1.

Initial Setup
1.1. Robot Initialization
1.1.1. Speed ・・・・ 1.1. P1
[Auxiliary Function 301: Aux. Data Setting - Speed]
1.1.2. Block Instruction Change ・・・・ 1.1. P1
[Auxiliary Function 399: Aux. Data Setting - Auxiliary Integrated Instruction Setting]
1.1.3. Accuracy ・・・・ 1.1. P1
[Auxiliary Function 302: Aux. Data Setting - Accuracy]
1.1.4. Timer ・・・・ 1.1. P2
[Auxiliary Function 303: Aux. Data Setting - Timer]
1.1.5. Tool Coordinates ・・・・ 1.1. P2
[Auxiliary Function 304: Aux. Data Setting - Tool Coordinates]
1.1.6. Auto Load Measurement ・・・・ 1.1. P4
[Auxiliary Function 406: Basic Setting - Auto Load Measurement]
1.1.7. Teach/Check Speed ・・・・ 1.1. P8
[Auxiliary Function 401: Basic Setting - Teach/Check Speed]
1.1.8. Home Position ・・・・ 1.1. P8
[Auxiliary Function 402: Basic Setting - Home Position]
1.1.9. Check Specification ・・・・ 1.1. P9
[Auxiliary Function 807: System-Check Specification]
1.1.10. Change Operation Level ・・・・ 1.1. P9
[Auxiliary Function 898: System - Change Operation Level]
1.1.11. KLogic Control ・・・・ 1.1. P9
[Auxiliary Function 620: Input/Output Signal - KLogic Control]
1.2. System Initialization
1.2.1. System Switch ・・・・ 1.2. P1
[Auxiliary Function 502 - Advanced Setting - System Switch]
1.2.2. Dedicated Input Signals ・・・・ 1.2. P4
[Auxiliary Function 601: Input/Output Signal - Dedicated Input Signals]
1.2.3. Dedicated Output signals ・・・・ 1.2. P4
[Auxiliary Function 601: Input/Output signal - Dedicated Output Signals]
1.2.4. OX Specification Setting ・・・・ 1.2. P8
[Auxiliary Function 604: Input/Output Signal - OX specification setting]
1.2.5. Clamp Specifications ・・・・ 1.2. P9
[Auxiliary Function 605: Input/Output Signal - Clamp Specifications]
1.2.6. Configuring Device Net ・・・・ 1.2. P12
[Auxiliary Functions 611 and 608: Input/Output signals - Number of I/O Signals, Signal Allocation]
1.2.7. CC-LinkIE Configuration ・・・・ 1.2. P17
[Auxiliary Function 609: Input/Output Signal - Fieldbus Setting]
1.3. Servo Gun Initialization
1.3.1. Servo Weld Gun Mechanical Parameter ・・・・ 1.3. P1
[Auxiliary Function 1011: Spot Welding - Servo Gun Mechanical Parameter]
1.3.2. Servo Weld Gun Data ・・・・ 1.3. P2
[Auxiliary Function 1021: Spot Welding - Servo Weld Gun Data]
1.3.3. Tip Force Setting ・・・・ 1.3. P4
[Auxiliary Function 1025: Spot Welding - Clamp Data]
1.3.4. Wear Measurement Parameters ・・・・ 1.3. P5
[Auxiliary Function 1029: Spot Welding -Wear Measurement Parameters]
1.3.5. Data for Gun Zeroing ・・・・ 1.3. P6
[Auxiliary Function 1012: Spot Welding - Data for Gun Zeroing]
1.3.6. Dedicated Input/Output Signals for servo weld gun ・・・・ 1.3. P7
[Auxiliary Function 602: Dedicated Output Signals, 610: Input/Output Signals in Robot Arm]

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Table of Contents1. Initial Setup
1 P1
1.1.1. Speed [Auxiliary Function 301: Aux. Data Setting - Speed]

This function sets the speed data for auxiliary data [Speed 0] to [Speed 9], for SPEED instructions in block
teaching. All speed data are normally set as a percentage(%) of the maximum speed.
For joint interpolation: Percentage of the maximum speed for each axis
For linear/circular interpolation: Percentage of the maximum speed in interpolation motion

1.1.2. Block Instruction Change[Auxiliary Function 399: Aux. Data Setting - Auxiliary Integrated Instruction Setting]

This function sets whether the acceleration/deceleration instruction is included in the compound instructions ]
used in block teaching. Setting [ACCEL. AND DECEL.] to [Enable] makes the robot accelerate/decelerate at the
values set to each block teaching speed in [Auxiliary Function 0301 Speed]. Setting [Disable] enables ACCEL
and DECEL command.

1.1.3. Accuracy [Auxiliary Function 302: Aux. Data Setting - Accuracy]

This fuction sets the accuracy values for auxiliary data [Accuracy0]-Accuracy4] of ACCURACY instruction in
block teaching. [Accuracy 0] is based on current pose value and [Accuracy 1 - 4] is based on command value.
Used when positioning control is needed such as transferring work.

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1.1.1. Speed
1.1. P1
1.1.4. Timer [Auxiliary Function 303: Aux. Data Setting - Timer]

This function sets the actual waiting time in auxiliary data [Timer 1] - [Timer 9], for TIMER instructions in block
teaching.

1.1.5. Tool Coordinates [Auxiliary Function 304: Aux. Data Setting - Tool Coordinates]

This function records data specific to auxiliary data [Tool 1] - [Tool 9], for TOOL instructions in block teaching.
1. Defines a reference point for positioning/trajectory control, and the moving direction of the tool based on the
tool cordinates.
2.Used for controlling motion through a variety of functions - acceleration/deceleration control, vibration
control, collision detection, etc.
3. Used for controlling teach/check speed based on the position of the edge point of the tool.
The set data includes :
① X, Y, Z coordinate values of the tool coordinates origin measured, based on the null tool coordinates,
and rotation amount of tool coordinates
② Mass of tool, center of gravity, moment of inertia
③ Tool form
First, register the coordinate data with respect to the
null tool coordinate.

null tool coordinates

Note that the tool Z axis should be parallel to the
x operating direction of the gun axis,and the tool X
z
axis should be parallel to the surface including the
y gun axis and yoke.(Refer to the left figure)

z *The null tool coordinate is set based on the center

of flange surface of the robot that attaching the tool

y tool coordinates and indicated as tool coordinate data(0, 0, 0, 0, 0, 0).

x

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1.1.4. Timer
1.1. P2
 Tool numbers are as shown in the table below.

Robot Type
Tools gun Hand With ATC
Number 2 guns 3 guns 2 hands 2 guns 1 gun 1 gun
1 Hand 1 Hand 2 hands
1 gun Hand Gun1 Gun1 Hand 1 Gun1 Gun1 Gun1
2 Gun2 Gun2 Hand 2 Gun2 Hand Hand 1
3 Gun3 Hand 1 Hand 2
4
5
6
7
8
9 ATC ATC ATC ATC ATC ATC
Hand 1 = YP5, Hand 2 = YLA

The following figure shows the tool coordinate system for X and C guns.

In the case of X guns In the case of

C cancer

Z Z

X Y X Y

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1.1.5. Tool Coordinates
1.1. P3
1.1.6. Auto Load Measurement [Auxiliary Function 406: Basic Setting - Auto Load Measurement]

This function is used to automatically measure and calulate the mass, center of gravity and the load moment
with the actual load(tool+workpiece) mounted at the end of robot arm by moving axes JT3, 4, 5 and 6.
Use this function to calculate the load for 1.1.5

① Call up Auxiliary Function screen and select [4. Basic setting] and then [6. Auto Load Measurement]
Set the tool number to be measured and registered. This tool number corresponds to the tool number in Aux. 0304.

② Set the operational area for auto load measurement. During measurement, JT3 to 6 moves within the operational
area set here only in the plus direction fromn the current pose and not to minus direction.
Set the data making sure that robot does not interfere with the peripheral equipment.

Set the operation panel and TP setting

as follows.

1) Teach Lock OFF

2) TEACH/REPEAT REPEAT
3) A + MOTOR ON MOTOR lamp ON
4) A + RUN RUN lamp ON

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1.1.6. Auto load measurement
1.1. P4
③ Check the operational area for auto load measurement in low speed.

Selecting [Skip] proceeds to (4) auto load measurement.

Selecting [Yes] sets the check program, so operate Cycle Start.
Check auto load measurement in low speed and proceed to (4)auto load measurement

④ Executing Auto Load Measurement

After selecting [Skip] above, or after checking the auto load measurement in low speed, and then confirming the
safety of the operational area for auto load measurement and no proble is found, execute auto load measurement.

Selecting [Yes] sets the measurement program.

Selecting [Yes] in step 1 displyas the screen

to request "Cycle Start ON" as shown.
Press [A]+[Cycle Start].
Press.
"Measuring auto load measurement…" is
displayed.

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1.1.6. Auto load measurement
1.1. P5
 "Auto Load Measuremet is completed." is
displayed when process is finished.
Them, press <Close>.

⑤ Registering results after auto load measurement

When measurement process completes with no problem, the results are displayed. Results can be edited at this
time by inputting numbers directly.

The results are displayed.

Selecting [Yes] registers the data as the load of

the tool set in ［1.1.6.①］
Selecting [No] does not register them.

The result cannot be registered if the load mass value is beyond mass capacity as shown in screen above.
For load moment, note that the result can still be registered even if it exceeds the max. allowed moment,
only a warning is displayed as shown in screen above.

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1.1.6. Auto load measurement
1.1. P6
⑥ Approximate moments of inertia around tool center of gravity
Moment of inertia about the tool center of gravity cannot be determined by auto load measurement.
It is possible to be calculated when setting the approximate value.
Setting an approximate value is sufficient for practical use. Moments of ineritia can be approximated both ways
by judging the general shape of the tool as either a rectangular solid or as a cylinder.
<To approximate as a rectangural solid>
Moments of inertia of a rectangular solid whose center occupies the same point as the tool center of gravity
are calculated by these formulas.

ZF’
Ix 
12

M 2 2
b c 
IZ c
IY YF ’ Iy 
12

M 2 2
c a 
IX a
XF ’
Iz  
M 2 2
12
a b 
b

<To approximate as a cylinder>

Diameter:a, Height:h

ZF’
Ix  Iy 
12

M 2 2
3a  h 
IZ
IY
YF’ M 2
Iz  a
2
IX

XF ’

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1.1.6. automatic load measurement
1.1. P7
1.1.7. Teach/Check Speed [Auxiliary Function 401: Basic Setting - Teach/Check Speed]

This function sets the speeds correspoinding to the speed levels [Speed 1] to [Speed 5] for teach/check motion.

1.1.8. Home position [Auxiliary Function 402: Basic Setting - Home Position]

This function sets two home poses (Home Position 1 and 2) for robot operation.
(You can register 1 and 2 home poses.)
1.Returning the robot to a pre-set home pose, using HOME instruction of AS language.
2.Externally outputting a signal to indicate that the robot has reached the set home pose.
*Refer to the section of [Dedicated Input/Output signals] for the method of external output signal.

<Current Pose> Set (record) the current robot pose as the home pose.
<Key Entry> Set the home pose by entering numeric values for each axis.
<Home Range> A home pose signal is output when the robot stays within the range of a circle whose
center is Home Position 1(2) and radius is Home Range.
Note if setting value of home range is too small, home signal may not be output.
For the setting value, 5mm-10mm is recommended.

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1.1.7. Teach/Check Speed
1.1. P8
1.1.9. Check Specification [Auxiliary Function 807: System-Check Specification]

This function sets whether or not to execute CALL, TIMER, JUMP/END, OX(output signal), WX(input signal),
clamp instructions, etc., when executing taught programs in check mode.
Enable [Step continuous] as factory setting.

[Step continuous]
Enabled: While CHECK ONCE is selected, it is possible to go to the next or previous step by [CHECK GO]
or [CHECK BACK].
Disable: While CHECK ONCE is selected, it is possible to go to the next or previous step by [A]+[CHECK GO]
or [CHECK BACK].

1.1.10. Change Operation Level [Auxiliary Function 898: System - Change Operation Level]

1.1.11. K-LOGIC Control [Auxiliary function 620: Input/output signal - KLOGIC control]

In setting menu, turn on Klogic Auto Start (AUTOSTART.LSQ).

With this setting, KLOGIC runs when power is ON.

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1.1.9. Check specification
1.1. P9
1.2.1. System Switch [Auxiliary Function 502 - Advanced Setting - System Switch]

This function defines ON/OFF or effective/ineffective for system switches which set fundamental system
specifications. The system switches that are available vary depending on application or software version.
The following screens show typical system switches.
Moving cursor to a switch displays an explanation for that switch at the bottom of the screen.

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1.2.1. system switch
1.2. P1
P.1 CHECK.HOLD □ON ■OFF P.2 MESSAGES ■ON □OFF
CP ■ON □OFF SCREEN ■ON □OFF
CYCLE.STOP □ON ■OFF AUTOSTART.PC □ON ■OFF
OX.PREOUT □ON ■OFF AUTOSTART2.PC □ON ■OFF
PREFETCH.SIGINS □ON ■OFF AUTOSTART3.PC □ON ■OFF
QTOOL ■ON □OFF AUTOSTART4.PC □ON ■OFF
REP_ONCE ■ON □OFF AUTOSTART5.PC □ON ■OFF
REP_ONCE.RPS_LAST □ON ■OFF ERRSTART.PC □ON ■OFF
RPS ■ON □OFF AUTOSTART.LSQ ■ON □OFF
STP_ONCE □ON ■OFF DISPIO_01 □ON ■OFF
AFTER.WAIT.TMR □ON ■OFF HOLD.STEP □ON ■OFF
FLEXCOMP □ON ■OFF WS_COMPOFF ■ON □OFF
P.3 WS.ZERO □ON ■OFF P.4 PLC.CHECK □ON ■OFF
SG.BACK.CLAMP □ON ■OFF FLOWRATE □ON ■OFF
HOME.PRG.RESET □ON ■OFF EBMATCIRC □ON ■OFF
SI.UNIT ■ON □OFF EB2MATCIRC □ON ■OFF
SG.CHECK ■ON □OFF SINGULAR ■ON □OFF
SLOW_START ■ON □OFF SG_MEASURE_CHECK □ON ■OFF
ABS.SPEED □ON ■OFF SG.IN.HOME.POS □ON ■OFF
SGUN.AS.MOVE □ON ■OFF TPSPEED.RESET □ON ■OFF
UDP_EMSG ■ON □OFF OXZERO □ON ■OFF
TOUCH.ENA ■ON □OFF IFAKEY □ON ■OFF
TOUCHST.ENA ■ON □OFF DISP.EXESTEP ■ON □OFF
JOINT_LOCK ■ON □OFF DISP.EXESTEP_NM ■ON □OFF
P.5 NO_SJISCONV □ON ■OFF P.6 ERROUT_TEACH □ON ■OFF
NOPENABLE □ON ■OFF CBS_TOOLCHG □ON ■OFF
SIGRSTCONF ■ON □OFF CBS_AUXTOOL1 □ON ■OFF
WEITREL AUTO □ON ■OFF CBS_BASE □ON ■OFF
STAT_ON_KYBD ■ON □OFF SIGMON_TEACH □ON ■OFF
CONF_VARIABLE □ON ■OFF IFPLABELLANG2 □ON ■OFF
PROG.DATE □ON ■OFF OUT_RPSCODE_MAINPG □ON ■OFF
INSERTSTEP_CURRENT □ON ■OFF COINC_DISPONCE_CHK ■ON □OFF
MODIFYSTEP_CURRENT □ON ■OFF USE_ISO8859_5 □ON ■OFF
RECODE_NO_CONFIRM □ON ■OFF CLOCK_SYNC □ON ■OFF
PGNAME_DISP □ON ■OFF CLOCK_SYNC_HI_PRIO* □ON ■OFF
DIVIDE.TPKEY_S □ON ■OFF OPELV_RESET ■ON □OFF
P.7 HOME1,PRG,RESET,ERR □ON ■OFF P.8 PGSTEPCHGCHK □ON ■OFF
HOME2,PRG,RESET,ERR □ON ■OFF LOCAL_VAR_DISP □ON ■OFF
KLGCNT_SAVE ■ON □OFF FB_UNSIGNED_WORD □ON ■OFF
CP_ACCU1_BLEND □ON ■OFF UDP_SEND_NOBIND □ON ■OFF
SG,GUNMOVE,SYNC ■ON □OFF DEST_CIRINT □ON ■OFF
SG,MEASWEAR,P2K □ON ■OFF INVALID.TPKEY_S □ON ■OFF
HOMEPOS_SET_DISPPAGE □ON ■OFF PCENDMSG_MASK □ON ■OFF
CURSOR_LEFT_A_KEY □ON ■OFF INTERP_FTOOL □ON ■OFF
FB_DISCON_ERR □ON ■OFF LIST_VERTICAL □ON ■OFF
PGFILE_AUTO_RECOVER ■ON □OFF INSERT_NO_CONFIRM □ON ■OFF
JOINT.PARAL.SIM ■ON □OFF
PGCHGPOSGHK □ON ■OFF

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1.2.1. system switch
1.2. P2
 REP _ ONCE.RPS _ LAST whether to End program execution at the step where END instruction is taught when repeat
condition is set to once.
AUTOSTART.LSQ Whether to executes lsqpg()when turning the controller power ON.
SG.BACK-CLAMP whether to apply pressure when the check GO/BACK.
HOME.PRG.RESET Program can be reset only for HOME 1
SI.UNIT Switch the pressure unit.
SG.CHECK Switch the gun open/close operation method after welding is completed in the check mode.
SGUN.AS.MOVE When SGUN.AS.MOVE is ON, the gun axis operates according to the operation instruction
of the AS language.
TOUCHST.ENA Whether is able to operate the TP status lamp with the (HOLD/RUN, MOTOR ON) touch panel.
SG _ MEASURE _ CHECK Pressure measurement in check mode
JT5MTN Switch for 4-axis robot (Not currently used)
SG.IN.HOME.POS Whether the gun axis is included in the home signal
NOP _ ENABLE NOP instruction available (ON for stationary gun only)
SF _ OPEN _ ERROR Whether to make the safety fence open as an error

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1.2.1. system switch
1.2. P3
1.2.2. Dedicated input signals [Auxiliary Function 601: Input/Output Signal - Dedicated Input Signals]
1.2.3. Dedicated output signals [Auxiliary Function 601: Input/Output signal - Dedicated Output Signals]

This function sets the dedicated input/output signals. Refer to the External I/O manual(,90204-1023) for the
function of each signal. The table below shows the current specifications.

① Dedicated input signals

EXT. MOTOR ON □DEDICATED ■CANCEL
EXT. ERROR RESET ■DEDICATED (129 □CANCEL
EXT. CYCLE START ■DEDICATED (129 □CANCEL
EXT. PROGRAM RESET ■DEDICATED (129 □CANCEL
EXT. prg. select (JUMP) □DEDICATED ■CANCEL
JUMP _ ON ( )
JUMP _ OFF ( )
JUMP _ ST ( )
EXT. prog. select (RPS) ■DEDICATED □CANCEL
RPS _ ON (1320)
RPS _ ST ( 320)
Number of RPS code signals ( 8 )
RPS CODE FIRST SIGNAL NUMBER (1001)
RPS CODE ■BINARY
EXT. STOP (EXT _ IT) ■DEDICATED (129 □CANCEL
EXT. SLOW REPEAT MODE □DEDICATED ■CANCEL
I/F PANEL PAGE 1 SELECT □DEDICATED ■CANCEL
I/F PANEL PAGE 2 SELECT □DEDICATED ■CANCEL
I/F PANEL PAGE 3 SELECT □DEDICATED ■CANCEL
I/F PANEL PAGE 4 SELECT □DEDICATED ■CANCEL
ABRASION MEASUREMENT SENSOR INPUT SIGNAL□DEDICATED ■CANCEL
CHIP WEAR REFERENCE REGISTRATION SIGNAL (1 □DEDICATED ■CANCEL
CHIP WEAR REFERENCE REGISTRATION SIGNAL (2 □DEDICATED ■CANCEL
AUTOMATIC SAVE EXECUTION CONDITION 1 □DEDICATED ■CANCEL
AUTOMATIC SAVE EXECUTION CONDITION 2 □DEDICATED ■CANCEL
AUTOMATIC SAVE EXECUTION CONDITION 3 □DEDICATED ■CANCEL
SERVO WELDGUN MANUAL OPENING (7) □DEDICATED ■CANCEL
SERVO WELDGUN MANUALLY CLOSED (7) □DEDICATED ■CANCEL
FORCED CHIP REMOVAL FEED (1) □DEDICATED ■CANCEL
EXT. MANUAL ENERGIZATION (1) □DEDICATED ■CANCEL
SERVO WELDGUN MANUAL ENERGIZATION OPEN ( □DEDICATED ■CANCEL
SERVO WELDGUN MANUAL ENERGIZATION CLOSE □DEDICATED ■CANCEL
GUN CONNECTION SIGNAL (1) □DEDICATED ■CANCEL
External PC Program1 strat. □DEDICATED ■CANCEL
External PC Program2 strat. □DEDICATED ■CANCEL
External PC Program3 strat. □DEDICATED ■CANCEL
External PC Program4 strat. □DEDICATED ■CANCEL
External PC Program5 strat. □DEDICATED ■CANCEL
External PC program1 abort. □DEDICATED ■CANCEL
External PC program2 abort. □DEDICATED ■CANCEL
External PC program3 abort. □DEDICATED ■CANCEL
External PC program4 abort. □DEDICATED ■CANCEL
External PC program5 abort. □DEDICATED ■CANCEL

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1.2.2. dedicated input/output signal
1.2. P4
② dedicated output signal
MOTOR ON ■DEDICATED (306 □CANCEL
ERROR ■DEDICATED (310 □CANCEL
AUTOMATIC ■DEDICATED (305 □CANCEL
Panel switch in RUN ■SET □CANCEL
EXT_IT not set to hold. □SET ■CANCEL
Panel switch in REPEAT ■SET □CANCEL
Repeat continuous. □SET ■CANCEL
Step continuous ■SET □CANCEL
TEACH LOCK OFF ■SET □CANCEL
CYCLE START ON □SET ■CANCEL
RGSO ON □SET ■CANCEL
Dryrun mode off □SET ■CANCEL
CYCLE EXTERNAL START □SET ■CANCEL
CYCLE START ■DEDICATED (307 □CANCEL
TEACH MODE ■DEDICATED (312 □CANCEL
HOME1 ■DEDICATED (311 □CANCEL
HOME2 □DEDICATED ■CANCEL
POWER ON □DEDICATED ■CANCEL
RGSO □DEDICATED ■CANCEL
Ext. prog. select (RPS) enabled □DEDICATED ■CANCEL
WORK_SPACE 1 □DEDICATED ■CANCEL
WORK_SPACE2 □DEDICATED ■CANCEL
WORK_SPACE 3 □DEDICATED ■CANCEL
WORK_SPACE 4 □DEDICATED ■CANCEL
WORK_SPACE5 □DEDICATED ■CANCEL
WORK_SPACE 6 □DEDICATED ■CANCEL
WORK_SPACE7 □DEDICATED ■CANCEL
WORK_SPACE8 □DEDICATED ■CANCEL
WORK_SPACE9 □DEDICATED ■CANCEL
Program number □DEDICATED ■
No. of prog. Number signals ( )
First signal No. of prog. Number ( )
STEP NUMBER □DEDICATED ■
Number of step No. signals ( )
First signal No. of step. Number ( )
Encoder and brake power off □DEDICATED ■CANCEL
POWER SHUT-OFF (7) (NEGATIVE LOGIC) □DEDICATED ■CANCEL
TEACH LOCK ON □DEDICATED ■CANCEL
AUTOSAVE WARNING ■DEDICATED (294 □CANCEL
MANUAL ENERGIZATION AND PRESSURIZATION CO□DEDICATED ■CANCEL
CHIP DRESSER START SIGNAL (1) □DEDICATED ■CANCEL
PRESSURIZATION ARRIVAL SIGNAL (1) □DEDICATED ■CANCEL
SERVO_READY_STATUS □DEDICATED ■CANCEL
External PC Program 1 executing. □DEDICATED ■CANCEL
External PC Program 2 executing. □DEDICATED ■CANCEL
External PC Program 3 executing. □DEDICATED ■CANCEL
External PC Program 4 executing. □DEDICATED ■CANCEL
External PC Program 5 executing. □DEDICATED ■CANCEL
EMERGENCY STOP ■DEDICATED (314 □CANCEL
IN THE RUN MODE □DEDICATED ■CANCEL
HOLDING □DEDICATED ■CANCEL
DEVICE NET ERROR ■DEDICATED (309 □CANCEL

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1.2.2. dedicated input/output signal
1.2. P5
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1.2.2. dedicated input/output signal
1.2. P6
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1.2.2. dedicated input/output signal
1.2. P7
1.2.4. OX Specification setting [Auxiliary Function 604: Input/Output Signal - OX specification setting]

This function sets the specifications for the OX signal.

Type : <0: Step>, <1: Keep>, <2: Double>, <3: Pulse>

pulse value When a pulse is selected in Type, sets the length of the set time.

<0: Step>
Teaching this OX instruction outputs a signal in step increments. After robot reaches axis coincidence at a step,
the memory changes, movement begins toward the next step where OX is taught, and the OX signal turns ON.
When the memory changes to a step where OX is not taught, the signal turns OFF.

<1: Keep>
The timing for turning ON the signal is the same as <0:Step>, but keep type signals remain ON until the siganls
are turned OFF at a step taught to turn OFF

<2: Double>
A pair of OX siganls of this type turns one signal ON and the other OFF, or vice versa.

<3: Pulse>
When the robot reaches axis coincidence with the pose in the step where this signal is taught, the pulse
signal is output in the length of the set time. Set the length of pulse from 0 to 9.9s in seconds. But setting 0 outputs 0.4 seconds of pulse.

[NOTE] For the OX signals of Step and Keep type, turn OFF OX.PREOUT of the system switch enables to change
the output after reaching axis coincidence.

The specifications are as follows.

OX Signal 1 (work complete) ->Type: 3 [pulse], Pulse Value: 1

other than OX signal 1 ->Type: 1 [keep]

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1.2.4. OX Specification Setting
1.2. P8
1.2.5. Clamp Specifications [Auxiliary Function 605: Input/Output Signal - Clamp Specifications]

This part indicates Clamp signal specification, etc. for spot welding and handling operations.

<(1) Clamp application field>

The required setting items and contents of clamp instructions vary depending on the application field of the robot.
You can use up to eight commands from one clamp command.
This describes the required setting for specializing clamp command used in spot welding and handling operations.

0 : Not used Instruction not used.

1: Spot Weld Used to start welding sequence in spot welding.
2: Handling Used for open/close of hand in handling application.
3: Painting Sealing

<(2) Clamp Condition>

Set each data corresponding to the clamp condition (CC) number of the teaching data.

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1.2.5. Clamp Specifications
1.2. P9
<(3) Spot welding clamp data>
Set data for I/O siganals or 2-stroke retractable guns to each clamp used for spot welding.
For setting, change as shown in the table and figure below.

Weld Control Number 1

Gun Clamp Command Output 81

<Weld Control Numberr>

Sets welding controller 8 type numbers used for spot welding.

<Gun Clamp Command Output>

Set the Gun Clamp Command Output number to be used.
When set "0", the Gun Clamp Command does not output

<(4) Spot Welding Controller>

Set I/O signal specifications for the spot welding controllers 1 ~ 8.
For setting, change as shown in the table and figure below.

Weld Start Output 105

Weld Schedule Output Top Signal 97
Number of Signals to Use 8
Weld Comp. Input Signal 1097

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KAWASAKI 97160-1043DJE
1.2.5. Clamp Specifications
1.2. P10
 Weld Start Output Sets the number of the Weld Strat Output signal sent to welding controller.
Output Time Sets output duration time for Weld Start Output. This signal is level output.

Weld Schedule Output Top Signal Sets the first signal number that is output to welding controller.
Number of signals to use Sets the number of signals to use for weld schedule output signals.
Output Format Sets how the Weld Schedule Output Top Signal is output.
Set whether to output as binary or individual signal.
Weld Comp. Input Signal Sets the number of the Weld Comp. Input Signal sent from spot welding controller to the robot.
Weld Comp. Input Monitor When Weld Comp. Input Signal is not received within time set here, an error
occurs and robot stops after Weld Start Output has been sent.(Default is 3 sec)
When set 0 disables this error detected.
Welding Fault Input Signal Sets the number of the weld Fault Input Signal sent from spot welding controller
to the robot. When set 0 disables the Weld Fault detected.
Weld Fault Reset Output Sets the number of the Weld Fault Reset Output signal sent to welding controller.
When this signal is set and an abnormality occurs in the welding controller, the
Weld Fault Reset Output signal is send to spot welding controller.
When set does not output the Weld Fault Reset Output.

<(5) Spot welding gun>

Set the gun type and specifications of the 2-stroke retaractable spot welding gun.

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KAWASAKI 97160-1043DJE
1.2.5. Clamp Specifications
1.2. P11
1.2.6. Configuring Device Net [Auxiliary Functions 611 and 608: Input/Output signals - Number of I/O Signals, Signal Allocation]

<(1) Set the Number of Signals>

Set the number of external input/output signals and the number of internal signals used in the fieldbus as follows.
■Number of DO Signal ( 16 )
■Number of DI Signal ( 16 )
■Number of internal signal ( 512 )
■Number of FB1 signal (1024 )
■Number of FB2 signal ( 256 )

<(2) Signal allocation>

Assign each 16 AS application signals as shown below.

<AS signal start number>

Set the channel position start point for each DIO、FB1、FB2 port assigned by the signal number in 16 units.

<Number of signals>
This is corresponding to the number of signals used in the actual program.

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KAWASAKI 97160-1043DJE
1.2.6. Configuring Device Net
1.2. P12
<(3) Signal Allocation-I/O Interface Assignment>
This is related to the position where the slave I/F card is installed.
When setting [4] to the slave port, attach it to the CN1 connector of the 1JF board.

<(4) Signal Allocation - Setting signal arrangement order>

Set the signal arrangement order.

When the setting is made by the above procedure, the slave device is initialized, and the environment is
able to be recognized by the master device.
[NOTE] If it is not recognized by the master device, confirm the following points again.
・Is the MAC _ ID of the slave IF card duplicated with the MAC _ ID of another slave device?
・Is the slave IF card's baud rate the same as the master device?
・Does the 1JF board's DIP switch enable mounting of I/F card?

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KAWASAKI 97160-1043DJE
1.2.6. Configuring Device Net
1.2. P13
<(5) Master setting>

1) Board Settings [Auxiliary 0609 -12]

Set master MAC _ ID to 0

Unify the baud rate setting for the same network (Set value follows the instruction of the line controller).
Set the MAC _ ID of each slave according to the instruction of the person in charge of the line control.
After changing the DIP switch, it is necessary to turn the power of the robot controller OFF and then on.

*No identical MAC _ ID in the same network

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KAWASAKI 97160-1043DJE
1.2.6. Configuring Device Net
1.2. P14
2) Scanner Settings

Set the standard default value (Change setting when scan time-over occurs, etc.).
<Default Settings>

3) Nodelist setting

Set all slave stations on the network

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KAWASAKI 97160-1043DJE
1.2.6. Configuring Device Net
1.2. P15
 *EDS file:DeviceNet setting file Can obtain from the manufacturer Web site of the unit
As it is a text file, you can check the contents with Notepad.
<MAC ID>
Set MAC ID (Nord address)
<Vendor ID>
Set the Vendor ID of the MAC _ ID unit being set
<Device Type>
Set the device type of the MAC _ ID unit being set
<Product Code>
Set the product code of the MAC _ ID unit being set
<Revision (Major)>
Set the revision (Major) of the MAC _ ID unit being set
<Revision (minor)>
Set the revision (minor) of the MAC _ ID unit being set
<Data size (INPUT)>
Set the number of input points of the MAC _ ID unit being set (1 byte = 8 bits).
<AS Offset (INPUT)>
Offset The number of input points of the MAC_ID unit being set from the head device assigned by MAC_ID.
(1 byte = 8 bits)
<Data size (OUTPUT)>
Set the number of output points of the MAC _ ID unit being set (1 byte = 8 bits).
<AS Offset (OUTPUT)>
Offset The number of output points of the MAC_ID unit being set from the head device assigned by MAC_ID.
(1 byte = 8 bits)
<Background Port Rate>
Set the ratio of the slave scan cycle corresponding to the scan cycle.

<Settings>
Set the entered values

*For details, refer to the instructions from the person in charge of line control, the instruction manual, the EDS
file of the unit, etc.

4) IO Check

Conduct the actual IO check.

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KAWASAKI 97160-1043DJE
1.2.6. Configuring Device Net
1.2. P16
1.2.7. CC-Link IE Configuration [Auxiliary Function 609: Input/Output Signal - Fieldbus Setting]

1) CC-Link IE Settings

<station number>
Set the station number
<Network number>
Set the network number of the station being set.
<Number of word data>
Set the word data number of the station number being set.

<Settings>
Set with entered values

2) IO Check

Conduct the actual IO check.

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KAWASAKI 97160-1043DJE
1.2.7. CC-Link IE Configuration
1.2. P17
1.3.1. Servo Gun Mechanical Parameter [Auxiliary Function 1011: Spot Welding - Servo Gun Mechanical Parameter]

Set each parameter values. When using multiple guns, set their parameter values likewise
by pressing <Next Page>.

<Limit-Upper/Lower>
For the Limit-Upper/Lower of the servo weld gun, set the value obtained by subtracting 5 mm from motion stroke
when moving the gun with tip of wear from closing end to opening end .(mechanical stop)
The Limit-Lower of the servo weld gun changes depending on the tip wear amount, so set it as follows.
Set - [max. wear limit + α] (α > 0, about 100 mm margin)

<Resolution, Motion direction, Max. speed, Acceleration time>

Check the factory shipment and register.

[NOTE] Simply registering the data refered to this page is in sufficient to operate the servo weld gun under the
new condition. Can be effected after executing the gun change on the software

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KAWASAKI 97160-1043DJE
1.3.1. Servo Gun Mechanical Parameter
1.3. P1
 1.3.2. Servo Weld Gun Data [Auxiliary Function 1021: Spot Welding - Servo Weld Gun Data]

Set each parameter values. When using multiple guns, set their parameter values likewise
by pressing <Next Page>.

Clearance (Moving tip) 10 mm

Clearance (Fixed tip) 10 mm
Clearance before force (Moving tip side) 2mm
Clearance before force (Fixed tip side) 2mm
Clearance after force (Moving tip side) 2mm
Clearance after force (Fixed tip side) 2mm
Dressing force 1.47 KN
Dressing time 2 sec

moving tip side clearance

Moving tip side

Before force the movable After pressing the moving tip
side Clearance side Clearance

Before force on Fixed After fixed tip force

Side Clearance Clearance
Fixed tip Side

Fixed tip side clearance

<Clearance - Moving/Fixed tip>

Set distance for moving/fixed tip to depart from workpiece after welding.
When input non-zero vlaues into [Clearance-Moving/Fixed Tip], take precedence over AS function.

<Clamp force-Teaching>
Set the tip force when operation the [AXIS] keys and [CL1] key in teach mode

<Clamp force during wear measurement >

Sets the tip force used when measring the wear.

<Tool + Z direction>
Set + direction for tool coordinates Z axis (motion direction of gun axis) to be either [Close] or [Open].
Tip wear compensation, etc. is executed according to the data set here.

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KAWASAKI 97160-1043DJE
1.3.2. Servo Weld Gun Data
1.3. P2
<Force for stuck detection>
Set a threshold force value for detecting a stuck tip. When gun opens after input of Weld completion signal, if
the gun force equals or exceeds this threshold, error (E5029:Gun tip stuck) arises. Weld stuck detection is not
executed when "0"is set.

<press speed>
In the final stage of the closing motion in the weld point, drives the moving tip at this speed
until tip force reaches the set force.

<clearance before force>

Set clearance before pressurizing for moving/fixed side tip.

<clearance distance after force>

After gun opens up to the set "Clearance after force", starts moving to the next weld point.
(At this time, the gun keeps opening until it opens up to the "Clearance distance", and the cycle time becomes
shorter by the time requiere for moving from the "Clearance after force"
point to the "Clearance distanve" point.

<Gun input signal>

Specify input signal number for checking the gun selection when changing guns in repeat mode.
This signal(gun ID) is input at gun change and is compared with the taught gun NO., if no match is found error
arises. In repeat mode, the matching of actual gun ID NO. with that in the taught data is checked at every step.
Setting "0" is disables this check

<Gun-tip touch signal>

Set input signal number for confirming a contact of the fixed tip. When the tip contacts workpiece, this siganl is
input to robot and the teach pendant buzzer sounds. (In teach mode and only when [Deadman] switch is ON).
Setting "0" disables this detection function.

<waiting time or servo weld gun pressurization>

Set the wait time until the start of pressurization after reaching the teaching point. Input by × 16 ms.
Setting a small value starts the presurizing sooner and decrease cycle time but is may allow greater vibrations
when pressurizing the workpiece. Set in consideration of the effect on cycle time and impact against
the workpiece.

<Max clamp force limit>

Set a max tip force limit for the gun. If the weld condition is set aboce this limit, pressurization for the step is
automatically executed at this max. tip force limit value. Also, if the tip force set for teaching or for wear
measurement is greater than the max. tip force limit value, data error occurs and that force data cannot be
registered.

<Dressing force>
Tip force set here is applied instead of that of WS code taught at the point in tip dressing mode.

<Dressing time>
Gun axis opens and moves to the next step after receiving Weld completion signal or passing pressurizing time set
here, whichever comes fast.

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KAWASAKI 97160-1043DJE
1.3.2. Servo Weld Gun Data
1.3. P3
1.3.3. Tip Force Setting [Auxiliary Function 1025: Spot Welding - Clamp Data]

Set a tip force value in a teaching point via WS code. Force values can also be set in [Force] in the Clamp data
screen. However, to make the WS Code specified force values valied 0 must be input into [Force] in the Clamp
data screen, otherwise settings in Aux. 1025 are ignored.

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KAWASAKI 97160-1043DJE
1.3.3. Tip Force Setting
1.3. P4
1.3.4. Wear Measurement Parameters [Auxiliary Function 1029: Spot Welding -Wear Measurement Parameters]

Set parameter values for tip wear.

When using multiple guns, set their parameter values likewise by pressing <Next Page>.

Allowed wear limit (moving tip) 8mm *When the tip diameter is Φ 16, it is 8 mm.
Allowed wear limit (Fixed tip) 8mm When the tip diameter is Φ 13, it is 7 mm.
Wear reset signal (moving tip) 1087
Wear reset signal (Fixed tip) 1087
Wear error signal output (moving tip) 87
Wear error signal output (Fixed tip) 88
wear error signal output level 75%

<allowable wear on the movable side and allowable wear on the fixed side> (Setting Range: 0.00 ~ 327.67 mm)
Set a max. allowed wear limit for the tips. When the wear on moving/Fixed tip exceeds this value, error arises.
(E5034: Tip wear exceeds limit.(MOVING SIDE)) or (E5035: Tip wear exceeds limit.(FIXED SIDE)).
When error occurs, the wear measurement data is not updated. When "0" is set, error check of the tip wear
is not executed.

<current wear on moving/fixed tip side>

Displays wear for moving/fixed tip. (Display does not update in real time.)
Set values here when inputting the wear manually. This data will be cleared to "0" when the moving/fixed
tip wear clear signal is input.

<Wear clear signal-Moving/Fixed tip>

Set an input signal number for resetting the current wear(0 clear). If this signal is input to the robot, the current
wear of the gun is reset(0 clear). When 0 is set, wear clear by the input siganl cannot be executed.

<Wear error signal output level>

When the percentage of current tip wear to allowed max wear limit exceeds the value set here, outputs the Wear
error signal at wear measurement or current wear setting.

<Wear detection sensor signal>

Wear detection sensor can be used instead of the wear measurement reference plate. Set the input signal
number for the sensor signal. Set "0" if not used the sensor signal.

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KAWASAKI 97160-1043DJE
1.3.4. Wear Measurement Parameters
1.3. P5
1.3.5. Data for Gun Zeroing [Auxiliary Function 1012: Spot Welding - Data for Gun Zeroing]

Automatic zeroing of the gun axis is made as follows based on the calibration data set as shown below.
① Reset of encoder counter for gun axis
② Opening motion to full open point(mechanical stop)
③ Closing motion by 5 mm from there

Press A + <spot point information> and manually perform the separator/connection on the software of the servo
weld gun. Calibration is executed and the zeroing data of the servo weld gun is calculated/set automatically.
Calculated/set. As the zeroing data, refer to the gun axis limit-max value that the gun axis value is set to be "0"
when close the gun with mounting the wear value 0 tip, the gun axis is registered at the open end of the gun.

① Perform detach operation (No need to unchuck the gun)

Press <spot point information> or the A + CL auxiliary key to open the clamp information input screen.

1) In [spot point information] of the clamp information input screen, enter "0 (separating)" and close the screen.

2) Press the A key + <spot point information> of the function key to execute software disconnection.

② Execute connection operation

1) Press <spot point information> or the A + CL auxiliary key to open the clamp information input screen.

2) In [spot point information] of the clamp information input screen, enter "1 (Normal weld Point/Connection)"
and close the screen.

3) Turn ON the motor and press the A key + <spot position information> of the function key.
It is connected and the calibration operation is executed.
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KAWASAKI 97160-1043DJE
1.3.5. Data for Gun Zeroing
1.3. P6
1.3.6. Dedicated Input/Output Siganls for servo weld gun [Auxiliary Function 602: Dedicated Output Signals,
610: Input/Output Signals in Robot Arm]

When connecting or disconnecting a gun using the ATC, the "Encoder and brake power supply" of the gun axis
The signal must be set.

① Set the encoder/brake power signal.

Set the signal number you want to use for the encoder/brake power (gun axis number).
By outputting the signal set here, the encoder/brake power for the gun axis is turned OFF when the gun is
changed, and the gun is able to be disconnected.

② Set the signal of the valve output board.

By transmitting the signal status set in (1) above using the 4th channel of the valve output board, the encoder/
brake power is turned ON/OFF.
The signal of the first valve output board channel can be set by the following procedure.
1) Set "internal valve output" to "Enabled".
2) Set "starting signal number" to the signal number -3 set in (1).
The initial value is set to 9.

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KAWASAKI 97160-1043DJE for servo weld gun 1.3. P7
2. Sample program
Contents Page
2.1. Common program
2.1.1. Program name [reference] ・・・・ 2.1. P1
2.1.2. Style verify pg (pg.check) ・・・・ 2.1. P2
2.1.3. Collation pg (r.check) ・・・・ 2.1. P3
2.1.4. Signal reset program (io.reset) ・・・・ 2.1. P4
2.1.5. Mastering position check program (pg 000) ・・・・ 2.1. P7

2.2. Spot program

2.2.1. Main program (pg0) ・・・・ 2.2. P1
2.2.2. Main program (pg0) gun change gun1 or gun2 ・・・・ 2.2. P2
2.2.3. Main program (pg0) gun change gun1 or gun2 or gun3 ・・・・ 2.2. P4
2.2.4. Welding program (pg ***) ・・・・ 2.2. P7
2.2.5.1. Tip dress (Carried servo gun) ・・・・ 2.2. P9
2.2.5.2. Tip dress (Fixed servo gun) ・・・・ 2.2. P11
2.2.6.1. Tip wear compensation (Tip wear measure) (Carried servo gun) ・・・・ 2.2. P14
2.2.6.2. Tip wear compensation (Tip wear measure) (Fixed servo gun) ・・・・ 2.2. P15
2.2.7.1. Tip wear calibration (Carried servo gun) ・・・・ 2.2. P20
2.2.7.2. Tip wear calibration (Fixed servo gun) ・・・・ 2.2. P21
2.2.8. Tip wear reset ・・・・ 2.2. P24
2.2.9. Home return ・・・・ 2.2. P25
2.2.10. Weld mode check ・・・・ 2.2. P26
2.2.11.1. Check tip wear value (Carried servo gun) ・・・・ 2.2. P27
2.2.11.2. Check tip wear value (Fixed servo gun) ・・・・ 2.2. P28
2.2.12. Store tip wear value for fixed tip ・・・・ 2.2. P29
2.2.13. Warming up ・・・・ 2.2. P30
2.2.14. Tip wear value output ・・・・ 2.2. P31
2.2.15. Tip dresser shift advance (dres _ adv) ・・・・ 2.2. P32
2.2.16. Tip dresser shift return (dres _ ret) ・・・・ 2.2. P33
2.2.17. Fixture plate advance (plate _ adv) ・・・・ 2.2. P34
2.2.18. Fixture plan return (plate _ ret) ・・・・ 2.2. P35

2.3. Handling program

2.3.1. Main program (pg0) ・・・・ 2.3. P1
2.3.2. Handling program (pg ***) ・・・・ 2.3. P2
2.3.3. Tool put program for ATC (pg071) ・・・・ 2.3. P6
2.3.4. Tool get program for ATC (pg072) ・・・・ 2.3. P8
2.3.5. Work 1 Presence on (work1 on.chk) ・・・・ 2.3. P10
2.3.6. Work1 presence off (workoff.chk) ・・・・ 2.3. P11
2.3.7. Hand1 open (hand1.op) ・・・・ 2.3. P12
2.3.8. Hand1 close (hand1.cl) ・・・・ 2.3. P13
2.3.9. Hand open check (handop.chk) ・・・・ 2.3. P14
2.3.10. All tools presence on (tool.on.chk) ・・・・ 2.3. P15
2.3.11. Tool 1 presence off (tool1.off.chk) ・・・・ 2.3. P16
2.3.12. ATC connect on (atc.on.chk) ・・・・ 2.3. P17
2.3.13. ATC connect off (atc.off.chk) ・・・・ 2.3. P18
2.3.14. ATC cover1 open (cover1.op) ・・・・ 2.3. P19
2.3.15. ATC cover close (cover.cl) ・・・・ 2.3. P20

2.4. Turn table program

2.4.1. Turn table rotate (tt _ run) ・・・・ 2.4. P1
2.4.2. Turn table reference position set (tt _ ref) ・・・・ 2.4. P3
2.4.3. Turn table safety pin lock (pin _ in) ・・・・ 2.4. P4
2.4.4. Turn table safety pin unlock (pin _ out) ・・・・ 2.4. P5

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KAWASAKI 97160-1043DJE
Contents2.Sample Program
2 P1
2.1.1. Program name [reference]

Contents Program name Comment

Common Vehicle Verification program pg.check Style Verify Pg
program
Program Verification program r.check Collation Pg
IO Initialization Program io.reset IO _ Reset
Home Position Return Program pg 000 Master Position
Spot Main Program (Spot) pg0 Main Program
Program
Welding Work Program 1 pg 11 YP5 ASEAN _ RH
Welding Work Program 2 pg 12 YP5 ASEAN _ LH
Welding Work Program 3 pg 211 YP5P 24 _ RH
Tip dressing program pg 128 Tip Dress Pg
Handling Main Program (handling) pg0 Main Program
program
Handling Work Program 1 pg 31 YP5-ASEAN _ RH
Handling Work Program 2 pg 32 YP5-ASEAN _ LH
Handling Work Program 3 pg 231 YP5-P 24 _ RH
Tool 1 Placing Work Program pg 71 Tool1 _ Put
Tool 1 Picking Work program pg 72 Tool1Get
Tool 2 Placing Work Program pg 271 Tool 2 Put
Tool 2 Picking Work Program pg 272 Tool2Get
Workpiece1 ON Confirmation Macro work1 on.chk Work1 Presence ON
Workpiece2 ON Confirmation Macro work2on.chk Work2 Presence ON
WorkpieceOFF Confirmation Macro workoff.chk Work Presence OFF
Hand 1 OP Macro hand1.op Hand1 _ Open
Hand 2 OP Macro hand2.op Hand2 _ Open
Hand 1 CL Macro hand1.cl Hand1 _ Close
Hand 2 CL Macro hand2.cl Hand2 _ Close
All CL Open Confirmation Macro handop.chk Hand Open Check
ON Confirmation Macro for All Tools tool.on.chk ALL Tools Pres OFF
OFF Confirmation Macro for Hand 1 tool1.off.chk Tool 1 Pres OFF
OFF Confirmation Macro for Hand 2 tool2.off.chk Tool2Pres OFF
ATC Surface Contact ON Confirmation Macro atc.on.chk ATC Connect ON
ATC Surface Contact OFF Confirmation Macro atc.off.chk ATC Connect OFF
ATC Cover 1 Open Macro cover1.op ATC Cover 1 Open
ATC Cover 2 Open Macro cover2.op ATC Cover 2 Open
All ATC Cover Close Macro cover.cl ATC Cover Close

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KAWASAKI 97160-1043DJE
2.1.1. Program name [reference]
2.1. P1
2.1.2. Style verify pg（pg.check）

.PROGRAM pg.check()#0;Style Verify pg

IF (SIG(312)==ON) GOTO 10
pg.check = BITS(1001,8)
IF pg.no==pg.check THEN ;Style Verify
GOTO 10
ELSE
TYPE "Style Verify Alarm！ pg.no ⇒",pg.no ;It confirms it on the keyboard screen！
TYPE " pg.check⇒",pg.check
SIGNAL 8
HALT ;Reactivation is impossible!Please Reset Program.
END
;
10
RETURN
.END

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KAWASAKI 97160-1043DJE
2.1.2. Style Verify pg
2.1. P2
2.1.3. Collation pg（r.check）

.PROGRAM r.check()#0;Collation Pg
IF (SIG(312)==ON) GOTO 1
IF s.pro==0 THEN
s.pro = 100
END
IF s.pro==100 AND r.pro==0 THEN
GOTO 1
ELSE
IF r.pro==999 THEN
TYPE "It jumped to step 1. ROBOT NO MOVE",/F3.0,miss+1,"The"
TYPE "Please call pg0. "
SIGNAL 10
HALT ;Reactivation is impossible!Please Reset Program.
END
END
1; OX312 TEACH MODE
r.pro = 999 OX10 USER ALARM
RETURN (OTHERS)
.END OX8 USER ALARM
(STYLE MISMATCH)

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KAWASAKI 97160-1043DJE
2.1.3. Collation pg
2.1. P3
2.1.4. Signal reset program（io.reset）

.PROGRAM io.reset(); SIGNAL -52 ; OUTPUT 36

WAIT SIG(-1) ; SIGNAL -53 ; OUTPUT 37
SIGNAL -1 ; CYCLE COMPLETE SIGNAL -54 ; OUTPUT 38
SIGNAL 2 ; OK TO TRANSFER SIGNAL -55 ; OUTPUT 39
; SIGNAL -56 ; OUTPUT 40
SIGNAL -5 ; USER ALARM (PART PRESENCE) SIGNAL -57 ; OUTPUT 41 (SPARE)
SIGNAL -6 ; USER ALARM (HAND CLAMP LS) SIGNAL -58 ; OUTPUT 42 (SPARE)
SIGNAL -7 ; USER ALARM (SEALER CHECK) SIGNAL -59 ; OUTPUT 43 (SPARE)
SIGNAL -8 ; USER ALARM (STYLE MISMATCH) SIGNAL -60 ; OUTPUT 44 (SPARE)
SIGNAL -9 ; USER ALARM (WEAR AMOUNT) SIGNAL -61 ; OUTPUT 45 (SPARE)
SIGNAL -10 ; USER ALARM (OTHERS) SIGNAL -62 ; OUTPUT 46 (SPARE)
; SIGNAL -63 ; OUTPUT 47 (SPARE)
SIGNAL -13 ; WARM UP COMPLETE SIGNAL -64 ; OUTPUT 48 (SPARE)
; SIGNAL -65 ; OUTPUT 49 (SPARE)
SIGNAL -17 ; OUTPUT 1 SIGNAL -66 ; OUTPUT 50 (SPARE)
SIGNAL -18 ; OUTPUT 2 SIGNAL -67 ; OUTPUT 51 (SPARE)
SIGNAL -19 ; OUTPUT 3 SIGNAL -68 ; OUTPUT 52 (SPARE)
SIGNAL -20 ; OUTPUT 4 SIGNAL -69 ; OUTPUT 53 (SPARE)
SIGNAL -21 ; OUTPUT 5 SIGNAL -70 ; OUTPUT 54 (SPARE)
SIGNAL -22 ; OUTPUT 6 SIGNAL -71 ; OUTPUT 55 (SPARE)
SIGNAL -23 ; OUTPUT 7 SIGNAL -72 ; OUTPUT 56 (SPARE)
SIGNAL -24 ; OUTPUT 8 SIGNAL -73 ; OUTPUT 57 (SPARE)
SIGNAL -25 ; OUTPUT 9 SIGNAL -74 ; OUTPUT 58 (SPARE)
SIGNAL -26 ; OUTPUT 10 SIGNAL -75 ; OUTPUT 59 (SPARE)
SIGNAL -27 ; OUTPUT 11 SIGNAL -76 ; OUTPUT 60 (SPARE)
SIGNAL -28 ; OUTPUT 12 SIGNAL -77 ; OUTPUT 61 (SPARE)
SIGNAL -29 ; OUTPUT 13 SIGNAL -78 ; OUTPUT 62 (SPARE)
SIGNAL -30 ; OUTPUT 14 SIGNAL -79 ; OUTPUT 63 (SPARE)
SIGNAL -31 ; OUTPUT 15 SIGNAL -80 ; OUTPUT 64 (SPARE)
SIGNAL -32 ; OUTPUT 16 SIGNAL -81 ; GUN1 PRESS NOTIFICATION
SIGNAL -33 ; OUTPUT 17 SIGNAL -82 ; GUN1 PRESS
SIGNAL -34 ; OUTPUT 18 SIGNAL -83 ; GUN1 2'ND ST. or BU OPEN
SIGNAL -35 ; OUTPUT 19 SIGNAL -84 ; GUN1 LOWER PRESSURE
SIGNAL -36 ; OUTPUT 20 ;
SIGNAL -37 ; OUTPUT 21 SIGNAL -87 ; GUN1 TIP WEAR AMOUNT WARNING
SIGNAL -38 ; OUTPUT 22 (MOVING SIDE)
SIGNAL -39 ; OUTPUT 23 SIGNAL -88 ; GUN1 TIP WEAR AMOUNT WARNING
SIGNAL -40 ; OUTPUT 24 (FIXED SIDE)
SIGNAL -41 ; OUTPUT 25 SIGNAL -89 ; GUN1 TIP CHANGE POSITION
SIGNAL -42 ; OUTPUT 26 ;
SIGNAL -43 ; OUTPUT 27 SIGNAL -97 ; TC1 WELD SCHEDULE 1
SIGNAL -44 ; OUTPUT 28 SIGNAL -98 ; TC1 WELD SCHEDULE 2
SIGNAL -45 ; OUTPUT 29 SIGNAL -99 ; TC1 WELD SCHEDULE 4
SIGNAL -46 ; OUTPUT 30 SIGNAL -100 ; TC1 WELD SCHEDULE 8
SIGNAL -47 ; OUTPUT 31 SIGNAL -101 ; TC1 WELD SCHEDULE 16
SIGNAL -48 ; OUTPUT 32 SIGNAL -102 ; TC1 WELD SCHEDULE 32
SIGNAL -49 ; OUTPUT 33 SIGNAL -103 ; TC1 WELD SCHEDULE 64
SIGNAL -50 ; OUTPUT 34 SIGNAL -104 ; TC1 WELD SCHEDULE 128
SIGNAL -51 ; OUTPUT 35 SIGNAL -105 ; TC1 RUN/STOP

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KAWASAKI 97160-1043DJE
2.1.4. Signal reset program
2.1. P4
2.1.4. Signal reset program（io.reset）

SIGNAL -106 ; TC1 STEPPER RESET 1 SIGNAL -172 ; D.A.W. WELD SCH.8
SIGNAL -107 ; TC1 STEPPER RESET 2 SIGNAL -173 ; D.A.W. WELD SCH.16
SIGNAL -108 ; TC1 STEPPER RESET 3 SIGNAL -174 ; D.A.W. WELD SCH.32
SIGNAL -109 ; TC1 STEPPER RESET 4 ;
SIGNAL -110 ; TC1 GUN FAULT CHECK SIGNAL -177 ; ADVANCE HEAD IN TEACH 1
SIGNAL -111 ; TC1 OFFSET MODE SIGNAL -178 ; ADVANCE HEAD IN TEACH 2
SIGNAL -112 ; TC1 SHORT CIRCUIT DETECTION SIGNAL -179 ; ADVANCE HEAD IN TEACH 3
SIGNAL -113 ; GUN2 PRESS NOTIFICATION SIGNAL -180 ; ADVANCE HEAD IN TEACH 4
SIGNAL -114 ; GUN2 PRESS SIGNAL -181 ; ADVANCE HEAD IN TEACH 5
SIGNAL -115 ; GUN2 GUN1 2'ND ST. or BU OPEN ;
SIGNAL -116 ; GUN2 LOWER PRESSURE SIGNAL -193 ; RELEASE CHUCK
; SIGNAL -194 ; HOLD CHUCK
SIGNAL -119 ; GUN2 TIP WEAR AMOUNT WARNING ;
(MOVING SIDE) SIGNAL -197 ; AHC TOOL WITH GUN
SIGNAL -120 ; GUN2 TIP WEAR AMOUNT WARNING SIGNAL -198 ; AHC TOOL WITH NO-2'ND ST. GUN
(FIXED SIDE) ;
SIGNAL -121 ; GUN2 TIP CHANGE POSITION SIGNAL -201 ; AHC TOOL1 LEAVE TO JIG/BODY
; SIGNAL -202 ; AHC TOOL2 LEAVE TO JIG/BODY
SIGNAL -129 ; TC2 WELD SCHEDULE 1 SIGNAL -203 ; AHC TOOL3 LEAVE TO JIG/BODY
SIGNAL -130 ; TC2 WELD SCHEDULE 2 SIGNAL -204 ; AHC TOOL4 LEAVE TO JIG/BODY
SIGNAL -131 ; TC2 WELD SCHEDULE 4 SIGNAL -205 ; AHC TOOL5 LEAVE TO JIG/BODY
SIGNAL -132 ; TC2 WELD SCHEDULE 8 SIGNAL -206 ; AHC TOOL6 LEAVE TO JIG/BODY
SIGNAL -133 ; TC2 WELD SCHEDULE 16 ;
SIGNAL -134 ; TC2 WELD SCHEDULE 32 SIGNAL -225 ; SEALER 1 DISPENSE (on/off VALVE)
SIGNAL -135 ; TC2 WELD SCHEDULE 64 SIGNAL -226 ; SEALER 1 OPEN SHUT OFF VALVE
SIGNAL -136 ; TC2 WELD SCHEDULE 128 ;
SIGNAL -137 ; TC2 RUN/STOP SIGNAL -229 ; SEALER 2 DISPENSE (on/off VALVE)
SIGNAL -138 ; TC2 STEPPER RESET 1 SIGNAL -230 ; SEALER 2 OPEN SHUT OFF VALVE
SIGNAL -139 ; TC2 STEPPER RESET 2 ;
SIGNAL -140 ; TC2 STEPPER RESET 3 SIGNAL -232 ; LASER 1 RADIATION INTERRUPTION
SIGNAL -141 ; TC2 STEPPER RESET 4 SIGNAL -233 ; LASER 2 RADIATION INTERRUPTION
SIGNAL -142 ; TC2 GUN FAULT CHECK ;
SIGNAL -143 ; TC2 OFFSET MODE SIGNAL -235 ; SEALER PURGE RUNNING
SIGNAL -144 ; TC2 SHORT CIRCUIT DETECTION SIGNAL -241 ; SSW START FEED
SIGNAL -145 ; TD1 FORWARD ;
SIGNAL -146 ; TD1 REVERSE SIGNAL -243 ; SSW NUT COLLECTOR SENSOR CHECK
; SIGNAL -244 ; SSW UNDER WELD
SIGNAL -149 ; TD2 FORWARD SIGNAL -245 ; SSW OPEN
SIGNAL -150 ; TD2 REVERSE SIGNAL -246 ; SSW HALF OPEN
; ;
SIGNAL -161 ; D.A.W. START #1 SIGNAL -321 ; CLOSE CLAMP1
SIGNAL -162 ; D.A.W. START #2 SIGNAL -322 ; OPEN CLAMP1
SIGNAL -163 ; D.A.W. START #3 SIGNAL -323 ; CLOSE CLAMP2
SIGNAL -164 ; D.A.W. START #4 SIGNAL -324 ; OPEN CLAMP2
SIGNAL -165 ; D.A.W. START #5 SIGNAL -325 ; CLOSE CLAMP3
; SIGNAL -326 ; OPEN CLAMP3
SIGNAL -169 ; D.A.W. WELD SCH.1 SIGNAL -327 ; CLOSE CLAMP4
SIGNAL -170 ; D.A.W. WELD SCH.2 SIGNAL -328 ; OPEN CLAMP4
SIGNAL -171 ; D.A.W. WELD SCH.4 SIGNAL -329 ; CLOSE CLAMP5

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KAWASAKI 97160-1043DJE
2.1.4. Signal reset program
2.1. P5
2.1.4. Signal reset program（io.reset）

SIGNAL -330 ; OPEN CLAMP5 SIGNAL -394 ; OPEN CLAMP29

SIGNAL -331 ; CLOSE CLAMP6 SIGNAL -395 ; CLOSE CLAMP30
SIGNAL -332 ; OPEN CLAMP6 SIGNAL -396 ; OPEN CLAMP30
SIGNAL -333 ; CLOSE CLAMP7 SIGNAL -397 ; CLOSE CLAMP31
SIGNAL -334 ; OPEN CLAMP7 SIGNAL -398 ; OPEN CLAMP31
SIGNAL -335 ; CLOSE CLAMP8 SIGNAL -399 ; CLOSE CLAMP32
SIGNAL -336 ; OPEN CLAMP8 SIGNAL -400 ; OPEN CLAMP32
SIGNAL -337 ; CLOSE CLAMP9 ;
SIGNAL -338 ; OPEN CLAMP9 SIGNAL -417 ; GUN1 EXTEND TIP REFERENCE PLATE SHIFT
SIGNAL -339 ; CLOSE CLAMP10 SIGNAL -418 ; GUN1 RETRACT TIP REFERENCE PLATE SHIFT
SIGNAL -340 ; OPEN CLAMP10 SIGNAL -419 ; GUN1 EXTEND TIP DRESSER SHIFT
SIGNAL -341 ; CLOSE CLAMP11 SIGNAL -420 ; GUN1 RETRACT TIP DRESSER SHIFT
SIGNAL -342 ; OPEN CLAMP11 SIGNAL -421 ; GUN2 EXTEND TIP REFERENCE PLATE SHIFT
SIGNAL -343 ; CLOSE CLAMP12 SIGNAL -422 ; GUN2 RETRACT TIP REFERENCE PLATE SHIFT
SIGNAL -344 ; OPEN CLAMP12 SIGNAL -423 ; GUN2 EXTEND TIP DRESSER SHIFT
SIGNAL -345 ; CLOSE CLAMP13 SIGNAL -424 ; GUN2 RETRACT TIP DRESSER SHIFT
SIGNAL -346 ; OPEN CLAMP13 SIGNAL -425 ; GUN1 BRAKE TIP REFERENCE PLATE SHIFT
SIGNAL -347 ; CLOSE CLAMP14 SIGNAL -426 ; GUN2 BRAKE TIP REFERENCE PLATE SHIFT
SIGNAL -348 ; OPEN CLAMP14 ;
SIGNAL -349 ; CLOSE CLAMP15 SIGNAL -433 ; EXTEND GROUNDING ELECTRODE1
SIGNAL -350 ; OPEN CLAMP15 SIGNAL -434 ; RETRACT GROUNDING ELECTRODE1
SIGNAL -351 ; CLOSE CLAMP16 SIGNAL -435 ; EXTEND GROUNDING ELECTRODE2
SIGNAL -352 ; OPEN CLAMP16 SIGNAL -436 ; RETRACT GROUNDING ELECTRODE2
; SIGNAL -437 ; EXTEND GROUNDING ELECTRODE3
SIGNAL -369 ; CLOSE CLAMP17(25) SIGNAL -438 ; RETRACT GROUNDING ELECTRODE3
SIGNAL -370 ; OPEN CLAMP17(25) SIGNAL -439 ; EXTEND GROUNDING ELECTRODE4
SIGNAL -371 ; CLOSE CLAMP18(26) SIGNAL -440 ; RETRACT GROUNDING ELECTRODE4
SIGNAL -372 ; OPEN CLAMP18(26) SIGNAL -441 ; EXTEND GROUNDING ELECTRODE5
SIGNAL -373 ; CLOSE CLAMP19(27) SIGNAL -442 ; RETRACT GROUNDING ELECTRODE5
SIGNAL -374 ; OPEN CLAMP19(27) ;
SIGNAL -375 ; CLOSE CLAMP20(28) SIGNAL -449 ; OPEN AHC COVER1
SIGNAL -376 ; OPEN CLAMP20(28) SIGNAL -450 ; CLOSE AHC COVER1
SIGNAL -377 ; CLOSE CLAMP21(29) SIGNAL -451 ; OPEN AHC COVER2
SIGNAL -378 ; OPEN CLAMP21(29) SIGNAL -452 ; CLOSE AHC COVER2
SIGNAL -379 ; CLOSE CLAMP22(30) SIGNAL -453 ; OPEN AHC COVER3
SIGNAL -380 ; OPEN CLAMP22(30) SIGNAL -454 ; CLOSE AHC COVER3
SIGNAL -381 ; CLOSE CLAMP23(31) SIGNAL -455 ; OPEN AHC COVER4
SIGNAL -382 ; OPEN CLAMP23(31) SIGNAL -456 ; CLOSE AHC COVER4
SIGNAL -383 ; CLOSE CLAMP24(32) ;
SIGNAL -384 ; OPEN CLAMP24(32) SIGNAL -465 ; OPEN AHC COVER5
SIGNAL -385 ; CLOSE CLAMP25 SIGNAL -466 ; CLOSE AHC COVER5
SIGNAL -386 ; OPEN CLAMP25 SIGNAL -467 ; OPEN AHC COVER6
SIGNAL -387 ; CLOSE CLAMP26 SIGNAL -468 ; CLOSE AHC COVER6
SIGNAL -388 ; OPEN CLAMP26 ;
SIGNAL -389 ; CLOSE CLAMP27 SIGNAL -481 ; LED LIGHT1 ON
SIGNAL -390 ; OPEN CLAMP27 SIGNAL -482 ; LED LIGHT2 ON
SIGNAL -391 ; CLOSE CLAMP28 RETURN
SIGNAL -392 ; OPEN CLAMP28 .END
SIGNAL -393 ; CLOSE CLAMP29

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KAWASAKI 97160-1043DJE
2.1.4. Signal reset program
2.1. P6
2.1.5. Mastering position check program（pg000）

.PROGRAM pg000();Mastering Position pg

原位置復帰ﾌﾟﾛｸﾞﾗﾑ pg000
;Mastering Position Check Program
;M/B
;RB407W
JOINT SPEED0 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0 CL2=0.000,0.0,0.0,0.0,0.0
#[0.0000,0.0000,0.0000,0.0000,0.0000,0.0000,30.0000] ; HOME POS
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0 CL2=0.000,0.0,0.0,0.0,0.0
#[0.0000,0.0000,0.0000,0.0000,0.0000,0.0000,30.0000] ; HOME POS
RETURN
.END

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
1 JOINT 0 1 0 1 0 W1 [ ] [ ]
2 JOINT 9 1 0 1 0 W1 [ ] [ ]

Gun Status

Gun Status
No Write COMMENT
0 R1 Release
1 W1 Weld
2 K1 Clamp
3 P1 Plate
4 C1 Copper
5 M1 Gap-Measure
6 F1 Fast Mode
7 D1 Dressing Mode
9 I1 Wait_Indep._Move
※If clamp condition is not inputted, the information on R1 enters and
servo gun is disconnected.

Note)
When you teach the origin, the maximum open amount to an external axis for welding gun.

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KAWASAKI 97160-1043DJE
2.1.5. Mastering position check program
2.1. P7
2.2.1. Main program（pg0）

.PROGRAM pg0();Main Program

;Main Program
r.pro = 0
s.pro = 0
pg.no = 0 ;Reset Program Number
pg.check = 0 ;Reset Program Check
;
CALL io.reset
;
HOME ;MOVE HOME POS
;
TWAIT 0.5
pg.no = BITS(1001,8) ;Set Program Number
;
IF pg.no==11 THEN;Style 1
CALL pg11
GOTO 999
END
;
IF pg.no==128 THEN;Tip Dress Program
CALL pg128
GOTO 999
END
;
;No Pertinent Program
TYPE "Current Program Number<",pg.no,">" ;It confirms it on the keyboard screen!
SIGNAL 22
;
HALT ;Reactivation is impossible!Please Reset Program.
999
HOME ;MOVE HOME POS
CALL io.reset
.END

OX8 USER ALARM

(STYLE MISMATCH)
WX1～WX8 STYLE Number
WX10 START #1

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KAWASAKI 97160-1043DJE
2.2.1. Main program
2.2. P1
2.2.2. Main program（pg0）gun change gun1 or gun2

.PROGRAM pg0();Main Program (case gun1 + gun2)

;Main Program
TIMER (1) = 0
10
r.pro = 0
s.pro = 0
pg.no = 0 ;Reset Program Number
pg.check = 0 ;Reset Program Check
tip_change = 0 ;Gun1orGun2orGun3 Tip change
tip_dress manual = 0 ;Gun Tip Dress start
time.up = 5
;
CALL io.reset;
;
HOME ;Move Home Pos.
;
IF SIG(1010) GOTO 30
IF TIMER(1)<time.up GOTO 10
IF SIG(-1010) GOTO 20
30
pg.no = BITS(1001,8) ;Set Program Number
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[0.0009,-46,-26,0,-106,-0.0009,43] ;
;
IF pg.no==1 THEN
CALL pg11;YP5-P14
GOTO 999
END
;
IF pg.no==21 THEN
CALL pg21;YP5-P24
GOTO 999
END
;
IF pg.no==31 THEN
CALL pg311;YLA
GOTO 999
END Signal
;
;
IF pg.no==128 THEN
4000
IF SIG(-1106,-1107) GOTO 5000
tip_dress manual = 1
GOTO 4000
;
5000
IF SIG(1090) GOTO 1000
IF SIG(1106) GOTO 1000
IF SIG(1107) GOTO 2000
GOTO 5000
;
1000
;Tip Dress Gun1
CALL pg271 ; Gun2 Put
CALL pg72 ; Gun1 Get
CALL pg128 ; Tip Dress Prog Gun1

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KAWASAKI 97160-1043DJE
2.2.2. Main program
2.2. P2
2.2.2. Main program（pg0）

6000
IF SIG(1090) GOTO 2000
IF SIG(1107) GOTO 2000
IF SIG(-1107) GOTO 1111
GOTO 6000
;
2000
;Tip Dress Gun2
CALL pg71 ; Gun1 Put
CALL pg272 ; Gun2 Get
CALL pg129 ; Tip Dress Prog Gun2
;
1111
;Tip Dress Change
IF tip_change = 0 GOTO 999
;Tip Dress Gun1
CALL pg271 ; Gun2 Put
CALL pg72 ; Gun1 Get
CALL pg128 ; Tip Dress Prog Gun1
GOTO 999
END
;
;
;No Pertinent Program
TYPE Current Program Number<".pg.no,"> ;It confierms it on the keyboard screen!
SIGNAL 8
;
HALT ;Reactivation is impossible! Please Reset Program
999
TIMER (1) = 0
tip_dress manual = 0 ;Gun Tip Dress start
HOME ;Move Home Pos.
CALL io.reset;
GOTO 10
20
.END

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KAWASAKI 97160-1043DJE
2.2.2. Main program
2.2. P3
2.2.3. Main program（pg0）gun change gun1 or gun2 or gun3

.PROGRAM pg0();Main Program (case gun1 + gun2 + gun3)

;Main Program
TIMER (1) = 0
10
r.pro = 0
s.pro = 0
pg.no = 0 ;Reset Program Number
pg.check = 0 ;Reset Program Check
tip_change = 0 ;Gun1orGun2orGun3 Tip change
tip_dress manual = 0 ;Gun Tip Dress start
time.up = 5
;
CALL io.reset;
;
HOME ;Move Home Pos.
;
IF SIG(1010) GOTO 30
IF TIMER(1)<time.up GOTO 10
IF SIG(-1010) GOTO 20
30
pg.no = BITS(1001,8) ;Set Program Number
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[0.0009,-46,-26,0,-106,-0.0009,43] ;
;
IF pg.no==1 THEN
CALL pg11;YP5-P14
GOTO 999
END
;
IF pg.no==21 THEN
CALL pg21;YP5-P24
GOTO 999
END
;
IF pg.no==31 THEN
CALL pg311;YLA
GOTO 999
END
;
;
IF pg.no==128 THEN
4000
IF SIG(-1106,-1107,-1108) GOTO 5000
tip_dress manual = 1
GOTO 4000
;
5000
IF SIG(1090) GOTO 1000
IF SIG(1106) GOTO 1000
IF SIG(1107) GOTO 2000
IF SIG(1108) GOTO 3000
GOTO 5000
;
1000
;Tip Dress Gun1
CALL pg271 ; Gun2 Put
CALL pg371 ; Gun3 Put
CALL pg72 ; Gun1 Get
CALL pg128 ; Tip Dress Prog Gun1

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KAWASAKI 97160-1043DJE
2.2.3. Main program
2.2. P4
2.2.3. Main program（pg0）

6000
IF SIG(1090) GOTO 2000
IF SIG(1107) GOTO 2000
IF SIG(1108) GOTO 3000
IF SIG(-1107,-1108) GOTO 1111
GOTO 6000
;
2000
;Tip Dress Gun2
CALL pg71 ; Gun1 Put
CALL pg371 ; Gun3 Put
CALL pg272 ; Gun2 Get
CALL pg129 ; Tip Dress Prog Gun2
7000
IF SIG(1090) GOTO 3000
IF SIG(1106) GOTO 1000
IF SIG(1108) GOTO 3000
IF SIG(-1106,-1108) GOTO 1111
GOTO 7000
;
3000
;Tip Dress Gun3
CALL pg71 ; Gun1 Put
CALL pg271 ; Gun2 Put
CALL pg372 ; Gun3 Get
CALL pg130 ; Tip Dress Prog Gun3
8000
IF SIG(1090) GOTO 1111
IF SIG(1106) GOTO 1000
IF SIG(1108) GOTO 3000
IF SIG(-1106,-1107) GOTO 1111
GOTO 8000
;
1111
;Tip Dress Change
IF tip_change == 0 GOTO 999
;Tip Dress Gun1
CALL pg271 ; Gun2 Put
CALL pg371 ; Gun3 Put
CALL pg72 ; Gun1 Get
CALL pg128 ; Tip Dress Prog Gun1
;Tip Dress Gun2
CALL pg71 ; Gun1 Put
CALL pg371 ; Gun3 Put
CALL pg272 ; Gun2 Get
CALL pg129 ; Tip Dress Prog Gun2
GOTO 999
END
;

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KAWASAKI 97160-1043DJE
2.2.3. Main program
2.2. P5
2.2.3. Main program（pg0）

;
;No Pertinent Program
TYPE Current Program Number<".pg.no,"> ;It confierms it on the keyboard screen!
SIGNAL 8
;
HALT ;Reactivation is impossible! Please Reset Program
999
TIMER (1) = 0
tip_dress manual = 0 ;Gun Tip Dress start
HOME ;Move Home Pos.
CALL io.reset;
GOTO 10
20
.END

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KAWASAKI 97160-1043DJE
2.2.3. Main program
2.2. P6
2.2.4. Welding program（pg***）

.PROGRAM pg11();YP5-ASEAN
;YP5-ASEAN
;M/B
;RB407W
CALL r.check
CALL pg.check
CALL io.reset ;
JOINT SPEED0 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=2,19,17 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.467,18.595,46.73,0,-118.13,-59.533,9.9988] ;
;TO X-RB NO-I/F1
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=-19 WX=19
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.469,19.175,48.48,0,-119.3,-59.531,24] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX= WX=19
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.469,19.175,48.48,0,-119.3,-59.531,15.355] ;
JOINT SPEED9 ACCU4 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=2,17 WX=11
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-12.019,-6.4901,28.886,0,-80.17,-29.909,24.5] ;
CALL pg.check
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=-2,-17 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-12.02,-6.492,28.883,0,-80.169,-29.909,24.5] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.098,-2.8935,24.365,-52.57,-40.495,44.433,24.432] ;
;SP45115 ↓↓welding point
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (ON,181,1,1) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-29.26,-3.9341,24.304,-49.19,-40.11,41.38,3.5218] ;
JOINT SPEED9 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=-19 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-43.81,11.592,37.635,-64.461,-50.285,121.97,24] ;
;TO X-RB NO-I/F1
;SP32039 ↓↓welding point
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (ON,182,1,1) 2 (OFF,0,0,O) OX=19 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-45.829,16.428,48.747,-60.856,-55.042,119.39,2.0047] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-44.658,19.306,56.587,-58.17,-56.071,113.5,24.617] ;

～omission～

JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=1,-2,-17 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-61.671,-9.8734,-1.4583,-56.349,-65.068,-29.353,24.5] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=2,17 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-61.672,-9.8725,-1.4579,-56.35,-65.068,-29.353,24.5] ;
JOINT SPEED9 ACCU4 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-39.132,-0.8798,35.854,-12.32,-104.79,-26.172,24.5] ;
CALL io.reset
;HOME POS.
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) 2 (OFF,0,0,O) OX=2,17,19 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.522,13.993,45.47,0,-121.48,-57.478,20] ;
RETURN
.END
OX1 CYCLE COMPLETE
OX2 OK TO TRANSFER
OX19 OUTPUT 3(TO X-RB NO-I/F1)
OX17 (#70 NO-I/F)
Input the welding number before welding point
WX11 START #2
example) ;SP*****
WX19 INPUT 3 (FROM X-RB NO-I/F1)

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KAWASAKI 97160-1043DJE
2.2.4. Welding program
2.2. P7
2.2.4. Welding program（pg***）

Clamp ON,OFF Gun Status

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
1 CALL r.check ←Collation Pg
2 CALL pg.check ←Style Verify Pg
3 CALL io.reset ←IO_Reset
4 JOINT 0 2 0 1 0 W1 [2,17,19 ] [ ] ←OK to transfer
5 JOINT 9 2 0 1 0 W1 [-19 ] [19 ]
6 JOINT 9 2 0 1 0 W1 [ ] [19 ]
7 JOINT 9 4 0 1 0 W1 [2,17 ] [11 ] ←Start #2
8 CALL pg.check ←Style Verify Pg
9 JOINT 9 2 0 1 0 W1 [-2,17 ] [ ]
10 JOINT 9 2 0 1 0 W1 [ ] [ ]
11 ;SP45115 ←welding number
12 JOINT 9 1 0 1 0 1 W1 [-19 ] [ ] ←welding point
13 JOINT 9 3 0 1 0 [19 ] [ ]
14 ;SP32039 ←welding number
15 JOINT 9 1 0 1 0 1 W1 [ ] [ ] ←welding point
16 JOINT 9 2 0 1 0 W1 [ ] [ ]
・
・
・
17 JOINT 9 2 0 1 0 W1 [ ] [ ]
18 JOINT 9 2 0 1 0 W1 [1,-2,-17] [ ] ←cycle complete
19 JOINT 9 2 0 1 0 W1 [2,17 ] [ ] ←OK to transfer
20 JOINT 9 4 0 1 0 W1 [ ] [ ] Between these step,the output signal to the
21 CALL io.reset completion of work for more than 0.5 second.
22 JOINT 9 2 0 1 0 W1 [2,17,19 ] [ ] If the time of 0.5 seconds or more can not be
23 RETURN secured in the travel time, then the Put a timer
to teaching.

Gun Status OX（Output) WX(Input)

No Write COMMENT 1 CYCLE COMPLETE 11 START #2
0 R1 Release 2 OK TO TRANSFER 19 INPUT 3 (FROM X-RB NO-I/F1)
1 W1 Weld 17 OUTPUT 1 (#30 NO-I/F)
2 K1 Clamp 19 OUTPUT 3 (TO X-RB NO-I/F1)
3 P1 Plate
4 C1 Copper
7 D1 Dressing Mode
8 E1 Simple Measure ※Start #2 Position without interference, shuttle / work etc.
9 I1 Wait_Indep._Move ※cycle complete Position without interference, shuttle / work etc.
10 V1 Gun Clamp
※If clamp condition is not inputted, the information on R1 enters and
servo gun is disconnected.

Add a step to the previous one in the same position, if the signal is turned ON, put the signal OFF.
ex) Case the signal is turned ON
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) OX=-17 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[6.252,-34.594,-23.185,-0.1079,-102.36,-6.2731,42.754] ;
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) OX=17 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[6.252,-34.594,-23.185,-0.1079,-102.36,-6.2731,42.754] ;
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (ON,0,1,2) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[0.477,-34.863,-23.324,-30.00,-102.523,-0.47,-0.02] ;
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[50.478,-60.863,10.324,-0.673,-50.565,-30.596,-0.02] ;

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.4. Welding program
2.2. P8
2.2.5.1. Tip dress (Carried servo gun)

.PROGRAM pg00128(); Tip Dress Prg

SPEED 10, ACCURACY 0
JMOVE #near_home_pos
CALL IO_RESET
CALL TWD_RESET
100
SPEED 10, ACCURACY 0
JMOVE #near_home_pos
twd_reset_flag = 0
SIGNAL 106
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p1] ;
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p2] ;
LINEAR SPEED5 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p3] ;
r99 = SYSDATA(M.SPEED)
MON_SPEED 100
SIGNAL 113
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p4] ;
LINEAR SPEED2 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[dress_pos] ;
LINEAR SPEED2 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,10) 2 (OFF,1,2,1)
FC1=89,89,0,0 OX= WX= #[dress_pos,t15] ;
TWAIT r30
LINEAR SPEED2 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p4] ;
LINEAR SPEED2 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p6] ;
LINEAR SPEED2 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p7] ;
LINEAR SPEED5 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p3] ;
SIGNAL -113
SIGNAL -106
MON_SPEED r99
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p2] ;
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p8] ;
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[approach_1] ;
CALL TWD
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[approach_1] ;
IF SIG(1090) GOTO 300
SIGNAL 111
LINEAR SPEED5 ACCU4 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,10) 2 (OFF,1,2,1)
FC1=88,2,0,0 OX= WX= #[p10,0] ;
SIGNAL -111

DRAW. No 2.2.5.1. Tip dress PAGE

KAWASAKI 97160-1043DJE (Carried servo gun) 2.2. P9
2.2.5.2. Tip dress ( Carried Servo gun )

SPEED 10, ACCURACY 0

JMOVE #near_home_pos
CALL WDN_CHK
IF twd_reset_flag==1 GOTO 100
CALL IO_RESET
RETURN
GOTO 300
300
SPEED 50, ACCURACY 4
JMOVE #near_home_pos
LINEAR SPEED4 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,10) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p20] ;
LINEAR SPEED4 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,10) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p21] ;
SPEED 30, ACCURACY 0
JMOVE #tip_change_pos
CALL TWD_RESET
SIGNAL 89
SWAIT 1089
SIGNAL -89
LINEAR SPEED4 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,10) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p21] ;
LINEAR SPEED4 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,10) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[p20] ;
SPEED 50, ACCURACY 4
JMOVE #near_home_pos
GOTO 100
.END

DRAW. No 2.2.5.1. Tip dress PAGE

KAWASAKI 97160-1043DJE (Carried servo gun) 2.2. P10
2.2.5.2. Tip dress (Fixed servo gun)

.PROGRAM pg00128(); Tip Dress main

WAIT dress_move==0
dress_move = 1
;
SIGNAL xxxx ; FIX GUN DRESSING
;
CALL tip_drs1
;
dress_move = 0
;
SIGNAL -xxxx ; FIX_GUN_DRESSING
;
SIGNAL -xxxx; GUN TIP CH.POS
SIGNAL -xxxx; TC WELD SCH.1
SIGNAL -xxxx; TC WELD SCH.2
SIGNAL -xxxx; TC WELD SCH.4
SIGNAL -xxxx; TC WELD SCH.8
SIGNAL -xxxx; TC WELD SCH.16
SIGNAL -xxxx; TC WELD SCH.32
SIGNAL -xxxx; TC WELD SCH.64
SIGNAL -xxxx; TC WELD SCH.128
SIGNAL -xxxx; TC RUN/STOP
SIGNAL -xxxx; TC RESET STEP1
SIGNAL -xxxx; TC RESET STEP2
SIGNAL -xxxx; TC RESET STEP3
SIGNAL -xxxx; TC RESET STEP4
SIGNAL -xxxx; TC GUN FAULT CHK
SIGNAL -xxxx; TC MEASUREMENT OFFSET MODE
SIGNAL -xxxx; TC SHORT CIRCUIT DETECT START
SIGNAL -xxxx; TIP DRESSURE FORWARD
SIGNAL -xxxx; TIP DRESSURE REVERSE
RETURN
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.5.2. Tip dress (Fixed servo gun)
2.2. P11
2.2.5.2. Tip dress (Fixed servo gun)

.PROGRAM tip_drs1()#0; Tip Dress_sub

KI320[ 7 ]
;
;
SIGNAL -xxxx ; CYCLE STOP POS
SIGNAL -xxxx ; TIP CHANGE POSITION
;
; CALL twd_rst
;
;
;
;
100
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;
;
CALL plate_ret
CALL dres_adv
;
twd_reset_flag = 0
SIGNAL xxxx ; TC1 STEPPER RST1
;
;
SIGNAL xxxx ; TIP DRESSER FORWARD
;
;
;
;
;
; Gun Dress Move
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,7) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,0,0] ;
;
;
;
;
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;
SIGNAL -113 ; TIP DRESSER FORWARD
SIGNAL -116 ; TC1 STEPPER RST1
;
CALL dres_ret
;
CALL twd
;

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.5.2. Tip dress (Fixed servo gun)
2.2. P12
2.2.5.2. Tip dress (Fixed servo gun)

; Gun Move HOME POS

SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;
;
CALL plate_ret
;
; Tip Change Request
IF SIG(xxxx) GOTO 300 ; GUN TIP CHANGE REQUEST
;
SIGNAL xxxx ; TC MEASUREMENT OFFSET MODE
;
;MEASUREMENT OFFSET RESISTANCE
; Gun Welding
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,0,0] ;
;
SIGNAL -xxxx ; TC MEASUREMENT OFFSET MODE
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;
;
CALL wdn_chk_p
;
IF twd_reset_flag==1 GOTO 100
;
RETURN
;
GOTO 300
300
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;
;
; CALL twd_rst
;
SIGNAL xxxx ; GUN TIP CHG POSITION
SWAIT xxxx ; GUN TIP CHANGE COMPLETE
SIGNAL -xxxx ; GUN TIP CHG POSITION
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;
;
GOTO 100
IF SIG(1090) GOTO 300 ; GUN TIP CHANGE REQUEST
;
RETURN
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.5.2. Tip dress (Fixed servo gun)
2.2. P13
2.2.6.1. Tip wear compensation (Tip wear measure) (Carried servo gun)

.PROGRAM tw_updat(); Update wear vals

CALL TW_MV2PT(1,1)
LINEAR SPEED9 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,2) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[r21] ;
CALL TW_MV2PT(1,1)
CALL DRES_RET
CALL PLATE_ADV
CALL TW_MV2PT(1,2)
LINEAR SPEED9 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (ON,1,1,3) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[r21] ;
CALL TW_MV2PT(1,2)
CALL TW_MV2PT(1,1)
CALL PLATE_RET
.END

DRAW. No 2.2.6.1. Tip wear compensation PAGE

KAWASAKI 97160-1043DJE (Tip wear measure) (Carried servo gun) 2.2. P14
2.2.6.2. Tip wear compensation (Tip wear measure) (Fixed servo gun)

.PROGRAM twd()#0; Measure Tip Wdn

;----------------------------- ;
; TIP WEAR DOWN CHECK ;
;----------------------------- ;
;
;
;
;
;
;MOVE TO APPROACH POS ;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;APPROACH_1 G1
;
;
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;TOUCH TO TIP G1
CALL tw_upd01;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;TOUCH TO TIP G1
;
new_tip_flag = 0;
;
;
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;TOUCH TO TIP G1
;MOVE TO APPROACH POS ;
;
; Gun Move HOME POS
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;APPROACH_1 G1
.END

DRAW. No 2.2.6.2. Tip wear compensation PAGE

KAWASAKI 97160-1043DJE (Tip wear measure) (Fixed servo gun) 2.2. P15
2.2.6.2. Tip wear compensation (Tip wear measure) (Fixed servo gun)

.PROGRAM tw_updat(.gno,.mode)#0; Update wear vals

;Program description ;
; Update fixture-based wear meas ;
;
;Input parameter(s) ;
; AR[1]: Gun number ;
;
;Data register(s) used ;
; R[10] ;
;
;Position register(s) used ;
; PR[21] ;
;
;Version info / revisions ;
;v6.22: multi-gun support ;
;v6.31: parameter reduction ;
;
;Move to posn away from fixture ;
; parm1: gun number ;
; parm2: posn number ;
; parm3: data register ;
CALL tw_mv2pt(.gno,1);
;
;Calibrate 0 with worn tips ;
; parm1: gun number ;
; parm2: data register1 ;
; parm3: position register ;
; Gun1 Move No Plate
CALL twkzrclb(.gno,10,21);
;
;Move to fixture position ;
; parm1: gun number ;
; parm2: posn number ;
; parm3: data register ;
CALL tw_mv2pt(.gno,1);
;
CALL dres_ret;
CALL plate_adv;
;
CALL tw_mv2pt(.gno,2);
;
;Measure open distance ;
; parm1: gun number ;
; parm2: data register1 ;
; parm3: position register1 ;
; parm4: new-1/worn-0 ;
; Gun1 Move Pre Plate
CALL twkfxtch(.gno,10,21,.mode);

DRAW. No 2.2.6.2. Tip wear compensation PAGE

KAWASAKI 97160-1043DJE (Tip wear measure) (Fixed servo gun) 2.2. P16
2.2.6.2. Tip wear compensation (Tip wear measure) (Fixed servo gun)

;
;Move to zero calibration posn ;
; parm1: gun number ;
; parm2: posn number ;
; parm3: data register ;
CALL tw_mv2pt(.gno,2);
CALL tw_mv2pt(.gno,1);
CALL plate_ret;
.END

.PROGRAM tw_mv2pt(.gno,.mode)#0; Move 2 measmt pt

;Set value for jump label ;
;--arg1:gun number ;
;--arg2:posn number ;
; 1: Away from fixture (Posn1) ;
; 2: Straddling fixture (Posn2) ;
;--arg3:work register ;
.move_type = .mode*10
.move_type = .move_type+.gno
;
;Move to position ;
IF .move_type==11 GOTO 11
IF .move_type==12 GOTO 12
IF .move_type==13 GOTO 13
IF .move_type==14 GOTO 14
IF .move_type==15 GOTO 15
IF .move_type==16 GOTO 16
IF .move_type==17 GOTO 17
IF .move_type==18 GOTO 18
IF .move_type==21 GOTO 21
IF .move_type==22 GOTO 22
IF .move_type==23 GOTO 23
IF .move_type==24 GOTO 24
IF .move_type==25 GOTO 25
IF .move_type==26 GOTO 26
IF .move_type==27 GOTO 27
IF .move_type==28 GOTO 28
GOTO 999
;Teach position with Gun open ;
11
; Gun1 Move Pre No Plate
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
21
; Gun1 Move Pre Plate
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;

DRAW. No 2.2.6.2. Tip wear compensation PAGE

KAWASAKI 97160-1043DJE (Tip wear measure) (Fixed servo gun) 2.2. P17
2.2.6.2. Tip wear compensation (Tip wear measure) (Fixed servo gun)

RETURN
;
12
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,2,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
22
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,2,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;
RETURN
;
13
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,3,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
23
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,3,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;
RETURN
;
14
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,4,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
24
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,4,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;
RETURN
;
15
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,5,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
25
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,5,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;
RETURN
;
16
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,6,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
26
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,6,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;
RETURN
;
17
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,7,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;

DRAW. No 2.2.6.2. Tip wear compensation PAGE

KAWASAKI 97160-1043DJE (Tip wear measure) (Fixed servo gun) 2.2. P18
2.2.6.2. Tip wear compensation (Tip wear measure) (Fixed servo gun)

RETURN
27
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,7,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,80,0] ;
RETURN
;
18
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,8,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
28
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,8,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,20,0] ;
RETURN
;
999
PRINT "MESSAGE[Invalid gun or posn num]"
PRINT "ABORTING"
PAUSE
.END

DRAW. No 2.2.6.2. Tip wear compensation PAGE

KAWASAKI 97160-1043DJE (Tip wear measure) (Fixed servo gun) 2.2. P19
2.2.7.1. Tip wear calibration (Carried servo gun)

.PROGRAM twd_mstr(); Master Tip Calib

SPEED 10, ACCURACY 0
JMOVE #home_pos
r99 = SYSDATA(M.SPEED)
MON_SPEED 100
CALL TW_SET01
new_tip_flag = 1
twd_act_gun = 0
twd_act_robot = 0
twd_act_all = 0
two_step_gun = 0
two_step_robot = 0
two_step_all = 0
tip_jduge_value=0
MON_SPEED r99
LINEAR SPEED5 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,1,1,1) 2 (OFF,1,2,1)
FC1=0,0,0,0 OX= WX= #[10] ;
SPEED 30, ACCURACY 0
JMOVE #home_pos
.END

DRAW. No 2.2.7.1. Tip wear calibration PAGE

KAWASAKI 97160-1043DJE (Carried servo gun) 2.2. P20
2.2.7.2. Tip wear calibration (Fixed servo gun)

.PROGRAM twd_mstr(); Master Tip Calib

;----------------------------- ;
; GET NOMINAL DATA OF MASTER TIP;
;----------------------------- ;
;
;
;
;
;
;
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;Home Pos.
;
CALL dres_ret
CALL plate_ret
;
; MOVE TO APPROACH POS ;
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;APPROACH_1 G1
;
;
;
;
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,50,0] ;TOUCH TO TIP G1
CALL tw_set01
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,50,0] ;TOUCH TO TIP G1
;
new_tip_flag = 1
;
;$MCR.$GENOVERRIDE=R[99:ROBOT OVERRIDE] ;
;
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,50,0] ;TOUCH TO TIP G1
; MOVE TO APPROACH POS ;
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;APPROACH_1 G1
;
CALL plate_ret
;
SGINDP SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) FC1=0,0,0,0 OX= WX=
SLABEL1='' #[0,0,0,0,0,0,100,0] ;Home Pos.
.END

DRAW. No 2.2.7.2. Tip wear calibration PAGE

KAWASAKI 97160-1043DJE (Fixed servo gun) 2.2. P21
2.2.7.2. Tip wear calibration ( Fixed Servo gun )

.PROGRAM tw_set01(); Setup tw on gun1

; Program description
; Setup wear measmt for
; specified gun number
;
;
; Use the following call for
; fixture-based wear measurement
; Parm1: gun number
; CALL tw_setup(1)
CALL tw_setup(1)
.END

.PROGRAM tw_setup(.gno)#0; Setup tipwear

; Program description
; Setup fixture-based wear measm
;
; Input parameter(s)
; .gno:Gun numer
;
; Initialize gun data
; parm1:gun number
CALL twkinit(.gno)
;
; Move to posn away from fixture
; parm1: gun number
; parm2: posn number
; parm3: data register
CALL tw_mv2pt(.gno,1,10)
;
; Set force threshold
; NOTE:Gun is opened via TWTTHOLD
; parm1: gun number
; parm2: posn number
; parm3: data register
CALL twkthold(.gno,10,21)
;
; Move to posn away from fixture
; parm1: gun number
; parm2: posn number
; parm3: data register
CALL tw_mv2pt(.gno,1,10)
;
; Calibration 0 with master tips
; parm1: gun number
; parm2: posn number
; parm3: data register
CALL twkzrclb(.gno,10,21)
;
; Move to fixture position
; parm1: gun number

DRAW. No 2.2.7.2. Tip wear calibration PAGE

KAWASAKI 97160-1043DJE (Fixed servo gun) 2.2. P22
2.2.7.2. Tip wear calibration ( Fixed Servo gun )

; parm2: posn number

; parm3: data register
CALL tw_mv2pt(.gno,1,10)
;
CALL dres_ret
CALL plate_adv
;
CALL tw_mv2pt(.gno,2,10)
;
; Measure open distance
; parm1: gun number
; parm2: posn number
; parm3: data register
CALL twkfxtch(.gno,10,21)
;
; Move to posn away from fixture
; parm1: gun number
; parm2: posn number
; parm3: data register
CALL tw_mv2pt(.gno,2,10)
CALL tw_mv2pt(.gno,1,10)
CALL plate_ret
.END

DRAW. No 2.2.7.2. Tip wear calibration PAGE

KAWASAKI 97160-1043DJE (Fixed servo gun) 2.2. P23
2.2.8. Tip wear reset

.PROGRAM tip_wear_reset(); Reset Tip Wdn

CALL TWRSMV1
CALL TWRSFX1
TWD_RESET_FLAG=1
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.8. Tip wear reset
2.2. P24
2.2.9. Home return

.PROGRAM home_pos(); Ret to Home Pos

SPEED 10, ACCURACY 0
JMOVE #home_pos
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.9. Home return
2.2. P25
2.2.10. Weld mode check

.PROGRAM weld_chk(); Weld Mode Check

100
IF xxx THEN GOTO 200
GOTO 300
200
PULSE 10, 1
UDERR 10
GOTO 100
300
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.10. Weld mode check
2.2. P26
2.2.11.1. Check tip wear value (Carried servo gun)

.PROGRAM wdn_chk(); Tip Wdn Check

TIP_WEAR_MOVE = SGCHIP(1,0)
TIP_WEAR_FIX = SGCHIP(1,1)
IF TIP_WEAR_MOVE >=8 || TIP_WEAR_FIX >=8 THEN GOTO 100
IF TIP_WEAR_MOVE <=-5 || TIP_WEAR_FIX <=-5 THEN GOTO 100
RETURN
100
PULSE 9,1
UDERR 11
CALL TWD_RST
.END

DRAW. No 2.2.11.1. Check tip wear value PAGE

KAWASAKI 97160-1043DJE (Carried servo gun) 2.2. P27
2.2.11.2. Check tip wear value (Fixed servo gun)

.PROGRAM wdn_chk_p(); Tip Wdn Check

; -- Set Mov Tip Wdn to Reg -- ;
tip_wear_move = SGCHIP(1,0) ; TIP WEAR MOVE
; -- Set Fix Tip Wdn to Reg -- ;
tip_wear_fix = SGCHIP(1,1) ; TIP WEAR FIX
IF tip_wear_move>=8 || tip_wear_fix>=8 GOTO 100
IF tip_wear_move<=-5 || tip_wear_fix<=-5 GOTO 100
RETURN
;
100
WAIT dress_move==0
; --- Please Change Tip --- ;
; ---- TIP WEAR EXCESS --- ;
PULSE xxxx,1 ; UALM(WEAR AMOUNT)
UDERR 1
; ---- TIP WEAR EXCESS ---- ;
; "The motion just before "TWD_RESET" input "FINE" order!!"
CALL twd_rst
RETURN
.END

DRAW. No 2.2.11.2. Check tip wear value PAGE

KAWASAKI 97160-1043DJE (Fixed servo gun) 2.2. P28
2.2.12. Store tip wear value for fixed tip

.PROGRAM fix_wdn(); Set Fix Wdn

TIP_WEAR_FIX = SGCHIP(1,1)
POINT #tip_wear_fix = #[0,0,0,0,0,0,tip_wear_fix]
.END

DRAW. No 2.2.12. Store tip wear value for PAGE

KAWASAKI 97160-1043DJE fixed tip 2.2. P29
2.2.13. Warming up

.PROGRAM warm_up(); WARM UP OVERRIDE

IF SIG(-warm_up_sig) THEN
GOTO 100
warm_up = 1
100
IF warm_up == 0 THEN
GOTO 300
MON_SPEED warmup_override
IF warmup_override >= 100 THEN
GOTO 200
warmup_override = warmup_override + warmup_add
IF warmup_override < 100 THEN
GOTO 300
warmup_override = 100
GOTO 300
200
PULSE warm_up_complete_sig, 1.0
warm_up = 0
warmup_override = 20
300
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.13. Warming up
2.2. P30
2.2.14. Tip wear value output

.PROGRAM tipwear(); TIP_WEAR_VALUE

SIGNAL(-tip_wear_amount_cnt7_sig)
SIGNAL(-tip_wear_amount_cnt14_sig)
gun_wear_value = tip_wear_move * 5
robot_wear_value = tip_wear_fix * 5
IF gun_wear_value >= 0 THEN
GOTO 10
gun_wear_value = -gun_wear_value
SIGNAL(tip_wear_amount_cnt7_sig)
10
BITS gun_wear_value_sig, 6 = gun_wear_value
IF robot_wear_value >= 0 THEN
GOTO 20
robot_wear_value = -robot_wear_value
SIGNAL(tip_wear_amount_cnt14_sig)
20
BITS robot_wear_value_sig, 6 = robot_wear_value
.END

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.2.14. Tip wear value output
2.2. P31
2.2.15. Tip dresser shift advance (dres_adv)

.PROGRAM dres_adv();Dress Shift ADV

100
SWAIT xxxx ; GUN1 TIP REFERENCE PLATE SHIFT
SIGNAL -xxxx ; GUN1 RETRACT TIP DRESSER SHIFT
SIGNAL xxxx ; GUN1 EXTEND TIP DRESSER SHIFT
TIMER 1 = 0
WHILE SIG(xxxx) DO ; GUN1 TIP DRESSER SHIFT RETRACTED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
TIMER 1 = 0
WHILE SIG(-xxxx) DO ; GUN1 TIP DRESSER SHIFT EXTENDED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
SIGNAL -xxxx ; GUN1 EXTEND TIP DRESSER SHIFT
RETURN
;
200
;--- DRESSER SHIFT FAULT --- ;
PULSE xxxx,1 ; UALM(OTHERS)
UDERR 1 ;
;--- DRESSER SHIFT FAULT --- ;
GOTO 100
.END

DRAW. No 2.2.15. Tip dresser shift advance PAGE

KAWASAKI 97160-1043DJE (dres_adv) 2.2. P32
2.2.16. Tip dresser shift return (dres_ret)

.PROGRAM dres_ret();Dress Shift RET

100
SIGNAL -xxxx ; GUN1 EXTEND TIP DRESSER SHIFT
SIGNAL xxxx ; GUN1 RETRACT TIP DRESSER SHIFT
TIMER 1 = 0
WHILE SIG(xxxx) DO ; GUN1 TIP DRESSER SHIFT EXTENDED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
TIMER 1 = 0
WHILE SIG(-xxxx) DO ; GUN1 TIP DRESSER SHIFT RETRACTED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
SIGNAL -xxxx ; GUN1 RETRACT TIP DRESSER SHIFT
TWAIT 1
RETURN
;
200
;--- DRESSER SHIFT FAULT --- ;
PULSE xxxx,1 ; UALM(OTHERS)
UDERR 1 ;
;--- DRESSER SHIFT FAULT --- ;
GOTO 100
.END

DRAW. No 2.2.16. Tip dresser shift return PAGE

KAWASAKI 97160-1043DJE (dres_ret) 2.2. P33
2.2.17. Fixture plate advance (plate_adv)

.PROGRAM plate_adv();Fixture Plate ADV

100
SWAIT xxxx ; GUN TIP DRESSER SHIFT RETRACTED
SIGNAL -xxxx ; GUN1 RETRACT TIP REFERENCE PLATE SHIFT
SIGNAL xxxx ; GUN1 EXTEND TIP REFERENCE PLATE SHIFT
TIMER 1 = 0
WHILE SIG(xxxx) DO ; GUN1 TIP REFERENCE PLATE SHIFT RETRACTED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
TIMER 1 = 0
WHILE SIG(-xxxx) DO ; GUN1 TIP REFERENCE PLATE SHIFT EXTENDED
IF TIMER(1)>timeout GOTO 200
TWAIT 0.1
END
SIGNAL -xxxx ; GUN1 EXTEND TIP REFERENCE PLATE SHIFT
RETURN
;
200
; !--- FIXTURE PLATE FAULT --- ;
PULSE xxxx,1 ; UALM(OTHERS)
UDERR 1 ;
; !--- FIXTURE PLATE FAULT --- ;
GOTO 100
.END

DRAW. No 2.2.17. Fixture plate advance PAGE

KAWASAKI 97160-1043DJE (plate_adv) 2.2. P34
2.2.18. Fixture plate return (plate_ret)

.PROGRAM plate_ret();Fixture Plate RET

100
SIGNAL -xxxx ; GUN1 EXTEND TIP REFERENCE PLATE SHIFT
SIGNAL xxxx ; GUN1 RETRACT TIP REFERENCE PLATE SHIFT
TIMER 1 = 0
WHILE SIG(xxxx) DO ; GUN1 TIP REFERENCE PLATE SHIFT EXTENDED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
TIMER 1 = 0
WHILE SIG(-xxxx) DO ; GUN1 TIP REFERENCE PLATE SHIFT RETRACTED
IF TIMER(1)>5 GOTO 200
TWAIT 0.1
END
SIGNAL -xxxx ; GUN1 RETRACT TIP REFERENCE PLATE SHIFT
RETURN
;
200
; !--- FIXTURE PLATE FAULT --- ;
PULSE xxxx,1 ; UALM(OTHERS)
UDERR 1 ;
; !--- FIXTURE PLATE FAULT --- ;
GOTO 100
.END

DRAW. No 2.2.18. Fixture plate return PAGE

KAWASAKI 97160-1043DJE (plate_ret) 2.2. P35
2.3.1. Main program（pg0）

.PROGRAM pg0();Main Program

;Main Program
TIMER(1)=0
10
r.pro = 0
s.pro = 0
pg.no = 0 ;Reset Program Number
pg.check = 0 ;Reset Program Check
time.up = 5
;
CALL io.reset ;
;
HOME ;Move Home Pos.
;
IF SIG(1010) GOTO 30
IF TIMER(1)<time.up GOTO 10
IF SIG(-1010) GOTO 20
30
pg.no = BITS(1001,8) ;Set Program Number
;
;near original position
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0 #[-54.193,-44.768,-35.039,66.63,62.085,-49.561] ;
;
IF pg.no==11 THEN; YP5
CALL pg271
CALL pg072
CALL pg031
GOTO 999
END
;
IF pg.no==21 THEN; YLA
CALL pg071
CALL pg272
CALL pg231
GOTO 999
END
;
;No Pertinent Program
TYPE Current Program Number<".pg.no,"> ;It confierms it on the keyboard screen!
SIGNAL 8
;
HALT ;Reactivation is impossible! Please Reset Program
TIMER(1)=0
HOME ; Move Home Pos.
CALL io.reset OX8 USER ALARM
GOTO 10 (WEAR AMOUNT)
20 WX1～WX8 Style Number
.END WX10 START #1

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.3.1. Main program
2.3. P1
2.3.2. Handling program（pg***）

.PROGRAM pg031();YP5-ASEAN
; YP5-ASEAN
;M/B
;RB407W
CALL r.check
CALL pg.check
CALL io.reset ;
JOINT SPEED0 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=19 WX=11,19
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-54.193,-44.768,-35.039,66.63,62.085,-49.561] ;
;#4070 PICK UP OK
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-19 WX=11,17,19 CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029]
CALL pg.check
CALL handop.chk
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=17 WX=17 CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-17 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.346,-9.1095,20.862,118.63,37.938,-125.05] ;
LINEAR SPEED0 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-31.446,6.4302,21.29,119.97,37.417,-126.33] ;
CALL work1on.chk
CALL hand1.op
CALL hand1.cl
TWAIT 1
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-40 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-35.677,-39.874,16.312,110.68,38.915,-116.28] ;
CALL work1on.chk
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-17,-20,40 WX=20 CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.671,-33.404,-34.219,47.254,43.564,-39.606] ;
CALL work1on.chk
JOINT SPEED0 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX=20 CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-27.947,-29.219,-41.338,39.178,49.406,-29.429] ;
;TO Y-RB NO-I/F1
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=19,17,18,48 WX=18 CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-29.875,-31.285,-37.692,43.81,45.538,-35.432] ;
; #4080 PUT ON OK
JOINT SPEED0 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-18,-48 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-29.875,-31.285,-37.692,43.81,45.538,-35.432] ;
JOINT SPEED0 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-29.875,-31.285,-37.692,43.81,45.538,-35.432] ;
JOINT SPEED5 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-40.201,40.103,-87.857,42.048,88.2,-1.6496] ;
LINEAR SPEED0 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.89,41.609,-80.614,35.081,82.36,-5.8215] ;
LINEAR SPEED0 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.861,41.533,-80.587,35.066,82.062,-5.6816] ;
CALL hand1.cl
CALL hand1.op
LINEAR SPEED0 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-41 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.861,41.533,-50.587,35.066,82.062,-5.6816] ;
CALL workoff.chk
JOINT SPEED9 ACCU3 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=1,20,41,-18,17 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-51.244,-13.82,-56.662,58.146,70.081,-30.102] ;
CALL io.reset
;HOME POS.
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=1,17,18,19,20,-40,-41,-48,-321,-322 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-54.1,-44.7,-35.0,66.6,62.0,-49.5] ;
RETURN
.END

OX1 CYCLE COMPLETE WX11 START #2

OX17 OUTPUT 1 (#70 NO-I/F) WX17 INPUT 1 (#70 PICK UP OK)
OX18 OUTPUT 2 (#80 NO-I/F) WX18 INPUT 2 (#80 PUT ON OK)
OX19 OUTPUT 3 (TO X-RB NO-I/F1) WX19 INPUT 3 (FROM X-RB NO-I/F1)
OX20 OUTPUT 4 (TO Y-RB NO-I/F1) WX20 INPUT 4 (FROM Y-RB NO-I/F1)
OX40 OUTPUT 24 (#70 PICK UP COMP) OX321 CLOSE CLAMP1
OX41 OUTPUT 25 (#80 PUT ON COMP) OX322 OPEN CLAMP1
OX48 OUTPUT 32 (TO Y-RB NO-I/F1)

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.3.2. Handling program
2.3. P2
2.3.2. Handling program（pg***）

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
1 CALL r.check
2 CALL pg.check
3 CALL io.reset
4 JOINT 0 2 0 1 0 R1 [19 ] [11,19 ]
5 JOINT 9 2 0 1 0 R1 [-19 ] [11,17,19]
6 CALL pg.check
7 CALL handop.chk
8 JOINT 9 2 0 1 0 R1 [17 ] [17 ]
9 JOINT 9 2 0 1 0 R1 [-17 ] [ ]
10 JOINT 9 2 0 1 0 R1 [ ] [ ]
11 LINEAR 0 0 0 1 0 R1 [ ] [ ]
work 12 CALL work1on.chk
clamp 13 CALL hand1.op
Position
14 CALL hand1.cl
15 TWAIT 1 R1
16 JOINT 9 2 0 1 0 R1 [-40 ] [ ]
17 CALL work1on.chk
18 JOINT 9 2 0 1 0 R1 [-17,-20,40 ] [20 ]
19 CALL work1on.chk
20 JOINT 0 2 0 1 0 R1 [ ] [20 ]
21 ;waiting for interference from YRB
22 JOINT 9 2 0 1 0 R1 [19,17,18,48 ] [18 ]
23 JOINT 0 2 0 1 0 R1 [-18,-48 ] [ ]
24 JOINT 0 2 0 1 0 R1 [ ] [ ]
25 JOINT 5 1 0 1 0 R1 [ ] [ ]
26 LINEAR 0 1 0 1 0 R1 [ ] [ ]
27 LINEAR 0 0 0 1 0 R1 [ ] [ ]

work
28 CALL hand1.cl
open 29 CALL hand1.op
Position 30 LINEAR 0 0 0 1 0 R1 [-41 ] [ ]
31 CALL workoff.chk
32 JOINT 9 3 0 1 0 R1 [1,20,41,-18,17 ] [ ]
33 CALL io.reset
34 JOINT 9 2 0 1 0 R1 [1,17,18,19,20,-40,-41,-48,-321,-322] [ ]
35 RETURN
36 .END

Gun Status OX（Output） WX（Input）

No Write COMMENT 1 CYCLE COMPLETE 11 START #2
0 R1 Release 17 OUTPUT 1 (#70 NO-I/F) 17 INPUT 1 (#70 PICK UP OK)
1 W1 Weld 18 OUTPUT 2 (#80 NO-I/F) 18 INPUT 2 (#80 PUT ON OK)
2 K1 Clamp 19 OUTPUT 3 (TO X-RB NO-I/F1) 19 INPUT 3 (FROM X-RB NO-I/F1)
3 P1 Plate 20 OUTPUT 4 (TO Y-RB NO-I/F1) 20 INPUT 4 (FROM Y-RB NO-I/F1)
4 C1 Copper 40 OUTPUT 24 (#70 PICK UP COMP)
5 M1 Gap-Measure 41 OUTPUT 25 (#80 PUT ON COMP)
6 F1 Fast Mode 48 OUTPUT 32 (TO Y-RB NO-I/F1)
7 D1 Dressing Mode 321 CLOSE CLAMP1
9 Ｉ1 Wait_Indep._Move 322 OPEN CLAMP1

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KAWASAKI 97160-1043DJE
2.3.2. Handling program
2.3. P3
2.3.2. Handling program（pg***）

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
A JOINT 9 2 0 1 0 R1 [ ] [ ]
B LINEAR 2 1 0 1 0 R1 [ ] [ ]
same C
LINEAR 0 0 0 1 0 R1 [ ] [ ]
PositionD CALL work1on.chk
CALL hand1.op
CALL hand1.cl
TWAIT 1
E LINEAR 2 1 0 1 0 R1 [ ] [ ]
CALL work1on.chk
F JOINT 9 2 0 1 0 R1 [ ] [ ]
CALL work1on.chk
ＳＴＥＰ Ａ ＳＴＥＰ Ｆ

Gun Status
No Write COMMENT
0 R1 Release
1 W1 Weld
2 K1 Clamp
3 P1 Plate
4 C1 Copper
ＳＴＥＰ Ｂ 5 M1 Gap-Measure
ＳＴＥＰ Ｅ
6 F1 Fast Mode
above about 30mm above about 30mm 7 D1 Dressing Mode
for work for jig 9 I1 Wait_Indep._Move

OX（Output） WX（Input）
321 CLOSE CLAMP1
322 OPEN CLAMP1

ＳＴＥＰ C ＳＴＥＰ Ｄ

work clamp position work clamp position

Same position

DRAW. No PAGE
KAWASAKI 97160-1043DJE
2.3.2. Handling program
2.3. P4
2.3.2. Handling program（pg***）

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
A JOINT 9 2 0 1 0 R1 [ ] [ ]
B LINEAR 2 1 0 1 0 R1 [ ] [ ]
same C LINEAR 0 0 0 1 0 R1 [ ] [ ]
PositionD
CALL hand1.cl
CALL hand1.op
E LINEAR 2 1 0 1 0 R1 [ ] [ ]
CALL work1off.chk
F JOINT 9 2 0 1 0 R1 [ ] [ ]
CALL work1off.chk

ＳＴＥＰ Ａ ＳＴＥＰ Ｆ
above about 300mm above about 300mm
for jig for work

Gun Status
No Write COMMENT
0 R1 Release
1 W1 Weld
2 K1 Clamp
3 P1 Plate
4 C1 Copper
ＳＴＥＰ Ｂ ＳＴＥＰ Ｅ 5 M1 Gap-Measure
6 F1 Fast Mode
above about 30mm above about 30mm 7 D1 Dressing Mode
for jig for work
9 I1 Wait_Indep._Move

OX（Output） WX（Input）
321 CLOSE CLAMP1
322 OPEN CLAMP1

ＳＴＥＰ C ＳＴＥＰ Ｄ

work clamp position work unclamp

Same position

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KAWASAKI 97160-1043DJE
2.3.2. Handling program
2.3. P5
2.3.3. Tool put program for ATC（pg071）

.PROGRAM pg071();Tool put

; TOOL1 PUT
;M/B
;RB407W
1;
IF (SIG(1449)==ON) AND (SIG(1451)==ON) THEN
GOTO 10
ELSE
IF (SIG(1449)==OFF) AND (SIG(1451)==ON) THEN
GOTO 2
ELSE
IF (SIG(1449)==ON) AND (SIG(1451)==OFF) THEN
GOTO 10
ELSE
TYPE "Tool Presence Fault!"
TYPE " Signal Check WX449.451"
SIGNAL 10 ;USER ALARM (OTHERS)
GOTO 1
;
2;
CALL tool1.off.chk
CALL atc.on.chk
CALL atc_cl
JOINT SPEED0 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX=450,-449 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-54.193,-44.768,-35.039,66.63,62.085,-49.561] ;cover1 close
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX=-450,449 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029] ;cover1 open
CALL cover1.op
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.346,-9.1095,20.862,118.63,37.938,-125.05] ;
CALL atc_cl
LINEAR SPEED0 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-31.446,6.4302,21.29,119.97,37.417,-126.33] ;
CALL tool.on.chk
CALL atc_cl
LINEAR SPEED0 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-31.446,6.4302,21.29,119.97,37.417,-126.33] ;
TWAIT 0.5
CALL atc_op
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-35.677,-39.874,16.312,110.68,38.915,-116.28] ;
CALL atc.off.chk
CALL tool.on.chk
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX=-450,449 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.671,-33.404,-34.219,47.254,43.564,-39.606] ;cover1 open
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX=450,-449 WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.671,-33.404,-34.219,47.254,43.564,-39.606] ;cover1 close
CALL cover.cl
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-54.193,-44.768,-35.039,66.63,62.085,-49.561]

10;
RETURN OX10 USER ALARM (OTHERS) WX449 TOOL PRESENCE 1-1
.END
OX193 RELEASE CHUCK WX451 TOOL PRESENCE 2-1
OX194 HOLD CHUCK

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KAWASAKI 97160-1043DJE
2.3.3. Tool put program for ATC
2.3. P6
2.3.3. Tool put program for ATC（pg071）

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
1;
IF (SIG(1449)==ON) AND (SIG(1451)==ON) THEN
GOTO 10
ELSE
IF (SIG(1449)==OFF) AND (SIG(1451)==ON) THEN
GOTO 2
ELSE
IF (SIG(1449)==ON) AND (SIG(1451)==OFF) THEN
GOTO 10
ELSE
TYPE "Tool Presence Fault"
TYPE "Signal Check WX449.451"
SIGNAL 10 ;USER ALARM (OTHERS)
GOTO 1
; HAND 1
2;
CALL tool1.off.chk
CALL atc.on.chk
CALL atc_cl
JOINT 0 2 0 1 0 R1 [-449,450] [ ]
A JOINT 9 2 0 1 0 R1 [449,-450] [ ]
CALL cover1.op
B JOINT 9 2 0 1 0 R1 [ ] [ ]
C JOINT 9 2 0 1 0 R1 [ ] [ ]
CALL atc_cl
LINEAR 0 0 0 1 0 R1 [ ] [ ]
D CALL tool.on.chk
CALL atc_cl
same
Position LINEAR 0 0 0 1 0 R1 [ ] [ ]
E TWAIT 0.5 timer 0.5
JOINT 9 2 0 9 0 R1 [ ] [ ]
F CALL atc.off.chk
CALL tool.on.chk
JOINT 9 2 0 9 0 R1 [449,-450] [ ]
G JOINT 9 2 0 9 0 R1 [-449,450] [ ]
CALL cover.cl;
JOINT 9 2 0 9 0 R1 [ ] [ ]
10;
RETURN
.END Gun Status
Tool changer
No Write COMMENT
ＳＴＥＰ Ａ ＳＴＥＰ G 0 R1 Release
position above hand table same position
1 W1 Weld
for A 2 K1 Clamp
3 P1 Plate
4 C1 Copper
5 M1 Gap-Measure
6 F1 Fast Mode
7 D1 Dressing Mode
LS LS
9 I1 Wait_Indep._Move

OX（Output） WX（Input）
193 RELEASE CHUCK 193 CHUCK RELEASED
ＳＴＥＰ Ｂ ＳＴＥＰ F 194 HOLD CHUCK 194 CHUCK HELD
same position 449 OPEN AHC COVER1 449 TOOL PRESENCE 1-1

for Ｆ ATC bos s 450 CLOSE AHC COVER1 450 TOOL PRESENCE 1-2

e xi t

LS LS

ＳＴＥＰ C，Ｄ ＳＴＥＰ Ｅ

Tool adaputer 0～0.5㎜ above about 30㎜

0～
0.5㎜

LS LS

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KAWASAKI 97160-1043DJE
2.3.3. Tool put program for ATC
2.3. P7
2.3.4. Tool get program for ATC（pg072）

.PROGRAM pg072(); Tool get

; TOOL1 GET
;M/B
;RB407W
1;
IF (SIG(1449)==ON) AND (SIG(1451)==ON) THEN
GOTO 2
ELSE
IF (SIG(1449)==OFF) AND (SIG(1451)==ON) THEN
GOTO 10
ELSE
TYPE "Tool Presence Fault"
TYPE " Signal Check WX449.451"
SIGNAL 10 ;USER ALARM (OTHERS)
GOTO 1
;
2;
CALL tool.on.chk
CALL atc.off.chk
CALL atc_op
JOINT SPEED0 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=450,-449 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-54.193,-44.768,-35.039,66.63,62.085,-49.561] ;cover1
close
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-450,449 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029] ;cover1
open
CALL cover1.op
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.437,-55.381,-14.346,67.105,35.634,-64.029] ;
JOINT SPEED9 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-32.346,-9.1095,20.862,118.63,37.938,-125.05] ;
CALL atc.off.chk
CALL atc_op
LINEAR SPEED0 ACCU1 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-31.446,6.4302,21.29,119.97,37.417,-126.33]
CALL atc.on.chk
LINEAR SPEED0 ACCU1 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-31.446,6.4302,21.29,119.97,37.417,-126.33]
TWAIT 0.5
CALL atc_Cl
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-35.677,-39.874,16.312,110.68,38.915,-116.28] ;
CALL atc.on.chk
CALL tool1.off.chk
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-450,449 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.671,-33.404,-34.219,47.254,43.564,-39.606] ;cover1
open
CALL atc_on.chk
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX=-449,450 WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.671,-33.404,-34.219,47.254,43.564,-39.606] ;cover1
close
CALL cover.cl
JOINT SPEED9 ACCU2 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-54.193,-44.768,-35.039,66.63,62.085,-49.561] ;

10;
RETURN
.END

OX10 USER ALARM (OTHERS) WX449 TOOL PRESENCE 1-1

OX193 RELEASE CHUCK WX451 TOOL PRESENCE 2-1
OX194 HOLD CHUCK
OX449 OPEN AHC COVER1

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KAWASAKI 97160-1043DJE
2.3.4. Tool get program for ATC
2.3. P8
2.3.4. Tool get program for ATC（pg***）

STEP INTERP SPEED ACCU TIMER TOOL WORK CLAMP J/E OUTPUT *OX INPUT *WX
1;
IF (SIG(1449)==ON) AND (SIG(1451)==ON) THEN
GOTO 2
ELSE
IF (SIG(1449)==OFF) AND (SIG(1451)==ON) THEN
GOTO 10
ELSE
TYPE "Tool Presence Fault!"
TYPE "Signal Check WX449.451"
SIGNAL 10 ;USER ALARM (OTHERS)
GOTO 1
; tool changer
2;
CALL tool.on.chk
CALL atc.off.chk
CALL atc_op
JOINT 0 2 0 9 0 R1 [-449,450] [ ]
A JOINT 9 2 0 9 0 R1 [-450,449] [ ]
CALL cover1.op
B JOINT 9 2 0 9 0 R1 [ ] [ ]
C JOINT 9 2 0 9 0 R1 [ ] [ ]
CALL atc.off.chk
D LINEAR 0 0 0 9 0 R1 [ ] [ ]
same CALL atc.on.chk
Position CALL atc_op
E LINEAR 0 0 0 9 0 R1 [ ] [ ]
TWAIT 0.5 timer 0.5
CALL atc_cl
F JOINT 9 2 0 1 0 R1 [ ] [ ]
CALL atc.on.chk
CALL tool1.off.chk
G JOINT 9 2 0 1 0 R1 [-450,449] [ ]
CALL atc_on.chk
JOINT 9 2 0 1 0 R1 [-449,450] [ ]
CALL cover.cl hand 1
JOINT 9 2 0 1 0 R1 [ ] [ ]
10;
RETURN
.END Gun Status
No Write COMMENT
ＳＴＥＰ Ａ ＳＴＥＰ G 0 R1 Release
same position 1 W1 Weld
separate from hand
for G 2 K1 Clamp
3 P1 Plate
4 C1 Copper
5 M1 Gap-Measure
6 F1 Fast Mode
7 D1 Dressing Mode
LS LS
9 I1 Wait_Indep._Move

OX（Output） WX（Input）
193 RELEASE CHUCK 193 CHUCK RELEASED
ＳＴＥＰ Ｂ ＳＴＥＰ F 194 HOLD CHUCK 194 CHUCK HELD
same position 449 OPEN AHC COVER1 449 TOOL PRESENCE 1-1

ATC bos s for B 450 CLOSE AHC COVER1 450 TOOL PRESENCE 1-2

enter

LS LS

ＳＴＥＰ C ＳＴＥＰ Ｄ，Ｅ

tool adaputer 0～0.5㎜

ATC pi n
enter 0～
0.5㎜

LS LS

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KAWASAKI 97160-1043DJE
2.3.4. Tool get program for ATC
2.3. P9
2.3.5. Work1 presence on (work1on.chk)

.PROGRAM work1on.chk();Work1 Presence On OX5 USER ALARM (PART PRESENCE)

;WORK1 PRESENCE ON WX16 TEST RUN
WX399 SENSOR INPUT63
;M/B
(Work1 Presence Check)
;RB407W
IF SIG(1016) THEN
TYPE " Work1 Presence is not checked!. "
GOTO 999
END
;
DELAY 0.1
TIMER (1) = 0
10;
IF SIG(1399,-1400) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 5 ;User Alarm (PART PRESENCE)
TYPE " Work1 Presence Fault "
TYPE " Signal Check ON=WX399,OFF=WX400"
WAIT SIG(1399,-1400)
SIGNAL -5
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.5. Work1 presence on
2.3. P10
2.3.6. Work1 presence off (workoff.chk)

.PROGRAM workoff.chk(); Work1 Presence Off OX5 USER ALARM (PART PRESENCE)
;WORK1 PRESENCE OFF WX16 TEST RUN
WX399 SENSOR INPUT63
;M/B
(Work1 Presence Check)
;RB407W WX400 SENSOR INPUT64
IF SIG(1016) THEN (Work1 Presence Check)
TYPE " Work1 Presence is not checked!. "
GOTO 999
END
;
DELAY 0.1
TIMER (1) = 0
10;
IF SIG(-1399,-1400) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 5 ;User Alarm(PART PRESENCE)
TYPE " Work1 Presence Fault "
TYPE " Signal Check OFF=WX399,400"
WAIT SIG(-1399,-1400)
SIGNAL -5
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.6. Work1 presence off
2.3. P11
2.3.7. Hand1 open (hand1.op)

.PROGRAM hand1.op();Hand Open OX 6 USER ALARM

;HAND1 OPEN (HAND CLAMP LS)
;M/B OX 321 CLOSE CLAMP1
;RB407W OX 322 OPEN CLAMP1
DELAY 0.1 WX 321 SENSOR INPUT1
TIMER (1) = 0 (HAND1 CLAMPD)
10 WX 322 SENSOR INPUT2
SIGNAL 322,-321 (HAND1 OPEND)
IF SIG(1322,-1321) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 6 ;User Alarm (HAND CLAMP LS)
TYPE " ;Hand1 Clamp Fault"
TYPE " signal check ON=WX322"
WAIT SIG(1322,-1321)
SIGNAL -6
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.7. Hand1 open
2.3. P12
2.3.8. Hand1 close (hand1.cl)

.PROGRAM hand1.cｌ();Hand Close OX 6 USER ALARM

;HAND1 CLAMP (HAND CLAMP LS)
;M/B OX 321 CLOSE CLAMP1
;RB407W OX 322 OPEN CLAMP1
DELAY 0.1 WX 321 SENSOR INPUT1
TIMER (1) = 0 (HAND1 CLAMPD)
10 WX 322 SENSOR INPUT2
SIGNAL -322,321 (HAND1 OPEND)
IF SIG(1321,-1322) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 6 ;User Alarm (HAND CLAMP LS)
TYPE " Hand1 Clamp Fault"
TYPE " signal check ON=WX321"
WAIT SIG(1321,-1322)
SIGNAL -6
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.8. Hand1 close
2.3. P13
2.3.9. Hand open check (handop.chk)

.PROGRAM handop.chk();Hand Open OX6 USER ALARM

(HAND CLAMP LS)
;HAND OPEN
WX321 SENSOR INPUT1
;M/B (HAND1 CLAMPD)
;RB407W WX322 SENSOR INPUT2
DELAY 0.1 (HAND1 OPEND)
TIMER (1) = 0 WX323 SENSOR INPUT3
10 (HAND2 CLAMPD)
IF SIG(1322,1324,-1321,-1323) GOTO 999 WX324 SENSOR INPUT4
IF TIMER(1)<time.up GOTO 10 (HAND2 OPEND)
SIGNAL 6 ;User Alarm (HAND CLAMP LS)
TYPE " Hand Clamp Fault"
TYPE " signal check ON=WX322,324"
WAIT SIG(1322,1324,-1321,-1323)
SIGNAL -6
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.9. Hand open check
2.3. P14
2.3.10. All tools presence on (tool.on.chk)

.PROGRAM tool.on.chk();All Tools Presence On OX10 USER ALARM (OTHERS)

;ALL TOOLS PRESENCE ON WX449 TOOL PRESENCE 1-1
;M/B WX451 TOOL PRESENCE 2-1
;RB407W
DELAY 0.1
TIMER (1) = 0
10;
IF SIG(1449,1451) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 10 ;user alarm (others)
TYPE " Tool Presence Fault"
TYPE " signal check ON=WX449,451"
WAIT SIG(1449,1451)
SIGNAL -10
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.10. All tools presence on
2.3. P15
2.3.11. Tool1 presence off (tool1.off.chk)

.PROGRAM tool1.off.chk();Tool1 Presence Off OX10 USER ALARM (OTHERS)

;ALL TOOLS PRESENCE ON WX449 TOOL PRESENCE 1-1
;M/B WX451 TOOL PRESENCE 2-1
;RB407W
DELAY 0.1
TIMER (1) = 0
10;
IF SIG(-1449,1451) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 10 ;user alarm (others)
TYPE " Tool1 Presence Fault "
TYPE " signal check ON=WX451,OFF=WX449"
WAIT SIG(-1449,1451)
SIGNAL -10
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.11. Tool1 presence off
2.3. P16
2.3.12. ATC connect on (atc.on.chk)

.PROGRAM atc.on.chk();ATC Connect On OX10 USER ALARM (OTHERS)

;ATC CONNECT ON WX195 AHC SURFACE CONTACT
;M/B
;RB407W
DELAY 0.1
TIMER (1) = 0
10;
IF SIG(1195) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 10 ;USER ALARM (OTHERS)
TYPE " ATC Touched Fault "
TYPE " Signal check ON=WX195"
WAIT SIG(1195)
SIGNAL -10
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.12. ATC connect on
2.3. P17
2.3.13. ATC connect off (atc.off.chk)

.PROGRAM atc.off.chk();ATC Connect Off OX10 USER ALARM (OTHERS)

;ATC CONNECT OFF WX195 AHC SURFACE CONTACT
;M/B
;RB407W
DELAY 0.1
TIMER (1) = 0
10;
IF SIG(-1195) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 10 ;USER ALARM (OTHERS)
TYPE " ATC Touched Fault "
TYPE " Signal check OFF=WX195"
WAIT SIG(-1195)
SIGNAL -10
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.13. ATC connect off
2.3. P18
2.3.14. ATC cover1 open (cover1.op)

.PROGRAM cover1.op();Open ATC Cover1 OX10 USER ALARM (OTHERS)

;OPEN ATC COVER1 OX449 OPEN AHC COVER1
;M/B OX450 CLOSE AHC COVER1
;RB407W
DELAY 0.1 WX457 AHC COVER1 OPENED
TIMER (1) = 0 WX458 AHC COVER1 CLOSED
10
SIGNAL 450,-449
SIGNAL -450,449
IF SIG(-1458,1457) GOTO 999
IF TIMER(1)<time.up GOTO 10
SIGNAL 10 ;user alarm (others)
TYPE "ATC Cover Fault"
TYPE "Signal check ON=WX457 OFF=WX458"
WAIT SIG(-1458,1457)
SIGNAL -10
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.14. ATC cover1 open
2.3. P19
2.3.15. ATC cover close (cover.cl)

.PROGRAM cover.cl();Close ATC Cover OX10 USER ALARM (OTHERS)

;CLOSE ATC COVER OX449 OPEN AHC COVER1
;M/B OX450 CLOSE AHC COVER1
;RB407W OX451 OPEN AHC COVER2
DELAY 0.1 OX452 CLOSE AHC COVER2
TIMER (1) = 0
10 WX457 AHC COVER1 OPENED
SIGNAL -450,-452,449,451 WX458 AHC COVER1 CLOSED
SIGNAL 450,452,-449,-451 WX459 AHC COVER2 OPENED
IF SIG(-1457,-1459,1458,1460) GOTO 999 WX460 AHC COVER1 CLSEED
IF TIMER(1)<time.up GOTO 10
SIGNAL 10 ;user alarm (others)
TYPE ";ATC Cover Fault"
TYPE "Signal check ON=WX458,460 OFF=WX457,459"
WAIT SIG(-1458,1457)
SIGNAL -10
GOTO 10
;
999
RETURN
.END

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KAWASAKI 97160-1043DJE
2.3.15. ATC cover close
2.3. P20
2.4.1. Turn table rotate (tt_run)

.PROGRAM tt_run();TT RUN

SWAIT xxxx; T/T TURN
SWAIT xxxx; T/T NON-INT
SIGNAL -xxxx; T/T APPROACH OK
;
SWAIT xxxx; T/T NON-INT B ROB
SIGNAL -xxxx; T/T APP. OK TO B ROB
;
SWAIT xxxx; T/T NON-INT C ROB
SIGNAL -xxxx; T/T APP. OK TO C ROB
;
100
WAIT SIG(xxxx) || SIG(xxxx) || SIG(xxxx) || SIG(xxxx) || SIG(xxxx)
IF SIG(xxxx) GOTO 10; TURN TO POSITION1
IF SIG(xxxx) GOTO 20; TURN TO POSITION2
IF SIG(xxxx) GOTO 30; TURN TO POSITION3
IF SIG(xxxx) GOTO 40; TURN TO POSITION4
IF SIG(xxxx) GOTO 50; TURN TO POSITION5
TWAIT 0.002
GOTO 100
;
10; POS1:0deg.
CALL tt_ref
CALL pin_out
EXT_DRIVE 1,xxxx,0;0deg
GOTO 200
;
20; POS2:90deg.
CALL tt_ref
CALL pin_out
EXT_DRIVE 1,xxxx,90;90deg
GOTO 200
;
30; POS3:180deg.
CALL tt_ref
CALL pin_out
EXT_DRIVE 1,xxxx,180;180deg
GOTO 200
;
40; POS4:-90deg.
CALL tt_ref
CALL pin_out
EXT_DRIVE 1,xxxx,-90;-90deg
GOTO 200
;
50; POS5:xxxxdeg.
CALL tt_ref
CALL pin_out
EXT_DRIVE 1,xxxx,xxxx;xxxxdeg
GOTO 200

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KAWASAKI 97160-1043DJE
2.4.1. Turn table rotate
2.4. P1
2.4.1. Turn table rotate (tt_run)

;
200
CALL pin_in
SIGNAL xxxx; T/T APP.OK TO B ROB
SIGNAL xxxx; T/T APP.OK TO C ROB
SIGNAL xxxx; T/T APPROACH OK
RETURN
.END

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KAWASAKI 97160-1043DJE
2.4.1. Turn table rotate
2.4. P2
2.4.2. Turn table reference position set (tt_ref)

.PROGRAM tt_ref(); TT REF SET

;
SIGNAL -xxxx ; POSITION 1
SIGNAL -xxxx ; POSITION 2
SIGNAL -xxxx ; POSITION 3
SIGNAL -xxxx ; POSITION 4
SIGNAL -xxxx ; POSITION 5
;
.END

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KAWASAKI 97160-1043DJE
2.4.2. Turn table reference position set
2.4. P3
2.4.3. Turn table safety pin lock (pin_in)

.PROGRAM pin_in(); SAFETY PIN IN

100
;
WAIT SIG(xxxx) || SIG(xxxx) || SIG(xxxx) || SIG(xxxx) || SIG(xxxx) ;
;
SIGNAL -xxxx ; T/T SAFTY PIN UNLOCKED
SIGNAL xxxx ; T/T SAFTY PIN LOCKED
TIMER (1) = 0
WHILE SIG(xxxx) DO ; SAFTY PIN UNLOCKED
IF TIMER(1)>5 GOTO 200 ; TIMEOUT
TWAIT 0.002
END
TIMER (1) = 0
WHILE SIG(-xxxx) DO ; SAFTY PIN LOCKED
IF TIMER(1)>5 GOTO 200 ; TIMEOUT
TWAIT 0.002
END
SIGNAL -xxxx ; T/T SAFTY PIN LOCKED
RETURN ;
;
200
; --- PIN LOCK FAULT ---
PULSE xxxx,1 ; USER ALARM (OTHERS) ;
; --- PIN LOCK FAULT ---
GOTO 100 ;
.END

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KAWASAKI 97160-1043DJE
2.4.3. Turn table safety pin lock
2.4. P4
2.4.4. Turn table safety pin unlock (pin_out)

.PROGRAM pin_out(); SAFETY PIN OUT

100; PIN UNLOCK ;
SIGNAL -xxxx ; T/T SAFTY PIN LOCKED
SIGNAL xxxx ; T/T SAFTY PIN UNLOCKED
TIMER (1) = 0
WHILE SIG(xxxx) DO ; SAFTY PIN LOCKED
IF TIMER(1)>5 GOTO 200 ; TIMEOUT
TWAIT 0.002
END
TIMER (1) = 0
WHILE SIG(-xxxx) DO ; SAFTY PIN UNLOCKED
IF TIMER(1)>5 GOTO 200 ; TIMEOUT
TWAIT 0.002
END
SIGNAL -xxxx ; T/T SAFTY PIN UNLOCKED
RETURN ;
;
200
; --- PIN LOCK FAULT ---
PULSE xxxx,1 ; USER ALARM (OTHERS) ;
; --- PIN LOCK FAULT ---
GOTO 100 ;
.END

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KAWASAKI 97160-1043DJE
2.4.4. Turn table safety pin unlock
2.4. P5