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FANUC Robot series

(R-J3iB CONTROLLER SPOT TOOL+)
Built-in Spot Welding Timer Controller {DENGENSHA Spec.)

OPERATOR'S MANUAL

B-81814EN/01

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Ȧ No part of this manual may be reproduced in any form.

Ȧ All specifications and designs are subject to change without notice.

In this manual we have tried as much as possible to describe all the

various matters.
However, we cannot describe all the matters which must not be done,
or which cannot be done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in
this manual should be regarded as ”impossible”.

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B-81814EN/01 Contents

CONTENTS

1 PREFACE .....................................................................................................................1
2 SETTING .......................................................................................................................2
2.1 SETTING THE WELDING TIMER TYPE..............................................................................2
2.2 SETTING SIGNALS.................................................................................................................2
2.2.1 Contactor Unit Signals......................................................................................................2
2.2.2 Checking the Iso contactor Signal ....................................................................................4
2.2.3 Stepper Ready Signal ........................................................................................................4
2.2.4 Shunt trip Signal Output Settings ...................................................................................5
2.3 SWITCHING BETWEEN THE TURNED-ON TURNED-OFF STATES...............................6
2.3.1 Switching Using an External Signal ................................................................................6
2.3.2 Switching Using the Teach Pendant ................................................................................7
2.4 SETTING THE BUILT-IN TIMER ..........................................................................................9
2.5 SETUP SCREENS..................................................................................................................10
2.5.1 DEP COMMON (Common) .............................................................................................11
2.5.2 DEP Seq (Schedule).........................................................................................................11
2.5.3 Procedure for Saving and Loading a Single Welding Condition ...................................13
2.5.4 DEP COUNT/STEP Screen (Gun) ..................................................................................15
2.5.5 DEP FUNCTION Screen (Special) .................................................................................15
2.5.6 DEP HARD Screen (Hardware)......................................................................................16
2.6 SAVING SCHEDULE AND SETUP DATA ...........................................................................17
3 PROGRAM..................................................................................................................18
3.1 SPOT COMMAND..................................................................................................................18
3.2 RESET STEPPER COMMAND .............................................................................................18
3.3 RESET WELDER COMMAND..............................................................................................18
3.4 ISO CONTACTOR COMMAND.............................................................................................19
4 START MODES AND OPENING AND CLOSING THE CONTACTOR ......................20
4.1 START MODES ......................................................................................................................20
4.2 OPENING AND CLOSING THE CONTACTOR...................................................................21
5 WELDING SPOT ID MANAGEMENT (PART ID AND WELD ID)...............................22
6 ALARM SCREENS .....................................................................................................23
6.1 ORDINARY ALARM SCREEN ..............................................................................................24
6.2 SCREEN DEDICATED TO THE INTERNAL TIMERS.......................................................27
6.3 ALARM HISTORY SCREEN .................................................................................................28
7 MONITORING WELDING RESULTS..........................................................................30
7.1 DEP Monitor SCREEN...........................................................................................................30
7.2 DEP Data Log .........................................................................................................................31
8 EXTERNALLY OUTPUTTING WELDING RESULTS .................................................33
9 CHANGING THE NUMBER OF WELDING CONDITIONS .........................................36
10 GUN CHANGE ............................................................................................................37
11 RESTRICTIONS..........................................................................................................38

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Contents B-81814EN/01

12 OTHER NOTES...........................................................................................................39
13 ALARMS .....................................................................................................................40
14 SYSTEM VARIABLES ................................................................................................45
Index ................................................................................................................................ i-1

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B-81814EN/01 1.PREFACE

1 PREFACE
This operator's manual is prepared for welding timer boards
manufactured by DENGENSHA MFG. Co., LTD.
For details of each function or signal of the built-in
welding timer, refer to the specifications and operator's
manual provided by DENGENSHA.
The welding timer board (timer controller PMU-0531 manufactured
by DENGENSHA MFG. Co., LTD.) is referred to as the "timer board"
in this manual.
The design of the robot software is based on SPOT TOOL+.
Up to two timer boards are available to control.

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2.SETTING B-81814EN/01

2 SETTING

2.1 SETTING THE WELDING TIMER TYPE

Before using the built-in timer, set the following system
variables.
Use the Control Start screen to set the system variables.

$SPOTCONFIG.$WELD_TYPE = 4 (built-in welding timer)

$SPOTCONFIG.$IWC_VENDOR = 2 (DENGENSHA type)
When no timer board is mounted, set $weld_type = 1 (digital
type).

2.2 SETTING SIGNALS

There are signals dedicated to the built-in timers manufactured by
DENGENSHA.
You must assign the following signals according to the wiring
conditions.
Use the Weld Interface screen and system variables to set
the signals.

2.2.1 Contactor Unit Signals

Operation
MENU → I/O → F1[TYPE] → Weld interface

Output signals (OUT)

I/O Weld Out Joint 100%

NAME OUT PT SIM STATUS

1 Iso contactor: DO[ 0] U ***
2 Shunt trip: DO[ 1] U OFF
3 Alarm code: GO[ 1] U 7

[ TYPE ] IN/OUT

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B-81814EN/01 2.SETTING

Press F3 to switch between IN and OUT.

Input signals (IN)

I/O Weld In Joint 100%

NAME IN PT SIM STATUS

1 Iso contactor: DI[ 0] U ***
2 Leak input: DI[ 1] U OFF

[ TYPE ] IN/OUT

Each signal is described below. Always set the Shunt trip

output and Iso contactor output and input signals.

Output signals (OUT)

Iso contactor Sets the number of the output signal to the IC close
signal on the contactor unit.
IC close signal When you want to change the type for the signal, see
(signal name used "Additional information" below.
on the contactor) Note) Install wiring so that the contactor is closed
when this signal is on. (See Subsection 2.2.2.)
For details of contactor open/close operation, see
Section 4.2.
2.Shunt trip Sets the number of the output signal to the CB shunt
trip signal on the contactor unit.
CB shunt trip When you want to change the type for the signal, see
"Additional information" below.
This signal is output by a shunt trip request from the
timer board. The circuit breaker on the contactor unit
is tripped by the pulse output.
A directive for tripping the circuit breaker is transferred
from the timer board to the robot, then to the
contactor unit.
3.Alarm code Signal for outputting a timer board alarm I/O code to
peripherals. Set a GO (group output) at least 4 bits
Signal output to long.
peripherals The signals to be used additionally require group
output (GO) assignment.

Input signals (IN)

Iso contactor Signal for detecting the contactor open/close status.
Set this signal so that it is on when the contactor is
IC auxiliary closed or off when the contactor is open.
contact output
signal
2.Leak Input Signal for detecting a leakage of current. When this
signal is turned on, SPOT-384 leak input occurs in the
robot.
After changing any setting number or type, turn the
power off, then on again.

Additional information: To change the type for a signal

listed above (such as changing SDO to RDO), change the
corresponding system variable listed below:
Output
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2.SETTING B-81814EN/01

1.Iso contactor $SPOTWELDIO[card-number].$DO_ISOCNT_T

2.Shunt trip $SPOTWELDIO[card-number].$DO_SHNTRP_T
3.Alarm code $IWCPCFG.$wdal_ot_typ[card-number]
Input
1.Iso contactor $SPOTWELDIO[card-number].$DI_ISOCNT_T
2.Leak Input $IWCPCFG. $leak_in_typ [card-number]
*1) Card number
Set the number of the target DENGENSHA welding timer board
on the PC104 board for card-number.
For example, when the target board is the first card, set 1.

*2) After changing the type for Leak Input, turn the power
off, then on again.

The table at right lists signals and their corresponding

system variable values.
Type of Integer
signal
SDO 2
RDO 9
GO 19
SDI 1
RDI 8
GI 18

Example)
To use RDO for Iso contactor DO for card No. 1,
set $SPOTWELDIO[1].$DO_ISOCNT_T=9.

2.2.2 Checking the Iso contactor Signal

After completion of wiring and setting, check the following
two points:
Check 1: Turn Iso contactor DO on.
The contactor on the welding machine is closed.
Iso contactor DI is turned on.
Check 2: Turn Iso contactor DO off.
The contactor is opened.
Iso contactor DI is turned off.

2.2.3 Stepper Ready Signal

When each stepper is ready, the robot can output a signal to
peripherals.
Use system variables to set the type and number of the signal.
This signal is on when the stepper is ready or off when the
RESET STEPPER command is executed for the stepper.
Type of signal $IWCPCFG.$STPC_TYP[(card-number - 1) × 4 +
SDO gun-number]
RDO 2 for DO
9 for RO

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B-81814EN/01 2.SETTING

19 for GO
Number [n] $IWCPCFG.$STPC_IDX[(card-number - 1) × 4 +
gun-number]
*1) Card number
Set the number of the target DENGENSHA welding timer board
on the PC104 board for card-number.
For example, when the target board is the first card, set
1.
Guns 1 to 4 of card 1 correspond to array elements 1 to 4.
For gun 1, set 1.
Guns 1 to 4 of card 2 correspond to array elements 5 to 8.
Note) Do not set signals other than DO, RO, and GO or
nonexistent numbers.

2.2.4 Shunt trip Signal Output Settings

You can use the following system variables to change settings
related to the Shunt trip signal output to the contactor
unit.
Use the Weld Interface screen to set the t signal and its
number. (See Subsection 2.2.1.)

Enable/disable $IWCPCFG.$SHUNT_ENABLE[card-number]

TRUE: Enabled, FALSE: Disabled

Initial setting: TRUE
Pulse $IWCPCFG.$SHUNT_PULS[card-number]
output/holding
output 1: Pulse output, 0: Holding output
Initial setting: 1 (pulse output)
Pulse width $IWCPCFG.$SHUNT_TIME[card-number]

Specifies the pulse width in ms.

Initial setting: 500 ms
*1) Card number
Set the number of the target DENGENSHA welding timer board
on the PC104 board for card-number.
For example, when the target board is the first card, set
1.

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2.SETTING B-81814EN/01

2.3 SWITCHING BETWEEN THE TURNED-ON TURNED-OFF

STATES
There are two methods to switch between the turned-on and
turned-off states:
Switching using an external signal (See Subsection 2.3.1.)
Switching using the teach pendant (See Subsection 2.3.2.)
When the teach pendant is enabled, switching using an
external signal is disabled.
Switching using the teach pendant is enabled only when the
teach pendant is enabled.

2.3.1 Switching Using an External Signal

Use the Remote NO WELD signal. The welding machine is turned
or when this signal is on or turned off when the signal is
off.
Operation
MENU →I/O → F1[TYPE] → Cell Intface

You can use F3 to switch between IN and OUT. Display the

input signal screen.

I/O Cell Inputs G1 JOINT 100 %

1/21
INPUT SIGNAL TYPE # SIM STATUS
:
8 Remote NO WELD DI[ 0] U ***
9 Remote NO STROKE DI[ 0] U ***

[ TYPE ] CONFIG IN/OUT SIM UNSIM >

Position the cursor on Remote NO WELD and press F2「CONFIG」.

I/O Cell Inputs G1 JOINT 100 %

Input Signal Details 1/1

Signal name: Remote NO WELD

1 Input type/no: DI [ 20]

[ TYPE ]PREV_IO NEXT-IO VERIFY>

Set the number of the signal on this screen.
After changing the setting, turn the power off, then on
again.

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B-81814EN/01 2.SETTING

This function is enabled only when the following conditions

are all satisfied:
INTERLOCK mode SOFT PANEL screen
MENU →Soft panel→F2[SHOW]→General）
Isolate/Interlock mode:INTERLCK
Mode switch: Auto The mode (T1, T2, and AUTO) switch on the robot operator's panel is
in the AUTO position.
Teach pendant: Disabled The teach pendant enable/disable key is in the disable position.
Remote/Local: REMOTE SYSTEM CONFIG screen
MENU →Nex page → SYSTEM →F1[TYPE] → CONFIG
Set ”Remote/Local setup:" to REMOTE. Use F4 to change the
setting.

2.3.2 Switching Using the Teach Pendant

Use the SOFT PANEL screen.

Operation
MENU →Soft panel→F2[SHOW]→General

SOFT PANEL GENERAL G1 JOINT 10 %

1/1
Con.Rel. key status: AUTO
1 Isolate/Interlock mode: ISOLATE
Tryout mode: DISABLED

Robot must be in ISOLATE for changes

[ TYPE ][ SHOW ] HELP ISOLATE INTERLCK
Set the Isolate/Interlock mode item (whose options are
ISOLATE and INTERLOCK) to ISOLATE (press F4 ISOLATE).

Then, press F2[SHOW] and select 「3 Applic」.

SOFT PANEL GENERAL G1 JOINT 10 %
1/1
Con.Rel. key status: AUTO
1 Isolate/Interlock mode: ISOLATE
Tryout mode: DISABLED
_________________
| 1 General |
| 2 Manual |
| 3 Applic. |
-----+ +-----
[ TYPE ]| SHOW | HELP ISOLATE INTERLCK

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2.SETTING B-81814EN/01

The following screen appears:

SOFT PANEL G1 JOINT

10 %
2/6
1 Gun operation: STROKE
2 Weld controller mode: NOWELD
3 Initiate repair program: DISABLED
4 Return home from repair: DISABLED
5 Return home from pounce: DISABLED
6 Force process complete: DISABLED

[ TYPE ] [ SHOW ] WELD NOWELD

Move the cursor to the 「Weld controller mode」 line and use
F4 and F5 to switch between WELD and NOWELD.

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B-81814EN/01 2.SETTING

2.4 SETTING THE BUILT-IN TIMER

This section explains how to operate the built-in timer board setup
screens.
The settings related to the built-in timer are organized
under MENU ->DEP.

STYLE SW JOINT 50%

MENUS 1/2
1 1:J P[1] 100% FINE
SELECT
2 2:J P[2] 100% FINE
EDIT
:
3 DATASPOT[BU=C,S=1,BU=*]
3:J P[3] 100% FINE
4 STATUS
: BACKUP[CLOSE]
5 POSITION
[End]
6 SYSTEM
7
8 USER2
9 DEP
0 -- NEXT --

Screen map

DEP

1 Alarm 2 Monitor 3 Setup

Active Monitor
TOP

history Log

Alarm screens for the Common

built-in timer board
(Section 6.2) Welding result monitor
screens (7) Schedule

Gun

Special

Hardware

Screens for setting welding

conditions and others (2.5)

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2.SETTING B-81814EN/01

2.5 SETUP SCREENS

Operation
MENU → DEP → F1[TYPE] → Setup

DEP setup Joint 100%

Data entry panel(DG) setup list

WC:1

1 Common <*DETAIL*>
2 Schedule <*DETAIL*>
3 Gun <*DETAIL*>
4 Special <*DETAIL*>
5 Hardware <*DETAIL*>

[ TYPE ] WC_NUM

Position the cursor on <*DETAIL*> and press the ENTER key

to display the detail setup screen for the corresponding item.

Common … Sequence C(Common sequence)

…DEP COMMON
Schedule … Schedule 1-255(Weld Schedules)
…DEP Seq
Gun … Sequence G1-4
…DEP COUNT/STEP
Special … Sequence S(Special Function)
…DEP FUNCTION
Hardware … Sequence H(Hardware,Gain)
…DEP HARD

On each screen, F3 is 「WC_NUM」.

Use this key when you use two or more welding timer boards.
When you use only one welding timer board, you need not use
WC_NUM.
NOTE
Do not change any value on each screen during
welding operation.

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B-81814EN/01 2.SETTING

2.5.1 DEP COMMON (Common)

Operation
MENU → DEP → F1[TYPE] → Setup →｢1 common」

DEP COMMON JOINT 100%

1/7
WC: 1

1 WELD TIME COMP(CYC) 0

2 WELD TIME SHORT(CYC) 0
3 WELD Time Limit(CYC) 1000
4 WELD SOURCE VOLT(V) 400
5 WELD SOURCE LOW LIMIT(%) 20
6 WELD SOURCE HIGH LIMIT(%) 20
7 WELD CURRENT FAULT LIMIT(%) 30

[ TYPE ] WC_NUM

For details of each item, refer to the operator's manual

provided by DENGENSHA.

2.5.2 DEP Seq (Schedule)

Operation
MENU → DEP → F1[TYPE] → Setup →｢2 Schedule」

DEP Seq JOINT 100%

1 Welding condition
/29 number
WC: 1
Seq. num 1

1 SQUEEZE(CYC) 50
2 UP-SLOPE(CYC) 3
3 WELD 1(CYC) 0
4 COOL(CYC) 0
5 WELD 2(CYC) 0
6 HOLD(CYC) 20
7 IMPULSE No 1
8 CURRENT 1(A) 2000
9 CURRENT 2(A) 2000
10 HEAT 1(%) 20
11 HEAT 2(%) 20
12 CURRENT HIGH LIMIT(%) 20
13 CURRENT LOW LIMIT(%) 20
14 HEAT HIGH LIMIT(%) 100
15 HEAT LOW LIMIT(%) 10
16 TRANS TURNS(x0.1) 2000
17 CURRENT CTRL(VC=0/CC=1) 0
18 MAX CURRENT(A) 60000
19 STEP 1 CURRENT(%) 100
20 STEP 2 CURRENT(%) 100
21 STEP 3 CURRENT(%) 100
22 STEP 4 CURRENT(%) 100
23 STEP 5 CURRENT(%) 100
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2.SETTING B-81814EN/01

24 STEP 6 CURRENT(%) 100

25 STEP 7 CURRENT(%) 100
26 STEP 8 CURRENT(%) 100
27 STEP 9 CURRENT(%) 100
28 GUN No(1-4) 1
29 MONITOR IMPULSE(1-2) 1

[ TYPE ] SCHE_NUM WC_NUM COPY >

SAVE LOAD PRINT >

For details of each item, refer to the operator's manual

provided by DENGENSHA.
The number of welding conditions is 32 as standard. You can
increase that number to a maximum of 255. (See Chapter 9,
"CHANGING THE NUMBER OF WELDING CONDITIONS.")

NOTE
The DEP Seq screen is long. While you are editing
「29 MONITOR IMPULSE」, you cannot see the
welding
condition number or card number at the top of the
screen.
Before changing a parameter, check the welding
condition number and card number.
Be careful not to change another welding condition.

Function keys

Page 1
F2 SCHE_NUM Changes the welding condition number.
F3 WC_NUM Changes the card number.
F4 COPY Copies the condition. You can copy the currently displayed welding condition with
another welding condition number.

Page 2
F1 SAVE Saves the welding condition being displayed.
The file name is 「card-number」sch｢welding-condition-number｣.dt.
For example, for welding condition 10 for card 1, the file name is 1sch10.dt.
Data is saved in ASCII code. For details, see Subsection 2.5.
For how to save and load data using the File screen, see Section 2.6, "SAVING
SCHEDULE AND SETUP DATA."
F2 LOAD Loads the welding condition in a file named as described above.
For details, see Subsection 2.5.3.
F3 PRINT Outputs text data in the same format as displayed on the screen. The data is saved
onto the device in the selected state.
The file name is 「card-number」sch｢welding-condition-number｣.ls.
For welding condition 5 for card 1, the file name is 1sch5.ls.
To output data to a printer, set the printer with port setting, then select the serial printer
to the device on the file screen. After that, print data on this screen.
You cannot upload or download data via FTP.

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B-81814EN/01 2.SETTING

*1) Card number

Set the number of the target DENGENSHA welding timer board
on the PC104 board for card-number.
For example, when the target board is the first card, set 1.

2.5.3 Procedure for Saving and Loading a Single Welding Condition

DEP Seq JOINT 100%

1/29
WC : 1
Seq. num 1

1 SQUEEZE(CYC) 50
2 UP-SLOPE(CYC) 3
3 WELD 1(CYC) 0

SAVE LOAD PRINT >

F1 F2

Press F1 SAVE to save a welding condition or F2 Load to load

it.

DEP Seq JOINT 100%

1/29
WC: 1
Seq. num 1

1 SQUEEZE(CYC) 50
2 UP-SLOPE(CYC) 3
3 WELD 1(CYC) 0
Select range(prev to exit)
ThisSch. ALL SPECIFY >
F1 F2 F3

Press one of F1 to F3 according to the range of welding

conditions you want to save or load.
F1 This Sch. － Saves or loads the currently selected
welding condition.
F2 ALL －Saves all welding conditions into separate files.
F3 SPECIFY － Specifies the welding condition range.
After pressing F3, specify the range as follows.
Input card number(0 is all):
Specify a card.
When you use one welding timer board, this message does not
appear.
Enter 0 to save data for all cards.
Save from schedule(0 is all):
Specify the number of the first welding condition you want
to save or load.
Enter 0 to save or load all welding conditions for the
specified card.

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2.SETTING B-81814EN/01

to(0 saves all after “frrom” schedule):

Specify the number of the last welding condition you want
to save or load.
Enter 0 to save or load the welding condition having the
number specified in ④ and all subsequent welding
conditions.
Enter a value greater than or equal to the starting number.

Examples (Number of cards: 2, number of welding conditions:

32)
Specified range
Save/load range
Card from To
1 2 5 Welding conditions 2 to 5 for card 1
2 8 0 Welding conditions 8 to 32 for card 2
1 8 2 No welding condition is saved or loaded.
1 7 7 Welding condition 7 for card 1
1 0 Not Welding conditions 1 to 32 for card 1
required
0 0 Not All welding conditions
required
0 8 0 Welding conditions 1 to 32 for cards 1 and 2
0 2 5 Welding conditions 2 to 5 for cards 1 and 2

When ALL or SPECIFY is selected, multiple files are saved

or loaded.
If a load or save error occurs during operation, processing
stops at that point. The remaining files are not saved or
loaded.

Example of a saved single welding condition

This file was created on 22-OCT-01 17:54 from SpotTool+ (N. A.) V6.2041

Robot F-Number:F00000

FILE:1sch32.dt

Robot Hostname:ROBOT

50,3,0,0,0,0,0,0,20,1,2000,2000,2000, 3.2, .032, .31,32,20,100,10,2000,1,60000,100,100,100,100,100,100,100,100,100,1,1

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B-81814EN/01 2.SETTING

2.5.4 DEP COUNT/STEP Screen (Gun)

Operation
MENU → DEP → F1[TYPE] → Setup → ｢3 Gun」

DEP COUNT/STEP JOINT 100%

WC: 1
GUN 1
1 TIP DRESS COUNT 0
2 TIP REPLACE COUNT 0
3 STEP 0 COUNT 0
4 STEP 1 COUNT 0
5 STEP 2 COUNT 0
6 STEP 3 COUNT 0
7 STEP 4 COUNT 0
8 STEP 5 COUNT 0
9 STEP 6 COUNT 0
10 STEP 7 COUNT 0
11 STEP 8 COUNT 0
12 STEP 9 COUNT 0

[ TYPE ] GUN_NUM WC_NUM

For details of each item, refer to the operator's manual

provided by DENGENSHA.
Set the counters and number of stampings at each stepper
point for guns 1 to 4.
Use F2 GUN_NUM to switch to another gun.

2.5.5 DEP FUNCTION Screen (Special)

Operation
MENU → DEP → F1[TYPE] → Setup → ｢4 Special」

DEP FUNCTION JOINT 100%

WC: 1

1 REWELD OFF
2 FAULT RESET BY PILOT OFF
3 STEPPER OFF
4 TOROID SENSITIVITY STD
5 PWM FREQUENCY 600

[ TYPE ] WC_NUM
For details of each item, refer to the manual provided by
DENGENSHA.

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2.SETTING B-81814EN/01

2.5.6 DEP HARD Screen (Hardware)

Operation
MENU → DEP → F1[TYPE] → Setup →｢5 Hardware」

DEP HARD JOINT 100%

WC: 1

1 PRIM-CT GAIN 10000

2 2ND TOROID GAIN 10000
3 WELD SOURCE VOLT GAIN 10000
4 TIP RESISTANCE GAIN 10000
5 STRAIN SENSOR 1 GAIN 10000
6 STRAIN SENSOR 2 GAIN 10000

[ TYPE ] WC_NUM UPDATE

For details of each item, refer to the operator's manual
provided by DENGENSHA.
To reflect a changed value, press F4 (UPDATE).

NOTE
Hardware data, timer board circuit compensation
values, is factory-set by DENGENSHA. You need not
change any setting normally. The data is retained not
on the robot side, but only in memory in the timer board.

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B-81814EN/01 2.SETTING

2.6 SAVING SCHEDULE AND SETUP DATA

The data listed below is saved into the following SV files. The files
are saved by 「All of above」 or 「System files」 on the File screen.
To load the files, use the Control Start screen.

IWDGSCHE.SV
The following data is saved:
All welding conditions (For how to save a schedule or
individual condition, see Subsection2.5.3.)
Number of welding conditions ($IWCDGSNUM)

IWDGCONF.SV
The following data is saved:
DEP COMMON (Common)
DEP COUNT/STEP (Gun)
DEP FUNCTION (Special)
Current values for the tip dress replace counter, stepper
counter, and others (You cannot set the screen.)

NOTE
The settings on the DEP HARD screen (Hardware)
cannot be saved.

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3.PROGRAM B-81814EN/01

3 PROGRAM

3.1 SPOT COMMAND

The SPOT command directs the timer board to start welding
according to the specified welding condition. After
completion of welding, the next line in the program is
executed:

SPOT [S=1]

S: Welding condition number

3.2 RESET STEPPER COMMAND

The RESET STEPPER command resets stepper counters, tip dress
counter, and tip replace counter to 0.

RESET STEPPER [WC=1,SN=1,SV=0]

WC: Timer board number (1 or 2)

SN: G1-4 series (1 to 4)
SV: Option
0: Clears the "stepper counters" and "stepper step counts"
for the gun specified by SN to 0.
1: Clears the "tip dress counter" for the gun specified by
SN to 0.
2: Clears the "tip replace counter" for the gun specified
by SN to 0.

3.3 RESET WELDER COMMAND

The RESET WELDER command is used to reset a welding error on
the welding timer board from the robot controller.

RESET WELDER [WC=card-number]

NOTE
A welding error can also be reset using the RESET key
on the TP and the Fault reset signal from the robot.
This command resets an error only on the timer
board.

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B-81814EN/01 3.PROGRAM

3.4 ISO CONTACTOR COMMAND

The ISO CONTACTOR command turns the Iso contactor signal on
and off.

ISO CONTACTOR [open/close]

NOTE
Before executing this command, set the Iso contactor
signal correctly.
Execute ISO CONTACTOR[close] at the beginning of a
spot welding program.

1: ISO CONTACTOR[close]
2: J P[1] 100% FINE Always insert this
3: L P[2] 500mm/sec FINE SPOT[S=1] command.

If ISO contactor[close] is not executed, the contactor is

not closed by a program started in the Style start mode. For
this reason, close the contactor at the beginning of the
program.

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4.START MODES AND OPENING AND CLOSING THE CONTACTOR B-81814EN/01

4 START MODES AND OPENING AND

CLOSING THE CONTACTOR

4.1 START MODES

There are the following three external start modes:

1 Style start
2 RSR start Production start (*1)
3 PNS start

IMPORTANT
To use this function, always use the Style
external start mode.

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B-81814EN/01 4.START MODES AND OPENING AND CLOSING THE CONTACTOR

4.2 OPENING AND CLOSING THE CONTACTOR

The Iso contactor signal is turned on or off when each
relevant condition listed below is satisfied.

In a production start mode

Turned on or off by the ISO CONTACTOR[CLOSE/OPEN] command.
Turned off when the program temporarily stops or terminates.
Turned on when the program temporarily stops in the contactor
closed state, then restarts in a production start mode.
In a mode other than a production start mode (*1)
Automatically turned on or off when the SPOT command is
executed.
Turned off when the program temporarily stops or terminates.

*1
Start modes other than production start modes
Shift + FWD
SOP start
External signal macro

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5.WELDING SPOT ID MANAGEMENT (PART ID AND WELD ID) B-81814EN/01

5 WELDING SPOT ID MANAGEMENT

(PART ID AND WELD ID)
This function uses numeric values, part IDs and weld IDs,
to identify welding data.
As welding results, part IDs and weld IDs are recorded
together with parameters, and displayed on the following
screens and stored in the following file:
Hist screen (See Section 6.3, "ALARM HISTORY SCREEN.")
DEP Monitor screen (See Chapter 7, "MONITORING WELDING
RESULTS.")
DEP Data Log screen (See Section 7.2, "DEP Data Log.")
Welding result and alarm history file (See Chapter8,
"EXTERNALLY OUTPUTTING WELDING RESULTS.")

A part ID is the number of a program to be started in the

Style start mode.
An external start number (style number) and program name are
assigned to a program in advance. A part ID means this style
number.
Use the Prog Select screen to assign a style number to each
program.

Prog Select JOINT 100%

Style Table Setup 1/32
Style Progname Valid Comment
1 JOB123 YES 2 door
2 STYLE2 YES 4 door
3 JB7 YES Hatchback
Style numbers 4
5

[ TYPE ] PART_ID SAVE

When you want to execute a program by Shift + FWD or SOP,

set Style Select GI[ ] to 0. The part ID of the program is
set to 0 and data related to the program can be distinguished
from production data in the Style start mode.

A weld ID is a position number in a program.

Example) JB7.TP (Style number: 3)

1: JP[1]100％FINE Part ID Weld ID
2: J P[2] 100% FINE SPOT[S=1] 3 2
3: J P[10] 100% FINE SPOT[S=2] 3 10

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B-81814EN/01 6.ALARM SCREENS

6 ALARM SCREENS
You can check timer board alarms on the following two
screens: ordinary alarm screen and screen dedicated to the
built-in timers.
Ordinary alarm screen (See Section 6.1.)
You can check timer board alarms together with other alarms.
Screen dedicated to the built-in timers (See Section 6.2.)
You can check timer board alarms that have not been reset
and alarms at each spot.

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6.ALARM SCREENS B-81814EN/01

6.1 ORDINARY ALARM SCREEN

Operation
MENU →Alarm

If a timer board alarm is issued, it is displayed and recorded like other

alarms.
There are the following two types of timer board alarms:
SPOT-063 "alarm-message" ……Temporary stop
SPOT-064 "alarm-message" ……Warning
You can check the alarm message to determine the cause of the timer
board alarm.
No. Alarm message I/O code (*1) Severity (*2)
1 CURRENT LOW 1 Alarm
2 CURRENT HIGH 2 Alarm
3 HEAT %LOW 3 Alarm
4 HEAT %HIGH 4 Alarm
5 LINE VOLT LOW 5 Alarm
6 LINE VOLT HIGH 6 Alarm
7 STEP END Alarm
8 TIP DRESS END 7 Alarm
9 TIP CHANGE END Alarm
10 LINE CLOCK 8 Fault
11 NO CURRENT 9 Fault
12 CURRENT FAULT Fault
10
13 TIME FAULT Fault
14 TRANS OVER TEMP Fault
11
15 SCR OVER TEMP Fault
16 SCR SHORT Fault
12
17 SCR HALF CYCLE Fault
20 MEMORY ERROR Error
21 W-CUR PROGRAM LOW Error
22 W-CUR PROGRAM HIGH 15 Error
23 TOTAL W-TIME LONG Error
24 PARAMETER OUT LIMIT Error

NOTE
The alarm messages depend on the specifications of
the used timer board.
For action to be taken for an alarm, refer to the
operator's manual provided by DENGENSHA.

*1
The I/O code can be output to the group signal output. For
how to set the signal, see Section 2.2, "SETTING SIGNALS."
The number indicates the value output for the corresponding
alarm.

*2

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B-81814EN/01 6.ALARM SCREENS

For timer board alarms, there are three types of alarm severity:
Alarm, Fault, and Error. In ordinary cases, Alarm corresponds to
WARN on the robot and Fault and Error correspond to STOP.G
(temporary stop).
Timer board Robot
ERROR
STOP.G (temporary stop alarm)
FAULT
ALARM WARN (warning) (*3)

*3
When program temporary stop is specified for a timer board
alarm whose severity is Alarm on the DEP COMMON screen, the
severity of the alarm is handled as STOP.G.
If a request to temporarily stop a program is issued from
the timer board, the severity of the alarm is assumed to be
STOP.G. If a request to temporarily stop the robot is issued,
how the alarm is treated depends on the timer board
specifications.

If a STOP.G-level alarm (whose severity is Fault or Error or caused by

a request by the timer board) is issued while welding is not performed,
a SPOT-063 message is issued. In other cases, a SPOT-064 message
is issued.

Example

If an alarm is issued, the following screen appears.

(The actual screen may differ from this example depending
on the nature of the alarm.)
SPOT-010 Major alarm detected
AN_TEST LINE 1 PAUSED
ALARM Recovery G1 JOINT 10 %

ERROR: A MAJOR ALARM input was recieved

from the weld controller.

ACTION: Check the weld controller for

the cause of this alarm. Press
F4 [CHOICE] to select recovery
option.

Perform action, then press [CHOICE].

[ TYPE ] [CHOICE]

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6.ALARM SCREENS B-81814EN/01

Press F1[TYPE] and select "Alarm log".

SPOT-010 Major alarm detected
AN_TEST LINE 1 PAUSED
ALARM Recovery G1 JOINT 10 %

ERROR: A MAJOR ALARM input was recieved

from the weld controller.
__________________
| 1 Alarm Log |
| +----------
| TYPE | [CHOICE]

The following screen appears. This alarm has been issued

from the robot. Press F3 HIST.
SPOT-010 Major alarm detected
AN_TEST LINE 1 PAUSED
Alarm : Active G1 JOINT 10 %
1/1
1 SPOT-010 Major alarm detected

[ TYPE ] HIST RES_1CH

The following screen appears. The alarm displayed with the

smallest number is the newest alarm.
"1 SPOT-010 Major alarm detected" is the newest alarm in this
example.
Before this alarm,
"2 SPOT-064 W-CUR PROGRAM LOW" was issued.
In this case, a "W-CUR PROGRAM LOW" alarm was issued from
the welding machine.
As the result, the robot used SPOT-064 to indicate the alarm,
then issued a SPOT-010 message and stopped the program.

SPOT-010 Major alarm detected

AN_TEST LINE 1 PAUSED
Alarm : Hist G1 JOINT 10 %
1/100
1 SPOT-010 Major alarm detected
2 SPOT-064 W-CUR PROGRAM LOW
3RESET
(Omitted)
[ TYPE ] ACTIVE CLEAR HELP

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B-81814EN/01 6.ALARM SCREENS

6.2 SCREEN DEDICATED TO THE INTERNAL TIMERS

Operation
MENU → DEP → F1[TYPE] → Alarm

Fault Frequency J

WC 1

Message Level
1 CURRENT LOW Alarm
2 WELD TIME LONG Error

[ TYPE ] HIST
This screen displays up to four timer board alarms that have
not been reset.

After the timer board alarms are reset, the following screen
appears:

Fault Frequency J

WC 1

Message Level
1 NO ACTIVE ALARM

[ TYPE ] HIST

You can release a timer board alarm by resetting the robot

(teach pendant, UI, or SI). You can also reset the timer
board using the methods listed below:
Use the program command (RESET WELDER) to reset an alarm.
Assign the above command to an external start macro to reset
an alarm externally.

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6.ALARM SCREENS B-81814EN/01

6.3 ALARM HISTORY SCREEN

Operation
MENU → DEP → F1[TYPE] → Alarm→F4「HIST」

Fault Frequency JOINT 100%

Part=All/Weld=All
1/5
Fault # of occur
1 CURRENT LOW 4
2 CURRENT HIGH 2
3 HEAT% LOW 1
4 NO CURRENT 4
5 CUR SETTING HIGH 1

[ TYPE ] PART_ID SAVE

This screen displays alarms which were issued during

previous welding operation. From this screen, you can
display the number of alarms for each part ID or weld ID and
details of each alarm. (Alarm management for each spot)

Press F3”PART_ID. The following screen appears:

Fault Frequency JOINT 100%

Part=All/Weld=All

PART_ID/Style name # of Faults

1 2_DOOR 6
2 3_DOOR 4
3 4_DOOR 2
4 NON PRODUCTION FAULT 1
[ TYPE ] WELD_ID SAVE

You can check the number of alarms for each part ID. For
an explanation of part IDs, see Chapter 5, "WELDING SPOT ID
MANAGEMENT (PART ID AND WELD ID)."
For data with part ID = 0, "NON PRODUCTION FAULT" is
displayed.

Press F3「WELD_ID」. The following screen appears:

Fault Frequency JOINT 100%

Part=1/Weld=All

Weld_ID # of Faults
1 Weld ID #2 2
2 Weld ID #5 3
3 Weld ID #6 1

[ TYPE ] FAULTS SAVE

You can check the number of alarms for each weld ID (welding
number) with the specified part ID. (For an explanation of
weld IDs, see Chapter 5, "WELDING SPOT ID MANAGEMENT (PART
ID AND WELD ID).")

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B-81814EN/01 6.ALARM SCREENS

When the position number is 999 or greater, it is assumed

to be Weld ID #999.

Press F3「FAULTS」. The following screen appears:

Fault Frequency JOINT 100%

Part=1/Weld=5

FAULT # of
Faults
1 CURRENT LOW 1
2 CURRENT HIGH 1
3 HEAT% LOW 1

[ TYPE ] SAVE
You can check the number of alarms and type of each alarm
for the specified part ID and weld ID.

Press F4「SAVE」 to save the welding results and welding alarm

history. (See Chapter 8, "EXTERNALLY OUTPUTTING
WELDING RESULTS.")

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7.MONITORING WELDING RESULTS B-81814EN/01

7 MONITORING WELDING RESULTS

To check the latest welding results, display the DEP Monitor screen.
To check statistical data such as previous voltage (V) and
current (A) data, display the DEP Data Log screen.

7.1 DEP Monitor SCREEN

Operation
MENU → DEP → F1[TYPE] → Monitor

DEP Monitor JOINT 100%

1 PART ID 0
2 WELD ID 1
3 SCHEDULE No 15
4 WELD CURRENT(A) 2000
5 WELD TIME(CYC) 0
6 HEAT(%) 50
7 POWER FACTOR(%) 60
8 LINE VOLT(V) 400
9 GUN No 1
10 TIP DRESS COUNT 0
11 TIP CHANGE COUNT 0
12 STEP No 0
13 WELDS COUNT 0
14 TIP RESISTANCE(OHM) 0
15 EXPANSION 0
16 FIXED ARM STRAIN 0
17 MOVABLE ARM STRAIN 0

[ TYPE ] Log

The results of welding at the latest spot are displayed.

The displayed items differ depending on the option
configuration of the timer board.
Press F4 Log to display the DEP Data Log (previous data) screen.

NOTE
For details of each item, refer to the operator's
manual provided by DENGENSHA.

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B-81814EN/01 7.MONITORING WELDING RESULTS

7.2 DEP Data Log

Operation
MENU → DEP → F1[TYPE] → Monitor→ F4「Log」

DEP Data Log JOINT 100%

1/12
WC:1
PART_ID: 1(2_DOOR)
Weld Id: 2
Schedule: 1

Param Avg std var

V 460.10 0.56 0.31
I 51.25 11.34 128.51
PF 97.56 11.21 125.51
HEAT 94.7 0.9 0.81

[ TYPE ] PART_ID WC_NUM MONITOR

The results of previous welding at the latest 100 spots are

recorded.
For voltage (V), current (I), power factor (PF), and heat
ratio (HEAT), the average (avg), standard deviation (std),
and variance (var) are displayed.
Statistical data is displayed for the specified part ID and
weld ID.
(average, standard deviation, and variance)
When you specify numbers for PART_ID, Weld Id, and Schedule,
the relevant data recorded for the 100 spots is used for
statistical data processing and the resultant data is
displayed. When you specify 0 for an item, the item is
ignored. When you specify 0 for all items, statistical data
for the 100 spots is processed and displayed.
You can also specify a value for PART_ID as follows.
Press F2｢PART_ID｣. The following screen appears:

DEP Part ID by Style

STYLE: 2_DOOR 1/32
ID Program Name
1 JOB123
2 STYLE2
3 JB7
4 ********
5 ********

[ TYPE ] SELECT

Position the cursor on the program for which you want to

display data and press SELECT.

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7.MONITORING WELDING RESULTS B-81814EN/01

The corresponding number is input for PART_ID on the DEP Data

Log screen.

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B-81814EN/01 8.EXTERNALLY OUTPUTTING WELDING RESULTS

8 EXTERNALLY OUTPUTTING WELDING

RESULTS
The welding results and alarms for the latest 100 spots are
output to a text file. The file name is iwdg.dg.
You can use the following three methods to save the data.
The data output with the three methods is the same.
Save data using the File screen.
Operation

MENU → File → F4 [Backup] → Select All of above or

Diagnostic.

Save data using the IWC alarm history screen (Section 6.3,
"ALARM HISTORY SCREEN")
Get data to a PC via FTP.

The contents of iwdg.dg are shown below.

Following the header line, parameters are listed in CSV
format. The data, if not modified, is hard to read, but you
can paste the data onto a spreadsheet such as Excel to make
it easy to arrange.

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8.EXTERNALLY OUTPUTTING WELDING RESULTS B-81814EN/01

This file was created on 06-DEC-01 10:18 from SpotTool+ (N. A.) V6.2048 RWC2000 1001000800000000

Robot F-Number:F00000

FILE:IWDG.DG

Robot Hostname:ROBOT

PART ID , WELD ID , SCHEDULE No , WELD CURRENT(A) ,

WELD TIME(CYC) , HEAT(%) , POWER FACTOR(%) , LINE VOLT(V) ,

GUN No , TIP DRESS COUNT , TIP CHANGE COUNT , STEP No ,

WELDS COUNT , TIP RESISTANCE(OHM) , EXPANSION , FIXED ARM STRAIN ,

MOVABLE ARM STRAIN , TIME, CURRENT LOW , CURRENT HIGH ,

HEAT% LOW , HEAT% HIGH , LINE VOLT LOW , LINE VOLT HIGH ,

STEP END , TIP DRESS END , TIP CHANGE END , LINE CLOCK ,

NO CURRENT , CURRENT FAULT , TIME FAULT , TRANS OVER TEMP ,

SCR OVER TEMP , SCR SHORT , SCR HALF CYCLE , OVER CURRENT ,

SPARE , MEMORY ERROR , W-CUR PROGRAM LOW , W-CUR PROGRAM HIGH ,

TOTAL W-TIME LONG , PARAMETER OUT LIMIT

0, 1, 1, 2000, 0, 50, 60, 400, 1, 0, 0, 0, 0, 0, 0, 0, 0, 06-DEC-01 09:41 , 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0

0, 2, 2, 0, 0, 0, 0, 0, 1, 0, 0, 0, 0, 0, 0, 0, 0, 06-DEC-01 09:41 , 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 1, 0, 0, 0

0, 1, 3, 0, 0, 0, 0, 0, 1, 0, 0, 0, 0, 0, 0, 0, 0, 06-DEC-01 09:42 , 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 1, 0, 0, 0, 0, 0, 0, 0, 0

0, 2, 4, 2000, 0, 50, 60, 400, 1, 0, 0, 0, 0, 0, 0, 0, 0, 06-DEC-01 09:42 , 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 1, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0

For Excel, use the following procedure to display the data

as shown in the figure (the procedure does not include the
row height or width, or ruled line setting).
- Select all text in iwdg.dg and paste it on Excel.
- Specify delimiter positions and delimit data with commas.
Alternatively,
- Open iwdg.dg on Excel.
Specify delimiter positions using the automatically
displayed text file wizard.

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B-81814EN/01 8.EXTERNALLY OUTPUTTING WELDING RESULTS

This file was created on 06-DEC-01 10:18 from SpotTool+ (N. A.) V6.2048 RWC2000 1001000800000000
Robot F-Number:F00000
FILE:IWDG.DG
Robot Hostname:ROBOT
W- W- TOT
WEL FIXE MOV CUR CUR AL
D D ABLE LINE PRO PRO W-
SCHE CUR EXPA ARM ARM CUR CUR HEAT HEAT VOL GRA GRA TIME
PAR WELD DULE RENT NSIO STR STR RENT RENT % % T M M LON
T ID ID No (A) N AIN AIN TIME LOW HIGH LOW HIGH LOW LOW HIGH G
0 1 1 2000 0 0 0 06-DEC-01 09:41 0 0 0 0 0 0 0 0
0 2 2 0 0 0 0 06-DEC-01 09:41 0 0 0 0 0 1 0 0
0 1 3 0 0 0 0 06-DEC-01 09:42 0 0 0 0 0 0 0 0
0 2 4 2000 0 0 0 06-DEC-01 09:42 0 0 0 0 0 0 0 0
JOB12 1 5 2000 0 0 0 06-DEC-01 09:42 1 0 0 0 0 0 0 0
JOB12pos2 6 2000 Om i t t e d 0 0 0 06-DEC-01 09:42 0 1 0 0 0 Om i t t e d 0 0 0
JOB12 1 7 2000 0 0 0 06-DEC-01 09:42 0 0 0 0 1 0 0 0
JOB12 2 8 2000 0 0 0 06-DEC-01 09:42 0 0 0 0 0 0 0 0
JOB12 1 9 2000 0 0 0 06-DEC-01 09:42 0 0 1 0 0 0 0 0
JOB12 2 10 2000 0 0 0 06-DEC-01 09:43 0 0 0 1 0 0 0 0
STYLE 1 11 2000 0 0 0 06-DEC-01 09:43 0 0 0 0 0 0 0 0
STYLECorner1 12 2000 0 0 0 06-DEC-01 09:43 0 0 0 0 0 0 0 0
STYLE 1 13 2000 0 0 0 06-DEC-01 09:43 0 0 0 0 0 0 0 0
STYLE 2 14 2000 0 0 0 06-DEC-01 09:43 0 0 0 0 0 0 0 0

Welding data Alarms

The welding time is recorded for TIME.

Welding data is shown on the left of TIME.
Welding alarms are shown on the right of TIME. When a value
of 1 is recorded, the corresponding welding error occurred.
In this example, "CURRENT LOW" occurred during welding
operation corresponding to the fifth data item from the top.
For data in the Style start mode, the program name
corresponding to the part ID is output.
For data in the Style start mode, data in the WELD ID column
is a position comment. When no comment is set, the position
number is displayed.
The data cannot be saved in the controlled start mode or in
the status in which no timer board is mounted.

NOTE
File messages
"This file is not available at controlled start."
An attempt was made to save data in the controlled
start
mode. The data is not saved. "No IWC(DG) board"
An attempt was made to save data in the status in
which
no timer board was mounted. The data is not saved.

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9.CHANGING THE NUMBER OF WELDING CONDITIONS B-81814EN/01

9 CHANGING THE NUMBER OF WELDING

CONDITIONS
The number of available welding conditions is 32 as standard.
You can increase the number to a maximum of 255.
Use the following procedure to change the number.

Procedure
Change $IWCDGSNUM (default: 32).
Perform controlled start operation.
Perform cold start operation.

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B-81814EN/01 10.GUN CHANGE

10 GUN CHANGE
When you want to use a gun change, create welding conditions for
each gun.
(Example)
Welding conditions 1-50 ……Gun 1
Welding conditions 51-100 ……Gun 2

This is because stepper data and the number of turns of the

winding of the transformer are set for each welding
condition.
Conversely, a common welding condition is available for
multiple guns with the same transformer winding ratio and
for which the same steppers and counters can be used.

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11.RESTRICTIONS B-81814EN/01

11 RESTRICTIONS
- This software option can control only built-in timers
manufactured by DENGENSHA.
- When the SPOT command is executed alone with no
additional operation command, Part_id and weld_id are
not supported.
- During execution of welding, data cannot be written onto the
welding timer board.
For example, no value can be changed on the DEP Seq screen
during welding operation.
- Do not change any system variable related to the built-in
timer using a parameter command.
- You cannot use multiple programs simultaneously to
perform spot welding.
Up to two value can be used as the number of welding
machines for robot control (EQ). (Two integrated timer
boards are requried.)
- The monitor system does not record any detected
leakage.
- Do not set any invalid index for Iso contactor DI.
If the SPOT command is executed in this status, an error
indicated by the message "INTP-347(SWEXEC,#) Read
I/O value failed" may occur.

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B-81814EN/01 12.OTHER NOTES

12 OTHER NOTES
- This software option does not support any dual guns.
- If two or more timer boards are required for one robot
control unit, contact FANUC in advance.
- Be sure to set a value longer than the welding time for
the welding time-out parameter ($SPOTWELDIO[card-
number].$WLD_COMP_TO). If the automatic welding
retry function is used, the retry command due to a
welding time-out may cross a welding completion
notification from the welding machine, resulting in
double welding. After changing the value of the welding
parameter, perform actual welding to confirm that the
parameter setting is sufficiently longer than the welding
time.
- The welding conditions and settings can be updated via
FTP (iwdgsche.sv and iwdgconf.sv can be put via FTP)
only in the controlled start mode.
- If a program started in the Style start mode (External
start mode) is stopped, then restarted by Shift + FWD
(manual), the contactor is not automatically closed at
execution of the SPOT command.
Restart a program started in the Style start mode in the
external start mode.

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13.ALARMS B-81814EN/01

13 ALARMS
SPOT-008 PAUSE Weld complete timeout
[Cause]
A welding completion time-out occurred.
① An error may occur during welding operation.
② If no alarm was issued from the welding machine, the
welding time may be longer than the time-out setting.
[Action]
① On the alarm history screen, check whether a welding
alarm was issued.
If any, remove the cause.
② Adjust the welding condition so that a shorter welding
time or longer time-out setting is specified.
Specify the time-out period for the following system
variable in ms:
$spotweldio[gun-number].$wld_comp_to
Normally, set 1 for gun-number.
SPOT-010 PAUSE Major alarm detected
[Cause]
A PAUSE-level alarm was issued.
[Action]
On the alarm history screen (MENU → Alarm → F3 HIST), check
the alarms issued before this alarm.

SPOT-011 WARN Minor alarm detected

[Cause]
A warning-level alarm was issued.
[Action]
On the alarm history screen (MENU → Alarm → F3 HIST), check
the alarms issued before this alarm.

SPOT-046 WARN Weld auto retried retry-count time(s)

[Cause]
An alarm was issued from the welding machine and the
indicated number of retries were performed.
[Action]
This message notifies you that retries were performed.
When retry is successful, the program does not stop.
Check the alarms issued before retries.

SPOT-061 WARN Request Failed

[Cause]
A request to the timer board failed.
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B-81814EN/01 13.ALARMS

[Action]
This alarm may be issued after a parameter is rewritten.
It may be issued during welding operation. Retry while no
welding is performed.

SPOT-063 PAUSE "alarm-message"

SPOT-064 WARN "alarm-message"
An alarm was issued from the timer board. Refer to the
manual provided by DENGENSHA.
Two examples of alarm messages are shown below.
For the severity of each alarm and an example, see Chapter
6, "ALARM SCREENS."
(Example)
SPOT-064 WARN W-CUR PROGRAM LOW
[Cause]
The setting of TRANS TURNS (transformer winding ratio) in
the welding condition may be invalid.
[Action]
Set a correct winding ratio.

(Example)
SPOT-064 WARN Weld request not exec
[Cause]
A welding request was rejected.
The timer board was in the welding disable status.

[Action]
If an alarm was issued from the welding machine, remove the
cause.

SPOT-066 WARN Iwc NOT ready

[Cause]
① No timer board is mounted.
② The software on the built-in timer has not started up.
③ Communication with the timer board is stopped.
[Action]
① Check that a timer board is mounted.
② This alarm may occur for a few seconds after cold start.
Wait a while, and you can reset this alarm.

When cause ② is removed and this alarm occurs during

operation, the cause is ③.
Check the alarm history, and turn the power off, then on
again.

SPOT-067 PAUSE No Shunt Trip output for WC:card-number

[Cause]

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13.ALARMS B-81814EN/01

Shunt trip DO is not set.

[Action]
Check the number set for Shunt trip DO on the Weld Interface
I/O screen. Always set Shunt trip DO.

SPOT-381 WARN IWC(DG) system error(%d)

[Cause]
A problem occurs in communication with the timer board.
[Action]
Write down the number and contact a service representative.
Possible causes are listed below:
Number(s) Possible cause
1,2, 13 The temporary pool area may be almost exhausted.
3 The timer board could not be initialized successfully.
4 A parameter could not be written to the timer board
successfully.
5,6,7,8,9 A parameter could not be read from the timer board.
12 A counter value could not be written to the timer board
successfully.

SPOT-382 PAUSE IWC(DG) illegal stepper number(%s)

[Cause]
An invalid gun series number (SN) is specified in RESET
STEPPER[WC,SN,SV].
[Action]
Set 1 to 4.

SPOT-384 PAUSE "IWC(DG) leak input (#)

[Cause]
The Leak Input signal is on.
[Action]
① Remove the cause of the leakage.
② Check that OFF is displayed for Leak input on the Weld
Interface I/O screen.
③ Perform a reset.

If the Leak Input signal is still on after action ② is taken,

check wiring.
Check whether the polarity of the input signal is reversed.

To disable this check, set the signal number for Leak input
to 0 on the Weld Interface screen, and turn the power off,
then on again.

SPOT-385 PAUSE IWC(DG) illegal counter specified(#)

[Cause]
An invalid counter value (SV) is specified in RESET
STEPPER[WC,SN,SV].

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B-81814EN/01 13.ALARMS

[Action]
Set a value between 0 and 2.

SPOT-386 PAUSE Reset stepper timeout %s

[Cause]
RESET STEPPER was executed, but a time-out period had elapsed
before response was received from the welding timer board.
[Action]
If a SPOT-387 to 390 alarm may is issued, there is a problem
in communication with the timer board. Turn the power off,
then on again.

The time-out period for RESET STEPPER may be too short.

If a small value is specified for $spotweldio[1].$rstwc_to,
specify a larger value.
The unit is ms.

SPOT-387 WARN IWC(DG) timer no response

[Cause]
No response was received from the welding timer board. The
requested operation could not be executed.
[Action]
Turn the power off, then on again.

SPOT-388 WARN IWC(DG) timer acc stat err(%d)

[Cause]
Because the access status of the welding timer board remains
on, the requested operation cannot be performed.
[Action]
Turn the power off, then on again.

SPOT-389 WARN IWC(DG) timer exe flag err(#)

[Cause]
Because a welding timer board execution flag remains on, the
requested operation cannot be performed.
#
1 The SYSRDY signal is on.
2 The data read flag is on.
3 The data write flag is on.
4 The function name read flag is on.
5 The counter set/reset flag is on.
6 The welding flag is on.
7 The data command execution flag is on.

[Action]
Turn the power off, then on again.

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13.ALARMS B-81814EN/01

SPOT-390 WARN IWC(DG) timer bad response

[Cause]
An error occurred in the interface with the welding timer
board.
[Action]
Contact a service representative. Check whether a software
or hardware setting of the welding timer board was changed
before the error occurred.

SPOT-391 PAUSE IWC(DG) timer memory error

[Cause]
An error occurred in the hardware system saved in memory in
the welding timer board.
[Action]
Turn the power off, then on again. The hardware system is
initialized, so readjustment is required.
(See Subsection 2.5.6, "DEP HARD Screen (Hardware.")
For adjustment data, ask DENGENSHA..

SPOT-392 WARN IWC(DG) timer not running

[Cause]
An error occurred because the welding timer board had not
started.
[Action]
*systdy from the timer board is not turned off. Contact
DENGENSHA.

SPOT-394 WARN IWC(DG) drv sys error(%d)

[Cause]
A system error occurred during processing of communication
with the timer board.
[Action]
Check the number at the end of the error message.
Smaller Write down the number and contact a service
than 500 representative.
500 or Check the I/O settings such as Shunt trip I/O output and
greater stepper ready I/O output. Check whether a value outside
the range is specified as the I/O type or number.

SPOT-395 PAUSE IWC(DG) timer now in weld

[Cause]
An attempt was made to start welding during welding
operation.
[Action]
The welding time-out period is not sufficiently long as
compared with the welding time.
Set a long value for the welding time-out parameter
($SPOTWELDIO[card-number].$WLD_COMP_TO) as compared with
the welding time.
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B-81814EN/01 14.SYSTEM VARIABLES

14
Variable name
SYSTEM VARIABLES
Description Default
$IWCDGPCFG.$READ[c TRUE: Resets all timer board settings to their defaults at the next cold FALSE
ard-number] start.
FALSE: Does not read any timer board default.
When a timer board has never been inserted, this variable is set to TRUE.
After a timer board has been inserted, the variable is set to FALSE.
To reset all parameters to their defaults, set TRUE.
$IWCDGPCFG.$PNUM[ ] Internally used. Do not change this variable.
$IWCDGPCFG.$WDAL_ Type for the alarm output signal 19(GO)
OT_TYP[card-number]
$IWCDGPCFG.$WDAL_ Index of the alarm output signal 0
OT_IDX[card-number]
$IWCDGPCFG.$LEAK_I Type for the Leak input signal 1(DI)
N_TYP[card-number] To reflect the change, turn the power off, then on again.
$IWCDGPCFG.$LEAK_I Index of the Leak input signal 0
N_IDX[card-number] To reflect the change, turn the power off, then on again.
$IWCDGPCFG.$DISP_G Currently not supported. Do not change this variable. TRUE
NUM[card-number]
$IWCDGPCFG.$STPC_ Type for the stepper ready signal 2(DO)
OT_TYP [card-number
× 4 ＋ gun-number]
$IWCDGPCFG.$STPC_ Index of the stepper ready signal 0
OT_IDX [card-number ×
4 ＋ gun-number]
$IWCDGPCFG. $SH Specifies whether to enable or disable Shunt trip I/O output. TRUE
UNT_ENABLE[card-num
ber]

$IWCDGPCFG. $SH Specifies pulse output or holding output for Shunt trip I/O output. 1 (pulse)
UNT_PULS[card-number]

$IWCDGPCFG. $SH Specifies the pulse output time width for Shunt trip in ms. 500 (ms)
UNT_TIME[card-number]

$IWCDGS[ ].$PARM Saves the contents of each welding condition.

If this variable is changed, the actual welding condition is not changed.
Do not change this variable.
$IWCDGS2[ ].$PARM Saves the contents of each welding condition.
If this variable is changed, the actual welding condition is not changed.
Do not change this variable.
$IWCDGSNUM Sets the number of welding conditions. 32
Common to all boards
For how to change the number of welding conditions, see Chapter 9,
"CHANGING THE NUMBER OF WELDING CONDITIONS."
$IWCDGCON[ ].$PARM Saves the settings other than welding conditions.
If this variable is changed, no actual setting is changed.

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14.SYSTEM VARIABLES B-81814EN/01

Do not change this variable.

$IWCDGCOU[ ] Saves the value of each counter.
If this variable is changed, the change is not reflected on the card.
Do not change this variable.
$IWCDGHIST[ ] For internal log
Do not change this variable.
$IWCDGRSV[ ] Currently not used. Do not change this variable.

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B-81814EN/01 Index

INDEX

A P

ALARM HISTORY SCREEN 28 PREFACE 1

ALARM SCREENS 23 Procedure for Saving and Loading a Single
ALARMS 40 Welding Condition 13
PROGRAM 18
C
R
CHANGING THE NUMBER OF WELDING
CONDITIONS 36 RESET STEPPER COMMAND 18
Checking the Iso contactor Signal 4 RESET WELDER COMMAND 18
Contactor Unit Signals 2 RESTRICTIONS 38

D S

DEP COMMON (Common) 11 SAVING SCHEDULE AND SETUP DATA 17

DEP COUNT/STEP Screen (Gun) 15 SCREEN DEDICATED TO THE INTERNAL
DEP Data Log 31 TIMERS 27
DEP FUNCTION Screen (Special) 15 SETTING 2
DEP HARD Screen (Hardware) 16 SETTING SIGNALS 2
DEP Monitor SCREEN 30 SETTING THE BUILT-IN TIMER 9
DEP Seq (Schedule) 11 SETTING THE WELDING TIMER TYPE 2
SETUP SCREENS 10
E
Shunt trip Signal Output Settings 5
EXTERNALLY OUTPUTTING WELDING
SPOT COMMAND 18
RESULTS 33
START MODES 20
G START MODES AND OPENING AND
CLOSING THE CONTACTOR 20
GUN CHANGE 37
Stepper Ready Signal 4
I
SWITCHING BETWEEN THE TURNED-ON
ISO CONTACTOR COMMAND 19 TURNED-OFF STATES 6
Switching Using an External Signal 6
M
Switching Using the Teach Pendant 7
MONITORING WELDING RESULTS 30
SYSTEM VARIABLES 45
O
W
OPENING AND CLOSING THE CONTACTOR
WELDING SPOT ID MANAGEMENT (PART
21
ID AND WELD ID) 22
ORDINARY ALARM SCREEN 24
OTHER NOTES 39

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© MyFANUC 46BB093A83A1492A9EAE2FF627DD7E84
 Revision Record
FANUC Robot series (R-J3iB CONTROLLER SPOT TOOL+) BUILT-IN SPOT WELDING TIMER CONTROLLER
(DENGENSHA SPECIFICATIONS) OPERATOR'S MANUAL (B-81814EN)

© MyFANUC 46BB093A83A1492A9EAE2FF627DD7E84
01 Apr.,
2002
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Edition Date Contents Edition Date Contents

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B-81814EN/01

* B - 8 1 8 1 4 E N / 0 1 *

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