESS CA
P TC1
N00299 X0083.2 Y0015.0

DI 667 M DO 121 A
AINT REQ UTOTD 1
R0334.0 Y0050.7 Y0048.3

H
DRESS CA DO 408 S DO 388 N
P TC1 WGBOLTAP UTFD APP
R0345.0
I
TIP MEM
1
N00300 K0005.0 Y0014.0

PULLED T DO 113 P
IP BYPS1 LTPBY SS
K0006.5
K
PULLED T
IP BYPS2
N00301 Y0085.7 R0351.0

DO 688 PULLDTIP
TIP WTR1 SEAL 1
N00302 R0351.0 ACT D0611.0

SEAL 1 P TIMER
N00303 R0220.6 Y0017.4

DI 958 P DO 141 A
LDTIP 1 PTB 1
R0220.7
O
DI 959 P
LDTIP 2
Ladder Diagram 44
N00304 Y0014.5 X0001.2 Y0109.0

DO 118 D DI 11 DO 873 T
K0005.3 Y0000.3
B
TEACH TD DO 4 RBT
ENABLE1 IN TCH
N00305 R0000.0 Y0014.5 X0001.2 Y0086.6

ON RSR ON 1 PLC AUTO D MTR ON
K0005.3 Y0000.3
D
TEACH TD DO 4 RBT
ENABLE1 IN TCH
N00306 X1020.2 X0000.0 R0220.6

RI 3 WTR DI 1 EXT DI 958 P
FL SW1 RNENBL LDTIP 1
R0220.6 D0611.0
F
DI 958 P PULLEDTI
LDTIP 1 P TIMER
N00307 K0004.6 Y0014.7

TD MTR F DO 120 T
LT BYPS1 DMFL BY1
N00308 D0605.0 R0411.0 R0412.0

H 1987 TD FAULT1
1TIM1 TOK1
N00309 Y0014.5 X0086.2 Y0109.2 K0004.6 Y0083.3 R0411.0

RSR ON 1 IP DR OK RVTPDROK LT BYPS1 ST WLD TOK1
R0411.0
J
TDCURREN
TOK1
N00310 R0412.0 ACT D0606.0

2TIM1
N00311 Y0014.5 ACT D0605.0

RSR ON 1 1TIM1
N00312 Y0083.3 R0411.0 D0606.0 R0415.0

ST WLD TOK1 2TIM1 1
R0408.0
N
TPRESFLT
1
R0415.0
O
TDMTRFLT
1
Ladder Diagram 45
N00313 R0415.0 Y0014.6

TDMTRFLT DO 119 T
1 DM FLT 1
N00314 Y0118.1 ACT D0604.0

ESCHKMD1 TIM1
N00315 D0604.0 R0409.0 R0408.0

TIM1 LAT1 1
N00316 Y0118.1 X0086.3 K0005.4 Y0083.3 R0409.0

ESCHKMD1 PDRRSOK1 ST BYPS1 ST WLD LAT1
R0409.0
E
TPRESFLT
LAT1
N00317 X0014.4 Y0121.2 Y0118.7 F1000.5 R0221.6

DI 117 I DO 971 P DO952 CL FAULT DI 966 R
NIT TD 1 EDDMPAPP RMOTZN1 NTDDMP1
X0014.6 X0083.2 Y0015.0 Y0121.5

G
DI 119 T DI 667 M DO 121 A DO 974
D DMP R1 AINT REQ UTOTD 1 TPWRCMP1
N00318 K0008.5 K0008.5

NTSR ENB NTSR ENB
1SS 1SS
N00319 K0008.5 X1025.1 K0008.5

1SS RESET 1SS
K0008.5 X0083.4
J
NTSR ENB DI 669 N
1SS EW TIP
N00320 K0015.6 K0015.6

DTSRENB1 DTSRENB1
SS SS
N00321 K0015.6 X1025.1 K0015.6

SS RESET SS
K0015.6 X0083.5
M
DTSRENB1 DI 670 D
SS RSSTIP1
N00322 K0008.5 K0005.1 Y0084.4

1SS PB1 TSR
X0015.3
O
DI 124 N
EWTPRST1
Ladder Diagram 46
N00323 K0015.6 K0008.6 Y0084.5

SS 1 TSR
Y0116.7 Y0054.2
B DRSSTIPSTPRST1
DO 936 DO 435 D
STP RST1 TSR1
N00324
C 2062 SUB72
SPE
N00325 ### P0004 ###

D 2063 SUB71 P0004
SP WATERVALVE1
N00326 X1020.2 X0001.6 Y0085.7

RI 3 WTR DI 15 SY DO 688
FL SW1 S WTR ON TIP WTR1
N00327 X0014.0 R0000.5 Y1020.3

Y1020.3 X1020.2
G
RO 4 WTR RI 3 WTR
RESET1 FL SW1
X1025.1
H
FAULT
RESET
N00328 Y1020.3 Y0122.0 ACT R0000.5

RO 4 WTR DO 977 TMR WTR RST
RESET1 WS PLSOP PULSE OP
Y1020.5
J
RO 6 WTR
RESET2
N00329
K 2081 SUB72
SPE
N00330 ### P0005 ###

L 2082 SUB71 P0005
SP OVRTMP/NOSTRK1
N00331 X1020.0 Y0086.4

RI 1 XF DO 693 X
RMR OT1 FMR OT
N00332 X1020.1 Y0086.5

RI 2 SRV DO 694 S
OMTR OT1 RVMTR OT
O
Ladder Diagram 47
N00333 X1020.0 X1025.1 R0500.0

R0500.0
B
XFRMR OT
MP SEAL1
N00334 X1020.1 X1025.1 R0500.1

RI 2 SRV FAULT SRVO MTR
OMTR OT1 RESET OTSEAL1
R0500.1
D
SRVO MTR
OTSEAL1
N00335 R0500.0 Y0016.2

XFRMR OT DO 131 X
MP SEAL1 FMR OTF1
N00336 R0500.1 Y0016.1

SRVO MTR DO 130 S
OTSEAL1 GM OTF1
N00337 R0500.0 K0005.0 R0220.6 R0500.1 D0004.1

XFRMR OT PULLED T DI 958 P SRVO MTR REMSTROK
MP SEAL1 IP BYPS1 LDTIP 1 OTSEAL1 EOK1
Y0048.3 Y0048.2
H
DO 388 N DO 387 W
UTFD APP LD2 APP
Y0048.2 Y0050.5
I
DO 387 W DO 406 N
LD2 APP TFD 2APP
Y0050.7
J
DO 408 S
WGBOLTAP
N00338 R0501.0 K0006.5 R0220.7 R0501.1 D0004.2

K 2113 REMOTE NO STROKE OK WC2
XFRMR OT PULLED T DI 959 P SRVOMTR REMSTROK
MP SEAL2 IP BYPS2 LDTIP 2 OT SEAL2 EOK2
Y0050.5
L
DO 406 N
TFD 2APP
Y0048.2
M
DO 387 W
LD2 APP
N00339 D0004.1 D0004.2 R0221.1

REMSTROK REMSTROK DI 961 R
EOK1 EOK2 EM STRK
N00340
O 2123 SUB72
SPE
Ladder Diagram 48
N00341 ### UALM ###

A 2124 SUB71 P0006
SP UALM
N00342 Y0120.2 X1025.1 Y0120.2

DO 963 FAULT DO 963
PRG FLT RESET PRG FLT
N00343 Y0120.2 G1008.0

DO 963 UALM1
PRG FLT
N00344 X0083.2 G1008.1

DI 667 M UALM2
AINT REQ
N00345 X0083.2 X0087.0 G1008.2

DI 667 M DI 697 T UALM 3
AINT REQ PCHNGRQ
X0091.2 X0087.1
F
DI 731 M DI 698 T
ANT REQ2 PCHNGRQW
N00346 X0014.1 G1008.7

DI 114 R UALM 8
STW TMR
N00347 Y0021.2 G1009.0

DO 171 T UALM 9
PCHG RQ2
N00348 X0083.3 G1009.1

DI 668 W UALM 10
ELD FLT1
N00349 X0091.3 G1009.2

DI 732 W UALM 11
ELD FLT2
N00350 Y0039.3 G1009.7

DO 316 W UALM 16
RNGTLSTD
N00351 X0001.6 G1010.3

DI 15 SY UALM 20
S WTR ON
N00352 Y0014.7 G1010.4

DO 120 T UALM 21
DMFL BY1
N00353 Y0014.6 G1010.5

DO 119 T UALM 22
DM FLT 1
N00354 K0010.0 Y0119.7 Y0000.3 G1010.6

TEACH DO 960 DO 4 RBT UALM23
MEMORY AUTO KEY IN TCH
Ladder Diagram 49
N00355 R0220.6 G1010.7

DI 958 P UALM 24
LDTIP 1
N00356 R0000.0 G1011.0

ALWAYS UALM 25
ON
N00357 K0004.5 G1011.1

EQUALENB UALM 26
L 1&2 SS
N00358 Y0120.6 G1011.2

DO 967 M UALM 27
AN WELD1
X0015.0
E
DI 121 R
M MAN W1
N00359 Y0017.2 G1011.3

DO 139 T UALM 28
PCHG RQ1
N00360 Y0002.7 G1011.4

DO 24 RB UALM 29
T LOOP
N00361 X1020.1 G1011.5

RI 2 SRV UALM 30
OMTR OT1
N00362 X1020.0 G1011.6

RI 1 XF UALM 31
RMR OT1
N00363 X0087.6 G1011.7

DI 703 W UALM 32
1 COMMOK
N00364
K 2178 SUB72
SPE

L 2179 SUB71 P0007
SP INTERFACE
O
Ladder Diagram 50
N00366 D0612.1 ACT D0612.0

MH IF PB TMR IF PB TO
TO
D0612.2
B
SEAL IF
PB TO
D0612.3
C
STUD IF
PB TO
D0612.4
D
SWG1 IF
PB TO
D0612.5
E
SWG2 IF
PB TO
O
Ladder Diagram 51
N00367 K0002.0 D0612.1

A 2189 MH IF PB TO
CLMP1CLS MH IF PB
TO
K0002.1
B
CLMP1OPN
K0002.2
C
CLMP2CLS
K0002.3
D
CLMP2OPN
K0002.4
E
CLMP3CLS
K0002.5
F
CLMP3OPN
K0002.6
G
CLMP4CLS
K0002.7
H
CLMP4OPN
K0003.0
I
CLMP5CLS
K0003.1
J
CLMP5OPN
K0003.2
K
CLMP6CLS
K0003.3
L
CLMP6OPN
K0003.4
M
CLMP7CLS
K0003.5
N
CLMP7OPN
K0003.6
O
CLMP8CLS
Ladder Diagram 52
K0003.7
A
CLMP8OPN
K0004.0
B
CLMP9CLS
K0004.1
C
CLMP9OPN
K0004.2
D
CLP10CLS
K0004.3
E
CLP10OPN
K0014.2
F
VAC 1 ON
PB
K0014.3
G
VAC 2 ON
PB
K0014.4
H
VAC 3 ON
PB
K0014.5
I
BLOWOFF
1 ON PB
K0014.6
J
BLOWOFF
2 ON PB
K0014.7
K
BLOWOFF
3 ON PB
K0000.4
L
RERUNPRC
PB
K0000.5
M
ACCPTPRC
PB
K0000.6
N
REJCTPRC
PB
K0000.7
O
INSPCTSE
LPB
Ladder Diagram 53
K0011.4
A
TC OPENG
UNCOVER
K0011.5
B
TC CLOS
GUNCOVER
K0016.1
C
VAC 4 ON
PB
K0016.2
D
BLOWOFF
4 ON PB
O
Ladder Diagram 54
N00368 Y0121.0 D0612.4

DO 969 F SWG1 IF
EDWLD1PB PB TO
Y0120.6
B
DO 967 M
AN WELD1
Y0083.3
C
DO 668 R
ST WLD
K0005.1
D
NEW TIP
PB1
K0008.6
E
DTSR PB
1
K0005.2
F
INIT AUT
O TD PB1
K0005.5
G
TIP ALGN
CLS PB1
K0005.6
H
TIP ALGN
OPN PB1
K0005.7
I
INITAUTO
TCPB1
K0006.0
J
ATC FLT
ACK PB1
K0015.1
K
ADVTIPDR
SSDUMP1
K0015.2
L
RETTIPDR
SSDUMP1
O
Ladder Diagram 55
N00369 Y0121.1 D0612.5

DO 970 F SWG2 IF
EDWLD2PB PB TO
Y0120.7
B
DO 968 M
AN WELD2
Y0091.3
C
DO 732 R
ST WLD2
K0006.6
D
NEW TIP
PB2
K0009.2
E
DTSR PB
2
K0006.7
F
INIT AUT
O TD PB2
K0007.2
G
TIP ALGN
CLS PB2
K0007.3
H
TIP ALGN
OPN PB2
K0007.4
I
INITAUTO
TCPB2
K0007.5
J
ATC FLT
ACK PB2
K0015.3
K
ADVTIPDR
SSDUMP2
K0015.4
L
RETTIPDR
SSDUMP2
N00370
M 2250 SUB72
SPE
N00371 ### MH ###

N 2251 SUB71 P0008
SP MH
N00372 Y0000.3 K0004.4 R1410.0

DO 4 RBT MAN GRP MAN GRP
IN TCH ENBLE SS ENABLE
Ladder Diagram 56
N00373 R1410.0 ACT

A 2256 SUB10 0000
MAN GRP JMP
ENABLE
N00374 R0000.0 Y0114.0

B 2259 OPEN CLAMP 1
ALWAYS DO 913
ON OPNCLMP1
N00375 R0000.0 Y0114.1

ALWAYS DO 914
ON CLSCLMP1
N00376 R0000.0 Y0114.2

D 2263 OPEN CLAMP 2
ALWAYS DO 915
ON OPNCLMP2
N00377 R0000.0 Y0114.3

ALWAYS DO 916
ON CLSCLMP2
N00378 R0000.0 Y0114.4

F 2267 OPEN CLAMP 3
ALWAYS DO 917
ON OPNCLMP3
N00379 R0000.0 Y0114.5

ALWAYS DO 918
ON CLSCLMP3
N00380 R0000.0 Y0114.6

H 2271 OPEN CLAMP 4
ALWAYS DO 919
ON OPNCLMP4
N00381 R0000.0 Y0114.7

ALWAYS DO 920
ON CLSCLMP4
N00382 R0000.0 Y0115.0

J 2275 OPEN CLAMP 5
ALWAYS DO 921
ON OPNCLMP5
N00383 R0000.0 Y0115.1

ALWAYS DO 922
ON CLSCLMP5
N00384 R0000.0 Y0115.2

L 2279 OPEN CLAMP 6
ALWAYS DO 923
ON OPNCLMP6
N00385 R0000.0 Y0115.3

ALWAYS DO 924
ON CLSCLMP6
N00386 R0000.0 Y0115.4

N 2283 OPEN CLAMP 7
ALWAYS DO 925
ON OPNCLMP7
N00387 R0000.0 Y0115.5

ALWAYS DO 926
ON CLSCLMP7
Ladder Diagram 57
N00388 R0000.0 Y0115.6

A 2287 OPEN CLAMP 8
ALWAYS DO 927
ON OPNCLMP8
N00389 R0000.0 Y0115.7

ALWAYS DO 928
ON CLSCLMP8
N00390 R0000.0 Y0116.0

C 2291 OPEN CLAMP 9
ALWAYS DO 929
ON OPNCLMP9
N00391 R0000.0 Y0116.1

ALWAYS DO 930
ON CLSCLMP9
N00392 R0000.0 Y0116.2

ALWAYS DO 931
ON OPNCLP10
N00393 R0000.0 Y0116.3

ALWAYS DO 932
ON CLSCLP10
N00394 R0000.0 Y0127.2

G 2299 VACUUM 1 ON
ALWAYS DO1019 V
ON AC1ON
N00395 R0000.0 Y0127.3

H 2301 BLOWOFF 1 ON
ALWAYS DO1020 B
ON LWOF1ON
N00396 R0000.0 Y0127.4

I 2303 VACUUM 2 ON
ALWAYS DO1021 V
ON AC2ON
N00397 R0000.0 Y0127.5

J 2305 BLOWOFF 2 ON
ALWAYS DO1022 B
ON LWOF2ON
N00398 R0000.0 Y0127.6

K 2307 VACUUM 3 ON
ALWAYS DO1023 V
ON AC3ON
N00399 R0000.0 Y0127.7

L 2309 BLOWOFF 3 ON
ALWAYS DO1024 B
ON LWOF3ON
N00400 R0000.0 Y0118.5

M 2311 VACUUM 4 ON
ALWAYS DO 950 V
ON AC4ON
N00401 R0000.0 Y0118.6

N 2313 BLOWOFF 4 ON
ALWAYS DO 951 B
ON LWOF4ON
N00402
O 2315 SUB30
JMPE
Ladder Diagram 58
N00403 R1410.0 ACT R0001.1

A 2316 SUB 3 0038
MAN GRP TMR MAN GRP
ENABLE TO
N00404 R0001.1 ACT

B 2320 SUB10 0000
MAN GRP JMP
TO
N00405 K0002.1 X1026.1 Y0114.0

C 2323 OPEN CLAMP 1
CLMP1OPN SI9 DO 913
AUTOMDSW OPNCLMP1
N00406 Y0114.0 Y0009.0

DO 913 DO 73 OP
OPNCLMP1 N CLMP1
N00407 K0002.0 X1026.1 Y0114.1

CLMP1CLS SI9 DO 914
AUTOMDSW CLSCLMP1
N00408 Y0114.1 Y0009.1

DO 914 DO 74 CL
CLSCLMP1 S CLMP1
N00409 K0002.3 X1026.1 Y0114.2

G 2333 OPEN CLAMP 2
CLMP2OPN SI9 DO 915
AUTOMDSW OPNCLMP2
N00410 Y0114.2 Y0009.2

DO 915 DO 75 OP
OPNCLMP2 N CLMP2
N00411 K0002.2 X1026.1 Y0114.3

CLMP2CLS SI9 DO 916
AUTOMDSW CLSCLMP2
N00412 Y0114.3 Y0009.3

DO 916 DO 76 CL
CLSCLMP2 S CLMP2
N00413 K0002.5 X1026.1 Y0114.4

K 2343 OPEN CLAMP 3
CLMP3OPN SI9 DO 917
AUTOMDSW OPNCLMP3
N00414 Y0114.4 Y0009.4

DO 917 DO 77 OP
OPNCLMP3 N CLMP 3
N00415 K0002.4 X1026.1 Y0114.5

CLMP3CLS SI9 DO 918
AUTOMDSW CLSCLMP3
N00416 Y0114.5 Y0009.5

DO 918 DO 78 CL
CLSCLMP3 S CLMP3
N00417 K0002.7 X1026.1 Y0114.6

O 2353 OPEN CLAMP 4
CLMP4OPN SI9 DO 919
AUTOMDSW OPNCLMP4
Ladder Diagram 59
N00418 Y0114.6 Y0009.6

DO 919 DO 79 OP
OPNCLMP4 N CLMP4
N00419 K0002.6 X1026.1 Y0114.7

CLMP4CLS SI9 DO 920
AUTOMDSW CLSCLMP4
N00420 Y0114.7 Y0009.7

DO 920 DO 80 CL
CLSCLMP4 S CLMP4
N00421 K0003.1 X1026.1 Y0115.0

D 2363 OPEN CLAMP 5
CLMP5OPN SI9 DO 921
AUTOMDSW OPNCLMP5
N00422 Y0115.0 Y0010.0

DO 921 DO 81 OP
OPNCLMP5 N CLMP5
N00423 K0003.0 X1026.1 Y0115.1

CLMP5CLS SI9 DO 922
AUTOMDSW CLSCLMP5
N00424 Y0115.1 Y0010.1

DO 922 DO 82 CL
CLSCLMP5 S CLMP5
N00425 K0003.3 X1026.1 Y0115.2

H 2373 OPEN CLAMP 6
CLMP6OPN SI9 DO 923
AUTOMDSW OPNCLMP6
N00426 Y0115.2 Y0010.2

DO 923 DO 83 OP
OPNCLMP6 N CLMP6
N00427 K0003.2 X1026.1 Y0115.3

CLMP6CLS SI9 DO 924
AUTOMDSW CLSCLMP6
N00428 Y0115.3 Y0010.3

DO 924 DO 84 CL
CLSCLMP6 S CLMP 6
N00429 K0003.5 X1026.1 Y0115.4

L 2383 OPEN CLAMP 7
CLMP7OPN SI9 DO 925
AUTOMDSW OPNCLMP7
N00430 Y0115.4 Y0010.4

DO 925 DO 85 OP
OPNCLMP7 N CLMP 7
N00431 K0003.4 X1026.1 Y0115.5

CLMP7CLS SI9 DO 926
AUTOMDSW CLSCLMP7
N00432 Y0115.5 Y0010.5

DO 926 DO 86 CL
CLSCLMP7 S CLAMP7
Ladder Diagram 60
N00433 K0003.7 X1026.1 Y0115.6

A 2393 OPEN CLAMP 8
CLMP8OPN SI9 DO 927
AUTOMDSW OPNCLMP8
N00434 Y0115.6 Y0010.6

DO 927 DO 87 OP
OPNCLMP8 N CLMP8
N00435 K0003.6 X1026.1 Y0115.7

CLMP8CLS SI9 DO 928
AUTOMDSW CLSCLMP8
N00436 Y0115.7 Y0010.7

DO 928 DO 88 CL
CLSCLMP8 S CLAMP8
N00437 K0004.1 X1026.1 Y0116.0

E 2403 OPEN CLAMP 9
CLMP9OPN SI9 DO 929
AUTOMDSW OPNCLMP9
N00438 Y0116.0 Y0011.0

DO 929 DO 89 OP
OPNCLMP9 N CLMP9
N00439 K0004.0 X1026.1 Y0116.1

CLMP9CLS SI9 DO 930
AUTOMDSW CLSCLMP9
N00440 Y0116.1 Y0011.1

DO 930 DO 90 CL
CLSCLMP9 S CLMP9
N00441 K0004.3 X1026.1 Y0116.2

CLP10OPN SI9 DO 931
AUTOMDSW OPNCLP10
N00442 Y0116.2 Y0011.2

DO 931 DO 91 OP
OPNCLP10 N CLMP10
N00443 K0004.2 X1026.1 Y0116.3

CLP10CLS SI9 DO 932
AUTOMDSW CLSCLP10
N00444 Y0116.3 Y0011.3

DO 932 DO 92 CL
CLSCLP10 S CLMP10
N00445 K0014.2 X1026.1 K0014.1 Y0127.2

M 2423 VACUUM 1 ON
N00446 Y0127.2 Y0008.0

N 2427
DO1019 V DO 65 VA
AC1ON C 1 ON
N00447 K0014.5 X1026.1 K0014.1 Y0127.3

O 2429 BLOWOFF 1 ON
Ladder Diagram 61
N00448 Y0127.3 Y0008.1

A 2433
DO1020 B DO 66 BL
LWOF1ON WOFF1ON
N00449 K0014.3 X1026.1 K0014.1 Y0127.4

B 2435 VACUUM 2 ON
N00450 Y0127.4 Y0008.2

C 2439
DO1021 V DO 67 VA
AC2ON C 2 ON
N00451 K0014.6 X1026.1 K0014.1 Y0127.5

D 2441 BLOWOFF 2 ON
N00452 Y0127.5 Y0008.3

E 2445
DO1022 B DO 68 BL
LWOF2ON WOFF2ON
N00453 K0014.4 X1026.1 K0014.1 Y0127.6

F 2447 VACUUM 3 ON
N00454 Y0127.6 Y0008.4

G 2451
DO1023 V DO 69 VA
AC3ON C 3 ON
N00455 K0014.7 X1026.1 K0014.1 Y0127.7

H 2453 BLOWOFF 3 ON
N00456 Y0127.7 Y0008.5

I 2457
DO1024 B DO 70 BL
LWOF3ON WOFF3ON
N00457 K0016.1 X1026.1 K0014.1 Y0118.5

J 2459 VACUUM 4 ON
VAC 4 ON SI9 VAC/BLOW DO 950 V
N00458 Y0118.5 Y0008.6

K 2463
DO 950 V DO 71 VA
AC4ON C 4 ON
N00459 K0016.2 X1026.1 K0014.1 Y0118.6

L 2465 BLOWOFF 4 ON
BLOWOFF SI9 VAC/BLOW DO 951 B
N00460 Y0118.6 Y0008.7

M 2469
DO 951 B DO 72 BL
LWOF4ON WOFF4ON
N00461
N 2471 SUB30
JMPE
O
Ladder Diagram 62
N00462 Y0008.0 ACT K0014.1

DO 65 VA TMR VAC/BLOW
C 1 ON OFFTIMER
Y0008.1
B
DO 66 BL
WOFF1ON
Y0008.2
C
DO 67 VA
C 2 ON
Y0008.3
D
DO 68 BL
WOFF2ON
Y0008.4
E
DO 69 VA
C 3 ON
Y0008.5
F
DO 70 BL
WOFF3ON
Y0008.6
G
DO 71 VA
C 4 ON
Y0008.7
H
DO 72 BL
WOFF4ON
N00463 K0002.0 D0612.0 K0002.0

I 2483 CLMP1 CLOSE
N00464 K0002.1 D0612.0 K0002.1

J 2486 CLMP1 OPEN
N00465 K0002.2 D0612.0 K0002.2

K 2489 CLMP2 CLOSE
N00466 K0002.3 D0612.0 K0002.3

L 2492 CLMP2 OPEN
N00467 K0002.4 D0612.0 K0002.4

M 2495 CLMP3 CLOSE
N00468 K0002.5 D0612.0 K0002.5

N 2498 CLMP3 OPEN
N00469 K0002.6 D0612.0 K0002.6

O 2501 CLMP4 CLOSE
Ladder Diagram 63
N00470 K0002.7 D0612.0 K0002.7

A 2504 CLMP4 OPEN
N00471 K0003.0 D0612.0 K0003.0

B 2507 CLMP5 CLOSE
N00472 K0003.1 D0612.0 K0003.1

C 2510 CLMP5 OPEN
N00473 K0003.2 D0612.0 K0003.2

D 2513 CLMP6 CLOSE
N00474 K0003.3 D0612.0 K0003.3

E 2516 CLMP6 OPEN
N00475 K0003.4 D0612.0 K0003.4

F 2519 CLMP7 CLOSE
N00476 K0003.5 D0612.0 K0003.5

G 2522 CLMP7 OPEN
N00477 K0003.6 D0612.0 K0003.6

H 2525 CLMP8 CLOSE
N00478 K0003.7 D0612.0 K0003.7

I 2528 CLMP8 OPEN
N00479 K0004.0 D0612.0 K0004.0

J 2531 CLMP9 CLOSE
N00480 K0004.1 D0612.0 K0004.1

K 2534 CLMP9 OPEN
N00481 K0004.2 D0612.0 K0004.2

L 2537 CLMP10 CLOSE
CLP10CLS IF PB TO CLP10CLS
N00482 K0004.3 D0612.0 K0004.3

M 2540 CLMP10 OPEN
CLP10OPN IF PB TO CLP10OPN
N00483 K0014.2 D0612.0 K0014.2

N 2543
PB PB
N00484 K0014.3 D0612.0 K0014.3

O 2546
PB PB
Ladder Diagram 64
N00485 K0014.4 D0612.0 K0014.4

A 2549
PB PB
N00486 K0016.1 D0612.0 K0016.1

B 2552
PB PB
N00487 K0014.5 D0612.0 K0014.5

C 2555
1 ON PB 1 ON PB
N00488 K0014.6 D0612.0 K0014.6

D 2558
2 ON PB 2 ON PB
N00489 K0014.7 D0612.0 K0014.7

E 2561
3 ON PB 3 ON PB
N00490 K0016.2 D0612.0 K0016.2

F 2564
4 ON PB 4 ON PB
N00491 K0000.4 Y0012.6

RERUNPRC DO 103 R
PB ERUNPRC
N00492 K0000.5 Y0012.7

ACCPTPRC DO 104 A
PB CCPTPRC
N00493 K0000.6 Y0013.0

REJCTPRC DO 105 R
PB EJCTPRC
N00494 K0000.7 Y0013.1

INSPCTSE DO 106 I
LPB NSP SEL
K0001.3 K0001.5
K
VISIONIN ABORTPRO
TERVENSS CESS
N00495 K0000.4 D0612.0 K0000.4

PB PB
N00496 K0000.4 D0612.0 K0000.4

PB PB
N00497 K0000.5 D0612.0 K0000.5

PB PB
N00498 K0000.5 D0612.0 K0000.5

PB PB
Ladder Diagram 65
N00499 K0000.6 D0612.0 K0000.6

PB PB
N00500 K0000.6 D0612.0 K0000.6

PB PB
N00501 K0000.7 D0612.0 K0000.7

LPB LPB
N00502 K0000.7 D0612.0 K0000.7

LPB LPB
N00503 K0011.4 D0612.0 K0011.4

TC OPENG IF PB TO TC OPENG
UNCOVER UNCOVER
N00504 K0011.5 D0612.0 K0011.5

TC CLOS IF PB TO TC CLOS
GUNCOVER GUNCOVER
N00505 X0008.2 R0000.7

DI 67 PR PART PRE
T PRES1 SENT
X0008.3
H
DI 68 PR
T PRES2
X0008.4
I
DI 69 PR
T PRES3
X0008.5
J
DI 70 PR
T PRES4
X0008.6
K
DI 71 PR
T PRES5
X0008.7
L
DI 72 PR
T PRES6
N00506
M 2615 SUB72
SPE

N 2616 SUB71 P0009
SP APPLICATION
N00508 D0000.0 Y0048.0

MH APP DO 385 M
H APP
Ladder Diagram 66
N00509 D0000.1 Y0048.1

WELD 1 A DO 386
PP WLD1 APP
N00510 D0000.2 Y0048.2

WELD 2 A DO 387 W
PP LD2 APP
N00511 D0000.3 Y0048.3

NUT FEED DO 388 N
APP UTFD APP
N00512 D0000.4 Y0048.4

SEAL 1 A DO 389 S
PP LR 1 APP
N00513 D0000.5 Y0048.5

SEAL 2 DO 390 S
APP LR 2 APP
N00514 D0000.6 Y0048.6

STUD 1 A DO 391 S
PP TDW 1APP
N00515 D0000.7 Y0048.7

STUD 2 A DO 392 S
PP TDW 2APP
N00516 D0001.0 Y0049.0

TOOL CHA DO 393 T
NGE APP C APP
N00517 D0001.1 Y0049.1

RIVET 1 DO 394 R
APP VT 1 APP
N00518 D0001.2 Y0049.2

RIVET 2 DO 395 R
APP VT 2 APP
N00519 D0001.3 Y0049.3

NUT RUNN DO 396 N
ER APP UTR APP
N00520 D0001.4 Y0049.4

MIG WELD DO 397 M
APP IGW APP
N00521 D0001.5 Y0049.5

ROLLER H DO 398 R
EMM APP LLHEM AP
N00522 D0001.6 Y0049.6

LASER CU DO 399 L
T APP SRCT APP
N00523 D0001.7 Y0049.7

PLASMA C DO 400 P
UT APP LSMA APP
Ladder Diagram 67
N00524 D0002.0 Y0050.0

LASER WE DO 401 L
LD APP SRWLDAPP
N00525 D0002.1 Y0050.1

OPER LOA DO 402 O
D APP P LD APP
N00526 D0002.2 Y0050.2

VISION A DO 403 V
PP IS APP
N00527 D0002.3 Y0050.3

PROG LOC DO 404 P
APP RG LCAPP
N00528 D0002.4 Y0050.4

IF DEF DO 405
21 INDEFB21
N00529 D0002.5 Y0050.5

NUT FEED DO 406 N
ER 2 APP TFD 2APP
N00530 D0002.6 Y0050.6

IF DEF DO 407 I
23 NDEF B23
N00531 D0002.7 Y0050.7

H 2664 SWGBOLT FEEDER APPLICATION
SWGBOLT DO 408 S
APP WGBOLTAP
N00532 D0003.0 Y0051.0

IF DEF DO 409 I
25 NDEF B25
N00533 D0003.1 Y0051.1

IF DEF DO 410 I
26 NDEF B26
N00534 D0003.2 Y0051.2

IF DEF DO 411 I
27 NDEF B27
N00535 D0003.3 Y0051.3

IF DEF DO 412 I
28 NDEF B28
N00536 D0003.4 Y0051.4

IF DEF DO 413 I
29 NDEF B29
N00537 D0003.5 Y0051.5

IF DEF DO 414 I
30 NDEF B30
N00538 D0003.6 Y0051.6

IF DEF DO 415 I
31 NDEF B31
Ladder Diagram 68
N00539 D0003.7 Y0051.7

IF DEF DO 416 I
32 NDEF B32
N00540
B 2682 SUB72
SPE
N00541 ### P0015 ###

C 2683 SUB71 P0015
SP WELDCONTROL2
N00542 X0000.0 Y0091.0

DI 1 EXT DO 729 W
RNENBL C2 ENBL
N00543 X0095.6 Y0018.4

DI 767 W DO 149 W
2 COMMOK C2COM OK
N00544 Y0000.3 Y0091.1

DO 4 RBT DO 730 R
IN TCH BTCH WC2
N00545 X0094.1 Y0019.6

DI 754 I DO 159 I
-HI/LO 2 AVL WRN2
N00546 X0095.5 Y0021.3

H 2693
DI 766 A DO 172 A
DP MODE2 DPMODEN2
N00547 X0091.0 Y0019.3

DI 729 I DO 156 I
NWLDCYC2 NWD CY 2
N00548 X0091.1 Y0019.4

DI 730 W DO 157 H
ELD CMP2 AS WLD 2
N00549 X0091.3 Y0018.3

DI 732 W DO 148 N
ELD FLT2 OWLDFLT2
N00550 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

L 2701
DO 743 DO 744 DO 745 DO 746 DO 747 DO 748 DO 749
BP2 1 BP2 2 BP2 4 BP2 8 BP2 16 BP2 32 BP2 64
1 Y0093.5 R0306.1
DO 750 ROBOT WS
BP2 128 WC#2
N00551 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

N 2710
DO 743 DO 744 DO 745 DO 746 DO 747 DO 748 DO 749
BP2 1 BP2 2 BP2 4 BP2 8 BP2 16 BP2 32 BP2 64
1 Y0093.5 R0362.0
O
DO 750 WLD SCH
BP2 128 39 WC2
Ladder Diagram 69
N00552 Y0018.1 Y0018.2 Y0091.4

DO 146 W DO 147 W DO 733 W
N00553 X1020.5 X1020.3 X1020.4 D0004.5

N00554 Y0111.1 D0004.5 K0000.0 ACT R0364.0

BP1 2 WC2 MER2
Y0111.2
D
DO 891
BP2 2
Y0111.3
E
DO 892
BP4 2
Y0111.4
F
DO 893
BP8 2
Y0111.5
G
DO 894
BP16 2
Y0111.6
H
DO 895
BP32 2
Y0111.7
I
DO 896
BP64 2
Y0112.0
J
DO 897
BP128 2
N00555 Y0111.1 D0004.5 R0364.0 Y0092.6

N00556 Y0111.2 D0004.5 R0364.0 Y0092.7

N00557 Y0111.3 D0004.5 R0364.0 Y0093.0

N00558 Y0111.4 D0004.5 R0364.0 Y0093.1

N00559 Y0111.5 D0004.5 R0364.0 Y0093.2

Ladder Diagram 70
N00560 Y0111.6 D0004.5 R0364.0 Y0093.3

N00561 Y0111.7 D0004.5 R0364.0 Y0093.4

N00562 Y0112.0 D0004.5 R0364.0 Y0093.5

BP128 2 WC2 MER2 BP2 128
N00563 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

D 2771
DO 743 DO 744 DO 745 DO 746 DO 747 DO 748 DO 749
BP2 1 BP2 2 BP2 4 BP2 8 BP2 16 BP2 32 BP2 64
1 Y0093.5 R0361.0
DO 750 NOWLDSCH
BP2 128 WC2
N00564 R0361.0 X0095.6 K0000.0 Y0091.5

K0000.0 Y0116.6
G
DEBUG DO 935
RD SCHD2
N00565 Y0120.7 F1000.3 Y0000.1 R0223.1

H 2787
X0019.0 K0008.0 Y0000.5 F1000.3 F1000.2

I
Y0000.1 F1000.2 F1000.3

J
@ HOME RUNNING
N00566 Y0120.7 Y0000.1 F1000.2 F1000.3 R0213.7

X0019.0 K0008.0
L
DI 153 R AUTO/MAI
M MAN W2 NT SS
N00567 Y0050.5 Y0121.1 F1000.3 Y0000.1 R0220.5

TFD 2APP EDWLD2PB @ HOME EFEDWLD2
N00568 K0009.2 D0612.0 K0009.2

2 2
N00569 K0009.2 D0612.0 K0009.2

2 2
Ladder Diagram 71
N00570 K0006.6 D0612.0 K0006.6

PB2 PB2
N00571 K0006.6 D0612.0 K0006.6

PB2 PB2
N00572 K0006.7 D0612.0 K0006.7

O TD PB2 O TD PB2
N00573 K0006.7 D0612.0 K0006.7

O TD PB2 O TD PB2
N00574 K0007.2 D0612.0 K0007.2

CLS PB2 CLS PB2
N00575 K0007.2 D0612.0 K0007.2

CLS PB2 CLS PB2
N00576 K0007.3 D0612.0 K0007.3

OPN PB2 OPN PB2
N00577 K0007.3 D0612.0 K0007.3

OPN PB2 OPN PB2
N00578 K0007.4 D0612.0 K0007.4

TCPB2 TCPB2
N00579 K0007.4 D0612.0 K0007.4

TCPB2 TCPB2
N00580 K0007.5 D0612.0 K0007.5

ACK PB2 ACK PB2
N00581 K0007.5 D0612.0 K0007.5

ACK PB2 ACK PB2
N00582 Y0120.7 D0612.0 Y0120.7

AN WELD2 AN WELD2
N00583 Y0120.7 D0612.0 Y0120.7

AN WELD2 AN WELD2
N00584 Y0121.1 D0612.0 Y0121.1

EDWLD2PB EDWLD2PB
Ladder Diagram 72
N00585 Y0121.1 D0612.0 Y0121.1

EDWLD2PB EDWLD2PB
N00586 Y1020.1 Y1020.1

RO 2 RO 2
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
C
EQUALENB EQUALIZE
L 1&2 SS R 2 SS
N00587 Y1020.1 Y1020.1

RO 2 RO 2
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
E
EQUALENB EQUALIZE
L 1&2 SS R 2 SS
N00588 K0004.5 K0007.7

EQUALENB EQUALIZE
L 1&2 SS R 2 SS
N00589 K0000.0 Y0091.3 D0612.0 X1025.1 Y0091.3

ST WLD2 RESET ST WLD2
X1025.1
H
FAULT
RESET
N00590 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00591 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00592 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00593 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00594 K0015.3 Y0000.2 X1026.1 K0015.4 Y0021.5

M 2900
N00595 K0015.4 Y0000.2 X1026.1 K0015.3 Y0021.6

N 2905
O
Ladder Diagram 73
N00596 Y0120.7 K0014.0 D0610.2

X0019.0 K0008.0 K0014.0

B
M MAN W2 NT SS NB2
N00597 D0610.2 ACT D0610.2

DETIMR2 DETIMR2
N00598 X0054.5 Y0095.1

DI 438 C DO 762 C
CWELDMOD CWELDMD2
D0610.2
E
CCWELDMO
DETIMR2
N00599
F 2924 SUB72
SPE
N00600 ### P0016 ###

G 2925 SUB71 P0016
SP TIPDRESSER2
N00601 X0095.1 Y0021.2

DI 762 T DO 171 T
PCHNGRQ2 PCHG RQ2
X0095.0
I
DI 761 T
PCNGREQ2
Y0112.1
J
DO 898 T
PWRMOV2
Y0112.2
K
DO 899 T
PWRFIX2
N00602 K0007.2 Y0000.5 R0222.4

N00603 K0007.3 Y0000.5 R0222.5

N00604 X0091.4 Y0020.3

DI 733 N DO 164 N
EW TIP2 WTP RST2
O
Ladder Diagram 74
N00605 R0346.0 Y0092.5 X0001.2 K0008.0 R0346.0

2 TSR2 PLC AUTO NT SS 2
Y0119.1 K0006.7
B
DO 954 C INIT AUT
LRAV XFR O TD PB2
N00606 R0335.0 Y0109.1 Y0000.5 X0091.1 R0332.0

R0332.0
D
TD MEM W
C #2
N00607 X0091.4 K0008.0 Y0000.5 X0018.7 R0332.0 R0335.0

EW TIP2 NT SS @ MAINT D BYPSS2 C #2 P TC2
R0335.0
F
DRESS CA
P TC2
N00608 X0091.2 Y0019.0

DI 731 M DO 153 A
ANT REQ2 UTO TD 2
R0335.0 Y0050.5
H
DRESS CA DO 406 N
P TC2 TFD 2APP
R0346.0
I
TIP MEM
2
N00609 Y0093.7 R0352.0

DO 752 T PULLDTIP
IP WTR2 SEAL 2
N00610 R0352.0 ACT D0613.0

SEAL 2 P TIMER2
N00611 Y0018.5 X0001.2 Y0109.1

DO 150 D DI 11 DO 874 T
K0007.0 Y0000.3
M
TEACH TD DO 4 RBT
ENABLE2 IN TCH
N00612 R0000.0 Y0018.5 X0001.2 Y0094.6

ON RSR ON 2 PLC AUTO D MTRON2
K0007.0 Y0000.3
O
TEACH TD DO 4 RBT
ENABLE2 IN TCH
Ladder Diagram 75
N00613 X1020.5 X0000.0 R0220.7

RI 6 WTR DI 1 EXT DI 959 P
FL SW2 RNENBL LDTIP 2
R0220.7 D0613.0
B
DI 959 P PULLEDTI
LDTIP 2 P TIMER2
N00614 K0006.3 Y0018.7

TD MTR F DO 152 T
LT BYPS2 DMFL BY2
N00615 D0608.0 R0410.0 R0413.0

D 2996 TD FAULT2
1TIM2 TOK2
N00616 Y0018.5 X0094.2 Y0108.2 K0006.3 Y0091.3 R0410.0

RSR ON 2 IP DR OK RVTDOK2 LT BYPS2 ST WLD2 TOK2
R0410.0
F
TDCURREN
TOK2
N00617 R0413.0 ACT D0609.0

2TIM2
N00618 Y0018.5 ACT D0608.0

RSR ON 2 1TIM2
N00619 Y0091.3 R0410.0 D0609.0 R0416.0

ST WLD2 TOK2 2TIM2 2
R0406.0
J
TPRESFLT
2
R0416.0
K
TDMTRFLT
2
N00620 R0416.0 Y0018.6

TDMTRFLT DO 151 T
2 DM FLT 2
N00621 Y0118.2 ACT D0607.0

ESCHKMD2 TIM2
N00622 D0607.0 R0407.0 R0406.0

TIM2 LAT2 2
O
Ladder Diagram 76
N00623 Y0118.2 X0094.3 K0007.1 Y0091.3 R0407.0

ESCHKMD2 PDRRSOK2 ST BYPS2 ST WLD2 LAT2
R0407.0
B
TPRESFLT
LAT2
N00624 X0018.4 Y0121.2 Y0113.7 F1000.5 R0221.7

DI 149 I DO 971 P DO 912 C FAULT DI 967 R
NITTPDR2 EDDMPAPP LR ZN 13 NTDDMP2
X0018.6 X0091.2 Y0019.0 Y0121.7

D
DI 151 T DI 731 M DO 153 A DO 976
D DMP R2 ANT REQ2 UTO TD 2 TPWRCMP2
N00625 K0009.1 K0009.1

NTSR ENB NTSR ENB
2SS 2SS
N00626 K0009.1 X1025.1 K0009.1

2SS RESET 2SS
K0009.1 X0091.4
G
NTSR ENB DI 733 N
2SS EW TIP2
N00627 K0015.7 K0015.7

DTSRENB2 DTSRENB2
SS SS
N00628 K0015.7 X1025.1 K0015.7

SS RESET SS
K0015.7 X0091.5
J
DTSRENB2 DI 734 D
SS RSSTIP2
N00629 K0009.1 K0006.6 Y0092.4

2SS PB2 TSR2
X0019.3
L
DI 156 N
EWTPRST2
N00630 K0015.7 K0009.2 Y0092.5

SS 2 TSR2
Y0117.0 Y0054.3
N DRSSTIPSTPRST2
DO 937 DO 436 D
STP RST2 TSR2
N00631
O 3071 SUB72
SPE
Ladder Diagram 77
N00632 ### P0017 ###

A 3072 SUB71 P0017
SP WATERVALVE2
N00633 X1020.5 X0001.6 Y0093.7

RI 6 WTR DI 15 SY DO 752 T
FL SW2 S WTR ON IP WTR2
N00634 X0014.0 R0000.5 Y1020.5

Y1020.5 X1020.5
D
RO 6 WTR RI 6 WTR
RESET2 FL SW2
X1025.1
E
FAULT
RESET
N00635
F 3084 SUB72
SPE
N00636 ### P0018 ###

G 3085 SUB71 P0018
SP OVRTMP/NOSTRK2
N00637 X1020.3 Y0094.4

RI 4 XF DO 757 X
RMR OT2 FMR OT2
N00638 X1020.4 Y0094.5

RI 5 SRV DO 758 S
OMTR OT2 RVMTROT2
N00639 X1020.3 X1025.1 R0501.0

R0501.0
K
XFRMR OT
MP SEAL2
N00640 X1020.4 X1025.1 R0501.1

RI 5 SRV FAULT SRVOMTR
OMTR OT2 RESET OT SEAL2
R0501.1
M
SRVOMTR
OT SEAL2
N00641 R0501.0 Y0020.2

XFRMR OT DO 131 X
MP SEAL2 FMR OTF2
N00642 R0501.1 Y0020.1

SRVOMTR DO 162 S
OT SEAL2 GM OTF2
Ladder Diagram 78
N00643
A 3103 SUB72
SPE
N00644 ### P0020 ###

B 3104 SUB71 P0020
SP AIR
N00645 X1020.6 Y0001.5

RI 7 AIR DO 14 EO
FL SW A AIR ON
N00646
D 3108 SUB72
SPE
N00647 ### P0022 ###

E 3109 SUB71 P0022
SP SWGBOLT
N00648 X0000.0 Y0083.0

F 3111 WELD CONTROLLER #1 ENABLE
DI 1 EXT DO 665 W
RNENBL C1 ENBLE
N00649 X0087.6 Y0014.4

G 3113 WELD CONTROLLER COMM OK #1
DI 703 W DO 117 W
1 COMMOK C1COM OK
N00650 Y0000.3 Y0083.1

H 3115 ROBOT IN TEACH TO WC #1
DO 4 RBT DO 666 R
IN TCH BTCH WC1
N00651 K0004.7 Y0014.2 R0220.6 X1020.0 X1020.1 D0004.3

I 3117 WELD MODE IN WELD WC1
WELD / N DO 115 W DI 958 P RI 1 XF RI 2 SRV WELDMODE
O WELD1 D/NWD1MD LDTIP 1 RMR OT1 OMTR OT1 OK1
N00652 K0006.4 Y0014.2 R0220.7 X1020.3 X1020.4 D0004.4

J 3123 WELD MODE IN WELD WC2
WELD / N DO 115 W DI 959 P RI 4 XF RI 5 SRV WELDMODE
O WELD2 D/NWD1MD LDTIP 2 RMR OT2 OMTR OT2 OK2
N00653 D0004.3 Y0014.1

WELDMODE DO 114 W
OK1 D/NWD1SS
N00654 D0004.4 Y0018.1

L 3131 WELD/ NO WELD 2 SS
WELDMODE DO 146 W
OK2 D/NWD2SS
N00655 D0004.3 D0004.4 R0221.0

M 3133 REMOTE WELD / NO WELD MODE
WELDMODE WELDMODE DI 960 R
OK1 OK2 EM WELD
N00656 X0086.1 Y0015.6

N 3136 I AVAILABLE WARNING #1
DI 690 I DO 127 I
HI/LO AVL WRN1
N00657 X0087.5 Y0017.3

O 3138 ADAPTIVE MODE ENABLE
DI 702 A DO 140 A
DP MODE DP MODE
Ladder Diagram 79
N00658 X0083.0 Y0015.3

A 3140 IN WELD CYCLE #1
DI 665 I DO 124 I
NWLDCYC1 NWD CY 1
N00659 X0083.1 Y0015.4

B 3142 HAS WELDED #1
DI 666 W DO 125 H
ELD CMP1 AS WLD 1
N00660 X0083.3 Y0014.3

C 3144 NO WELD TIMER FAULT #1
DI 668 W DO 116 N
ELD FLT1 OWLDFLT1
N00661 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

D 3146
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0306.0
E ROBOT WELD SCHEDULE WELD CTRL1
DO 686 ROBOT WS
BP 128 WC#1
N00662 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

F 3155
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0307.0
G
DO 686 WLD SCH
BP 128 39 WC1
N00663 Y0014.1 Y0014.2 Y0083.4

H 3164 WELD / NO WELD
DO 114 W DO 115 W DO 669 W
N00664 X1020.2 X1020.0 X1020.1 D0004.0

I 3167 ALL WELD PARAMETER OK WC1
O
Ladder Diagram 80
N00665 Y0109.7 D0004.0 K0000.0 X0024.0 1

A 3171
DO 880 LETSWELD DEBUG DI 193 N
BP1 1 WC1 T FD HM1
Y0110.0
B
DO 881
BP2 1
Y0110.1
C
DO 882
BP4 1
Y0110.2
D
DO 883
BP8 1
Y0110.3
E
DO 884
BP16 1
Y0110.4
F
DO 885
BP32 1
Y0110.5
G
DO 886
BP64 1
Y0110.6
H
DO 887
BP128 1
1 ACT R0363.0
I SUB 3 0035 WELD BINARY WC1 TIMER
TMR BINARYTI
MER1
N00666 Y0109.7 D0004.0 R0363.0 X0024.0 Y0084.6

DO 880 LETSWELD BINARYTI DI 193 N DO 679
BP1 1 WC1 MER1 T FD HM1 BP 1
N00667 Y0110.0 D0004.0 R0363.0 X0024.0 Y0084.7

N00668 Y0110.1 D0004.0 R0363.0 X0024.0 Y0085.0

N00669 Y0110.2 D0004.0 R0363.0 X0024.0 Y0085.1

N00670 Y0110.3 D0004.0 R0363.0 X0024.0 Y0085.2

N00671 Y0110.4 D0004.0 R0363.0 X0024.0 Y0085.3

Ladder Diagram 81
N00672 Y0110.5 D0004.0 R0363.0 X0024.0 Y0085.4

N00673 Y0110.6 D0004.0 R0363.0 X0024.0 Y0085.5

N00674 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

C 3225
DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685
BP 1 BP 2 BP 4 BP 8 BP 16 BP 32 BP 64
1 Y0085.5 R0360.0
D NO WELD SCHEDULE WC1
DO 686 NOWLDSCH
BP 128 WC1
N00675 R0360.0 X0087.6 K0000.0 Y0083.5

E 3234 PRESSURE SWITCH INPUT
K0000.0 Y0116.5 X0024.0

F
DEBUG DO 934 DI 193 N
RD SCHD1 T FD HM1
N00676 Y0120.6 F1000.3 Y0000.1 X0024.0 R0223.0

G 3242
DO 967 M PAUSED DO 2 RBT DI 193 N DI 976 M
AN WELD1 @ HOME T FD HM1 AN WELD1
X0015.0 K0008.0 Y0000.5 F1000.3 F1000.2

H
Y0000.1 F1000.2 F1000.3

I
@ HOME RUNNING
N00677 Y0120.6 Y0000.1 F1000.2 F1000.3 X0024.0 R0213.6

J 3259 WELD AT HOME1
DO 967 M DO 2 RBT PROGRAM PAUSED DI 193 N DI 902 W
AN WELD1 @ HOME RUNNING T FD HM1 ELDHOME1
X0015.0 K0008.0
K
DI 121 R AUTO/MAI
M MAN W1 NT SS
N00678 Y0048.3 Y0121.0 F1000.3 Y0000.1 X0024.0 R0220.4

L 3268 SWGNUT REFFED REWELD 1
DO 388 N DO 969 F PAUSED DO 2 RBT DI 193 N DI 956 R
UTFD APP EDWLD1PB @ HOME T FD HM1 EFEDWLD1
Y0050.7
M
DO 408 S
WGBOLTAP
N00679 K0008.6 D0612.0 K0008.6

1 1
N00680 K0008.6 D0612.0 K0008.6

1 1
Ladder Diagram 82
N00681 K0005.1 D0612.0 K0005.1

PB1 PB1
N00682 K0005.1 D0612.0 K0005.1

PB1 PB1
N00683 K0005.2 D0612.0 K0005.2

O TD PB1 O TD PB1
N00684 K0005.2 D0612.0 K0005.2

O TD PB1 O TD PB1
N00685 K0005.5 D0612.0 K0005.5

CLS PB1 CLS PB1
N00686 K0005.5 D0612.0 K0005.5

CLS PB1 CLS PB1
N00687 K0005.6 D0612.0 K0005.6

OPN PB1 OPN PB1
N00688 K0005.6 D0612.0 K0005.6

OPN PB1 OPN PB1
N00689 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00690 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00691 K0006.0 D0612.0 K0006.0

ACK PB1 ACK PB1
N00692 K0006.0 D0612.0 K0006.0

ACK PB1 ACK PB1
N00693 Y0120.6 D0612.0 Y0120.6

AN WELD1 AN WELD1
N00694 Y0120.6 D0612.0 Y0120.6

AN WELD1 AN WELD1
N00695 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
Ladder Diagram 83
N00696 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
N00697 Y1020.0 Y1020.0

B 3329 S RDO 1 EQUALIZATION VALVE 1
RO 1 RO 1
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
C
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00698 Y1020.0 Y1020.0

D 3334 R RDO 1 EQUALIZATION VALVE 1
RO 1 RO 1
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
E
EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00699 K0004.5 K0006.2

EQUALENB EQUALIZE
L 1&2 SS R 1 SS
N00700 K0004.5 X1026.1 G1000.1 ACT K0004.5

G 3341 SUB 3 0033 R EQUALIZATION ENABLE 1&2 SS
N00701 K0000.0 Y0083.3 D0612.0 X1025.1 Y0083.3

H 3347 RESET WELDER
ST WLD RESET ST WLD
X1025.1
I
FAULT
RESET
N00702 K0015.1 D0612.0 K0015.1

J 3353 S ADVANCE TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00703 K0015.1 D0612.0 K0015.1

K 3356 R ADVANCE TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00704 K0015.2 D0612.0 K0015.2

L 3359 S RETRACT TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00705 K0015.2 D0612.0 K0015.2

M 3362 R RETRACT TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00706 K0015.1 Y0000.2 X1026.1 K0015.2 Y0017.5

N 3365
N00707 K0015.2 Y0000.2 X1026.1 K0015.1 Y0017.6

O 3370
Ladder Diagram 84
N00708 Y0109.7 Y0110.0 Y0110.1 Y0110.2 Y0110.3 Y0110.4 Y0110.5 1

A 3375
DO 880 DO 881 DO 882 DO 883 DO 884 DO 885 DO 886
BP1 1 BP2 1 BP4 1 BP8 1 BP16 1 BP32 1 BP64 1
1 Y0110.6 R0360.1
B BYPASS NUT PRESENT
DO 887 BYPSSNUT
BP128 1 PRSNT
N00709 X0001.1 ACT

C 3384 SUB10 0000
DI 10 AU JMP
TO REPT
N00710 X0024.0 R0360.1 Y0024.2

D 3387 S
DI 193 N BYPSSNUT DO 195 N
T FD HM1 PRSNT UTPRSNT1
N00711 X0024.0 Y0024.2

E 3390 R
DI 193 N DO 195 N
T FD HM1 UTPRSNT1
N00712
F 3392 SUB30
JMPE
N00713
G 3393 SUB72
SPE
N00714 ### P0025 ###

H 3394 SUB71 P0025
SP TOUCHUP1
N00715 K0000.1 Y0054.4

I 3396 PROGRAM TOUCHUP REQUEST
TOUCHUP1 DO 437 P
ENB RGTCHREQ
N00716
J 3398 SUB72
SPE
O
11 PMC Logic (S-Logic) SWGBolt + SWGNut for R-30iB
Controllers

Page 305 of 305
[f3l1bltnut1] Ladder Diagram 1
N00001 R0000.0 R0000.0

A 1 ALWAYS ON
ALWAYS__ ALWAYS__
ON ON
R0000.0
B
ALWAYS__
ON
N00002 R0000.0 G1000.0

ALWAYS__ NO_IMSTP
ON
N00003 X0000.0 R0100.5 K0004.5 G1000.1

D 6 NO HOLD
DI_1_EXT BREAK_A_ EQUALENB NO_HOLD
_RNENBL NO_HOLD L_1_2_SS
N00004 X1026.4 R0100.5

SI12_HOL BREAK_A_
DSW NO_HOLD
N00005 X1026.5 R0100.5

SI13_RES BREAK_A_
ETSW NO_HOLD
X1026.4 X1025.6
G
SI12_HOL CYCLE___
DSW START
X0000.1 X1026.4
H
DI_2_EX_ SI12_HOL
RNEN_RST DSW
N00006 R0000.0 G1000.2

I 20 SAFE SPEED
ALWAYS__ SFSPD
ON
N00007 X1000.3 G1000.3

J 22
O
N00008 X1025.1 G1000.4

A 24 FAULT RESET
FAULT___ RB_FAULT
RESET _RESET
X0000.1 X0001.2
B
DI_2_EX_ DI_11___
RNEN_RST PLC_AUTO
X1026.5
C
SI13_RES
ETSW
X0000.3
D
DI_4_EXT
_CY_STRT
X0000.2
E
DI_3_EXT
MTR_ON
Y0119.6
F
DO_959_F
LT_RESET
R0223.0
G
DI_976_M
AN_WELD1
R0220.4
H
DI_956_R
EFEDWLD1
R0223.1
I
DI_977_M
AN_WELD2
N00009 X1000.6 G1000.6

J 36 GO HOME
HOME
N00010 R0000.0 G1000.7

K 38 ENABLE
ALWAYS__ ENABLE
ON
N00011 F1000.0 Y1000.0

L 40
COMMAND_
ENABLE
N00012 F1000.1 Y1000.1

M 42
SYSTEM__
READY
Y1025.5
N MOTORS ENABLE
MOTORS__
ENABLE
N00013 F1000.2 Y1000.2

O 45
PROGRAM_
RUNNING
N00014 F1000.3 Y1000.3

A 47
PAUSED
N00015 F1000.4 Y1000.4

B 49
HELD
Y0000.0
DO_1_RUN
_ENB_ACK
N00016 F1000.5 ACT R0338.0

FAULT TMR INT_FLT_
__DELAY
N00017 F1000.5 G1000.4 R0397.0 R0338.0 Y1000.5

E 56
FAULT RB_FAULT FILTERED INT_FLT_
_RESET _FAULT __DELAY
Y0120.2 Y0000.4
DO_963__ DO_5_RBT
PRG_FLT _CNT_FLT
Y0001.6
G
DO_15_CO
LL_DTCT
N00018 F1000.6 Y1000.6

H 64
AT_HOME
Y0002.0 Y0000.1
I ROBOT AT HOME
DO_17_RB DO_2_RBT
T_@_HM1 _@_HOME
Y0002.1
J
DO_18_RB
T_@_HM2
Y0002.2
K
DO_19_RB
T_@_HM3
Y0002.3
L
DO_20_RB
T_@_HM4
Y0002.4
M
DO_21_RB
T_@_HM5
Y0002.5
N
DO_22_RB
T_@_HM6
Y0002.6
O
DO_23_RB
T_@_HM7
N00019 F1000.7 Y1000.7

A 74
TPENABLE
Y0119.7 Y0000.3
B ROBOT IN TEACH
DO_960__ DO_4_RBT
AUTO_KEY _IN_TCH
N00020 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

C 78
1 R1402.7 R1405.0
D S
ECO24___ FACILITY
FC128 _CODE_11
N00021 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 R1400.6 1

E 87
1 R1400.7 R1401.1 R1401.2 R1401.3 R1401.5 R1401.6 2

F
2 R1401.7 R1405.1
G
ECO16 ERROR_4
N00022 R1405.0 R1405.1 G1000.4 R1405.2

H 102 FENCE FAULT
FACILITY ERROR_4 RB_FAULT FENCE___
_CODE_11 _RESET FAULT
R1405.2
I
FENCE___
FAULT
N00023 R0000.1 F1000.5 R1466.0 F1000.0 F1000.1 K0010.3

INT_EXT_ FAULT BRK_PWR_ COMMAND_ SYSTEM__ PWR_FAIL
MTR_ON FL_RCVRY ENABLE READY _RECVRY
R0000.2
K
INT_EXT_
CYC_STRT
K0010.3
L
PWR_FAIL
_RECVRY
N00024 K0010.3 ACT R1466.0

PWR_FAIL TMR BRK_PWR_
_RECVRY FL_RCVRY
O
N00025 Y0000.3 F1000.0 Y0000.4 R0000.1 R0000.2 F1000.1 F1008.0 1

A 119
DO_4_RBT COMMAND_ DO_5_RBT INT_EXT_ INT_EXT_ SYSTEM__ STEP
_IN_TCH ENABLE _CNT_FLT MTR_ON CYC_STRT READY
R1404.5 Y0000.2
B
DRP_AUTO DO_3_RBT
_FAULT _IN_AUTO
1 F1008.2 X1025.0 R1405.2 K0010.0 Y0001.6 Y0000.2

TP______ FANUC___ FENCE___ TEACH___ DO_15_CO DO_3_RBT
E-STOP E-STOP FAULT MEMORY LL_DTCT _IN_AUTO
N00026 Y0119.5 Y0072.4

DO_958_I DO_581_I
NPUTSIM NPUTSIM
N00027 R1404.4 R1456.0 R1404.2 F1000.5 G1000.4 R0330.2 R0386.1 R1404.5

FC_AVAIL APPL____ FC_ZERO FAULT RB_FAULT SERVOGUN SVGN320_ DRP_AUTO
ALARMS _RESET _ALARM 326_LTCH _FAULT
N00028 F1000.5 R1404.5

FAULT DRP_AUTO
_FAULT
G1000.4
G
RB_FAULT
_RESET
N00029 F1000.5 R1404.0 R1404.1 R1404.4

H 149
FAULT ECO33___ ECO_____ FC_AVAIL
STROBE RETRIEVE
N00030 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 153
1 R1402.6 R1402.7 R1404.3

J S
ECO23___ ECO24___ SPOT____
FC64 FC128 ALARM
N00031 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

K 163
1 R1402.6 R1402.7 R0330.0

L S
ECO23___ ECO24___ ARC_____
FC64 FC128 ALARM
N00032 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

M 173
1 R1402.6 R1402.7 R0330.1

N S
ECO23___ ECO24___ SEALER__
FC64 FC128 ALARM
O
N00033 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

A 183
1 R1402.6 R1402.7 R0330.2

B S
ECO23___ ECO24___ SERVOGUN
FC64 FC128 _ALARM
N00034 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

C 193
1 R1402.6 R1402.7 R0330.3

D S
ECO23___ ECO24___ TOOLCHNG
FC64 FC128 __ALARM
N00035 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

E 203
1 R1402.6 R1402.7 R0330.4

F S
ECO23___ ECO24___ SYSTEM__
FC64 FC128 _ALARM
N00036 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

G 213
1 R1402.6 R1402.7 R1406.0

H S
ECO23___ ECO24___ FACILITY
FC64 FC128 _CODE_15
N00037 R1404.4 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 1

I 223
1 R1402.6 R1402.7 R1404.2

J
ECO23___ ECO24___ FC_ZERO
FC64 FC128
O
N00038 R1404.1 ACT R1404.3

A 233 SUB57 0001 R
ECO_____ DIFU SPOT____
RETRIEVE ALARM
R0330.0
B R
ARC_____
ALARM
R0330.1
C R
SEALER__
ALARM
R0330.2
D R
SERVOGUN
_ALARM
R0330.3
E R
TOOLCHNG
__ALARM
R0330.4
F R
SYSTEM__
_ALARM
R1405.0
G R
FACILITY
_CODE_11
R1406.0
H R
FACILITY
_CODE_15
N00039 R1404.4 ACT R1404.6

I 244 SUB 3 0006
FC_AVAIL TMR RETRIEVE
_DELAY
N00040 R1404.6 R1404.1

J 248 S
RETRIEVE ECO_____
_DELAY RETRIEVE
N00041 R1404.1 ACT R1404.1

K 250 SUB 3 0007 R
ECO_____ TMR ECO_____
RETRIEVE RETRIEVE
N00042 Y0015.5 Y0015.5

DO_126_W DO_126_W
LD_FLT_1 LD_FLT_1
N00043 X0083.1 Y0015.5

DI_666_W DO_126_W
ELD_CMP1 LD_FLT_1
N00044 Y0019.5 Y0019.5

DO_158_W DO_158_W
LD_FLT_2 LD_FLT_2
N00045 X0091.1 Y0019.5

DI_730_W DO_158_W
ELD_CMP2 LD_FLT_2
N00046 K0010.1 K0010.0 Y1025.5 R0000.1

A 262 S
EXT_MTR_ TEACH___ MOTORS__ INT_EXT_
ON MEMORY ENABLE MTR_ON
N00047 Y1025.5 R0000.1

B 266 R
MOTORS__ INT_EXT_
ENABLE MTR_ON
N00048 X0000.2 K0010.0 K0010.5 K0010.1

DI_3_EXT TEACH___ MAINT_ME EXT_MTR_
MTR_ON MEMORY M ON
X1026.5 Y0000.4 F1000.5

D
ETSW _CNT_FLT
X1025.1
E
FAULT___
RESET
X0000.1 X0001.2
F
DI_2_EX_ DI_11___
RNEN_RST PLC_AUTO
N00049 K0010.2 K0010.0 K0010.5 R0000.2

G 280
EXT_CYC_ TEACH___ MAINT_ME INT_EXT_
START MEMORY M CYC_STRT
N00050 X0000.3 K0010.0 K0010.2

DI_4_EXT TEACH___ EXT_CYC_
_CY_STRT MEMORY START
X1026.5 Y0000.4 F1000.5

I
ETSW _CNT_FLT
X1025.1
J
FAULT___
RESET
X0000.1 X0001.2
K
DI_2_EX_ DI_11___
RNEN_RST PLC_AUTO
R0340.0
L
MANUAL__
WELD
N00051 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 296
1 X0002.7 R0507.0
N PROGRAM 1
DI_24_PG PROGRAM_
_SLCT128 1
O
N00052 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 305
1 X0002.7 R0507.1
B PROGRAM 2
DI_24_PG PROGRAM_
_SLCT128 2
N00053 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 314
1 X0002.7 R0507.2
D PROGRAM 3
DI_24_PG PROGRAM_
_SLCT128 3
N00054 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 323
1 X0002.7 R0507.3
F PROGRAM 4
DI_24_PG PROGRAM_
_SLCT128 4
N00055 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 332
1 X0002.7 R0507.4
H PROGRAM 5
DI_24_PG PROGRAM_
_SLCT128 5
N00056 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 341
1 X0002.7 R0507.5
J PROGRAM 6
DI_24_PG PROGRAM_
_SLCT128 6
N00057 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 350
1 X0002.7 R0507.6
L PROGRAM 7
DI_24_PG PROGRAM_
_SLCT128 7
N00058 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 359
1 X0002.7 R0507.7
N PROGRAM 8
DI_24_PG PROGRAM_
_SLCT128 8
O
N00059 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 368
1 X0002.7 R0508.0
B PROGRAM 9
DI_24_PG PROGRAM_
_SLCT128 9
N00060 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 377
1 X0002.7 R0508.1
D PROGRAM 10
DI_24_PG PROGRAM_
_SLCT128 10
N00061 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 386
1 X0002.7 R0508.2
F PROGRAM 11
DI_24_PG PROGRAM_
_SLCT128 11
N00062 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 395
1 X0002.7 R0508.3
H PROGRAM 12
DI_24_PG PROGRAM_
_SLCT128 12
N00063 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 404
1 X0002.7 R0508.4
J PROGRAM 13
DI_24_PG PROGRAM_
_SLCT128 13
N00064 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

K 413
1 X0002.7 R0508.5
L PROGRAM 14
DI_24_PG PROGRAM_
_SLCT128 14
N00065 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

M 422
1 X0002.7 R0508.6
N PROGRAM 15
DI_24_PG PROGRAM_
_SLCT128 15
O
N00066 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

A 431
1 X0002.7 R0508.7
B PROGRAM 16
DI_24_PG PROGRAM_
_SLCT128 16
N00067 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

C 440
1 X0002.7 R0509.0
D PROGRAM 17
DI_24_PG PROGRAM_
_SLCT128 17
N00068 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

E 449
1 X0002.7 R0509.1
F PROGRAM 18
DI_24_PG PROGRAM_
_SLCT128 18
N00069 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

G 458
1 X0002.7 R0509.2
H PROGRAM 19
DI_24_PG PROGRAM_
_SLCT128 19
N00070 X0002.0 X0002.1 X0002.2 X0002.3 X0002.4 X0002.5 X0002.6 1

I 467
1 X0002.7 R0509.3
J PROGRAM 20
DI_24_PG PROGRAM_
_SLCT128 20
O
N00071 X0000.4 Y0000.2 F1000.2 F1000.3 F1000.6 X0001.2 G1000.1 1

A 476
DI_5_MV_ DO_3_RBT PROGRAM_ PAUSED AT_HOME DI_11___ NO_HOLD
TO_POUNC _IN_AUTO RUNNING PLC_AUTO
Y0000.2 F1000.3 F1000.2 X0001.2

B
DO_3_RBT PAUSED PROGRAM_ DI_11___
_IN_AUTO RUNNING PLC_AUTO
F1000.6 R0507.0 F1000.2 F1000.3

C
AT_HOME PROGRAM_ PROGRAM_ PAUSED
1 RUNNING
R0507.1
D
PROGRAM_
2
R0507.2
E
PROGRAM_
3
R0507.3
F
PROGRAM_
4
R0507.4
G
PROGRAM_
5
R0507.5
H
PROGRAM_
6
R0507.6
I
PROGRAM_
7
R0507.7
J
PROGRAM_
8
R0508.0
K
PROGRAM_
9
R0508.1
L
PROGRAM_
10
R0508.2
M
PROGRAM_
11
R0508.3
N
PROGRAM_
12
R0508.4
O
PROGRAM_
13
R0508.5
A
PROGRAM_
14
R0508.6
B
PROGRAM_
15
R0508.7
C
PROGRAM_
16
R0509.0
D
PROGRAM_
17
R0509.1
E
PROGRAM_
18
R0509.2
F
PROGRAM_
19
R0509.3
G
PROGRAM_
20
Y0000.2 F1000.3 F1000.2 X0000.1 X0001.2

H
DO_3_RBT PAUSED PROGRAM_ DI_2_EX_ DI_11___
_IN_AUTO RUNNING RNEN_RST PLC_AUTO
R0223.0
I
DI_976_M
AN_WELD1
R0223.1
J
DI_977_M
AN_WELD2
1 R0000.1 D0603.0 Y0000.4 R0100.5 F1000.5 G1000.5

K UOP CYCLE START
INT_EXT_ CYCLE___ DO_5_RBT BREAK_A_ FAULT UOP_CYC_
MTR_ON STRT_DLY _CNT_FLT NO_HOLD START
N00072 G1000.5 F1000.2 ACT D0603.0

UOP_CYC_ PROGRAM_ TMR CYCLE___
START RUNNING STRT_DLY
N00073 D0603.0 ACT D0603.0

CYCLE___ TMR CYCLE___
STRT_DLY STRT_DLY
N00074 F1000.2 D0603.0

PROGRAM_ CYCLE___
RUNNING STRT_DLY
N00075
O 539 SUB 1
END1
N00076 Y0119.7 ACT K0010.4

DO_960__ TMR TEACH_ME
AUTO_KEY M_DELAY
N00077 Y0000.3 X1026.5 X1025.1 X1025.6 K0010.0

B 544 TEACH MEMORY
DO_4_RBT SI13_RES FAULT___ CYCLE___ TEACH___
_IN_TCH ETSW RESET START MEMORY
K0010.4
C
TEACH_ME
M_DELAY
K0010.0
D
TEACH___
MEMORY
N00078 K0008.0 R0350.0

AUTO/MAI IN_MAINT
NT_SS
N00079 R0350.0 ACT D0610.0

IN_MAINT TMR MAINT___
DELAY
N00080 D0610.0 Y0000.2 Y0000.1 X1026.5 X1025.1 K0010.5

MAINT___ DO_3_RBT DO_2_RBT SI13_RES FAULT___ MAINT_ME
DELAY _IN_AUTO _@_HOME ETSW RESET M
K0010.5 X0000.6
H
MAINT_ME DI_7_MAI
M NT_PSCLR
N00081 X0000.2 X0000.3 Y0000.2 K0010.6

DI_3_EXT DI_4_EXT DO_3_RBT EXT_STRT
MTR_ON _CY_STRT _IN_AUTO _ANTI_TD
K0010.6
J
EXT_STRT
_ANTI_TD
N00082 X0002.0 G1001.0

K 571
DI_17_PG PNS_1
_SLCT_1
N00083 X0002.1 G1001.1

L 573
DI_18_PG PNS_2
_SLCT_2
N00084 X0002.2 G1001.2

M 575
DI_19_PG PNS_3
_SLCT_4
N00085 X0002.3 G1001.3

N 577
DI_20_PG PNS_4
_SLCT_8
N00086 X0002.4 G1001.4

O 579
DI_21_PG PNS_5
_SLCT_16
N00087 X0002.5 G1001.5

A 581
DI_22_PG PNS_6
_SLCT_32
N00088 X0002.6 G1001.6

B 583
DI_23_PG PNS_7
_SLCT_64
N00089 X0002.7 G1001.7

C 585
DI_24_PG PNS_8
_SLCT128
N00090 X0000.6 K0008.0 Y0120.5

DI_7_MAI AUTO/MAI DO_966__
NT_PSCLR NT_SS MAINTCLR
N00091 K0008.0 Y0001.4

AUTO/MAI DO_13_SN
NT_SS DRBT_MNT
N00092 Y0112.3 Y0003.0

DO_900__ DO_25_CL
CLR_ZN_1 R_ZON_1
N00093 Y0112.4 Y0003.1

DO_901__ DO_26_CL
CLR_ZN_2 R_ZON_2
N00094 Y0112.5 Y0003.2

DO_902__ DO_27_CL
CLR_ZN_3 R_ZON_3
N00095 Y0112.6 Y0003.3

DO_903__ DO_28_CL
CLR_ZN_4 R_ZON_4
N00096 Y0112.7 Y0003.4

DO_904__ DO_29_CL
CLR_ZN_5 R_ZON_5
N00097 Y0113.0 Y0003.5

DO_905__ DO_30_CL
CLR_ZN_6 R_ZON_6
N00098 Y0113.1 Y0003.6

DO_906__ DO_31_CL
CLR_ZN_7 R_ZON_7
N00099 Y0113.2 Y0003.7

DO_907__ DO_32_CL
CLR_ZN_8 R_ZON_8
N00100 Y0113.3 Y0004.0

DO_908__ DO_33_CL
CLR_ZN_9 R_ZON_9
N00101 Y0113.4 Y0004.1

DO_909_C DO_34_CL
LR_ZN_10 R_ZON_10
N00102 Y0113.5 Y0004.2

DO_910_C DO_35_CL
LR_ZN_11 R_ZON_11
N00103 Y0113.6 Y0004.3

DO_911_C DO_36_CL
LR_ZN_12 R_ZON_12
N00104 Y0113.7 Y0004.4

DO_912_C DO_37_CL
LR_ZN_13 R_ZON_13
N00105 Y0116.4 Y0004.5

DO_933_C DO_38_CL
LR_ZN_14 R_ZON_14
N00106 Y0118.7 Y0004.6

DO952_CL DO_39_CL
RMOTZN1 R_INDMOT
N00107 Y0119.0 Y0004.7

DO953_CL DO_40_CL
RMOTZN2 R_INDMT2
N00108 Y0119.1 X0000.0 Y0000.6

LRAV_XFR _RNENBL _ADV
N00109 Y0119.2 X0000.0 Y0000.7

LRET_XFR _RNENBL _RET_XFR
N00110 Y0119.3 X0000.0 Y0001.0

LR_UNCLP _RNENBL _2_UNCLP
N00111 Y0000.3 R1000.0 Y0073.0

J 633 PROMPT BOX
DO_4_RBT DO_19001 DO_585__
_IN_TCH _PRPTBX PRMPT_BX
N00112 R1402.0 R1402.1 R1402.2 R1402.3 R1402.4 R1402.5 R1402.6 1

K 636
1 R1402.7 R1405.3
ECO24___ SYS_FCLY
FC128 CODE
N00113 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 645
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0365.0

N00114 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 663
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0366.0

N00115 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 681
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0367.0

N00116 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 699
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0368.0

N00117 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 717
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.0

N00118 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 735
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0370.1

N00119 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 753
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.3

N00120 R1406.3 X1025.1 Y0001.6

SRVO-50 FAULT___ DO_15_CO
RESET LL_DTCT
Y0001.6
E
DO_15_CO
LL_DTCT
N00121 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

F 775
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

G
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.2

ECO13 ECO14 ECO15 ECO16 SRVO-65_
LOW_BATT
N00122 F1001.0 Y0001.1

BATALM DO_10_RB
T_BAT_LW
N00123 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 795
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0371.0

N00124 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 813
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R1406.1

NCE_EXCE
N00125 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 831
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0373.0

_CONTROL
N00126 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 849
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0374.0

_NTED_IN
N00127 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

G 867
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

H
2 R1401.4 R1401.5 R1401.6 R1401.7 R0375.0

_TP_OFF
N00128 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

J 885
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

K
2 R1401.4 R1401.5 R1401.6 R1401.7 R0376.0

_SVOFF_I
N00129 R1405.0 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

M 903
_CODE_11
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

N
2 R1401.4 R1401.5 R1401.6 R1401.7 R0387.0

O SRVO-378 SFDIxx STATUS ABNOR
_SFDIxx
N00130 F1008.1 ACT R0388.1

A 921 SUB24 0001 F1008.1_DELAY_ON
SYSRST TMRB F1008.1_
DELAY ON
B 0000000124
N00131 R0387.0 R0388.1 R0388.0

C 926 SRVO OPSFTY ABNORM FAULT LATCH
SRVO-378 F1008.1_ OPSFTY_F
_SFDIxx DELAY ON LT_LATCH
R0388.0 F1000.5
D
OPSFTY_F FAULT
LT_LATCH
N00132 R0388.0 Y0073.1

E 932 SAFETY CHAIN FAULT
OPSFTY_F DO_586_S
LT_LATCH FTY_CHN
N00133 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

F 934
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

G
2 R1401.4 R1401.5 R1401.6 R1401.7 R0377.0

H SYST-034 HOLD SIGNAL FROM SOP/
_HOLD_SI
N00134 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

I 952
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

J
2 R1401.4 R1401.5 R1401.6 R1401.7 R0378.0

K SYST-038 OPERATION MODE T1 SEL
_OPERATI
N00135 R1405.3 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

L 970
CODE
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

M
2 R1401.4 R1401.5 R1401.6 R1401.7 R0379.0

N
O
N00141 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

A 1078
_ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

B
2 R1401.4 R1401.5 R1401.6 R1401.7 R0385.0

C SVGN-320 THCKNESS1 ERR REQ RES
_THK1ERR
N00142 R0330.2 R1400.0 R1400.1 R1400.2 R1400.3 R1400.4 R1400.5 1

D 1096
_ALARM
1 R1400.6 R1400.7 R1401.0 R1401.1 R1401.2 R1401.3 2

E
2 R1401.4 R1401.5 R1401.6 R1401.7 R0386.0

F SVGN-326 THKNESS2 ERR REQ RES
_THK2ERR
N00143 R0385.0 R0386.1

G 1114 SVGN 320 _ 326 LATCH
SVGN-320 SVGN320_
_THK1ERR 326_LTCH
R0386.0
H
SVGN-326
_THK2ERR
R0386.1 G1000.4
I
SVGN320_ RB_FAULT
326_LTCH _RESET
N00144 R0397.0 F1000.0 R0397.0

J 1120 FILTERED FAULT
FILTERED COMMAND_ FILTERED
_FAULT ENABLE _FAULT
R0398.0
K
FILTER__
FLT_GRP1
R0399.0
L
FILTER__
FLT_GRP2
O
N00145 R0365.0 R0398.0

SRVO-001 FILTER__
FLT_GRP1
R0366.0
B
SRVO-002
R0367.0
C
SRVO-003
R0368.0
D
SRVO-005
R0369.0
E
R369.0__
RESERVED
R0370.0
F
SRVO-007
R0371.0
G
SRVO-101
R0372.0
H
R372.0__
RESERVED
R0373.0
I
SRVO-199
_CONTROL
R0374.0
J
SRVO-232
_NTED_IN
R0375.0
K
SRVO-233
_TP_OFF
R0376.0
L
SRVO-280
_SVOFF_I
R0385.0
M
SVGN-320
_THK1ERR
R0386.0
N
SVGN-326
_THK2ERR
R0370.1
O
SRVO-408
R1456.0
A
APPL____
ALARMS
N00146 R0377.0 R0399.0

SYST-034 FILTER__
_HOLD_SI FLT_GRP2
R0378.0
C
SYST-038
_OPERATI
R0379.0
D
SYST-039
R0380.0
E
SYST-040
_OPERATI
R0381.0
F
SYST-042
_DEADMAN
R0382.0
G
SYST-043
_TP_DISA
R0383.0
H
SYST-045
_TP_ENAB
R0384.0
I
SYST-154
_NO_STAR
X1025.0
J
FANUC___
E-STOP
F1008.2
K
TP______
E-STOP
X1026.1
L
SI9_____
AUTOMDSW
Y0000.3
M
DO_4_RBT
_IN_TCH
K0010.0
N
TEACH___
MEMORY
R1405.2
O
FENCE___
FAULT
N00147 R0330.0 F1000.5 R1456.0

A 1157
ARC_____ FAULT APPL____
ALARM ALARMS
R0330.1
B
SEALER__
ALARM
R0330.3
C
TOOLCHNG
__ALARM
R0330.4
D
SYSTEM__
_ALARM
R1404.3
E
SPOT____
ALARM
R1456.0
F
APPL____
ALARMS
N00148 D0001.0 Y0079.0

TOOL_CHA DO_633_T
NGE_APP C_LOCK
Y0079.1
DO_634_T
C_UNLOCK
N00149 D0001.0 ACT

I 1168 SUB10 0000
TOOL_CHA JMP
NGE_APP
N00150
J 1171 SUB66 P0001
CALLU TOOL_CHANGING
N00151
K 1173 SUB30
JMPE
N00152
L 1174 SUB66 P0022
CALLU SWGBOLT
N00153
M 1176 SUB66 P0003
CALLU TIPDRESSER1
N00154
N 1178 SUB66 P0004
CALLU WATERVALVE1
N00155
O 1180 SUB66 P0005
N00156
A 1182 SUB66 P0006
CALLU UALM
N00157
B 1184 SUB66 P0007
CALLU INTERFACE
N00158
C 1186 SUB66 P0008
CALLU MH
N00159
D 1188 SUB66 P0009
CALLU APPLICATION
N00160
E 1190 SUB66 P0020
CALLU AIR
N00161
F 1192 SUB66 P0015
CALLU WELDCONTROL2
N00162
G 1194 SUB66 P0016
CALLU TIPDRESSER2
N00163
H 1196 SUB66 P0017
CALLU WATERVALVE2
N00164
I 1198 SUB66 P0018
N00165
J 1200 SUB66 P0025
CALLU TOUCHUP1
N00166
K 1202 SUB 2
END2
N00167 ### TOOL_CHANGING ###

L 1203 SUB71 P0001
SP TOOL_CHANGING
O
N00168 X0080.0 R0347.0

A 1205 GUN ID NOT 0
DI_641__ GUN_ID__
TOOL_ID1 NOT_0
X0080.1
B
DI_642__
TOOL_ID2
X0080.2
C
DI_643__
TOOL_ID4
X0080.3
D
DI_644__
TOOL_ID8
N00169 X0080.0 X0080.1 X0080.2 X0080.3 R0321.0

E 1210
DI_641__ DI_642__ DI_643__ DI_644__ GUN_1_ON
N00170 X0080.0 X0080.1 X0080.2 X0080.3 R0322.0

F 1215
DI_641__ DI_642__ DI_643__ DI_644__ GUN_2_ON
N00171 X0080.0 X0080.1 X0080.2 X0080.3 R0323.0

G 1220
DI_641__ DI_642__ DI_643__ DI_644__ GUN_3_ON
N00172 X0080.0 X0080.1 X0080.2 X0080.3 R0324.0

H 1225
DI_641__ DI_642__ DI_643__ DI_644__ GUN_4_ON
N00173 X0080.0 X0080.1 X0080.2 X0080.3 R0325.0

I 1230
DI_641__ DI_642__ DI_643__ DI_644__ GUN_5_ON
N00174 X0080.0 X0080.1 X0080.2 X0080.3 R0326.0

J 1235
DI_641__ DI_642__ DI_643__ DI_644__ GUN_6_ON
N00175 X0080.0 X0080.1 X0080.2 X0080.3 R0326.1

K 1240
DI_641__ DI_642__ DI_643__ DI_644__ GUN_7_ON
N00176 X0080.0 X0080.1 X0080.2 X0080.3 R0326.2

L 1245
DI_641__ DI_642__ DI_643__ DI_644__ GUN_8_ON
O
N00177 R0321.0 R0328.6

GUN_1_ON TOOLONRO
_ARM BOT
R0322.0
B
GUN_2_ON
_ARM
R0323.0
C
GUN_3_ON
_ARM
R0324.0
D
GUN_4_ON
_ARM
R0325.0
E
GUN_5_ON
_ARM
R0326.0
F
GUN_6_ON
_ARM
R0326.1
G
GUN_7_ON
_ARM
R0326.2
H
GUN_8_ON
_ARM
N00178 R0321.0 R0322.0 R0323.0 R0324.0 R0325.0 R0326.0 R0326.1 1

I 1259
GUN_1_ON GUN_2_ON GUN_3_ON GUN_4_ON GUN_5_ON GUN_6_ON GUN_7_ON
_ARM _ARM _ARM _ARM _ARM _ARM _ARM
1 R0326.2 R0348.0
GUN_8_ON GEOTOOLP
_ARM RSNT
N00179 X0080.0 Y0038.0

DI_641__ DO_305__
TOOL_ID1 TOOL_ID1
N00180 X0080.1 Y0038.1

L 1270
DI_642__ DO_306__
TOOL_ID2 TOOL_ID2
N00181 X0080.2 Y0038.2

M 1272
DI_643__ DO_307__
TOOL_ID4 TOOL_ID4
N00182 X0080.3 Y0038.3

N 1274
DI_644__ DO_308__
TOOL_ID8 TOOL_ID8
O
N00183 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 X0038.6 1

A 1276
DI_305__ DI_306__ DI_307__ DI_308__ DI_309__ DI_310__ DI_311__
1 X0038.7 R0327.0
DI_312__ GUN_1-8
TCSTND8
N00184 Y0117.4 K0011.1

DO_941__ TC____RE
TC_UNLCK LEASED
N00185 Y0117.3 Y0000.2 X0079.4 X0079.5 R0328.6 Y0079.0

DO_940__ DO_3_RBT DI_637__ DI_638__ TOOLONRO DO_633_T
TC_LOCK _IN_AUTO RDY2LCK1 RDY2LCK2 BOT C_LOCK
F1000.7 Y0119.7 K0015.0 R0328.6

E
TPENABLE DO_960__ TC_LOCK_ TOOLONRO
AUTO_KEY PB BOT
N00186 Y0117.4 Y0117.3 Y0000.2 Y0079.0

F 1300 R TOOL CHANGER LOCK
DO_941__ DO_940__ DO_3_RBT DO_633_T
TC_UNLCK TC_LOCK _IN_AUTO C_LOCK
F1000.7 Y0119.7 K0016.0

G
TPENABLE DO_960__ TC_UNLOC
AUTO_KEY K_PB
N00187 X0079.0 Y0040.6

H 1309
DI_633__ DO_327_T
TC_LOCKD CCOUPMON
N00188 K0011.1 Y0079.0 Y0000.2 X0080.4 X0080.5 1

I 1311
TC____RE DO_633_T DO_3_RBT DI_645_T DI_646_T
LEASED C_LOCK _IN_AUTO SIV SRV
F1000.7 Y0119.7 K0016.0 R0328.6 2

J
TPENABLE DO_960__ TC_UNLOC TOOLONRO
AUTO_KEY K_PB BOT
1 R0328.6 Y0079.1
TOOLONRO DO_634_T
BOT C_UNLOCK
2
L
N00189 K0015.0 K0016.0 F1000.7 Y0119.7 K0015.0

TC_LOCK_ TC_UNLOC TPENABLE DO_960__ TC_LOCK_
PB K_PB AUTO_KEY PB
N00190 K0016.0 K0015.0 F1000.7 Y0119.7 K0016.0

TC_UNLOC TC_LOCK_ TPENABLE DO_960__ TC_UNLOC
K_PB PB AUTO_KEY K_PB
N00191 X0079.1 Y0040.7

O 1335
DI_634__ DO_328_T
TC_ULCKD CRELMON
N00192 R0328.6 K0008.0 R0218.4

TOOLONRO AUTO/MAI DI_940_T
BOT NT_SS C_NOTOOL
N00193 Y0117.5 Y0117.6 Y0000.2 Y0038.5

DO_942__ DO_943__ DO_3_RBT DO_310_T
TCOPNCVR TCCLSCVR _IN_AUTO C_OPNCVR
K0011.4 K0011.5 Y0000.3

C
TC_OPENG TC__CLOS DO_4_RBT
UNCOVER GUNCOVER _IN_TCH
N00194 Y0117.5 Y0117.6 Y0000.2 Y0038.6

DO_942__ DO_943__ DO_3_RBT DO_311_T
TCOPNCVR TCCLSCVR _IN_AUTO C_CLSCVR
K0011.5 K0011.4 Y0000.3

E
TC__CLOS TC_OPENG DO_4_RBT
GUNCOVER UNCOVER _IN_TCH
N00195 X0038.0 R0321.0 R0329.0

TCSTND1 _ARM ITION
X0038.0 X0039.3
G
DI_305__ DI_316_G
TCSTND1 EOTPDCK
N00196 X0038.1 R0322.0 R0329.1

TCSTND2 _ARM ITION
X0038.1 X0039.3
I
DI_306__ DI_316_G
TCSTND2 EOTPDCK
N00197 X0038.2 R0323.0 R0329.2

TCSTND3 _ARM ITION
X0038.2 X0039.3
K
DI_307__ DI_316_G
TCSTND3 EOTPDCK
N00198 X0038.3 R0324.0 R0329.3

TCSTND4 _ARM ITION
X0038.3 X0039.3
M
DI_308__ DI_316_G
TCSTND4 EOTPDCK
N00199 X0038.4 R0325.0 R0329.4

TCSTND5 _ARM ITION
X0038.4 X0039.3
O
DI_309__ DI_316_G
TCSTND5 EOTPDCK
N00200 X0038.5 R0326.0 R0329.5

TCSTND6 _ARM ITION
X0038.5 X0039.3
B
DI_310__ DI_316_G
TCSTND6 EOTPDCK
N00201 X0038.6 R0326.1 R0329.6

TCSTND7 _ARM ITION
X0038.6 X0039.3
D
DI_311__ DI_316_G
TCSTND7 EOTPDCK
N00202 X0038.7 R0326.2 R0329.7

TCSTND8 _ARM ITION
X0038.7 X0039.3
F
DI_312__ DI_316_G
TCSTND8 EOTPDCK
N00203 R0329.0 R0328.7

GUN1_POS GUN1-8_P
ITION OSITION
R0329.1
H
GUN2_POS
ITION
R0329.2
I
GUN3_POS
ITION
R0329.3
J
GUN4_POS
ITION
R0329.4
K
GUN5_POS
ITION
R0329.5
L
GUN6_POS
ITION
R0329.6
M
GUN7_POS
ITION
R0329.7
N
GUN8_POS
ITION
O
N00204 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1413
1 X0038.6 X0038.7 R0320.0

B TOOL 1 IN OPDOCK
N00205 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

C 1423
1 X0038.6 X0038.7 R0320.1

D TOOL 2 IN OPDOCK
N00206 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

E 1433
1 X0038.6 X0038.7 R0320.2

F TOOL 3 IN OPDOCK
N00207 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

G 1443
1 X0038.6 X0038.7 R0320.3

H TOOL 4 IN OPDOCK
N00208 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

I 1453
1 X0038.6 X0038.7 R0320.4

J TOOL 5 IN OPDOCK
N00209 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

K 1463
1 X0038.6 X0038.7 R0320.5

L TOOL 6 IN OPDOCK
N00210 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

M 1473
1 X0038.6 X0038.7 R0320.6

N TOOL 7 IN OPDOCK
O
N00211 X0039.3 X0038.0 X0038.1 X0038.2 X0038.3 X0038.4 X0038.5 1

A 1483
1 X0038.6 X0038.7 R0320.7

B TOOL 8 IN OPDOCK
N00212 R0320.0 R0319.0

TOOL1INO ALLTOOLS
PDOCK INOPDOCK
R0320.1
D
TOOL2INO
PDOCK
R0320.2
E
TOOL3INO
PDOCK
R0320.3
F
TOOL4INO
PDOCK
R0320.4
G
TOOL5INO
PDOCK
R0320.5
H
TOOL6INO
PDOCK
R0320.6
I
TOOL7INO
PDOCK
R0320.7
J
TOOL8INO
PDOCK
N00213 X0082.6 Y0038.7

K 1502
DI_663_T DO_312_T
CCOMMOK CCOMMOK
N00214 X0082.7 Y0039.2

L 1504
DI_664_T DO_315_T
CTLSLDPW LSLIDPWR
N00215 X0079.4 X0079.5 G1008.4

DI_637__ DI_638__ UALM_5
RDY2LCK1 RDY2LCK2
X0079.4 X0079.5
N
DI_637__ DI_638__
RDY2LCK1 RDY2LCK2
N00216 R0328.6 G1008.5

O 1512 NOTOOLONARM
TOOLONRO UALM_6
BOT
N00217 K0013.1 R0000.7 Y0126.7

NOTOOLON PART_PRE DO_1016_
N00218 K0013.1 R0000.7 K0013.1

NOTOOLON PART_PRE NOTOOLON
EOATSS SENT EOATSS
N00219 Y0039.3 Y0039.3

DO_316_W DO_316_W
RNGTLSTD RNGTLSTD
N00220 Y0039.3 X1025.1 Y0000.1 Y0039.3

DO_316_W FAULT___ DO_2_RBT DO_316_W
RNGTLSTD RESET _@_HOME RNGTLSTD
N00221
E 1526 SUB72
SPE

F 1527 SUB71 P0002
SP WELDCONTROL1
N00223 X0000.0 Y0083.0

DI_1_EXT DO_665_W
_RNENBL C1_ENBLE
N00224 X0087.6 Y0014.4

DI_703_W DO_117_W
1_COMMOK C1COM_OK
N00225 Y0000.3 Y0083.1

DO_4_RBT DO_666_R
_IN_TCH BTCH_WC1
N00226 K0004.7 Y0014.1

WELD_/_N DO_114_W
O_WELD1 D/NWD1SS
N00227 K0006.4 Y0018.1

WELD_/_N DO_146_W
O_WELD2 D/NWD2SS
N00228 Y0014.1 Y0018.1 R0221.0

DO_114_W DO_146_W DI_960_R
D/NWD1SS D/NWD2SS EM_WELD
N00229 X0086.1 Y0015.6

DI_690_I DO_127_I
_HI/LO AVL_WRN1
N00230 X0087.5 Y0017.3

DI_702_A DO_140_A
DP_MODE DP_MODE
N00231 X0083.0 Y0015.3

DI_665_I DO_124_I
NWLDCYC1 NWD_CY_1
N00232 X0083.1 Y0015.4

DI_666_W DO_125_H
ELD_CMP1 AS_WLD_1
N00233 X0083.3 Y0014.3

DI_668_W DO_116_N
ELD_FLT1 OWLDFLT1
N00234 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

C 1552
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0306.0
DO_686__ ROBOT_WS
BP_128 _WC#1
N00235 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

E 1561
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0307.0
F
DO_686__ WLD_SCH_
BP_128 39_WC1
N00236 Y0014.1 Y0014.2 Y0083.4

DO_114_W DO_115_W DO_669_W
N00237 X1020.2 X1020.0 X1020.1 D0004.0

O
N00238 Y0109.7 D0004.0 K0000.0 ACT R0363.0

BP1_1 WC1 MER1
Y0110.0
B
DO_881__
BP2_1
Y0110.1
C
DO_882__
BP4_1
Y0110.2
D
DO_883__
BP8_1
Y0110.3
E
DO_884__
BP16_1
Y0110.4
F
DO_885__
BP32_1
Y0110.5
G
DO_886__
BP64_1
Y0110.6
H
DO_887__
BP128_1
N00239 Y0109.7 D0004.0 R0363.0 Y0084.6

BP1_1 WC1 MER1 BP_1
N00240 Y0110.0 D0004.0 R0363.0 Y0084.7

BP2_1 WC1 MER1 BP_2
N00241 Y0110.1 D0004.0 R0363.0 Y0085.0

BP4_1 WC1 MER1 BP_4
N00242 Y0110.2 D0004.0 R0363.0 Y0085.1

BP8_1 WC1 MER1 BP_8
N00243 Y0110.3 D0004.0 R0363.0 Y0085.2

N00244 Y0110.4 D0004.0 R0363.0 Y0085.3

N00245 Y0110.5 D0004.0 R0363.0 Y0085.4

N00246 Y0110.6 D0004.0 R0363.0 Y0085.5

BP128_1 WC1 MER1 BP_128
N00247 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

B 1622
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0360.0
DO_686__ NOWLDSCH
BP_128 WC1
N00248 R0360.0 X0087.6 K0000.0 Y0083.5

K0000.0 Y0116.5
E
DEBUG DO_934__
RD_SCHD1
N00249 Y0120.6 F1000.3 Y0000.1 R0223.0

F 1638
X0015.0 K0008.0 Y0000.5 F1000.3 F1000.2

G
Y0000.1 F1000.2 F1000.3

H
_@_HOME RUNNING
N00250 Y0120.6 Y0000.1 F1000.2 F1000.3 R0213.6

X0015.0 K0008.0
J
DI_121_R AUTO/MAI
M_MAN_W1 NT_SS
N00251 Y0048.3 Y0121.0 F1000.3 Y0000.1 R0220.4

UTFD_APP EDWLD1PB _@_HOME EFEDWLD1
N00252 K0008.6 D0612.0 K0008.6

1 1
N00253 K0008.6 D0612.0 K0008.6

1 1
N00254 K0005.1 D0612.0 K0005.1

PB1 PB1
N00255 K0005.1 D0612.0 K0005.1

PB1 PB1
N00256 K0005.2 D0612.0 K0005.2

O_TD_PB1 O_TD_PB1
N00257 K0005.2 D0612.0 K0005.2

O_TD_PB1 O_TD_PB1
N00258 K0005.5 D0612.0 K0005.5

_CLS_PB1 _CLS_PB1
N00259 K0005.5 D0612.0 K0005.5

_CLS_PB1 _CLS_PB1
N00260 K0005.6 D0612.0 K0005.6

_OPN_PB1 _OPN_PB1
N00261 K0005.6 D0612.0 K0005.6

_OPN_PB1 _OPN_PB1
N00262 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00263 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00264 K0006.0 D0612.0 K0006.0

ACK_PB1 ACK_PB1
N00265 K0006.0 D0612.0 K0006.0

ACK_PB1 ACK_PB1
N00266 Y0120.6 D0612.0 Y0120.6

AN_WELD1 AN_WELD1
N00267 Y0120.6 D0612.0 Y0120.6

AN_WELD1 AN_WELD1
N00268 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
N00269 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
O
N00270 Y1020.0 Y1020.0

RO__1___ RO__1___
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
B
EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00271 Y1020.0 Y1020.0

RO__1___ RO__1___
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
D
EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00272 K0004.5 K0006.2

EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00273 K0004.5 X1026.1 G1000.1 ACT K0004.5

F 1733 SUB 3 0033 R EQUALIZATION ENABLE 1_2 SS
N00274 K0000.0 Y0083.3 D0612.0 X1025.1 Y0083.3

G 1739 RESET WELDER
ST_WLD RESET ST_WLD
X1025.1
H
FAULT___
RESET
N00275 K0015.1 D0612.0 K0015.1

SSDUMP1 SSDUMP1
N00276 K0015.1 D0612.0 K0015.1

SSDUMP1 SSDUMP1
N00277 K0015.2 D0612.0 K0015.2

SSDUMP1 SSDUMP1
N00278 K0015.2 D0612.0 K0015.2

SSDUMP1 SSDUMP1
N00279 K0015.1 Y0000.2 X1026.1 K0015.2 Y0017.5

M 1757
N00280 K0015.2 Y0000.2 X1026.1 K0015.1 Y0017.6

N 1762
O
N00281 Y0120.6 K0000.3 D0610.1

X0015.0 K0008.0 K0000.3

B
M_MAN_W1 NT_SS NB1
N00282 D0610.1 ACT D0610.1

DETIMR1 DETIMR1
N00283 X0054.5 Y0087.1

DI_438_C DO_698_C
CWELDMOD CWELDMOD
D0610.1
E
CCWELDMO
DETIMR1
N00284
F 1781 SUB72
SPE

G 1782 SUB71 P0003
SP TIPDRESSER1
N00286 X0087.1 Y0017.2

DI_698_T DO_139_T
PCHNGRQW PCHG_RQ1
X0087.0
I
DI_697_T
PCHNGRQ
Y0110.7
J
DO_888_T
PWRMOV1
Y0111.0
K
DO_889_T
PWRFIX1
N00287 K0005.5 Y0000.5 R0222.6

N00288 K0005.6 Y0000.5 R0222.7

N00289 X0083.4 Y0016.3

DI_669_N DO_132_N
EW_TIP WTP_RST1
O
N00290 R0345.0 Y0084.5 X0001.2 K0008.0 R0345.0

___1 TSR PLC_AUTO NT_SS ___1
Y0119.1 K0005.2
B
DO_954_C INIT_AUT
LRAV_XFR O_TD_PB1
N00291 R0334.0 Y0109.0 Y0000.5 X0083.1 R0333.0

R0333.0
D
TD_MEM_W
C_#1
N00292 X0083.4 K0008.0 Y0000.5 X0014.7 R0333.0 R0334.0

EW_TIP NT_SS _@_MAINT D_BYPSS1 C_#1 P_TC1
R0334.0
F
DRESS_CA
P_TC1
N00293 X0083.2 Y0015.0

DI_667_M DO_121_A
AINT_REQ UTOTD_1
R0334.0 Y0050.7 Y0048.3

H
DRESS_CA DO_408_S DO_388_N
P_TC1 WGBOLTAP UTFD_APP
R0345.0
I
TIP_MEM_
___1
N00294 K0005.0 Y0014.0

PULLED_T DO_113_P
IP_BYPS1 LTPBY_SS
K0006.5
K
PULLED_T
IP_BYPS2
N00295 Y0085.7 R0351.0

DO_688__ PULLDTIP
TIP_WTR1 _SEAL_1
N00296 R0351.0 ACT D0611.0

_SEAL_1 P_TIMER
N00297 R0220.6 Y0017.4

DI_958_P DO_141_A
LDTIP_1 PTB_1
R0220.7
O
DI_959_P
LDTIP_2
N00298 Y0014.5 X0001.2 Y0109.0

DO_118_D DI_11___ DO_873_T
K0005.3 Y0000.3
B
TEACH_TD DO_4_RBT
_ENABLE1 _IN_TCH
N00299 R0000.0 Y0014.5 X0001.2 Y0086.6

ON RSR_ON_1 PLC_AUTO D_MTR_ON
K0005.3 Y0000.3
D
TEACH_TD DO_4_RBT
_ENABLE1 _IN_TCH
N00300 X1020.2 X0000.0 R0220.6

RI_3_WTR DI_1_EXT DI_958_P
_FL_SW1 _RNENBL LDTIP_1
R0220.6 D0611.0
F
DI_958_P PULLEDTI
LDTIP_1 P_TIMER
N00301 K0004.6 Y0014.7

TD_MTR_F DO_120_T
LT_BYPS1 DMFL_BY1
N00302 D0605.0 R0411.0 R0412.0

H 1860 TD FAULT1
1TIM1 TOK1
N00303 Y0014.5 X0086.2 Y0109.2 K0004.6 Y0083.3 R0411.0

RSR_ON_1 IP_DR_OK RVTPDROK LT_BYPS1 ST_WLD TOK1
R0411.0
J
TDCURREN
TOK1
N00304 R0412.0 ACT D0606.0

2TIM1
N00305 Y0014.5 ACT D0605.0

RSR_ON_1 1TIM1
N00306 Y0083.3 R0411.0 D0606.0 R0415.0

ST_WLD TOK1 2TIM1 1
R0408.0
N
TPRESFLT
1
R0415.0
O
TDMTRFLT
1
N00307 R0415.0 Y0014.6

TDMTRFLT DO_119_T
1 DM_FLT_1
N00308 Y0118.1 ACT D0604.0

ESCHKMD1 TIM1
N00309 D0604.0 R0409.0 R0408.0

TIM1 LAT1 1
N00310 Y0118.1 X0086.3 K0005.4 Y0083.3 R0409.0

ESCHKMD1 PDRRSOK1 ST_BYPS1 ST_WLD LAT1
R0409.0
E
TPRESFLT
LAT1
N00311 X0014.4 Y0121.2 Y0118.7 F1000.5 R0221.6

DI_117_I DO_971_P DO952_CL FAULT DI_966_R
NIT_TD_1 EDDMPAPP RMOTZN1 NTDDMP1
X0014.6 X0083.2 Y0015.0 Y0121.5

G
DI_119_T DI_667_M DO_121_A DO_974__
D_DMP_R1 AINT_REQ UTOTD_1 TPWRCMP1
N00312 K0008.5 K0008.5

NTSR_ENB NTSR_ENB
1SS 1SS
N00313 K0008.5 X1025.1 K0008.5

1SS RESET 1SS
K0008.5 X0083.4
J
NTSR_ENB DI_669_N
1SS EW_TIP
N00314 K0015.6 K0015.6

DTSRENB1 DTSRENB1
SS SS
N00315 K0015.6 X1025.1 K0015.6

SS RESET SS
K0015.6 X0083.5
M
DTSRENB1 DI_670_D
SS RSSTIP1
N00316 K0008.5 K0005.1 Y0084.4

1SS PB1 TSR
X0015.3
O
DI_124_N
EWTPRST1
N00317 K0015.6 K0008.6 Y0084.5

SS 1 TSR
Y0116.7 Y0054.2
B DRSSTIPSTPRST1
DO_936__ DO_435_D
STP_RST1 TSR1
N00318
C 1935 SUB72
SPE

D 1936 SUB71 P0004
SP WATERVALVE1
N00320 X1020.2 X0001.6 Y0085.7

RI_3_WTR DI_15_SY DO_688__
_FL_SW1 S_WTR_ON TIP_WTR1
N00321 X0014.0 R0000.5 Y1020.3

Y1020.3 X1020.2
G
RO_4_WTR RI_3_WTR
_RESET1 _FL_SW1
X1025.1
H
FAULT___
RESET
N00322 Y1020.3 Y0122.0 ACT R0000.5

RO_4_WTR DO_977__ TMR WTR_RST_
_RESET1 WS_PLSOP PULSE_OP
Y1020.5
J
RO_6_WTR
_RESET2
N00323
K 1954 SUB72
SPE

L 1955 SUB71 P0005
SP OVRTMP/NOSTRK1
N00325 X1020.0 Y0086.4

RI_1__XF DO_693_X
RMR_OT1 FMR_OT
N00326 X1020.1 Y0086.5

RI_2_SRV DO_694_S
OMTR_OT1 RVMTR_OT
O
N00327 X1020.0 X1025.1 R0500.0

R0500.0
B
XFRMR_OT
MP_SEAL1
N00328 X1020.1 X1025.1 R0500.1

RI_2_SRV FAULT___ SRVO_MTR
OMTR_OT1 RESET _OTSEAL1
R0500.1
D
SRVO_MTR
_OTSEAL1
N00329 R0500.0 Y0016.2

XFRMR_OT DO_131_X
MP_SEAL1 FMR_OTF1
N00330 R0500.1 Y0016.1

SRVO_MTR DO_130_S
_OTSEAL1 GM_OTF1
N00331 R0500.0 K0005.0 R0220.6 R0500.1 D0004.1

XFRMR_OT PULLED_T DI_958_P SRVO_MTR REMSTROK
MP_SEAL1 IP_BYPS1 LDTIP_1 _OTSEAL1 EOK1
Y0048.3 Y0048.2
H
DO_388_N DO_387_W
UTFD_APP LD2_APP
Y0048.2 Y0050.5
I
DO_387_W DO_406_N
LD2_APP TFD_2APP
Y0050.7
J
DO_408_S
WGBOLTAP
N00332 R0501.0 K0006.5 R0220.7 R0501.1 D0004.2

K 1986 REMOTE NO STROKE OK WC2
XFRMR_OT PULLED_T DI_959_P SRVOMTR_ REMSTROK
MP_SEAL2 IP_BYPS2 LDTIP_2 OT_SEAL2 EOK2
Y0050.5
L
DO_406_N
TFD_2APP
Y0048.2
M
DO_387_W
LD2_APP
N00333 D0004.1 D0004.2 R0221.1

REMSTROK REMSTROK DI_961_R
EOK1 EOK2 EM_STRK
N00334
O 1996 SUB72
SPE
N00335 ### UALM ###

A 1997 SUB71 P0006
SP UALM
N00336 Y0120.2 X1025.1 Y0120.2

DO_963__ FAULT___ DO_963__
PRG_FLT RESET PRG_FLT
N00337 Y0120.2 G1008.0

DO_963__ UALM1
PRG_FLT
N00338 X0083.2 G1008.1

DI_667_M UALM2
AINT_REQ
N00339 X0083.2 X0087.0 G1008.2

DI_667_M DI_697_T UALM_3
AINT_REQ PCHNGRQ
X0091.2 X0087.1
F
DI_731_M DI_698_T
ANT_REQ2 PCHNGRQW
N00340 X0014.1 G1008.7

DI_114_R UALM_8
STW_TMR
N00341 Y0021.2 G1009.0

DO_171_T UALM_9
PCHG_RQ2
N00342 X0083.3 G1009.1

DI_668_W UALM_10
ELD_FLT1
N00343 X0091.3 G1009.2

DI_732_W UALM_11
ELD_FLT2
N00344 Y0039.3 G1009.7

DO_316_W UALM_16
RNGTLSTD
N00345 X0001.6 G1010.3

DI_15_SY UALM_20
S_WTR_ON
N00346 Y0014.7 G1010.4

DO_120_T UALM_21
DMFL_BY1
N00347 Y0014.6 G1010.5

DO_119_T UALM_22
DM_FLT_1
N00348 K0010.0 Y0119.7 Y0000.3 G1010.6

TEACH___ DO_960__ DO_4_RBT UALM23
MEMORY AUTO_KEY _IN_TCH
N00349 R0220.6 G1010.7

DI_958_P UALM_24
LDTIP_1
N00350 R0000.0 G1011.0

ALWAYS__ UALM_25
ON
N00351 K0004.5 G1011.1

EQUALENB UALM_26
L_1_2_SS
N00352 Y0120.6 G1011.2

DO_967_M UALM_27
AN_WELD1
X0015.0
E
DI_121_R
M_MAN_W1
N00353 Y0017.2 G1011.3

DO_139_T UALM_28
PCHG_RQ1
N00354 Y0002.7 G1011.4

DO_24_RB UALM_29
T_LOOP
N00355 X1020.1 G1011.5

RI_2_SRV UALM_30
OMTR_OT1
N00356 X1020.0 G1011.6

RI_1__XF UALM_31
RMR_OT1
N00357 X0087.6 G1011.7

DI_703_W UALM_32
1_COMMOK
N00358
K 2051 SUB72
SPE

L 2052 SUB71 P0007
SP INTERFACE
O
N00360 D0612.1 ACT D0612.0

MH_IF_PB TMR IF_PB_TO
_TO
D0612.2
B
SEAL_IF_
PB_TO
D0612.3
C
STUD_IF_
PB_TO
D0612.4
D
SWG1_IF_
PB_TO
D0612.5
E
SWG2_IF_
PB_TO
O
N00361 K0002.0 D0612.1

A 2062 MH IF PB TO
CLMP1CLS MH_IF_PB
_TO
K0002.1
B
CLMP1OPN
K0002.2
C
CLMP2CLS
K0002.3
D
CLMP2OPN
K0002.4
E
CLMP3CLS
K0002.5
F
CLMP3OPN
K0002.6
G
CLMP4CLS
K0002.7
H
CLMP4OPN
K0003.0
I
CLMP5CLS
K0003.1
J
CLMP5OPN
K0003.2
K
CLMP6CLS
K0003.3
L
CLMP6OPN
K0003.4
M
CLMP7CLS
K0003.5
N
CLMP7OPN
K0003.6
O
CLMP8CLS
K0003.7
A
CLMP8OPN
K0004.0
B
CLMP9CLS
K0004.1
C
CLMP9OPN
K0004.2
D
CLP10CLS
K0004.3
E
CLP10OPN
K0014.2
F
VAC_1_ON
_PB
K0014.3
G
VAC_2_ON
_PB
K0014.4
H
VAC_3_ON
_PB
K0014.5
I
BLOWOFF_
1_ON_PB
K0014.6
J
BLOWOFF_
2_ON_PB
K0014.7
K
BLOWOFF_
3_ON_PB
K0000.4
L
RERUNPRC
PB
K0000.5
M
ACCPTPRC
PB
K0000.6
N
REJCTPRC
PB
K0000.7
O
INSPCTSE
LPB
K0011.4
A
TC_OPENG
UNCOVER
K0011.5
B
TC__CLOS
GUNCOVER
K0016.1
C
VAC_4_ON
_PB
K0016.2
D
BLOWOFF_
4_ON_PB
O
N00362 Y0121.0 D0612.4

DO_969_F SWG1_IF_
EDWLD1PB PB_TO
Y0120.6
B
DO_967_M
AN_WELD1
Y0083.3
C
DO_668_R
ST_WLD
K0005.1
D
NEW_TIP_
PB1
K0008.6
E
DTSR_PB_
1
K0005.2
F
INIT_AUT
O_TD_PB1
K0005.5
G
TIP_ALGN
_CLS_PB1
K0005.6
H
TIP_ALGN
_OPN_PB1
K0005.7
I
INITAUTO
TCPB1
K0006.0
J
ATC_FLT_
ACK_PB1
K0015.1
K
ADVTIPDR
SSDUMP1
K0015.2
L
RETTIPDR
SSDUMP1
O
N00363 Y0121.1 D0612.5

DO_970_F SWG2_IF_
EDWLD2PB PB_TO
Y0120.7
B
DO_968_M
AN_WELD2
Y0091.3
C
DO_732_R
ST_WLD2
K0006.6
D
NEW_TIP_
PB2
K0009.2
E
DTSR_PB_
2
K0006.7
F
INIT_AUT
O_TD_PB2
K0007.2
G
TIP_ALGN
_CLS_PB2
K0007.3
H
TIP_ALGN
_OPN_PB2
K0007.4
I
INITAUTO
TCPB2
K0007.5
J
ATC_FLT_
ACK_PB2
K0015.3
K
ADVTIPDR
SSDUMP2
K0015.4
L
RETTIPDR
SSDUMP2
N00364
M 2123 SUB72
SPE
N00365 ### MH ###

N 2124 SUB71 P0008
SP MH
N00366 Y0000.3 K0004.4 R1410.0

DO_4_RBT MAN_GRP_ MAN_GRP_
_IN_TCH ENBLE_SS ENABLE
N00367 R1410.0 ACT

A 2129 SUB10 0000
MAN_GRP_ JMP
ENABLE
N00368 R0000.0 Y0114.0

B 2132 OPEN CLAMP 1
ALWAYS__ DO_913__
ON OPNCLMP1
N00369 R0000.0 Y0114.1

ALWAYS__ DO_914__
ON CLSCLMP1
N00370 R0000.0 Y0114.2

D 2136 OPEN CLAMP 2
ALWAYS__ DO_915__
ON OPNCLMP2
N00371 R0000.0 Y0114.3

ALWAYS__ DO_916__
ON CLSCLMP2
N00372 R0000.0 Y0114.4

F 2140 OPEN CLAMP 3
ALWAYS__ DO_917__
ON OPNCLMP3
N00373 R0000.0 Y0114.5

ALWAYS__ DO_918__
ON CLSCLMP3
N00374 R0000.0 Y0114.6

H 2144 OPEN CLAMP 4
ALWAYS__ DO_919__
ON OPNCLMP4
N00375 R0000.0 Y0114.7

ALWAYS__ DO_920__
ON CLSCLMP4
N00376 R0000.0 Y0115.0

J 2148 OPEN CLAMP 5
ALWAYS__ DO_921__
ON OPNCLMP5
N00377 R0000.0 Y0115.1

ALWAYS__ DO_922__
ON CLSCLMP5
N00378 R0000.0 Y0115.2

L 2152 OPEN CLAMP 6
ALWAYS__ DO_923__
ON OPNCLMP6
N00379 R0000.0 Y0115.3

ALWAYS__ DO_924__
ON CLSCLMP6
N00380 R0000.0 Y0115.4

N 2156 OPEN CLAMP 7
ALWAYS__ DO_925__
ON OPNCLMP7
N00381 R0000.0 Y0115.5

ALWAYS__ DO_926__
ON CLSCLMP7
N00382 R0000.0 Y0115.6

A 2160 OPEN CLAMP 8
ALWAYS__ DO_927__
ON OPNCLMP8
N00383 R0000.0 Y0115.7

ALWAYS__ DO_928__
ON CLSCLMP8
N00384 R0000.0 Y0116.0

C 2164 OPEN CLAMP 9
ALWAYS__ DO_929__
ON OPNCLMP9
N00385 R0000.0 Y0116.1

ALWAYS__ DO_930__
ON CLSCLMP9
N00386 R0000.0 Y0116.2

ALWAYS__ DO_931__
ON OPNCLP10
N00387 R0000.0 Y0116.3

ALWAYS__ DO_932__
ON CLSCLP10
N00388 R0000.0 Y0127.2

G 2172 VACUUM 1 ON
ALWAYS__ DO1019_V
ON AC1ON
N00389 R0000.0 Y0127.3

H 2174 BLOWOFF 1 ON
ALWAYS__ DO1020_B
ON LWOF1ON
N00390 R0000.0 Y0127.4

I 2176 VACUUM 2 ON
ALWAYS__ DO1021_V
ON AC2ON
N00391 R0000.0 Y0127.5

J 2178 BLOWOFF 2 ON
ALWAYS__ DO1022_B
ON LWOF2ON
N00392 R0000.0 Y0127.6

K 2180 VACUUM 3 ON
ALWAYS__ DO1023_V
ON AC3ON
N00393 R0000.0 Y0127.7

L 2182 BLOWOFF 3 ON
ALWAYS__ DO1024_B
ON LWOF3ON
N00394 R0000.0 Y0118.5

M 2184 VACUUM 4 ON
ALWAYS__ DO_950_V
ON AC4ON
N00395 R0000.0 Y0118.6

N 2186 BLOWOFF 4 ON
ALWAYS__ DO_951_B
ON LWOF4ON
N00396
O 2188 SUB30
JMPE
N00397 R1410.0 ACT R0001.1

A 2189 SUB 3 0038
MAN_GRP_ TMR MAN_GRP_
ENABLE TO
N00398 R0001.1 ACT

B 2193 SUB10 0000
MAN_GRP_ JMP
TO
N00399 K0002.1 X1026.1 Y0114.0

C 2196 OPEN CLAMP 1
AUTOMDSW OPNCLMP1
N00400 Y0114.0 Y0009.0

DO_913__ DO_73_OP
OPNCLMP1 N_CLMP1
N00401 K0002.0 X1026.1 Y0114.1

AUTOMDSW CLSCLMP1
N00402 Y0114.1 Y0009.1

DO_914__ DO_74_CL
CLSCLMP1 S_CLMP1
N00403 K0002.3 X1026.1 Y0114.2

G 2206 OPEN CLAMP 2
AUTOMDSW OPNCLMP2
N00404 Y0114.2 Y0009.2

DO_915__ DO_75_OP
OPNCLMP2 N_CLMP2
N00405 K0002.2 X1026.1 Y0114.3

AUTOMDSW CLSCLMP2
N00406 Y0114.3 Y0009.3

DO_916__ DO_76_CL
CLSCLMP2 S_CLMP2
N00407 K0002.5 X1026.1 Y0114.4

K 2216 OPEN CLAMP 3
AUTOMDSW OPNCLMP3
N00408 Y0114.4 Y0009.4

DO_917__ DO_77_OP
OPNCLMP3 N_CLMP_3
N00409 K0002.4 X1026.1 Y0114.5

AUTOMDSW CLSCLMP3
N00410 Y0114.5 Y0009.5

DO_918__ DO_78_CL
CLSCLMP3 S_CLMP3
N00411 K0002.7 X1026.1 Y0114.6

O 2226 OPEN CLAMP 4
AUTOMDSW OPNCLMP4
N00412 Y0114.6 Y0009.6

DO_919__ DO_79_OP
OPNCLMP4 N_CLMP4
N00413 K0002.6 X1026.1 Y0114.7

AUTOMDSW CLSCLMP4
N00414 Y0114.7 Y0009.7

DO_920__ DO_80_CL
CLSCLMP4 S_CLMP4
N00415 K0003.1 X1026.1 Y0115.0

D 2236 OPEN CLAMP 5
AUTOMDSW OPNCLMP5
N00416 Y0115.0 Y0010.0

DO_921__ DO_81_OP
OPNCLMP5 N_CLMP5
N00417 K0003.0 X1026.1 Y0115.1

AUTOMDSW CLSCLMP5
N00418 Y0115.1 Y0010.1

DO_922__ DO_82_CL
CLSCLMP5 S_CLMP5
N00419 K0003.3 X1026.1 Y0115.2

H 2246 OPEN CLAMP 6
AUTOMDSW OPNCLMP6
N00420 Y0115.2 Y0010.2

DO_923__ DO_83_OP
OPNCLMP6 N_CLMP6
N00421 K0003.2 X1026.1 Y0115.3

AUTOMDSW CLSCLMP6
N00422 Y0115.3 Y0010.3

DO_924__ DO_84_CL
CLSCLMP6 S_CLMP_6
N00423 K0003.5 X1026.1 Y0115.4

L 2256 OPEN CLAMP 7
AUTOMDSW OPNCLMP7
N00424 Y0115.4 Y0010.4

DO_925__ DO_85_OP
OPNCLMP7 N_CLMP_7
N00425 K0003.4 X1026.1 Y0115.5

AUTOMDSW CLSCLMP7
N00426 Y0115.5 Y0010.5

DO_926__ DO_86_CL
CLSCLMP7 S_CLAMP7
N00427 K0003.7 X1026.1 Y0115.6

A 2266 OPEN CLAMP 8
AUTOMDSW OPNCLMP8
N00428 Y0115.6 Y0010.6

DO_927__ DO_87_OP
OPNCLMP8 N_CLMP8
N00429 K0003.6 X1026.1 Y0115.7

AUTOMDSW CLSCLMP8
N00430 Y0115.7 Y0010.7

DO_928__ DO_88_CL
CLSCLMP8 S_CLAMP8
N00431 K0004.1 X1026.1 Y0116.0

E 2276 OPEN CLAMP 9
AUTOMDSW OPNCLMP9
N00432 Y0116.0 Y0011.0

DO_929__ DO_89_OP
OPNCLMP9 N_CLMP9
N00433 K0004.0 X1026.1 Y0116.1

AUTOMDSW CLSCLMP9
N00434 Y0116.1 Y0011.1

DO_930__ DO_90_CL
CLSCLMP9 S_CLMP9
N00435 K0004.3 X1026.1 Y0116.2

CLP10OPN SI9_____ DO_931__
AUTOMDSW OPNCLP10
N00436 Y0116.2 Y0011.2

DO_931__ DO_91_OP
OPNCLP10 N_CLMP10
N00437 K0004.2 X1026.1 Y0116.3

CLP10CLS SI9_____ DO_932__
AUTOMDSW CLSCLP10
N00438 Y0116.3 Y0011.3

DO_932__ DO_92_CL
CLSCLP10 S_CLMP10
N00439 K0014.2 X1026.1 K0014.1 Y0127.2

M 2296 VACUUM 1 ON
N00440 Y0127.2 Y0008.0

N 2300
DO1019_V DO_65_VA
AC1ON C_1_ON
N00441 K0014.5 X1026.1 K0014.1 Y0127.3

O 2302 BLOWOFF 1 ON
N00442 Y0127.3 Y0008.1

A 2306
DO1020_B DO_66_BL
LWOF1ON WOFF1ON
N00443 K0014.3 X1026.1 K0014.1 Y0127.4

B 2308 VACUUM 2 ON
N00444 Y0127.4 Y0008.2

C 2312
DO1021_V DO_67_VA
AC2ON C_2_ON
N00445 K0014.6 X1026.1 K0014.1 Y0127.5

D 2314 BLOWOFF 2 ON
N00446 Y0127.5 Y0008.3

E 2318
DO1022_B DO_68_BL
LWOF2ON WOFF2ON
N00447 K0014.4 X1026.1 K0014.1 Y0127.6

F 2320 VACUUM 3 ON
N00448 Y0127.6 Y0008.4

G 2324
DO1023_V DO_69_VA
AC3ON C_3_ON
N00449 K0014.7 X1026.1 K0014.1 Y0127.7

H 2326 BLOWOFF 3 ON
N00450 Y0127.7 Y0008.5

I 2330
DO1024_B DO_70_BL
LWOF3ON WOFF3ON
N00451 K0016.1 X1026.1 K0014.1 Y0118.5

J 2332 VACUUM 4 ON
VAC_4_ON SI9_____ VAC/BLOW DO_950_V
N00452 Y0118.5 Y0008.6

K 2336
DO_950_V DO_71_VA
AC4ON C_4_ON
N00453 K0016.2 X1026.1 K0014.1 Y0118.6

L 2338 BLOWOFF 4 ON
BLOWOFF_ SI9_____ VAC/BLOW DO_951_B
N00454 Y0118.6 Y0008.7

M 2342
DO_951_B DO_72_BL
LWOF4ON WOFF4ON
N00455
N 2344 SUB30
JMPE
O
N00456 Y0008.0 ACT K0014.1

DO_65_VA TMR VAC/BLOW
C_1_ON OFFTIMER
Y0008.1
B
DO_66_BL
WOFF1ON
Y0008.2
C
DO_67_VA
C_2_ON
Y0008.3
D
DO_68_BL
WOFF2ON
Y0008.4
E
DO_69_VA
C_3_ON
Y0008.5
F
DO_70_BL
WOFF3ON
Y0008.6
G
DO_71_VA
C_4_ON
Y0008.7
H
DO_72_BL
WOFF4ON
N00457 K0002.0 D0612.0 K0002.0

I 2356 CLMP1 CLOSE
N00458 K0002.1 D0612.0 K0002.1

J 2359 CLMP1 OPEN
N00459 K0002.2 D0612.0 K0002.2

K 2362 CLMP2 CLOSE
N00460 K0002.3 D0612.0 K0002.3

L 2365 CLMP2 OPEN
N00461 K0002.4 D0612.0 K0002.4

M 2368 CLMP3 CLOSE
N00462 K0002.5 D0612.0 K0002.5

N 2371 CLMP3 OPEN
N00463 K0002.6 D0612.0 K0002.6

O 2374 CLMP4 CLOSE
N00464 K0002.7 D0612.0 K0002.7

A 2377 CLMP4 OPEN
N00465 K0003.0 D0612.0 K0003.0

B 2380 CLMP5 CLOSE
N00466 K0003.1 D0612.0 K0003.1

C 2383 CLMP5 OPEN
N00467 K0003.2 D0612.0 K0003.2

D 2386 CLMP6 CLOSE
N00468 K0003.3 D0612.0 K0003.3

E 2389 CLMP6 OPEN
N00469 K0003.4 D0612.0 K0003.4

F 2392 CLMP7 CLOSE
N00470 K0003.5 D0612.0 K0003.5

G 2395 CLMP7 OPEN
N00471 K0003.6 D0612.0 K0003.6

H 2398 CLMP8 CLOSE
N00472 K0003.7 D0612.0 K0003.7

I 2401 CLMP8 OPEN
N00473 K0004.0 D0612.0 K0004.0

J 2404 CLMP9 CLOSE
N00474 K0004.1 D0612.0 K0004.1

K 2407 CLMP9 OPEN
N00475 K0004.2 D0612.0 K0004.2

L 2410 CLMP10 CLOSE
CLP10CLS IF_PB_TO CLP10CLS
N00476 K0004.3 D0612.0 K0004.3

M 2413 CLMP10 OPEN
CLP10OPN IF_PB_TO CLP10OPN
N00477 K0014.2 D0612.0 K0014.2

N 2416
_PB _PB
N00478 K0014.3 D0612.0 K0014.3

O 2419
_PB _PB
N00479 K0014.4 D0612.0 K0014.4

A 2422
_PB _PB
N00480 K0016.1 D0612.0 K0016.1

B 2425
_PB _PB
N00481 K0014.5 D0612.0 K0014.5

C 2428
1_ON_PB 1_ON_PB
N00482 K0014.6 D0612.0 K0014.6

D 2431
2_ON_PB 2_ON_PB
N00483 K0014.7 D0612.0 K0014.7

E 2434
3_ON_PB 3_ON_PB
N00484 K0016.2 D0612.0 K0016.2

F 2437
4_ON_PB 4_ON_PB
N00485 K0000.4 Y0012.6

RERUNPRC DO_103_R
PB ERUNPRC
N00486 K0000.5 Y0012.7

ACCPTPRC DO_104_A
PB CCPTPRC
N00487 K0000.6 Y0013.0

REJCTPRC DO_105_R
PB EJCTPRC
N00488 K0000.7 Y0013.1

INSPCTSE DO_106_I
LPB NSP_SEL
K0001.3 K0001.5
K
VISIONIN ABORTPRO
TERVENSS CESS
N00489 K0000.4 D0612.0 K0000.4

PB PB
N00490 K0000.4 D0612.0 K0000.4

PB PB
N00491 K0000.5 D0612.0 K0000.5

PB PB
N00492 K0000.5 D0612.0 K0000.5

PB PB
N00493 K0000.6 D0612.0 K0000.6

PB PB
N00494 K0000.6 D0612.0 K0000.6

PB PB
N00495 K0000.7 D0612.0 K0000.7

LPB LPB
N00496 K0000.7 D0612.0 K0000.7

LPB LPB
N00497 K0011.4 D0612.0 K0011.4

TC_OPENG IF_PB_TO TC_OPENG
UNCOVER UNCOVER
N00498 K0011.5 D0612.0 K0011.5

TC__CLOS IF_PB_TO TC__CLOS
GUNCOVER GUNCOVER
N00499 X0008.2 R0000.7

DI_67_PR PART_PRE
T_PRES1 SENT
X0008.3
H
DI_68_PR
T_PRES2
X0008.4
I
DI_69_PR
T_PRES3
X0008.5
J
DI_70_PR
T_PRES4
X0008.6
K
DI_71_PR
T_PRES5
X0008.7
L
DI_72_PR
T_PRES6
N00500
M 2488 SUB72
SPE

N 2489 SUB71 P0009
SP APPLICATION
N00502 D0000.0 Y0048.0

MH_APP DO_385_M
H_APP
N00503 D0000.1 Y0048.1

WELD_1_A DO_386__
PP WLD1_APP
N00504 D0000.2 Y0048.2

WELD_2_A DO_387_W
PP LD2_APP
N00505 D0000.3 Y0048.3

NUT_FEED DO_388_N
_APP UTFD_APP
N00506 D0000.4 Y0048.4

SEAL_1_A DO_389_S
PP LR_1_APP
N00507 D0000.5 Y0048.5

SEAL_2__ DO_390_S
APP LR_2_APP
N00508 D0000.6 Y0048.6

STUD_1_A DO_391_S
PP TDW_1APP
N00509 D0000.7 Y0048.7

STUD_2_A DO_392_S
PP TDW_2APP
N00510 D0001.0 Y0049.0

TOOL_CHA DO_393_T
NGE_APP C_APP
N00511 D0001.1 Y0049.1

RIVET_1_ DO_394_R
APP VT_1_APP
N00512 D0001.2 Y0049.2

RIVET_2_ DO_395_R
APP VT_2_APP
N00513 D0001.3 Y0049.3

NUT_RUNN DO_396_N
ER_APP UTR_APP
N00514 D0001.4 Y0049.4

MIG_WELD DO_397_M
_APP IGW_APP
N00515 D0001.5 Y0049.5

ROLLER_H DO_398_R
EMM_APP LLHEM_AP
N00516 D0001.6 Y0049.6

LASER_CU DO_399_L
T_APP SRCT_APP
N00517 D0001.7 Y0049.7

PLASMA_C DO_400_P
UT_APP LSMA_APP
N00518 D0002.0 Y0050.0

LASER_WE DO_401_L
LD_APP SRWLDAPP
N00519 D0002.1 Y0050.1

OPER_LOA DO_402_O
D_APP P_LD_APP
N00520 D0002.2 Y0050.2

VISION_A DO_403_V
PP IS_APP
N00521 D0002.3 Y0050.3

PROG_LOC DO_404_P
_APP RG_LCAPP
N00522 D0002.4 Y0050.4

IF_DEF__ DO_405__
21 INDEFB21
N00523 D0002.5 Y0050.5

NUT_FEED DO_406_N
ER_2_APP TFD_2APP
N00524 D0002.6 Y0050.6

IF_DEF__ DO_407_I
23 NDEF_B23
N00525 D0002.7 Y0050.7

H 2537 SWGBOLT FEEDER APPLICATION
SWGBOLT_ DO_408_S
APP WGBOLTAP
N00526 D0003.0 Y0051.0

IF_DEF__ DO_409_I
25 NDEF_B25
N00527 D0003.1 Y0051.1

IF_DEF__ DO_410_I
26 NDEF_B26
N00528 D0003.2 Y0051.2

IF_DEF__ DO_411_I
27 NDEF_B27
N00529 D0003.3 Y0051.3

IF_DEF__ DO_412_I
28 NDEF_B28
N00530 D0003.4 Y0051.4

IF_DEF__ DO_413_I
29 NDEF_B29
N00531 D0003.5 Y0051.5

IF_DEF__ DO_414_I
30 NDEF_B30
N00532 D0003.6 Y0051.6

IF_DEF__ DO_415_I
31 NDEF_B31
N00533 D0003.7 Y0051.7

IF_DEF__ DO_416_I
32 NDEF_B32
N00534
B 2555 SUB72
SPE

C 2556 SUB71 P0015
SP WELDCONTROL2
N00536 X0000.0 Y0091.0

DI_1_EXT DO_729_W
_RNENBL C2_ENBL
N00537 X0095.6 Y0018.4

DI_767_W DO_149_W
2_COMMOK C2COM_OK
N00538 Y0000.3 Y0091.1

DO_4_RBT DO_730_R
_IN_TCH BTCH_WC2
N00539 X0094.1 Y0019.6

DI_754_I DO_159_I
-HI/LO_2 AVL_WRN2
N00540 X0095.5 Y0021.3

H 2566
DI_766_A DO_172_A
DP_MODE2 DPMODEN2
N00541 X0091.0 Y0019.3

DI_729_I DO_156_I
NWLDCYC2 NWD_CY_2
N00542 X0091.1 Y0019.4

DI_730_W DO_157_H
ELD_CMP2 AS_WLD_2
N00543 X0091.3 Y0018.3

DI_732_W DO_148_N
ELD_FLT2 OWLDFLT2
N00544 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

L 2574
DO_743__ DO_744__ DO_745__ DO_746__ DO_747__ DO_748__ DO_749__
BP2_1 BP2_2 BP2_4 BP2_8 BP2_16 BP2_32 BP2_64
1 Y0093.5 R0306.1
DO_750__ ROBOT_WS
BP2_128 _WC#2
N00545 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

N 2583
DO_743__ DO_744__ DO_745__ DO_746__ DO_747__ DO_748__ DO_749__
BP2_1 BP2_2 BP2_4 BP2_8 BP2_16 BP2_32 BP2_64
1 Y0093.5 R0362.0
O
DO_750__ WLD_SCH_
BP2_128 39_WC2
N00546 Y0018.1 Y0018.2 Y0091.4

DO_146_W DO_147_W DO_733_W
N00547 X1020.5 X1020.3 X1020.4 D0004.5

N00548 Y0111.1 D0004.5 K0000.0 ACT R0364.0

BP1_2 WC2 MER2
Y0111.2
D
DO_891__
BP2_2
Y0111.3
E
DO_892__
BP4_2
Y0111.4
F
DO_893__
BP8_2
Y0111.5
G
DO_894__
BP16_2
Y0111.6
H
DO_895__
BP32_2
Y0111.7
I
DO_896__
BP64_2
Y0112.0
J
DO_897__
BP128_2
N00549 Y0111.1 D0004.5 R0364.0 Y0092.6

N00550 Y0111.2 D0004.5 R0364.0 Y0092.7

N00551 Y0111.3 D0004.5 R0364.0 Y0093.0

N00552 Y0111.4 D0004.5 R0364.0 Y0093.1

N00553 Y0111.5 D0004.5 R0364.0 Y0093.2

N00554 Y0111.6 D0004.5 R0364.0 Y0093.3

N00555 Y0111.7 D0004.5 R0364.0 Y0093.4

N00556 Y0112.0 D0004.5 R0364.0 Y0093.5

BP128_2 WC2 MER2 BP2_128
N00557 Y0092.6 Y0092.7 Y0093.0 Y0093.1 Y0093.2 Y0093.3 Y0093.4 1

D 2644
DO_743__ DO_744__ DO_745__ DO_746__ DO_747__ DO_748__ DO_749__
BP2_1 BP2_2 BP2_4 BP2_8 BP2_16 BP2_32 BP2_64
1 Y0093.5 R0361.0
DO_750__ NOWLDSCH
BP2_128 WC2
N00558 R0361.0 X0095.6 K0000.0 Y0091.5

K0000.0 Y0116.6
G
DEBUG DO_935__
RD_SCHD2
N00559 Y0120.7 F1000.3 Y0000.1 R0223.1

H 2660
X0019.0 K0008.0 Y0000.5 F1000.3 F1000.2

I
Y0000.1 F1000.2 F1000.3

J
_@_HOME RUNNING
N00560 Y0120.7 Y0000.1 F1000.2 F1000.3 R0213.7

X0019.0 K0008.0
L
DI_153_R AUTO/MAI
M_MAN_W2 NT_SS
N00561 Y0050.5 Y0121.1 F1000.3 Y0000.1 R0220.5

TFD_2APP EDWLD2PB _@_HOME EFEDWLD2
N00562 K0009.2 D0612.0 K0009.2

2 2
N00563 K0009.2 D0612.0 K0009.2

2 2
N00564 K0006.6 D0612.0 K0006.6

PB2 PB2
N00565 K0006.6 D0612.0 K0006.6

PB2 PB2
N00566 K0006.7 D0612.0 K0006.7

O_TD_PB2 O_TD_PB2
N00567 K0006.7 D0612.0 K0006.7

O_TD_PB2 O_TD_PB2
N00568 K0007.2 D0612.0 K0007.2

_CLS_PB2 _CLS_PB2
N00569 K0007.2 D0612.0 K0007.2

_CLS_PB2 _CLS_PB2
N00570 K0007.3 D0612.0 K0007.3

_OPN_PB2 _OPN_PB2
N00571 K0007.3 D0612.0 K0007.3

_OPN_PB2 _OPN_PB2
N00572 K0007.4 D0612.0 K0007.4

TCPB2 TCPB2
N00573 K0007.4 D0612.0 K0007.4

TCPB2 TCPB2
N00574 K0007.5 D0612.0 K0007.5

ACK_PB2 ACK_PB2
N00575 K0007.5 D0612.0 K0007.5

ACK_PB2 ACK_PB2
N00576 Y0120.7 D0612.0 Y0120.7

AN_WELD2 AN_WELD2
N00577 Y0120.7 D0612.0 Y0120.7

AN_WELD2 AN_WELD2
N00578 Y0121.1 D0612.0 Y0121.1

EDWLD2PB EDWLD2PB
N00579 Y0121.1 D0612.0 Y0121.1

EDWLD2PB EDWLD2PB
N00580 Y1020.1 Y1020.1

RO__2___ RO__2___
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
C
EQUALENB EQUALIZE
L_1_2_SS R_2_SS
N00581 Y1020.1 Y1020.1

RO__2___ RO__2___
EQLZVLV2 EQLZVLV2
K0004.5 K0007.7
E
EQUALENB EQUALIZE
L_1_2_SS R_2_SS
N00582 K0004.5 K0007.7

EQUALENB EQUALIZE
L_1_2_SS R_2_SS
N00583 K0000.0 Y0091.3 D0612.0 X1025.1 Y0091.3

ST_WLD2 RESET ST_WLD2
X1025.1
H
FAULT___
RESET
N00584 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00585 K0015.3 D0612.0 K0015.3

SSDUMP2 SSDUMP2
N00586 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00587 K0015.4 D0612.0 K0015.4

SSDUMP2 SSDUMP2
N00588 K0015.3 Y0000.2 X1026.1 K0015.4 Y0021.5

M 2773
N00589 K0015.4 Y0000.2 X1026.1 K0015.3 Y0021.6

N 2778
O
N00590 Y0120.7 K0014.0 D0610.2

X0019.0 K0008.0 K0014.0

B
M_MAN_W2 NT_SS NB2
N00591 D0610.2 ACT D0610.2

DETIMR2 DETIMR2
N00592 X0054.5 Y0095.1

DI_438_C DO_762_C
CWELDMOD CWELDMD2
D0610.2
E
CCWELDMO
DETIMR2
N00593
F 2797 SUB72
SPE

G 2798 SUB71 P0016
SP TIPDRESSER2
N00595 X0095.1 Y0021.2

DI_762_T DO_171_T
PCHNGRQ2 PCHG_RQ2
X0095.0
I
DI_761_T
PCNGREQ2
Y0112.1
J
DO_898_T
PWRMOV2
Y0112.2
K
DO_899_T
PWRFIX2
N00596 K0007.2 Y0000.5 R0222.4

N00597 K0007.3 Y0000.5 R0222.5

N00598 X0091.4 Y0020.3

DI_733_N DO_164_N
EW_TIP2 WTP_RST2
O
N00599 R0346.0 Y0092.5 X0001.2 K0008.0 R0346.0

___2 TSR2 PLC_AUTO NT_SS ___2
Y0119.1 K0006.7
B
DO_954_C INIT_AUT
LRAV_XFR O_TD_PB2
N00600 R0335.0 Y0109.1 Y0000.5 X0091.1 R0332.0

R0332.0
D
TD_MEM_W
C_#2
N00601 X0091.4 K0008.0 Y0000.5 X0018.7 R0332.0 R0335.0

EW_TIP2 NT_SS _@_MAINT D_BYPSS2 C_#2 P_TC2
R0335.0
F
DRESS_CA
P_TC2
N00602 X0091.2 Y0019.0

DI_731_M DO_153_A
ANT_REQ2 UTO_TD_2
R0335.0 Y0050.5
H
DRESS_CA DO_406_N
P_TC2 TFD_2APP
R0346.0
I
TIP_MEM_
___2
N00603 Y0093.7 R0352.0

DO_752_T PULLDTIP
IP_WTR2 _SEAL_2
N00604 R0352.0 ACT D0613.0

_SEAL_2 P_TIMER2
N00605 Y0018.5 X0001.2 Y0109.1

DO_150_D DI_11___ DO_874_T
K0007.0 Y0000.3
M
TEACH_TD DO_4_RBT
_ENABLE2 _IN_TCH
N00606 R0000.0 Y0018.5 X0001.2 Y0094.6

ON RSR_ON_2 PLC_AUTO D_MTRON2
K0007.0 Y0000.3
O
TEACH_TD DO_4_RBT
_ENABLE2 _IN_TCH
N00607 X1020.5 X0000.0 R0220.7

RI_6_WTR DI_1_EXT DI_959_P
_FL_SW2 _RNENBL LDTIP_2
R0220.7 D0613.0
B
DI_959_P PULLEDTI
LDTIP_2 P_TIMER2
N00608 K0006.3 Y0018.7

TD_MTR_F DO_152_T
LT_BYPS2 DMFL_BY2
N00609 D0608.0 R0410.0 R0413.0

D 2869 TD FAULT2
1TIM2 TOK2
N00610 Y0018.5 X0094.2 Y0108.2 K0006.3 Y0091.3 R0410.0

RSR_ON_2 IP_DR_OK RVTDOK2 LT_BYPS2 ST_WLD2 TOK2
R0410.0
F
TDCURREN
TOK2
N00611 R0413.0 ACT D0609.0

2TIM2
N00612 Y0018.5 ACT D0608.0

RSR_ON_2 1TIM2
N00613 Y0091.3 R0410.0 D0609.0 R0416.0

ST_WLD2 TOK2 2TIM2 2
R0406.0
J
TPRESFLT
2
R0416.0
K
TDMTRFLT
2
N00614 R0416.0 Y0018.6

TDMTRFLT DO_151_T
2 DM_FLT_2
N00615 Y0118.2 ACT D0607.0

ESCHKMD2 TIM2
N00616 D0607.0 R0407.0 R0406.0

TIM2 LAT2 2
O
N00617 Y0118.2 X0094.3 K0007.1 Y0091.3 R0407.0

ESCHKMD2 PDRRSOK2 ST_BYPS2 ST_WLD2 LAT2
R0407.0
B
TPRESFLT
LAT2
N00618 X0018.4 Y0121.2 Y0113.7 F1000.5 R0221.7

DI_149_I DO_971_P DO_912_C FAULT DI_967_R
NITTPDR2 EDDMPAPP LR_ZN_13 NTDDMP2
X0018.6 X0091.2 Y0019.0 Y0121.7

D
DI_151_T DI_731_M DO_153_A DO_976__
D_DMP_R2 ANT_REQ2 UTO_TD_2 TPWRCMP2
N00619 K0009.1 K0009.1

NTSR_ENB NTSR_ENB
2SS 2SS
N00620 K0009.1 X1025.1 K0009.1

2SS RESET 2SS
K0009.1 X0091.4
G
NTSR_ENB DI_733_N
2SS EW_TIP2
N00621 K0015.7 K0015.7

DTSRENB2 DTSRENB2
SS SS
N00622 K0015.7 X1025.1 K0015.7

SS RESET SS
K0015.7 X0091.5
J
DTSRENB2 DI_734_D
SS RSSTIP2
N00623 K0009.1 K0006.6 Y0092.4

2SS PB2 TSR2
X0019.3
L
DI_156_N
EWTPRST2
N00624 K0015.7 K0009.2 Y0092.5

SS 2 TSR2
Y0117.0 Y0054.3
N DRSSTIPSTPRST2
DO_937__ DO_436_D
STP_RST2 TSR2
N00625
O 2944 SUB72
SPE

A 2945 SUB71 P0017
SP WATERVALVE2
N00627 X1020.5 X0001.6 Y0093.7

RI_6_WTR DI_15_SY DO_752_T
_FL_SW2 S_WTR_ON IP_WTR2
N00628 X0014.0 R0000.5 Y1020.5

Y1020.5 X1020.5
D
RO_6_WTR RI_6_WTR
_RESET2 _FL_SW2
X1025.1
E
FAULT___
RESET
N00629
F 2957 SUB72
SPE

G 2958 SUB71 P0018
SP OVRTMP/NOSTRK2
N00631 X1020.3 Y0094.4

RI_4__XF DO_757_X
RMR_OT2 FMR_OT2
N00632 X1020.4 Y0094.5

RI_5_SRV DO_758_S
OMTR_OT2 RVMTROT2
N00633 X1020.3 X1025.1 R0501.0

R0501.0
K
XFRMR_OT
MP_SEAL2
N00634 X1020.4 X1025.1 R0501.1

RI_5_SRV FAULT___ SRVOMTR_
OMTR_OT2 RESET OT_SEAL2
R0501.1
M
SRVOMTR_
OT_SEAL2
N00635 R0501.0 Y0020.2

XFRMR_OT DO_131_X
MP_SEAL2 FMR_OTF2
N00636 R0501.1 Y0020.1

SRVOMTR_ DO_162_S
OT_SEAL2 GM_OTF2
N00637
A 2976 SUB72
SPE
N00638 ### AIR ###

B 2977 SUB71 P0020
SP AIR
N00639 X1020.6 Y0001.5

RI_7_AIR DO_14_EO
_FL_SW A_AIR_ON
N00640
D 2981 SUB72
SPE
N00641 ### SWGBOLT ###

E 2982 SUB71 P0022
SP SWGBOLT
N00642 X0000.0 Y0083.0

F 2984 WELD CONTROLLER #1 ENABLE
DI_1_EXT DO_665_W
_RNENBL C1_ENBLE
N00643 X0087.6 Y0014.4

G 2986 WELD CONTROLLER COMM OK #1
DI_703_W DO_117_W
1_COMMOK C1COM_OK
N00644 Y0000.3 Y0083.1

H 2988 ROBOT IN TEACH TO WC #1
DO_4_RBT DO_666_R
_IN_TCH BTCH_WC1
N00645 K0004.7 Y0014.2 R0220.6 X1020.0 X1020.1 D0004.3

I 2990 WELD MODE IN WELD WC1
WELD_/_N DO_115_W DI_958_P RI_1__XF RI_2_SRV WELDMODE
O_WELD1 D/NWD1MD LDTIP_1 RMR_OT1 OMTR_OT1 OK1
N00646 K0006.4 Y0014.2 R0220.7 X1020.3 X1020.4 D0004.4

J 2996 WELD MODE IN WELD WC2
WELD_/_N DO_115_W DI_959_P RI_4__XF RI_5_SRV WELDMODE
O_WELD2 D/NWD1MD LDTIP_2 RMR_OT2 OMTR_OT2 OK2
N00647 D0004.3 Y0014.1

WELDMODE DO_114_W
OK1 D/NWD1SS
N00648 D0004.4 Y0018.1

L 3004 WELD/ NO WELD 2 SS
WELDMODE DO_146_W
OK2 D/NWD2SS
N00649 D0004.3 D0004.4 R0221.0

M 3006 REMOTE WELD / NO WELD MODE
WELDMODE WELDMODE DI_960_R
OK1 OK2 EM_WELD
N00650 X0086.1 Y0015.6

N 3009 I AVAILABLE WARNING #1
DI_690_I DO_127_I
_HI/LO AVL_WRN1
N00651 X0087.5 Y0017.3

O 3011 ADAPTIVE MODE ENABLE
DI_702_A DO_140_A
DP_MODE DP_MODE
N00652 X0083.0 Y0015.3

A 3013 IN WELD CYCLE #1
DI_665_I DO_124_I
NWLDCYC1 NWD_CY_1
N00653 X0083.1 Y0015.4

B 3015 HAS WELDED #1
DI_666_W DO_125_H
ELD_CMP1 AS_WLD_1
N00654 X0083.3 Y0014.3

C 3017 NO WELD TIMER FAULT #1
DI_668_W DO_116_N
ELD_FLT1 OWLDFLT1
N00655 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

D 3019
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0306.0
E ROBOT WELD SCHEDULE WELD CTRL1
DO_686__ ROBOT_WS
BP_128 _WC#1
N00656 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

F 3028
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0307.0
G
DO_686__ WLD_SCH_
BP_128 39_WC1
N00657 Y0014.1 Y0014.2 Y0083.4

H 3037 WELD / NO WELD
DO_114_W DO_115_W DO_669_W
N00658 X1020.2 X1020.0 X1020.1 D0004.0

I 3040 ALL WELD PARAMETER OK WC1
O
N00659 Y0109.7 D0004.0 K0000.0 X0024.0 1

A 3044
DO_880__ LETSWELD DEBUG DI_193_N
BP1_1 WC1 T_FD_HM1
Y0110.0
B
DO_881__
BP2_1
Y0110.1
C
DO_882__
BP4_1
Y0110.2
D
DO_883__
BP8_1
Y0110.3
E
DO_884__
BP16_1
Y0110.4
F
DO_885__
BP32_1
Y0110.5
G
DO_886__
BP64_1
Y0110.6
H
DO_887__
BP128_1
1 ACT R0363.0
I SUB 3 0035 WELD BINARY WC1 TIMER
TMR BINARYTI
MER1
N00660 Y0109.7 D0004.0 R0363.0 X0024.0 Y0084.6

DO_880__ LETSWELD BINARYTI DI_193_N DO_679__
BP1_1 WC1 MER1 T_FD_HM1 BP_1
N00661 Y0110.0 D0004.0 R0363.0 X0024.0 Y0084.7

N00662 Y0110.1 D0004.0 R0363.0 X0024.0 Y0085.0

N00663 Y0110.2 D0004.0 R0363.0 X0024.0 Y0085.1

N00664 Y0110.3 D0004.0 R0363.0 X0024.0 Y0085.2

N00665 Y0110.4 D0004.0 R0363.0 X0024.0 Y0085.3

N00666 Y0110.5 D0004.0 R0363.0 X0024.0 Y0085.4

N00667 Y0110.6 D0004.0 R0363.0 X0024.0 Y0085.5

N00668 Y0084.6 Y0084.7 Y0085.0 Y0085.1 Y0085.2 Y0085.3 Y0085.4 1

C 3098
DO_679__ DO_680__ DO_681__ DO_682__ DO_683__ DO_684__ DO_685__
BP_1 BP_2 BP_4 BP_8 BP_16 BP_32 BP_64
1 Y0085.5 R0360.0
D NO WELD SCHEDULE WC1
DO_686__ NOWLDSCH
BP_128 WC1
N00669 R0360.0 X0087.6 K0000.0 Y0083.5

E 3107 PRESSURE SWITCH INPUT
K0000.0 Y0116.5 X0024.0

F
DEBUG DO_934__ DI_193_N
RD_SCHD1 T_FD_HM1
N00670 Y0120.6 F1000.3 Y0000.1 X0024.0 R0223.0

G 3115
DO_967_M PAUSED DO_2_RBT DI_193_N DI_976_M
AN_WELD1 _@_HOME T_FD_HM1 AN_WELD1
X0015.0 K0008.0 Y0000.5 F1000.3 F1000.2

H
Y0000.1 F1000.2 F1000.3

I
_@_HOME RUNNING
N00671 Y0120.6 Y0000.1 F1000.2 F1000.3 X0024.0 R0213.6

J 3132 WELD AT HOME1
DO_967_M DO_2_RBT PROGRAM_ PAUSED DI_193_N DI_902_W
AN_WELD1 _@_HOME RUNNING T_FD_HM1 ELDHOME1
X0015.0 K0008.0
K
DI_121_R AUTO/MAI
M_MAN_W1 NT_SS
N00672 Y0048.3 Y0121.0 F1000.3 Y0000.1 X0024.0 R0220.4

L 3141 SWGNUT REFFED REWELD 1
DO_388_N DO_969_F PAUSED DO_2_RBT DI_193_N DI_956_R
UTFD_APP EDWLD1PB _@_HOME T_FD_HM1 EFEDWLD1
Y0050.7
M
DO_408_S
WGBOLTAP
N00673 K0008.6 D0612.0 K0008.6

1 1
N00674 K0008.6 D0612.0 K0008.6

1 1
N00675 K0005.1 D0612.0 K0005.1

PB1 PB1
N00676 K0005.1 D0612.0 K0005.1

PB1 PB1
N00677 K0005.2 D0612.0 K0005.2

O_TD_PB1 O_TD_PB1
N00678 K0005.2 D0612.0 K0005.2

O_TD_PB1 O_TD_PB1
N00679 K0005.5 D0612.0 K0005.5

_CLS_PB1 _CLS_PB1
N00680 K0005.5 D0612.0 K0005.5

_CLS_PB1 _CLS_PB1
N00681 K0005.6 D0612.0 K0005.6

_OPN_PB1 _OPN_PB1
N00682 K0005.6 D0612.0 K0005.6

_OPN_PB1 _OPN_PB1
N00683 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00684 K0005.7 D0612.0 K0005.7

TCPB1 TCPB1
N00685 K0006.0 D0612.0 K0006.0

ACK_PB1 ACK_PB1
N00686 K0006.0 D0612.0 K0006.0

ACK_PB1 ACK_PB1
N00687 Y0120.6 D0612.0 Y0120.6

AN_WELD1 AN_WELD1
N00688 Y0120.6 D0612.0 Y0120.6

AN_WELD1 AN_WELD1
N00689 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
N00690 Y0121.0 D0612.0 Y0121.0

EDWLD1PB EDWLD1PB
N00691 Y1020.0 Y1020.0

B 3202 S RDO 1 EQUALIZATION VALVE 1
RO__1___ RO__1___
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
C
EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00692 Y1020.0 Y1020.0

D 3207 R RDO 1 EQUALIZATION VALVE 1
RO__1___ RO__1___
EQLZVLV1 EQLZVLV1
K0004.5 K0006.2
E
EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00693 K0004.5 K0006.2

EQUALENB EQUALIZE
L_1_2_SS R_1_SS
N00694 K0004.5 X1026.1 G1000.1 ACT K0004.5

G 3214 SUB 3 0033 R EQUALIZATION ENABLE 1_2 SS
N00695 K0000.0 Y0083.3 D0612.0 X1025.1 Y0083.3

H 3220 RESET WELDER
ST_WLD RESET ST_WLD
X1025.1
I
FAULT___
RESET
N00696 K0015.1 D0612.0 K0015.1

J 3226 S ADVANCE TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00697 K0015.1 D0612.0 K0015.1

K 3229 R ADVANCE TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00698 K0015.2 D0612.0 K0015.2

L 3232 S RETRACT TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00699 K0015.2 D0612.0 K0015.2

M 3235 R RETRACT TIP DRESS DUMP 1
SSDUMP1 SSDUMP1
N00700 K0015.1 Y0000.2 X1026.1 K0015.2 Y0017.5

N 3238
N00701 K0015.2 Y0000.2 X1026.1 K0015.1 Y0017.6

O 3243
N00702 Y0109.7 Y0110.0 Y0110.1 Y0110.2 Y0110.3 Y0110.4 Y0110.5 1

A 3248
DO_880__ DO_881__ DO_882__ DO_883__ DO_884__ DO_885__ DO_886__
BP1_1 BP2_1 BP4_1 BP8_1 BP16_1 BP32_1 BP64_1
1 Y0110.6 R0360.1
B BYPASS NUT PRESENT
DO_887__ BYPSSNUT
BP128_1 PRSNT
N00703 X0001.1 ACT

C 3257 SUB10 0000
DI_10_AU JMP
TO_REPT
N00704 X0024.0 R0360.1 Y0024.2

D 3260 S
DI_193_N BYPSSNUT DO_195_N
T_FD_HM1 PRSNT UTPRSNT1
N00705 X0024.0 Y0024.2

E 3263 R
DI_193_N DO_195_N
T_FD_HM1 UTPRSNT1
N00706
F 3265 SUB30
JMPE
N00707
G 3266 SUB72
SPE
N00708 ### TOUCHUP1 ###

H 3267 SUB71 P0025
SP TOUCHUP1
N00709 K0000.1 Y0054.4

I 3269 PROGRAM TOUCHUP REQUEST
TOUCHUP1 DO_437_P
ENB RGTCHREQ
N00710
J 3271 SUB72
SPE

Ford FANUC R30iA R30iB NextGen E

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VEHICLE OPERATION STRUCTURE AND STANDARDS

FORD Robot Programming Guide - FANUC Implementation

Appendix 2SWG – Dual Servo Weld Gun

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

10 PMC Logic (S-Logic) SWGBolt + SWGNut for R-30iA Controllers................... 304

11 PMC Logic (S-Logic) SWGBolt + SWGNut for R-30iB Controllers................... 305

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

1.1 Servo Gun Terminology

• Group 1 = Robot Servo System

• Tuning - The process of setting servo parameters to optimize the

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

10:L P[2] 2000mm/sec CNT50 SPOT[SD=1,EP=0,P=1,t=0.0,S=1,ED=1]

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

1.3.1 Single Gun for R-30iA Controllers

Motion Option format:

 Pressurization is performed according to the Start distance and pressure schedule

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Motion Option format:

 Pressurization is performed according to the Start distance, pressure schedule and

1.3.3 Dual Gun for R-30iA Controllers

i : Start Distance schedule number assigned to Gun 1

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

i : Start Distance schedule number assigned to Gun 1

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Z+ Stationary Tip towards

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Table 1: Backup Positions

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

[ TYPE ] EQUIP GUN RECORD CLEAR

• Setting Manual=True will cause the

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Table 2: Pressure Table

ROBOT PRESSURE TABLE

INDEX PRESSURE (LBF) PART THICKNESS MANUAL

81 USED FOR PRESSURE CALIBRATION 15.0

84 USED FOR PRESSURE CALIBRATION 15.0

85 USED FOR PRESSURE CALIBRATION 15.0

94 USED FOR TIP DRESS WITH NEW TIP

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

1.8.1 Gun Stroke Close Limit Setup Procedure

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

6. Scroll to “2 Close stroke limit (mm) : XX.X”. Press Enter.

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

1.9.1 Preparation for Auto-Tuning

If the BZAL or Pulse Not Established faults exist, they need to be

1.9.2 Gun Setup Utility

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Press enter to perform this step.

[ TYPE ] COMP OPEN CLOSE

14. Follow the steps listed on this screen in order.

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

Do you know your gun’s Stroke Limits?

Ford-FANUC R30iA_R30iB NextGen_ENET_Safe_2ServoWeldGun_Appendix - 2016_02_12.doc

1 Common setup: <DETAIL>