A_SW1B

A_SW2

MANUAL OF SPOT WELDING

APPLICATION PROGRAMS
WITH THE
C3G Plus
CONTROLLER
Version 5.4x

00755958/GB A_SW1B – 5.4x 03/0301

The information contained within this manual is the property of COMAU SYSTEMS S.p.A..

Any reproduction, even partial is forbidden without previous written authorisation from COMAU SYSTEMS
S.p.A..
COMAU SYSTEMS reserves the right to modify without previous warning, the characteristics of the product
presented in this manual.

PRINTED IN ITALY – 03/2001

Copyright © 2001 by COMAU SYSTEMS
 UPDATING LIST

In this issue of the manual, with respect to the previous one, changes to technical contents have
been performed due to the product updating. The modified sections are listed below.

Title: MANUAL OF SPOT WELDING APPLICATION PROGRAMS

WITH THE C3G Plus CONTROLLER

UPDATING CHAP. SUBJECT PAGE No. ACTION

01/0598 - Cover - Substituted

01/0598 - Back - -

01/0598 - Summary all Substituted

01/0598 1 Features all Substituted

01/0598 2 User Interface All Substituted

01/0598 3 Instructions All Substituted

01/0598 - Appendix A All Substituted

02/1000 - Cover - Substituted

02/1000 - Back - -

02/1000 - Summary All Substituted

02/1000 1 Features 1,4,6 Substituted

02/1000 2 User Interface All Substituted

02/1000 3 Instructions All Substituted

02/1000 4 Configurations 3 ÷ 24 Substituted

02/1000 - Appendix A 5 ÷ 22 Substituted

03/0301 - Cover - Substituted

03/0301 - Back - Substituted

03/0301 2 User Interface 2, 5 Substituted

03/0301 4 Configurations 5, 6, 14, 23 Substituted

A 03/0301
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03/0301 B
C3G Plus SUMMARY

SUMMARY
This manual includes:

Page
CHAPTER 1 – FEATURES
Description ...............................................................................................................................................1-1
Memory occupied ....................................................................................................................................1-1
Cards and I/O used ............................................................................................................................1-1
Program "startup.cod"..............................................................................................................................1-2
Initial installation procedure .....................................................................................................................1-2
Preliminary checks on application ......................................................................................................1-3
Checks permanently on......................................................................................................................1-5
Window management ..............................................................................................................................1-5
Routine to enable a new card to be displayed on the A_SW1B
spot welding application program ............................................................................................................1-6

CHAPTER 2 – USER INTERFACE

Presentation of application ......................................................................................................................2-1
Application status information..................................................................................................................2-1
Menu commands .....................................................................................................................................2-2
"Edit" command ..................................................................................................................................2-3
"View" command.................................................................................................................................2-4
"Utility" command................................................................................................................................2-6
"Arm" command..................................................................................................................................2-6
"Swap" command ...............................................................................................................................2-7
"Egun" command ................................................................................................................................2-7
"Help" command .................................................................................................................................2-7
Application on Teach Pendant.................................................................................................................2-8
Management of U1, U2, U3, U4 ..............................................................................................................2-9
Pushbuttons U1, U2, U3, U4 ..............................................................................................................2-9
Leds U1, U2, U3, U4 ..........................................................................................................................2-9
Management of U4 pushbutton and led (version 5.02) .........................................................................2-10
U1, U2, U3, U4 remote signals.........................................................................................................2-10
Management of A1, A2 ..........................................................................................................................2-10

chapter 3-instructions
Welding instructions common to all application programs ......................................................................3-1
Statements for messages and alarms .....................................................................................................3-2
Instructions for $WORD management.....................................................................................................3-3
Management of instructions in EZ environment ......................................................................................3-4

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SUMMARY C3G Plus

Page

CHAPTER 4 – CONFIGURATIONS
Configurations..........................................................................................................................................4-1
Application parameter configuration ........................................................................................................4-1
Application hardware configuration .........................................................................................................4-1
Automatic configuration of Hand 1 and Hand 2.......................................................................................4-3
A_SW1B parameters configuration file....................................................................................................4-4
A_SW1B hardware configuration file.......................................................................................................4-5
I/O connections ......................................................................................................................................4-14

CHAPTER 5 – DIALOGUE WITH WELDING TIMER

Management............................................................................................................................................5-1

APPENDIX A
A_SW1B application program ................................................................................................................ A-1
Specific items in the status window for A_SW1B .............................................................................. A-1
Specific instructions for A_SW1B...................................................................................................... A-1
List of predefined alarms and messages in A_SW1B ............................................................................ A-8
Application A_SW1B alarm codes..................................................................................................... A-8
A_SW2 application program ................................................................................................................... A-9
Specific items in the status window for A_SW2 ................................................................................ A-9
Specific instructions for A_SW2 ........................................................................................................ A-9
A_SW2 parameters configuration file .............................................................................................. A-11
A_SW2 hardware configuration file ................................................................................................. A-11
List of predefined alarms and messages in A_SW2 ....................................................................... A-12
I/O connections................................................................................................................................ A-12
Application A_SW2 alarm codes ..................................................................................................... A-16
Error messages .................................................................................................................................... A-16
Installation........................................................................................................................................ A-16
Communication Boards ................................................................................................................... A-17
Boards ............................................................................................................................................. A-17
General ............................................................................................................................................ A-18
Technological................................................................................................................................... A-19
Information messages .......................................................................................................................... A-20
Examples of tip change management in different cases of "Integrated spot" ...................................... A-21

ii 02/1000
 A_SW Spot Welding
C3G Plus Applications

FEATURES 1-1

FEATURES
USER INTERFACE 2-1
INSTRUCTIONS 3-1
CONFIGURATIONS 4-1
DIALOGUE WITH WELDING TIMER 5-1
APPENDIX A A-1

SUMMARY

Paragraph Page

Description 1-1
Memory occupied 1-1
Cards and I/O used 1-1
Program "startup.cod" 1-2
Initial installation procedure 1-2
Preliminary checks on application 1-3
Checks permanently on 1-5
Window management 1-5
Routine to enable a new card to be displayed on the A_SW1B
spot welding application program 1-6
A_SW Spot Welding
Applications C3G Plus

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C3G Plus FEATURES

DESCRIPTION
The application provides management of a spot welding station comprising a COMAU robot, C3G Plus
controller and welding timer.
Spot welding application programs can be divided into two main groups:
1) application programs with one timer per arm;
2) application programs with two timers per arm.
The A_SW1B application program belongs to the first group, the A_SW2 to the second.
The meaning of the names is shown below:

+--------------------------------- application
| ---+----------------------------- spot
| ---| +---------------------- welding
| ---| | +---------------- single timer
| ---| | | +---------- type B
| ---| | | |
A_S W 1 B

Welding control is provided by four instructions for use within the robot work programs and described in the
"WELDING INSTRUCTIONS" section.
Another five instructions described in the "INSTRUCTIONS" chapter may also be used in the robot work programs.
A number of station diagnostic functions are managed while there is also provision for management of
specific user-defined functions.
The application may be used to:
- select one of the timer welding programs with associated welding parameters;
- produce welding gun cycles, bypassing the welding timer with other parameters set by the user in
tables in the application;
- display user-defined alarms and messages;
- perform diagnosis of specific processes by way of programs generated by the user from
appropriate specifications;
- display the status of remote signals and system signals;
- display the status of user-defined $BIT.
The application is compatible with the EZ programming environment.
The following are required by the application:
- Software CONDITIONS from 33 to 99;
- CONDITION in the case of electric guns the application package also reserves conditions 200 to 256;
- TIMERS from 17 to 32 (from 1 to 16 available to the user).

MEMORY OCCUPIED
(A) From 160 Kb to 220 Kb must be available on the ram disk for files, depending on system configuration,
plus 50 Kb of buffer. In working memory approximately 350 Kb must be available for programs and 25 Kb
of buffer.
(B) If the application program is also used on the TP it requires an additional 10 Kb and 20 Kb respectively compared
to point (A).
(C) If the integrated SPOT application is used, it requires an additional 40 Kb and 60 Kb respectively
compared to point (A).
(D) 55 KB must be available on the ram disk and 80 KB in the working memory for files regarding
management of the electric gun and EDIT screen pages.

CARDS and I/O Used

Depend on the configuration file; see chapter "APPENDIX" to this manual.

☞
The CONDITIONS and TIMERS mentioned above must never be used/modified by PDL2 user
programs implementing the instructions of the application..

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FEATURES C3G Plus

PROGRAM "STARTUP.COD"
If this program has not already been created by the user, the default program must be loaded from diskette
when installing the application. This program activates the application program and the EZ environment (if
installed) at each re-start of the C3G Plus.
This program must also be used to run work programs written by the user.

Example of STARTUP.COD program:

PROGRAM startup NOHOLD
BEGIN
-- activation of application
SYS_CALL('PG','SX_REMO')
REPEAT
DELAY 1000
UNTIL PROG_STATE('SX_REMO') < 0
-- activation of EZ
SYS_CALL('PG','EZE')
REPEAT
DELAY 1000
UNTIL PROG_STATE('EZE') < 0
-- loading user libraries
SYS_CALL ('ML','library name')
-- activating work programs written by the user
SYS_CALL('PG', 'program name')
END startup
If a startup program other than "STARTUP.COD" is declared on the C3G Plus by mistake, it will not be
possible to start the application when the controller is switched on.
The mistake can be rectified and normal work conditions resumed by executing the startup program
declaration command (Configure Cntrler Startup) on C3G Plus for the "STARTUP.COD" program and saving
the new configuration on C3G Plus (Configure Save command).

INITIAL INSTALLATION PROCEDURE

The initial installation procedure is the first step in using the application program.

☞ If the procedure is implemented after the application has already been installed application
customization are not lost.

All the application software is held on a floppy disk.

The software in question can be transferred from the floppy disk to the RAM disk:
- from the unit control integrated floppy disk drive;
- using a PC connected to the COMP: serial port present on the control panel of the unit control;
- using a PC connected to the COM0: serial port present inside the control unit.
In all of these cases, the C3G Plus must be put into "PROGRAMMING" mode (selector switch to
PROGRAM) with DRIVES OFF.
Under these conditions, the transfer of program "SX_INST.COD" from floppy disk or PC to RAM DISK can
start
(command on C3G Plus: Filer Utility Install).
Time required from when the program is run until the application is fully activated is about 4 minutes.

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C3G Plus FEATURES

PRELIMINARY CHECKS ON APPLICATION

1) Ram disk
Check that at least 140 Kbytes are free.

2) I/O
Check that the cards the application requires are present inside the C3G Plus control unit.
In cases of error, the transfer does not start, an error message is displayed and the TP red alarm lamp
comes on.
The input and output groups required for the type of application and welding timer are configured.

3) Hardware configuration file

The application must be configured in function of the type of welding timer with which it is being installed.
For this reason, the floppy disk containing the application includes one file for each configuration possible.
Note also that there may be several updates of a file associated with a given machine type (new versions).
Configuration files are named as shown below:

Es: SX001_00.CNF
SX: prefix for application software
001: number associated with the hardware configuration file type _00: version of file

On installation of the application, the following situations may arise:

In ram-disk: no configuration file present.
On floppy disk:
a) One configuration file present.
Behaviour of application: performs configuration, automatically selecting the file on the floppy
disk.
b) Several configuration files present (different machines or different updatings).
Behaviour of application: produces a list of the files and waits for the user to select one
(up/down arrow keys + enter).
c) No configuration file present.
Behaviour of application: signals the error. The floppy disk may be replaced with another one
with at least one configuration file and the keys "SHIFT + SCRN" must be pressed to continue.
In ram-disk: configuration file already present (from a previous installation);
(Ex: SB001_00.CNF renamed SBHW.COD in ram disk)
On floppy disk:
a) Several files of the type present in ram-disk in different versions (updatings of the version)
(Ex: SB001_00.cnf and SB001_01.CNF)
Behaviour of the application: produces a list of the files and waits for the user to select one
(up/down arrow keys + enter).
b) No file of the type in ram-disk.
Behaviour of the application: maintains the configuration using the file present in ram-disk.
When wishing to change the type of configuration file, run the procedure described below before reinstalling
the application:
a) set the C3G Plus password:
(Configure Cntrler Password <****>)
b) reset the read/only attribute for file SBHW.COD:
(Filer Utility Attribute Read Only / Reset <SBHW.COD>)
c) delete the file from the ram-disk:
(Filer delete <SBHW.COD>)

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FEATURES C3G Plus

4) Correct EZ in ram disk

Checks that the EZ software for the Spot Welding application being loaded is present in the ram disk.
If the EZ that has been loaded in the ram disk is not compatible with the application program, an error is
generated.
If the EZ is not present in the ram disk or compatible with the application the installation routine will continue
without generating an error.
The congruence test can be disabled by setting bit 12 of the $CNTRL_CNFG to 1.

5) System language
The application is written in the same language as the system.

6) Teach - Pendant (TP) management

The Sx_DEV.CPK file of the application is tested to check whether this is the first installation.
If the file is not present:
a) C3G Plus with PC video or teach pendant display- annex:
the following prompt is displayed: Do you want TP software? N/Y
where the default value is N.
b) C3G Plus without PC video or teach pendant display- annex:
the following prompt is displayed: Do you want TP software? N/Y
where the default value is Y.
The user must answer accordingly (right/left arrow + enter).
If the file is present:
The software for management of the application on TP will be reloaded or not by the application program
according to the type of configuration set during initial installation.

7) Electric gun management

In the case of an electric gun the application package is set automatically to manage this.

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C3G Plus FEATURES

CHECKS PERMANENTLY ON
1) C3G Plus status: PROGRAM + DRIVES OFF
To be able to perform installation, the C3G Plus must be in the PROGRAM + DRIVES OFF status.
If it is not, the application will send a wait for correct status message and interrupt the installation procedure.
It will start again from where it was interrupted when the correct status is obtained.
2) Device: diskette + programs present
The installation is suspended if there is an error in the transfer from floppy disk or PC to ram-disk.
The error may be due to:
- no floppy disk present/PC;
- file not found on floppy disk/PC;
- communication error (Kermit, PCINT, cable, etc.).
In such cases, an error message is displayed and the procedure is interrupted until such time as the "SHIFT
+ SCRN" keys are pressed.
If the error conditions are removed, installation will continue from the point where it was interrupted.
If the installation procedure is completed, a number of settings needed for the application are made and the
startup program will be declared (see the "STARTUP.COD" sample program).
The user must then perform a "Configure Cntrler Restart Cold". The application will start automatically.
The display will always appear on the PC video or, but only in the case of this not being connected, on the
teach pendant display.
From this point on, all the instructions and functions in the application menu may be used.

WINDOW MANAGEMENT
The window modification programs "WINSPLIT.EXE" and "WINBACK.EXE" for personal computers included
on the application diskette may be used to modify the address comment strings on window files when
performing window personalization. The windows that may be modified are all those with extension ".win ".

WINSPLIT.EXE
Generates two files, "abc.att" and "abc.txt", from a window file "abc.win".
The only input required is the name of the file (the extension need not be specified as it will always be
".win"). The "abc.txt" file generated is an ascii file that can be modified using any of the usual ascii editors.

WINBACK.EXE
Produces the new window file "abc.win" from the modified "abc.txt" file and the "abc.att" generated
previously.
The only input required is the name of the ascii file (the extension need not be specified as it will always be
".txt").

A_SW SPOT WELDING APPLICATIONS 1-5

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FEATURES C3G Plus

ROUTINE TO ENABLE A NEW CARD TO BE DISPLAYED ON THE A_SW1B SPOT

WELDING APPLICATION PROGRAM
Edit the SBHWUSER.COD program and assign the name of the card to be displayed and the slot in which it
is installed to the sbws_rack_slot[x] variable.
Example:
- to display the words of the RIO card in slot 6 write:
sbws_rack_slot[6]:= “RIO”
- or to display the IOM card in slot 8 write:
sbws_rack_slot[8]:= “IOM”
- or to display the word of the annex C3G PFDP card on RBC write:
sbws_rack_slot[1]:= “PDP”
- or to display the word of the interbus Slave C3G EIM card in slot 6 write:
sbws_rack_slot[6]:= “IBS”
- or to display the word of the C3G EDN DeviceNet slave card in slot 7 write:
sbws_rack_slot[7]:= “DNT”.
It is then possible to proceed in one of the following ways:
1) Reinstall the application program, which will automatically copy the empty *.win files required to display
the cards requested;
2) Copy the files of the individual cards from the application disk and re-name these according to the
application standard. For example:
- for IOM cards, copy the sbstdiom.win file and rename it sb_iomxx.win where xx is the number ofthe
slot containing that IOM card (e.g.: SB_IOM05.win in case of IOM in slot 5);
- for RIO cards, copy the sbstdiom.win file and rename it sb_rxxyy.win where xx is the number ofthe
pair of words to be displayed (e.g.: 17 for $WORD 17 and 25, 18 for $WORD 18 and 26, etc.) and
yy is the number of the slot containing the RIO card (e.g.: sb_r1806.win is the page containing the
remarks relating to $WORD 18 and 26 of the RIO card in slot 6);
- for SINEC cards, copy the sbstds12.win file and rename it sb_sxxyy where xx is the number of the
pair of words to be displayed (e.g.: 17 for $WORD 17 and 25, 18 for $WORD 18 and 26, etc.) and
yy is the number of the slot containing the SINEC card (e.g.: sb_s1806.win is the page containing
the remarks relating to $WORD 18 and 26 of the SINEC card in slot 6).
Windows loaded in this way are empty and do not contain remarks. They can be modified by using the
winsplit.exe and winback.exe files on the application diskette.
These files must be copied on a PC together with the *.win files that must be modified.
From DOS prompt type:
winsplit filename
This command creates two files: filename.txt and filename.att.
Edit the .txt files, using a normal DOS editor and adding any appropriate remaks.
At this point, from DOS prompt type:
winback filename
This command reads the modified .txt file and re-creates a new .win file that can be loaded on the C3G Plus
controller.

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 A_SW Spot Welding
C3G Plus Applications

FEATURES 1-1

USER INTERFACE
USER INTERFACE 2-1
INSTRUCTIONS 3-1
CONFIGURATIONS 4-1
DIALOGUE WITH WELDING TIMER 5-1
APPENDIX A A-1

SUMMARY

Paragraph Page

Presentation of application 2-1

Application status information 2-1
Menu commands 2-2
"Edit" command 2-3
"View" command 2-4
"Utility" command 2-6
"Arm" command 2-6
"Swap" command 2-7
"Egun" command 2-7
"Help" command 2-7
Application on Teach Pendant 2-8
Management of U1, U2, U3, U4 2-9
Pushbuttons U1, U2, U3, U4 2-9
Leds U1, U2, U3, U4 2-9
Management of U4 pushbutton and led (version 5.02) 2-10
U1, U2, U3, U4 remote signals 2-10
Management of A1, A2 2-10
A_SW Spot Welding
Applications C3G Plus

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C3G Plus USER INTERFACE

PRESENTATION OF APPLICATION
The application is presented in the form of screens displayed in a dedicated window; this leaves the USER
window and the SYSTEM window still available for the user.
Pressing the SCRN key, takes you from the USER window to the SYSTEM window to the application window
and vice versa.
Example of a display screen on PC video or teach pendant display:
A_SW1B 5.4X State:READY Weld:2 P:2 W:N T:36.2 ¤:N Arm:1
<area dedicated to messages, warnings or alarms>

Tool Parameter
Edit View Utility Arm Swap Egun Help

The application screens are divided into three parts (as with the operating system):
1) the top part contains information on status of the application;
2) the middle part is used for display of the presentation screen (as in the figure), for entry or display of the
tool data, or to provide the user with help information (varies according to the menu selected);
3) the bottom part is used for the application menu.

APPLICATION STATUS INFORMATION

Information on status of the application is displayed at the top of the page.
This area is divided into “fields”, each field containing a particular item of information.
The “fields” included in all the spot welding applications are:

A_SW.. 5.4X State:READY P:1 W:N T:36.2 *:N Arm:

Significance of the common “fields”:
A_SW..5.4X: - name of application + number of the version
State: - status of the application (READY, ALARM, WORKING)
P: - number of the selected robot program
W: - welding timer included/excluded/suspended (y, n, *)
T: - time, in seconds, from the start of the program to the end of the program
¤:N - weld status yes/no
Arm: - arm controlled by the application

There are other “fields” that differ depending on which Spot Welding application is being used.
A description of these fields will be found in the APPENDIX to this manual.
If the application is opened on the TP, some items are abbreviated and some fields are not present because
of the reduced number of columns (40 instead of 80).

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 USER INTERFACE C3G Plus

MENU COMMANDS
There are a number of functions devised to make the application easy for the User to use.
All the commands are laid out in menus, as close in structure as possible to the operating system menu.
The menu structure is as follows:

Edit View Utility Arm Swap Egun Help

Distance Force Plate Calibrate Current Setup

Print Load Copy Low_Curr High_Curr Cal_Quote

From To

Parameter Tool I/O Bit User Comm Close

Rio Pfdp Ibsl Dnt Swim

System Slot4 Slot5 Slot6 Slot7 Slot8 Slot9

Input Output Pfdp

Parameter Tool Weld Egun

Opzione non disponibile

☞ The Tool data Edit, View and Copy commands are only available in the EZ environment.

The commands may be called up in either of the following ways:

- using arrows to select, then ENTER to confirm;
- directly using F1 ... F8.
When in a nested command (ex: View + Tool + Data) and wishing to go back up to the higher menu level,
the TOP/PREV key must be used.

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C3G Plus USER INTERFACE

"Edit" COMMAND
Tool Parameter
Edit View Utility Arm Swap Help
The Edit command is only enabled when the system is in programming mode and there are no alarms
pending.
After the instruction is selected, a page will be displayed with all the values of data items that it is possible to
modify.
At this point, a prompt is displayed asking for a value to be entered; the range of values that will be accepted
is also displayed.
After writing the new value, confirm by pressing ENTER.
If the value entered is inside the accepted range of values, the old value will be replaced by this new one.
If the value entered is outside the range, the message 'invalid data' will be displayed.
If you press ENTER without entering any value, the message 'no data entered' will be displayed.
It is possible to exit at any time by pressing the TOP/PREV or CTRL_C keys, in which case you will be asked
if the current data values are to be confirmed.
- Tool
Option available in EZ environment.
- Parameter
In this environment you can enter or modify some of the technological parameters, for example:
- Time_dress: duration of tip dressing. Time expressed in milliseconds, with a default of 500. The
acceptable values for this parameter range from 500 to 5000.
This parameter is not managed by functions of the application, but can be used in user programs
as it is provided by the variable exported from the application "SXwi_time_dress"
VAR SXwi_ time_dress: ARRAY[2] OF INTEGER EXPORTED FROM sx_appl
- Time_hand: length of time the welding gun is closed in cycles with the timer excluded. In the
cycles where the timer is excluded, it is the application that closes the gun at the welding spot,
leaving it closed for a time "Time_hand" and opening it again after this time is up. Time expressed
in milliseconds, with a default of 0. The acceptable values range from 0 to 3000.
- Weld
A variable of the application program can be used to select the meaning of the first Weld routine parameter.
This parameter can indicate:
1) the welding timer program to be used on that spot (sbvi_weld_par = 0);
2) the ‘name’ of the welding spot shown on the Weld screen (sbvi_weld_par = 1).
In this case when Weld (n, FALSE) is requested the values will be set in correspondence with point n on the
application package screen page.

Function only enabled with sbvi_weld_par = 1 and with the transfer technological parameters from
SWIM timer disabled.

The following items are to be found in the welding spot screen:

ITEM MEANING RANGE

Weld Name of welding spot indicated by weld 0..99999
Progr Welding timer program associated with spot 0..255
Thickness Thickness of sheet to be welded 0..30 mm
Pressure Force in daN to be applied during welding 0..500daN
DEC* Sticking electrode control function enabled on tip 0 (not enab.)..1 (enab.)
Figure 1. Example of Edit Weld screen
* The DEC function can only be enabled if the welding timer supports this mode.

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USER INTERFACE C3G Plus

- Egun

Refer to “ELECTRIC ACTUATOR TYPE WELD GUN MANAGEMENT MANUAL”.

Below are the commands that can be selected from the Weld and Egun screen pages.

COMMAND FUNCTION WELD EGUN

Ins Enters a new item onto the screen page P A
Del Removes the selected item from the screen page P A
Exit Exits the screen page saving any modifications P P
Quit Quits the screen page without saving any modifications P P
Copy Creates a renamed copy of an item P A
Save Saves modifications P P
Renm Renames an item P A
Find Locates an item on the screen page P A
Legend: P: Command present on screen page A: command absent from screen page
For safety reasons the Weld and Egun screen page data can only be edited when the control unit is in the
PROG status. The user can modify this default however by means of the suitable configuration variables
contained in the specific chapter.

"View" COMMAND
Tool Parameter I/O Bit User Comm Close
Edit View Utility Arm Swap Help

The View command is permanently enabled.

View functions:
- Tool
Option available in EZ environment.
- Parameter
This command may be used to display the values of the technological parameters managed by the
application in the "Edit Parameter" table, and concerning the arm (status window item) from which the
command was executed.
- I/O
In this environment it is possible to display status of all the input/output and of each of the bits of the words if
a communication card such as RIO, Profibus DP, Interbus Slave, DeviceNet Slave is included in the
configuration.
The application will display a graphic of the control rack, showing which card is installed in each slot.
All pages produced in this environment are closed automatically after 60 seconds if the C3G Plus selector
switch is set to remote as they could have negative repercussions on cycle time, if left on display.
Every 500 ms the application updates the page on display, rewriting only the signals that have changed status.
Both of the times mentioned above may be changed by the user (see the "CONFIGURATIONS" chapter).
System: system signals for which windows have been created that cannot be changed by the user as
they already have clearly-defined standard names.
Input: displays status of the 32 SIM system inputs coded $SDIN[1..32].
Output: displays status of the 32 SIM system outputs coded $SDOUT[1..32].
Pfdp: for each page it displays a pair of words (input and output) defining the status of the
individual DP Profibus word bits. The application requests the user to define which pair of
words must be displayed, indicating the range of acceptable values according to the type of
configuration and up to a maximum of the first eight pairs of words.

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C3G Plus USER INTERFACE

Slot..: displays logic address, status of the input/output and type of card in the slot.
In the case of a communication card, the application displays a pair of words (input and output) for each
page indicating the status of each word bit.
The application requests the user to define which pair of words must be displayed, indicating the range of
acceptable values according to the type of configuration.
- Bit
This command is used to display the status and comment strings of the $BIT defined by the user in file
SB_BIT.DAT of the application.
There are 7 pages available with this command, each with a display capacity of 32 $BIT.
To establish which $BIT to display, edit the file:
(command on C3G Plus: Filer Edit <SX_BIT.DAT>).
Enter the index of the $BIT and the comment string (maximum length 23 characters) to be displayed on the
same line.
At the end, perform an "EXIT" to save contents of the file
The first 32 lines typed in (comments excluded) will be displayed on page 1, the next 32 on page 2 and so
on. This short procedure can be executed with the application running as the personalizations will be read on
the next View Bit command from the application menu.
After personalization, the new SX_BIT.DAT file should be saved on an external device:
(command on C3G Plus: Filer Copy <SX_BIT.DAT>).
- Comm
Allows the communication card configuration data to be displayed.
- RIO: displays the RIO card data if present;
- Pfdp: displays the Annex C3G-Profibus DP card data if present;
- Ibs-Slave: displays the C3G EIN card data if present;
- DeviceNet: displays the C3G-EDN DeviceNet Slave card data if present;
- Swim: displays the C3G-SWIM card data if present.
If the operator has personalized the application program in order to display the words of the network
cards, after reconfiguring these, the application program must be reinstalled to create the windows
that correspond to the words declared in the new configuration.
- User
Users wishing to personalize the application with pages of diagnostics for the specific application on their station
can generate PDL2 programs which can be called up from the application menu using the 'View User' command.
Any such programs are generated in accordance with the following rules:
a) Names of programs:
The programs are named "SX_USER?.COD" (? = number of the arm the program refers to) and
are run in function of the arm (item in application status window) from which the 'View User"
command was executed.
b) Operations on PC video or teach pendat display:
The application provides the user with a window in which his data can be displayed. The window is
named as follows:
- for application A_SW1B: 'cb21:'
- for application A_SW2: 'c221:'
If the user wishes to display information also when the application is opened on the TP, the
sxru_refresh_tp routine must be declared in the "SX_USER?.COD" program as follows:
ROUTINE sxru_refresh_tp EXPORTED FROM sx_appl.
The sxru_refresh_tp routine must be called in the program each time the TP window is to be
refreshed with the new data of window 'cy21:'.
All the programs are de-activated as soon as another command is executed from the menu.
- Close
Used to close any open page of the application, automatically bringing the presentation page back on
display.

A_SW SPOT WELDING APPLICATIONS 2-5

03/0301
USER INTERFACE C3G Plus

"Utility" COMMAND
Print Load Copy
Edit View Utility Arm Swap Help

In this environment it is possible to print, transfer to working memory or copy the values of the parameters of
the arm (item in the application status window) from which the command was run.
Copy and print operations are executed with a default of 9600 baud. It is possible to modify the speed of
transmission (see the "CONFIGURATIONS" chapter).
Utility functions:
- Print
Used to print the A_TOOL values and the parameter values on a printer.
Simply connect a printer on the COM1: port of the C3G Plus unit control to use this command.
The printer must be configured as indicated by the application in the screen displayed on entering the
environment.
To modify configuration of the serial communication port, the procedure set by the operating system must be
executed (use the commands from the system menu).
If the COM1: communication port is used to communicate with the welding timer, the application will redirect
the command to port COM0: displaying the configuration of this.
- Load
Used to transfer the parameter values.
Useful when wishing to check the new data values after data is transferred from an external device to the
ram disk of the control unit.
- Copy
Used to copy parameter values from C3G Plus to an external device (COPY TO), or from an external device
to C3G Plus (COPY FROM).
To be able to use this command, you will need:
- Integrated floppy disk: in this case the port is FD:;
or
- Personal Computer with COMP: port (use of PCINT);
or
- Personal Computer with COMP: port (use of KERMIT protocol);

COM0: available only if there is no integrated floppy disk.

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C3G Plus USER INTERFACE

"Arm" COMMAND
Comment
Edit View Utility Arm Swap Help
The "Arm" command makes it possible to enter the application environment dedicated to the other arm.
The status window of the application program displays the information relating to the other arm, if this exists.
All data written on the status window of the arm that is not displayed are stored and are displayed when the
"Arm" command is sent.
The application program automatically displays data relating to the other arm when an alarm occurs on the
arm that is not currently available.
In case of an alarm on both arms, the most recent alarm is displayed; when this is reset, the status window
of the other arm is automatically displayed if the alarm condition still exists.
Any user pages opened with the "View User" application command are automatically closed.

"Swap" COMMAND
Comment
Edit View Utility Arm Swap Help
The Swap command can be used only when the TP option of the application has been requested during the
installation procedure. The Swap command is used to transfer the application from one device to the other
(e.g. from PC video to teach pendant display or from teach pendant display to PC video).
When the Swap command is performed, the commands associated with the U1, U2, U3, U4 pushbuttons are
transferred, while the indications of LEDs U1, U2, U3, U4 remain active on the teach pendant (if present).
Any alarms displayed in the status window are transferred to the device which receives the application.
All open pages are closed automatically on completion of the Swap command. Activation of the command is
preceded by display of a confirmation prompt.
There is a ten second wait before execution of the command.

"Egun" COMMAND
All commands that come under the Egun title regard management/characterization/testing of the electric gun
and are explained in the specific manual (“ELECTRIC ACTUATOR TYPE WELD GUN MANAGEMENT
MANUAL”).

"Help" COMMAND
Key Routine Menu
Edit View Utility Arm Swap Help
The Help command displays information to help the User.
Help functions:
- Key
Displays a help screen explaining the functions associated with the pushbuttons and leds (U1, U2, U3, U4) of
the teach pendant.
- Routine
Displays help screens on how to use the application instructions. There are 2 pages available with this
command. Type in the number of the page you wish to have displayed - the first page concerns welding
technology instructions and the second general instructions (tools, alarms, messages, etc.).
The command cannot be used when the application is opened on the TP.
- Menu
Displays a help screen explaining how the application menu is laid out.
The command cannot be used when the application is opened on the TP.

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USER INTERFACE C3G Plus

APPLICATION ON TEACH PENDANT

The application on TP is an option requested at installation time, remembering that if the user wishes to use
the TP option subsequently or to eliminate this, the application must be completely re-installed after erasing
the 'SX:DEV.CPK' file from the ram disk.
(command on C3G Plus: Filer Delete <SX_DEV.CPK'>)
The application can run on only one device at a time.
The device not used displays a screen to inform the user that the application is available on the other device.
It is possible to switch from one device to the other in two different ways:

1) from the command menu of the application using the SWAP command (see 'MENU COMMANDS'
section);
2) if the active device is disconnected (COMP: port dismount).

The application will display a prompt asking for confirmation of device swapping (press the ENTER key on
the inactive device).
The application behaves as follows in the various cases:
a) swapping between different devices.
This causes loss of the situation of the user interface; regardless of the state of the old device, the
initial screen of the application and the first menu level will be displayed on the new device.
Information on application status (alarms outstanding, etc.) is not lost.
b) swap on identical device.
The application program is restored to the situation prior to disconnection.

As the windows cannot be displayed in a single page, the application creates an imaginary box of the
dimensions of the teach pendant display being used that can be scrolled in the window that is loaded when
the application is opened on PC video (20 lines x 80 columns).
In this way, any page on teach pendant display will display only part of all the information.
To display the entire window and therefore to read all the information, the user must move the imaginary box
several times using the commands given in the application menu and those listed below:

- right arrow - to move one column to the right

- left arrow - to move one column to the left
- down arrow - to move one line down
- up arrow - to move one line up
- shift + right arrow - to move 40 columns to the right
- shift + left arrow - to move 40 columns to the left
- page - to move one page in the vertical direction indicated
- enter - to move to the next menu level
- esc - to return to the previous menu level

The commands required are enabled in the menu according to the information to be displayed.
In some screens, the box that scrolls on the data is smaller than the maximum dimensions of the TP in that
data heading parts are displayed.

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C3G Plus USER INTERFACE

MANAGEMENT OF U1, U2, U3, U4

The pushbuttons and leds U1, U2, U3 and U4 on the Teach-Pendant are used for a number of functions, as
illustrated below:

PUSHBUTTONS U1, U2, U3, U4

The table shows the assignment of push-buttons U1, U2, U3, U4 according to the application program used.

A_SW1B A_SW2
INTEGRATED TIMER /SWIM EXTERNAL TIMER
U1 Inclusion/Exclusion Incl./Excl. ARM1 Incl./Excl. timer 1 and 2 ARM1
U2 Weld yes/Weld no Incl./Excl. ARM2 Incl./Excl. timer 1 and 2 ARM2
U3 Reset fault Reset fault ARM1 Reset fault timer 1 and 2 ARM1
U4 Reserved (5.01 version) Reset fault ARM2 Reset fault timer 1 and 2 ARM2
Bypass water control (5.02
version with electric gun)

Push-buttons U1, U2 can be enabled/disabled in the Programming-Automatic Local machine states

using appropriate variables described in the manual.
Push-buttons U3 and U4 are enabled only if the matching led is off.
If the A_SW2 application is used, the function of the U1 pushbutton is to exclude/include both
timers (the U2 pushbutton is not used).
To include/exclude one timer only, use the "Incl/Escl" menu command (see menu COMMANDS
chapter).
In some applications the U4 pushbutton is dedicated to welding gun movement commands as well
as normal pre-stroke and closing movements that are usually effected by means of the T1 and T2
pushbuttons.

LEDS U1, U2, U3, U4

The table shows the assignment of LEDs U1, U2, U3, U4 according to the application program used.

A_SW1B A_SW2
INTEGRATED TIMER /SWIM EXTERNAL TIMER
U1 Inclusion/Exclusion Inclusion/Excl. ARM1 Incl./Excl. timer 1 and 2 ARM1
U2 Weld yes/Weld no Incl./Excl. ARM2 Incl./Excl. timer 1 and 2 ARM2
U3 No fault No fault ARM1 No fault timer 1 and 2 ARM1
U4 Reserved (5.01 version) No fault ARM2 No fault timer 1 and 2 ARM2
Bypass in progress (5.02
version)

If the A_SW2 application is used, LED U1 indicates the status of both timers. The LED is on when
one or both timers are included (LED U2 is not used).
In some applications, LED U4 is dedicated to indicating welding gun positions as well as the normal
retracted and closed positions, indicated by LEDs T1 and T2.

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USER INTERFACE C3G Plus

MANAGEMENT OF U4 PUSHBUTTON AND LED (version 5.02)

If an electric gun is used, by default the application manages the water flow in a different way so that the
robot cannot be moved in case of a failure in the water supply, which would damage the robot motor due to
lack of cooling water.
This control can, however, be excluded for a limited period (max 40 sec) in order to bring the robot to an
accessible position or to the maintenance / home position.
This "bypass" is activated by pressing the U4 key on the TP: in PROG status. During exclusion the LED that
corresponds to the U4 key on the TP: flashes.

U1, U2, U3, U4 REMOTE SIGNALS

The following tables represent the remote assignment of the U1, U2, U3, U4 signals, according to the
specific application.
INPUT
A_SW1B A_SW2
SIM RIO INTEGRATED TIMER EXTERNAL TIMER
U1 $SDIN[13] $SDIN[149] Inclus./Excl. timer Incl./Excl. ARM1 (*) ARM1
U2 $SDIN[14] $SDIN[150] Weld yes/Weld no Incl./Excl. ARM2 (*) ARM2
U3 $SDIN[15] $SDIN[151] Reset fault Reset fault ARM1 Reset fault timer 1 and 2
ARM1
U4 $SDIN[16] $SDIN[152] Reserved Reset fault ARM2 Reset fault timer 1 and 2
ARM2

(*) In case of the A_SW2 application program, the incl./excl. timer signals are passed to the $DIN[n] defined
by the user.
OUTPUT
A_SW1B A_SW2
SIM RIO INTEGRATED EXTERNAL TIMER
TIMER
U1 $SDOUT[13] $SDOUT[150] Inclusion/Exclusion Inclusion/Exclusion ARM1 (*) ARM1
U2 $SDOUT[14] $SDOUT[151] Weld yes/Weld no Inclusion/Exclusion ARM2 (*) ARM2
U3 $SDOUT[15] $SDOUT[152] No fault No fault ARM1 No alarm timer 1
and 2 ARM1
U4 $SDOUT[16] $SDOUT[153] Reserved No fault ARM2 No alarm timer 1
and 2 ARM2
(*) In case of the A_SW2 application, the incl./excl. timer signals are passed to the $DOUT[n] defined by the user.

With Input assigned to ON the welding timer is excluded. With Output assigned to ON the welding
timer is included.

MANAGEMENT OF A1, A2
The application handles these keys to allow the user to access and exit the application opened on the TP.
If the application program manages a single arm:
A1 makes it possible to pass from the system screen page to the application screen page and vice versa.
If the application program manages two arms:
A1 makes it possible to pass from the system screen page to the application screen page (forcing
display of the data of the first arm) and vice versa.
A2 makes it possible to pass from the system screen page to the application screen page (forcing
display of the data of the second arm) and vice versa.
If more than one application program is present on the control, A1 selects the A_SW1B application screen page.

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 A_SW Spot Welding
C3G Plus Applications

FEATURES 1-1

INSTRUCTIONS
USER INTERFACE 2-1
INSTRUCTIONS 3-1
CONFIGURATIONS 4-1
DIALOGUE WITH WELDING TIMER 5-1
APPENDIX A A-1

SUMMARY

Paragraph Page

Welding instructions common to all application programs 3-1

Statements for messages and alarms 3-2
Instructions for $WORD management 3-3
Management of instructions in EZ environment 3-4
A_SW Spot Welding
Applications C3G Plus

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C3G Plus INSTRUCTIONS

WELDING INSTRUCTIONS COMMON TO ALL APPLICATION PROGRAMS

WELD_INIT
Example of call:
ROUTINE weld_init EXPORTED FROM sx_appl
BEGIN
weld_init
...
...
END prog_1
Parameters:
None.
What it does:
Initializes variables, defines conditions; sets the program for welding or for controlling the welding gun on
board robot.
When to use it:
It must be called at the beginning of each program, each time this is activated, independently of whether
the timer is excluded for welding or machining.
Operation in detail:
When called, the WELD_INIT checks that:
- program calling it belongs to an arm enabled for welding; it has not already been called by the
same program, in which case it will not perform any initialization work as to do so would be
superfluous.
- It activates as many concurrent "SX_arm?" programs as there are timers managed; these are the
NOHOLD welding control programs.
- Links to the program that has called it; from this point on, if the application is interrupted, this
program will also be interrupted and if this program is interrupted, the "SX_arm?" programs will
also be interrupted.
BEFORE_HAND(x)
Example of call:
ROUTINE before_hand (ai_time: INTEGER) EXPORTED FROM SX_APPL
BEGIN
...
before_hand(60)
...
END prog_1
Parameters:
x -> INTEGER: [ms], if x > 0, start of welding is advanced in relation to the theoretical end of the movement;
if x <= 0, start of welding is delayed in relation to the theoretical end of welding.
What it does:
Defines the conditions that make it possible to advance or delay start of welding in relation to theoretical
reaching of the welding spot.
When to use it:
Each time it is necessary to define the time (expressed in milliseconds) by which welding is to be advanced
or delayed in relation to the theoretical end of movement. The advance or delay can be enabled/disabled
singly for each welding spot (see WELD).
.

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INSTRUCTIONS C3G Plus

Operation in detail:
When called, the BEFORE_HAND checks that:
- the calling program belongs to an arm enabled for welding;
- the advance/delay time is within a preset range from -1000 to 100 (default, see also application
parameter configuration). If out of range, the “BEFORE_HAND value out of range x..y” alarm is
output.
WELD
The description of the WELD instruction is available in the APPENDIX to this handbook.
PRESS
The description of the PRESS instruction is available in the APPENDIX to this handbook.
WELD_NOW
The description of the WELD_NOW instruction is available in the APPENDIX to this handbook.
SWING
The description of the SWING instruction is available in the APPENDIX to this handbook.
DEC_GLOBAL
The description of the DEC_GLOBAL instruction is available in the APPENDIX to this handbook.
NO_DEC
The description of the NO_DEC instruction is available in the APPENDIX to this handbook.
INCL_APPL
The description of the INCL_APPL instruction is available in the APPENDIX to this handbook.
LARGE_OPEN
The description of the LARGE_OPEN instruction is available in the APPENDIX to this handbook.

STATEMENTS FOR MESSAGES AND ALARMS

The application lets users manage in their own programs an infinite number of alarms and messages that
can be displayed on the application status display area.
A_ALARM('x')
where x represents a user-defined alarm string. An application alarm is generated and the red lamp on the
TP and PTU4 comes on.
The alarm interrupts execution of the work programs, causes LEDs U3 or U4 to switch off and the Output U3
or U4 signal to drop to remote, depending on whether the alarm is for the first or second arm managed.
Example:
PROGRAM test
ROUTINE a_alarm(as_alarm_code: STRING) EXPORTED FROM sx_appl
BEGIN
a_alarm('NO ANSWER FROM SOLENOID VALVE 1')
END test
After the fault has been checked, working conditions may be restored by pressing the alarm reset button (U3
or U4 on the TP) or by raising the reset alarm Input from remote (U3 or U4 from remote).
A number of predefined alarms are available with the application and may be used with the A_ALARM
instruction called with an x value ranging 1 to 10. A list of these alarms for each single application is given in
the APPENDIX to this manual.

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C3G Plus INSTRUCTIONS

A_MESSAGE('x')
where x represents a user-defined message string.
Example:
PROGRAM test
ROUTINE a_message(as_message_code: STRING) EXPORTED FROM sx_appl
BEGIN
a_message('WAITING FOR STROBE FROM PLC')
END test
The messages do not interrupt execution of the work program and do not produce an application alarm. A
number of predefined messages are available with the application and may be used with the A_MESSAGE
statement called with an x value ranging 1 to 10. A list of these messages for each single application is given
in the APPENDIX to this manual.

Where both statements are called with an x 10, an error will be signalled.

INSTRUCTIONS FOR $WORD MANAGEMENT

☞ The following instructions are only available in the A_SW1B and A_SW2 application programs in
configurations that foresee the use of a communication board, for example RIO, SINEC L2/DP.

Operations can be executed on single $WORD bits by means of three instructions supplied by the
application program.
SET_WORD(x,y,z)
Enables a specific bit of a specific $WORD to be assigned to the required value.
x = $WORD address
y = $WORD BIT from 1 to 16
z = BIT status (ON or OFF)
Example:
PROGRAM test
ROUTINE set_word(ai_w,ai_b: INTEGER; ab_v: BOOLEAN) EXPORTED FROM sx_appl
BEGIN
-- to assign bit 7 of $WORD 18 to OFF
set_word(18,7,OFF)
END test
WAIT_WORD(x,y,z)
Waits for a specific bit of a specific $WORD to move to the required status.
x = $WORD address
y = $WORD BIT from 1 to 16
z = BIT status (ON or OFF)
Example:
PROGRAM test
ROUTINE wait_word(ai_w, ai_b: INTEGER; ab_v: BOOLEAN) EXPORTED FROM sx_appl
BEGIN
-- waits until bit 4 of $WORD 17 is ON
wait_word(17,4,ON)
END test

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INSTRUCTIONS C3G Plus

WORD_BIT(x,y)
Returns the status of a specific bit of a specific $WORD.
x = $WORD address
y = $WORD BIT from 1 to 16
Example:
PROGRAM test
ROUTINE word_bit(ai_w,ai_b: INTEGER) EXPORTED FROM sx_appl
BEGIN
to test the value of bit 12 of $WORD 19
IF word_bit (19,12) THEN
-- bit to ON
ELSE
-- bit to OFF
ENDIF
END test

If these routines are called using an 'x' value outside the correct range or with a 'y' value not ranging
from 1 to 16, an error is signalled.

MANAGEMENT OF INSTRUCTIONS IN EZ ENVIRONMENT

In the EZ programming environment it is possible to insert calls for some application instructions.
A dedicated EZ software corresponds to each Spot Welding application, in that the procedure for adding
some instructions differs according to the specific application.
In particular, the WELD_INIT, BEFORE_HAND, WELD, WELD_NOW, PRESS, A_ALARM, A_MESSAGE,
SET_WORD, WAIT_WORD, SWING, DEC_GLOBAL, NO_DEC application instructions can be added.
WELD_INIT
The WELD_INIT instruction is available with the EZ menu commands:
"Ins" "Appl" "Init"
EZ will enter the instruction directly into the program open at the line on which the cursor is positioned.
WELD
The WELD instruction is available with the EZ menu commands:
"Ins" "Appl" "Weld"
Enter the welding program that is to be called (the range of acceptable values varies depending on the
welding timer) and indicate whether the start of welding must be advanced/delayed in relation to the theoretical
end of the movement (TRUE/FALSE).
EZ will enter the instruction directly into the program open at the line on which the cursor is positioned.

WELD_NOW
The WELD_NOW instruction is available with the EZ menu commands:
"Ins" "Appl" "wNow"
Enter the welding program that is to be called (the range of acceptable values varies depending on the
welding timer), the value -1 indicates that welding is to be performed with the currently selected welding
program.

☞ WELD_NOW is only available with the A_SW1B application.

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C3G Plus INSTRUCTIONS

BEFORE_HAND(x)
The BEFORE_HAND instruction is available with the EZ menu commands:
"Ins" "Appl" "Bhnd"
Enter the time by which welding is to be advanced or delayed, taking into account that the acceptable default
values range from -1000 to 100.
EZ will enter the instruction directly into the program open at the line on which the cursor is positioned.
PRESS
Enter the welding program to be called (the range of acceptable values varies depending to the welding
timer).
EZ will enter the instruction directly into the program open at the line on which the cursor is positioned.

A_ALARM(x)
The A_ALARM instruction is available with the EZ menu commands:
"Ins" "Appl" "Diag" "Alrm"
Enter the number of the alarm to be called, taking into account that acceptable values range from 1 to 10. EZ
will enter the instruction directly into the program open at the line on which the cursor is positioned. In the EZ
environment it is not possible to enter the instruction with an alarm string defined by the user.
A_MESSAGE(x)
The A_MESSAGE instruction is available with the EZ menu commands:
"Ins" "Appl" "Diag" "Mess"
Enter the number of the message that is to be called, taking into account that acceptable values range from
1 to 10. EZ will enter the instruction directly into the program open at the line on which the cursor is
positioned. In the EZ environment it is not possible to enter the instruction with a message string defined by
the user.

☞ The following instructions are available on the EZ menu for A_SW1B and A_SW2 Spot Welding
applications.

A_WARNING(x)
The A_WARNING instruction is available with the EZ menu commands:
"Ins" "Appl" "Diag" "Warn"
Enter the number of the warning that is to be called, taking into account that acceptable values range from 1
to 10. EZ will enter the instruction directly into the program open at the line on which the cursor is positioned.
In the EZ environment it is not possible to enter the instruction with an alarm string defined by the user.

SWING(x)
The SWING instruction is available with the EZ menu commands:
"Ins" "Appl" "Gun" "Swng"
Enter ON / OFF according to whether the additional gun movement must be activated / deactivated respectively.
DEC_GLOBAL(x)
The DEC_GLOBAL instruction is available with the EZ menu commands:
"Ins" "Appl" "Gun" "Dec" "Glbl"
Enter ON / OFF according to whether the sticking electrode control function must be activated / deactivated
respectively on all welding points.

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INSTRUCTIONS C3G Plus

NO_DEC
The NO_DEC instruction is available with the EZ menu commands:
"Ins" "Appl" "Gun" "Dec" "No"

LARGE_OPEN
The LARGE_OPEN instruction is available with the EZ menu commands:
"Ins" "Appl" "Gun" "Lopn"

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 A_SW Spot Welding
C3G Plus Applications

FEATURES 1-1

CONFIGURATIONS
USER INTERFACE 2-1
INSTRUCTIONS 3-1
CONFIGURATIONS 4-1
DIALOGUE WITH WELDING TIMER 5-1
APPENDIX A A-1

SUMMARY

Paragraph Page

Configurations 4-1
Application parameter configuration 4-1
Application hardware configuration 4-1
Automatic configuration of Hand 1 and Hand 2 4-3
A_SW1B parameters configuration file 4-4
A_SW1B hardware configuration file 4-5
I/O connections 4-14
A_SW Spot Welding
Applications C3G Plus

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C3G Plus CONFIGURATIONS

CONFIGURATIONS
The package can be personalized for its specific application by way of some configurations.

☞
Always consult the version notes.
These are files with .DOC extension held on the application program diskette. To consult only the
configurations, read the file SB_READ.ME.

APPLICATION PARAMETER CONFIGURATION

Some of the non-fundamental characteristics of the package can be modified through file "SX_CONF.COD".
File "SX_CONF.COD" is not linked to the machine type and is not loaded at installation.
The procedure to modify the "SX_CONF.COD" file is as follows:
a) Load the file on ram-disk
(Filer Copy <SX_CONF.COD>)
b) edit the file
(Program Edit <SX_CONF.COD>)
c) modify the data required
d) save the changes made
(Exit comand in Program Edit)
e) run the modified program
(Program Go <SX_CONF.COD>)
f) save the variables in file "SX_CONF.VAR"
(Memory Save <SX_CONF.COD>)
g) save the new configuration on diskette
(Filer Copy <SX_CONF.*>)
To return the application to its standard starting conditions, simply delete the "SX_CONF.VAR" file in ram-
disk and restart the application.
In the "APPENDIX" chapter, a generic description is given of the contents of the parameter configuration files
for each of the applications.

APPLICATION HARDWARE CONFIGURATION

Each application can work on different types of timers and with different hardware configurations.
The three packages are supplied with standard hardware configuration files, from which users can produce
personalized versions as they wish. These files are PDL2 programs containing constants, variables and
routines determining the behaviour of the application.
The hardware configuration file is a file loaded by the application in function of the selection made by the
user during the initial installation procedure and is called "SBHW.COD" in the ram-disk.
Accessible only in read mode. If required, the hardware configuration can be modified by means of two
procedures:
a) set the C3G Plus password
(Configure Cntrler Password <****>);
b) reset the file read/only attribute
(Filer Utility Attribute Read/Only <SXHW.COD>);
c) edit the file
(Program Edit <SXHW.COD>);
d) modify the data required;
e) save the changes made
(Exit command in Program Edit);

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CONFIGURATIONS C3G Plus

f) rename the file "SBHW.COD" SB..._00.CNF ( ... must be a three-digit number above 500)
(Filer Rename <SXHW.COD> <SX..._00.CNF>);
g) create a file SB..._00.ANM containing a comment string for the .CNF file (maximum length of string: 23
characters)
(Filer Edit <SX..._00.ANM>);
h) copy both files on to the application diskette
(Filer Copy <SX..._00.*>);
i) repeat installation of the application, this time with the new "SB..._00.CNF" file.
The "APPENDIX" chapter contains a general description of the contents of the hardware configuration files
for each application. For further details, read the sx_read.me file on your version disk.
To make the A_SW1B application software independent of the numerous applications in which it is used and
make it more flexible to suit different requirements, new hardware configuration files will only contain the
definition of the inputs/outputs that are essential to the application and the configuration flags assigned to
default values.
This file is always loaded in ramdisk with the name SBHW.COD. To personalize the application program
according to the specific application, the user can copy SBHW.COD into the SBHWUSER.COD file, and
make the modifications or additions considered necessary. For example selecting, at application program
installation time, the SB200_00 configuration file for the «C3G Plus spot Medium Frequency» (which is
renamed SBHW.COD in the ram disk), the inputs of the IOM in slot 4 will be defined as:
-- IOM 4 $DIN
sbwi_din_ev_ok[1] := 1
-- sbwi_din_tot_open[1] := 2 -- OPTION
-- sbwi_din_gun_open[1] := 3 -- OPTION
-- sbwi_din_gun_close[1] := 4 -- OPTION
-- sbwi_din_trafo_temp[1] := 5 -- OPTION
This means that the proportional solenoid valve OK input is on $DIN[1] and the $DIN for the welding gun fully
open, welding gun open, welding gun closed and welding transformer thermostat can also be assigned
optionally. Indices are shown to suggest which $DIN should be used.
After copying the SBHW.COD file into SBHWUSER.COD, the user can make the modifications required. He
may, for example, indicate that there is a welding gun open proximity switch and the welding transformer
thermostat:
-- IOM 4 $DIN
sbwi_din_ev_ok[1] := 1
-- sbwi_din_tot_open[1] := 2 -- OPTION
sbwi_din_gun_open[1] := 3 -- OPTION
-- sbwi_din_gun_close[1] := 4 -- OPTION
sbwi_din_trafo_temp[1] := 5 -- OPTION
Should the user wish to go back, it is possible to re-comment the line or set the variable to zero.
For standard predefined applications, the SBHWUSER.COD file is already prepared by the application
program. There is no need, therefore, to create it but it can be modified. See for example the files of the
application diskette SB200_00.C01 and SB200_00.C02 associated with the basic file SB200_00.CNF.

After modifying the SBHWUSER.COD file, a Configure Controller Restart Cold should be executed.
Should the modifications concern the definition of the I/O units or the cards inserted, the application
package must be reinstalled.

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C3G Plus CONFIGURATIONS

AUTOMATIC CONFIGURATION OF HAND 1 AND HAND 2

During the installation phase the application program is able to execute the configuration of HAND 1 and 2
automatically.
The parameters for executing this configuration are contained in the hardware file. The specific default
values may be changed by the user.
In order to modify the configuration it will suffice to change the parameters of the subsequent routine (or add
a second call for the same routine for Hand 2):
Cnfg_hand (arm1, hand2, type_single, 17, 0, 0)
--

Parameters list:

-- -- 1 = arm number (valid values: 1, 2);

-- -- 2 = hand number (valid values: T1, T2);

-- -- 3 = hand type (type_single, type_dual, type_pulse);
-- -- 4 = closing out index = index out line 1;
-- -- 5 = opening out index (0 = not used) = index out line 2;
-- -- 6 = out pulse time (only for type_pulse).

After modifying the SBHWUSER.COD file, a Configure Controller Restart Cold should be executed.
☞ Should the modifications concern the definition of the I/O units, the cards inserted or the Hand
parameters, the A_SW1B application package must be reinstalled.

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CONFIGURATIONS C3G Plus

A_SW1B PARAMETERS CONFIGURATION FILE

All the variables are to be interpreted as EXPORTED FROM sb_conf.
The A_SW1B variables that can be modified in file SB_CONF.COD are:
VAR sbwi_dtr: ARRAY[2] OF INTEGER
-- [ms] default tip dressing time [500]
VAR sbwi_str: ARRAY[2] OF INTEGER
-- [ms] max. tip dressing time [5000]
VAR sbwi_itr: ARRAY[2] OF INTEGER
-- [ms] min. tip dressing [500]
VAR sbwi_dtcp: ARRAY[2] OF INTEGER
-- [ms] default welding gun closing time (when welding timer excluded) [0]
VAR sbwi_stcp: ARRAY[2] OF INTEGER
-- [ms] max. max. welding gun closing time (welding timer excluded) [3000]
VAR sbwi_itcp: ARRAY[2] OF INTEGER
-- [ms] min. welding gun closing time (welding timer excluded) [0]
VAR sbvi_speed: INTEGER
-- [baud] com0: data transfer speed during a Copy and Print Utility command [9600]
The values possible are: 9600, 19200, 38400.
VAR sbvi_max_before: INTEGER
-- [ms] max. advance start time on end of movement to welding spot [100]
VAR sbwi_time_fk: ARRAY[2] OF INTEGER
-- [ms] timeout for end of sequence from welding timer [7000]
VAR sbwi_time_pr: ARRAY[2] OF INTEGER
-- [ms] timeout for welding gun proportional solenoid valve pressure OK [1000]
VAR sbwi_time_prx: ARRAY[2] OF INTEGER
-- [ms] timeout for welding gun opening [2000]
VAR sbwi_time_hand_2: ARRAY[2] OF INTEGER
-- [ms] timeout for welding gun prestroke [5000]
VAR sbwi_close_gun_time: ARRAY[2] OF INTEGER
-- [ms] gun closed time to detach the electrodes [500]
VAR sbwi_max_after: INTEGER
-- [ms] max. delay in relation to theoretical end of MOVE with which to start welding [-1000]
VAR sbwi_delay_pr: ARRAY[2] OF INTEGER
-- [ms] time after which the welding gun proportional solenoid valve OK signal is tested after a change of
pressure [50]
VAR sbwi_delay_open: ARRAY[2] OF INTEGER
-- [ms] delay after welding gun is opened (welding timer excluded) [500]
VAR sbvi_debug_clock: INTEGER
-- [ms] refresh time for I/O status during display. The recommended range of values is from 200 to 2000
[500]
VAR sbvi_tempo_max: INTEGER
-- [ms] max. display time of I/O in remote status [60000]
-- space for consideration of an axis in welding position
VAR sbvr_lin_delta: REAL
-- [mm] linear axes [200]
VAR sbvr_jnt_delta: REAL
-- [deg] rotating axes [20]
VAR sbwi_time_water_on: ARRAY[2] OF INTEGER
-- [ms] time by which the water must flow in the cooling circuit [10000]
VAR sbwi_time_water_off: ARRAY[2] OF INTEGER
-- [ms] time by which the water in the cooling circuit must stop [5000]

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C3G Plus CONFIGURATIONS

VAR sbwi_filter_water_off: ARRAY INTEGER [0]

-- maximum time during which there may be no flow of water without generating alarms
VAR sbvi_delay_cal: INTEGER
-- [ms] Delay during calibration of electric gun to wait for robot axes to stop [200]

The values in square brackets are the default values.

A_SW1B HARDWARE CONFIGURATION FILE

All the variables indicated below are to be interpreted as EXPORTED FROM sb_hw.
This application program can manage up to two arms with COMAU/BOSCH, FASE welding timers; it can
also manage the PSS2000 series COMAU/BOSCH timer, integrated in the Application Box; the PSS5000
series BOSCH timer (AC and MFDC) in the Application Box; the FASE 334 timer in the Application Box; the
SWIM timer integrated in the Bus VME; it recognizes the additional IOM, RIO, C3G-PFDP, C3G-EIN and
C3G-EDN cards.
The definitions required for hardware configuration are as follows:

CONST ki_num_weld_prog
-- number of welding programs
VAR sbvi_num_arms: INTEGER
-- number of arms controlled by the application (1 or 2)
VAR sbwi_an: ARRAY[2] OF INTEGER
-- number of the first arm (and of the second arm if sbvi_num_arms = 2)
VAR sbws_name: ARRAY[2] OF STRING[40]
-- name of the application
VAR sbws_rack_slot: ARRAY[9] OF STRING[5]
-- name of cards used from the fourth to the ninth slot
VAR sbwi_set: ARRAY[2] OF INTEGER
-- group of U keys used: 1 - U1, U3; 2 - U2, U4
VAR sbwi_din_ev_ok: ARRAY[2] OF INTEGER
-- index of the $DIN port for proportional solenoid valve ok
VAR sbwi_din_tot_open: ARRAY[2] OF INTEGER
-- index of the $DIN port for welding gun fully open prx
VAR sbwi_dout_start: ARRAY[2] OF INTEGER
-- index of the $DOUT port for welding start
VAR sbwi_din_fk: ARRAY[2] OF INTEGER
-- index of the $DIN port for end of welding sequence
VAR sbwi_gout_idx_wp: ARRAY[2] OF INTEGER
-- index of the $GOUT port for welding program
VAR sbwi_sp_wp: ARRAY[2] OF INTEGER
-- index of the $GOUT port for welding program
VAR sbwi_len_wp: ARRAY[2] OF INTEGER
-- number of $DOUT ports belonging to the above group
VAR sbvi_first_weld_prog: INTEGER
-- number of the first welding program
VAR sbvi_last_weld_prog: INTEGER
-- number of the last welding program
VAR sbwi_weld_code: ARRAY[2] OF INTEGER
-- coding of welding programs
VAR sbvb_spr: BOOLEAN
-- enables calculation of cycle time and program selection.

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CONFIGURATIONS C3G Plus

VAR sbwi_din_spr: ARRAY[2] OF INTEGER

-- index of the $DIN port for robot program start
(not to be initialized if the use of communication boards is foreseen)
VAR sbwi_gin_idx_spr: ARRAY[2] OF INTEGER
-- index of the $GIN port for selecting robot program
(not to be initialized if the use of communication boards is foreseen)
VAR sbwi_word_spr: ARRAY[2] OF INTEGER
-- index of $WORD for selecting robot program
(not to be initialized if the use of communication boards is not foreseen)
VAR sbwi_bit_spr: ARRAY[2] OF INTEGER
-- index of $WORD bit for robot program start
(not to be initialized if the use of communication boards is not foreseen)
VAR sbwi_sp_spr: ARRAY[2] OF INTEGER
-- if the use of communication boards is not foreseen:
index of the first $DIN port of the group for selecting the robot program number
-- if the use of communication boards is foreseen:
index of the first bit of the above $WORD for selecting the robot program number
VAR sbwi_len_spr: ARRAY[2] OF INTEGER
-- if the use of communication boards is not foreseen:
number of $DIN ports belonging to the above group
-- if the use of communication boards is foreseen:
number of bits belonging to the above $WORD for selecting the robot program number
VAR sbwi_dout_fpr: ARRAY[2] OF INTEGER
-- index of the $DOUT port for end of robot program (if the use of communication boards is not foreseen)
VAR sbwi_word_fpr: ARRAY[2] OF INTEGER
-- index of the $WORD for end of robot program (if the use of communication boards is foreseen)
VAR sbwi_bit_fpr: ARRAY[2] OF INTEGER
-- index of the $WORD bit for end of robot program (if the use of communication boards is foreseen)
VAR sbwi_din_ready: ARRAY[2] OF INTEGER
-- index of the $DIN port for timer ready
(initialized if the timer provides this information and it is passed to IOM)
VAR sbwi_word_ready: ARRAY[2] OF INTEGER
-- index of the $WORD for timer ready
(initialized if the timer provides this information and it is passed to the network card)
VAR sbwi_bit_ready: ARRAY[2] OF INTEGER
-- index of the $WORD bit for timer ready
(initialized if the timer provides this information and it is passed to the network card)
VAR sbvi_weld_par: INTEGER
-- meaning of the first weld parameter
-- 0 = welding program
1 = spot on weld table
VAR sbvi_timer_interface
-- interface between robot controller and welding timer
-- 0 = digital I/O
1 = serial line (BOSCH PSS 5100.521C)
2 = Fieldbus / VME bus

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C3G Plus CONFIGURATIONS

For guns with balancing sv:

VAR sbwi_dout_balance: ARRAY[2] OF INTEGER
-- port index $DOUT for gun balancing solenoid valve
VAR sbwb_dout_balance_in_weld: ARRAY[2] OF INTEGER
-- status of output sbwi_dout_balance[1] during welding phase

For electric guns:

VAR sbvb_water_opt: BOOLEAN
-- enables electric gun water flow management (default = TRUE with electric gun)
VAR sbvi_water_excl_time: INTEGER
-- maximum exclusion time for electric gun water flow control (range 0..40 sec.) [30]
VAR sbvb_t_chk: BOOLEAN
2
-- enables I T locking check on electric gun axis
VAR sbvi_test_wprog: INTEGER
-- code of welding program used to control Egun Weld with sbvi_weld_par ≠ 1
VAR sbvb_check_tip: BOOLEAN
-- flag to indicate testing of the electrode present / sheet thickness on electric gun
VAR sbvb_check_gun_open: BOOLEAN
-- flag to indicate enabling of electrode sticking control function using electric gun axis coordinates
Enabling of the last two functions affects the duration of the welding cycle(160 ms more for each
spot).

VAR sbwi_din_no_piece: ARRAY[2] OF INTEGER

-- index $DIN to indicate cycle without workpiece from PLC
VAR sbwi_dout_no_piece: ARRAY[2] OF INTEGER
-- index $DOUT to echo cycle without workpiece to PLC
VAR sbwi_inp_word_no_piece: ARRAY[2] OF INTEGER
-- index $WORD to indicate cycle without workpiece from PLC
VAR sbwi_inp_bit_no_piece: ARRAY[2] OF INTEGER
-- index $BIT to indicate cycle without workpiece from PLC
VAR sbwi_out_word_no_piece: ARRAY[2] OF INTEGER
-- index $WORD to echo cycle without workpiece to PLC
VAR sbwi_out_bit_no_piece: ARRAY[2] OF INTEGER
-- index $BIT to echo cycle without workpiece to PLC

In case of the INTEGRATED SPOT the value of some of the above variables is 1 instead of 2; new variables
have been introduced for the BOSCH welding timer:
VAR sbvi_intwt_code: INTEGER
-- code to identify the type of welding timer integrated in the C3G Plus cabinet or in the Application Box
VAR sbvb_gun_open_check: BOOLEAN
-- flag to indicate testing of the gun open micro before moving the robot after welding
VAR sbvb_gun_close_check: BOOLEAN
-- flag to indicate testing of the gun closed micro before moving the welding robot
VAR sbvb_local_weld_yn: BOOLEAN
-- flag to indicate enabling of the WELD YES/NO command from teach pendant
VAR sbwi_din_gun_open: ARRAY[1] OF INTEGER
-- index of the $DIN port for gun open micro
VAR sbwi_din_gun_close: ARRAY[1] OF INTEGER
-- index of the $DIN port for gun close micro
VAR sbwi_din_trafo_temp: ARRAY[1] OF INTEGER
-- index of the $DIN port for thermostat on welding transformer
VAR sbwi_din_water_flow: ARRAY[1] OF INTEGER

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CONFIGURATIONS C3G Plus

-- index of the $DIN port for gun electrode cooling water flow switch
VAR sbwi_din_air_press: ARRAY[1] OF INTEGER
-- index of the $DIN port for proportional solenoid valve air pressure switch
VAR sbwi_din_tele_close: ARRAY[1] OF INTEGER
-- index of the $DIN port for welding power contactor contact open/closed
VAR sbwi_din_prot_scr: ARRAY[1] OF INTEGER
-- index of the $DIN port for auxiliary contact of welding circuit breaker
VAR sbwi_din_pre_tip_change: ARRAY[1] OF INTEGER
-- index of the $DIN port for tip change pre-alarm from timer
VAR sbwi_din_alrm_tip_change: ARRAY[1] OF INTEGER
-- index of the $DIN port for tip change alarm from timer
VAR sbwi_din_weld_yn: ARRAY[1] OF INTEGER
-- index of the $DIN port for WELD YES/NO status from timer
VAR sbwi_gin_tmr_alrm: ARRAY[1] OF INTEGER
-- index of the $GIN port for timer alarm code reading
VAR sbwi_sp_in_tmr_alrm: ARRAY[1] OF INTEGER
-- index of the first $DIN port belonging to the group sbwi_gin_tmr_alrm
VAR sbwi_dout_tele: ARRAY[1] OF INTEGER
-- index of the $DOUT port to invoke closing of the power contactor
VAR sbwi_dout_ksr_reset: ARRAY[1] OF INTEGER
-- index of the $DOUT port for current alarm reset to timer
VAR sbwi_dout_gen_reset: ARRAY[1] OF INTEGER
-- index of the $DOUT port for general alarm reset to timer
VAR sbwi_dout_weld_yn: ARRAY[1] OF INTEGER
-- index of the $DOUT port for WELD YES/NO command to timer
VAR sbwi_dout_pre_tip_change: ARRAY[1] OF INTEGER
-- index of the $DOUT port to indicate tip change pre-alarm to the field
VAR sbwi_dout_alrm_tip_change: ARRAY[1] OF INTEGER
-- index of the $DOUT port to indicate tip change alarm to the field
VAR sbwi_gout_tmr_alrm: ARRAY[1] OF INTEGER
-- index of the $GOUT port to indicate timer alarm code to the field
VAR sbwi_word_pre_tip_change: ARRAY[1] OF INTEGER
-- index of the $WORD port to indicate change pre-alarm to the field
VAR sbwi_bit_pre_tip_change: ARRAY[1] OF INTEGER
-- index of the bit of the $WORD port to indicate change pre-alarm to the field
VAR sbwi_word_alrm_tip_change: ARRAY[1] OF INTEGER
-- index of the $WORD port to indicate tip change alarm to the field
VAR sbwi_bit_alrm_tip_change: ARRAY[1] OF INTEGER
-- index of the bit of the $WORD port to indicate tip change alarm to the field
VAR sbwi_word_tmr_alrm: ARRAY[1] OF INTEGER
-- index of the $WORD port to indicate timer alarm code to the field
VAR sbwi_len_tmr_alrm: ARRAY[1] OF INTEGER
-- number of bit to indicate the timer alarm code to the field
VAR sbwi_sp_out_tmr_alrm: ARRAY[1] OF INTEGER
-- index of the first bit of the $WORD sbwi_word_tmr_alrm
VAR sbwi_dout_ready: ARRAY[1] OF INTEGER
-- index of the $DOUT port to indicate the status of the welding timer to the field
VAR sbwi_din_weld_repeat: ARRAY[ki_num_arms] OF INTEGER
-- index of the $DIN port to select whether welding is to be repeated after a welding alarm
VAR sbvb_cntrl_hand_1: BOOLEAN
-- flag to enable invoking of gun closing/opening by robot control during welding
VAR sbvb_cntrl_hand_2: BOOLEAN

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C3G Plus CONFIGURATIONS

-- flag to enable invoking of the closing prestroke by the application

VAR sbvb_gout_wp_reset: BOOLEAN
-- flag to reset coding of the welding program at each welding operation
VAR sbvb_gun_stroke_check: BOOLEAN
-- flag to enable testing of the gun approached proximity switch after the prestroke command
VAR sbwi_din_autor_dec: ARRAY[1] OF INTEGER
-- index of the $DIN port for the electrode sticking control after welding
VAR sbwi_din_swing_open: ARRAY[1] OF INTEGER
-- index of the $DIN port to test swinging arm proximity open
VAR sbwi_din_swing_close : ARRAY[1] OF INTEGER
-- index of the $DIN port to test swinging arm proximity closed
VAR sbwi_dout_close_gun: ARRAY[1] OF INTEGER
-- index of the $DOUT port to invoke gun closing
VAR sbwi_dout_small_open_gun: ARRAY[1] OF INTEGER
-- index of the $DOUT port to invoke the welding gun opening prestroke
VAR sbwi_dout_big_open_gun: ARRAY[1] OF INTEGER
-- index of the $DOUT port to invoke the welding gun closing prestroke
VAR sbwi_gout_swing: ARRAY[1] OF INTEGER EXPORTED FROM sb_hw
-- index of the $GOUT port for control of the swinging arm of the welding gun (bistable sv)
VAR sbwi_sp_gout_swing: ARRAY[1] OF INTEGER
-- index of the first $DOUT port belonging to the group for swinging arm control
VAR sbwi_len_gout_swing: ARRAY[1] OF INTEGER
-- number of $DOUT ports belonging to the group for swinging arm control
VAR sbvb_maint_box: BOOLEAN
-- indicates whether the Maintenance Box is present (VOLVO option)
VAR sbvb_cntrl_hand_2_in_prog: BOOLEAN
-- indicates whether the application package must also manage retract closing in programming status
VAR sbvb_tp_auto_t_u1_enbl: BOOLEAN
-- flag to enable inclusion of the timer in Auto-Teach status
VAR sbvb_tp_u1_enbl: BOOLEAN
-- flag to enable inclusion of the timer during programming
VAR sbvb_tp_u2_enb: BOOLEAN
-- flag to enable Weld Yes during programming
VAR sbvb_no_air_then_hold: BOOLEAN
-- flag to enable a cycle stop generation function in the case of low pressure in the air circuit
VAR sbvi_ss_edit_param: INTEGER
-- form to enable editing of parameters according to selector position
VAR sbvi_ss_edit_tool: INTEGER
-- form to enable editing of tool dimensions according to selector position
VAR sbvi_severity: INTEGER
-- severity value of the alarms generated by the application program
VAR sbwi_dout_weld_fault: ARRAY[*] OF INTEGER
-- index of the $DOUT port to inform the field of a faulty welding alarm
VAR sbwi_dout_warning: ARRAY[*] OF INTEGER
-- index of the $DOUT port to inform the field of a minor faulty welding alarm
VAR sbwi_word_weld_fault: ARRAY[*] OF INTEGER
-- index of the $WORD port to inform the field of a faulty welding alarm
VAR sbwi_bit_weld_fault: ARRAY[*] OF INTEGER
-- index of the bit of the $DOUT port to inform the field of a faulty welding alarm

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CONFIGURATIONS C3G Plus

VAR sbwi_word_warning: ARRAY[*] OF INTEGER

-- index of the $WORD port to inform the field of a minor faulty welding alarm
VAR sbwi_bit_warning: ARRAY[*] OF INTEGER
-- index of the bit of the $WORD port to inform the field of a minor faulty welding alarm
VAR sbwi_dout_reset_fk: ARRAY[*] OF INTEGER
-- index of the $DOUT port for timer alarm reset and generation of an end of welding sequence
VAR sbwi_dout_reset_repeat: ARRAY[*] OF INTEGER
-- index of the $DOUT port for timer alarm reset and welding spot repeat
VAR sbwi_dout_alim_ev_prop: ARRAY[*] OF INTEGER
-- index of the $DOUT port to power the electronics of the proportional solenoid valve
VAR sbwi_dout_water_flow: ARRAY[*] OF INTEGER
-- index of the $DOUT port to drive the cooling circuit solenoid valve

Only for Maintenance Box:

VAR sbwi_din_close_gun: ARRAY[*] OF INTEGER
-- index of the $DIN port to request gun closing from the field

Only for Application Box:

VAR sbwi_gout_tele: ARRAY[*] OF INTEGER
-- index of the $GOUT port to control the welding power contactor
VAR sbwi_sp_gout_tele: ARRAY[*] OF INTEGER
-- index of the first $DOUT port belonging to the above group
VAR sbwi_len_gout_tele: ARRAY[*] OF INTEGER
-- number of $DOUT ports belonging to the above group
VAR sbwi_gin_tele: ARRAY[*] OF INTEGER
-- index of the $GIN port for reading of the position of the welding power contactor contacts
VAR sbwi_sp_gin_tele: ARRAY[*] OF INTEGER
-- index of the first $DIN port belonging to the above group
VAR sbwi_len_gin_tele: ARRAY[*] OF INTEGER
-- number of $DIN ports belonging to the above group

For Medium Frequency only (Inverter):

VAR sbwi_dout_mfpsu_reset: ARRAY[*] OF INTEGER
-- index of the $DOUT port for inverter alarm reset
VAR sbwi_dout_mfpsu_stop: ARRAY[*] OF INTEGER
-- index of the $DOUT port for disabling of the inverter
VAR sbwi_gin_mfpsu_alrm: ARRAY[*] OF INTEGER
-- index of the $GIN port for inverter fault coding
VAR sbwi_sp_mfpsu_alrm: ARRAY[*] OF INTEGER
-- index of the first $DIN port of the above group
VAR sbwi_len_mfpsu_alrm: ARRAY[*] OF INTEGER
-- number of $DIN ports belonging to the above group

The following variables have been introduced for the FASE 332 integrated welding timer:
VAR sbwi_din_alrm_1: ARRAY[1] OF INTEGER
-- index of the $DIN port for faulty welding alarm from timer
VAR sbwi_din_alrm_2: ARRAY[1] OF INTEGER
-- index of the $DIN port for hardware alarm from timer
VAR sbwi_din_low_cu: ARRAY[1] OF INTEGER
-- index of the $DIN port for excess current alarm from timer
VAR sbwi_word_alrm_1: ARRAY[1] OF INTEGER

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C3G Plus CONFIGURATIONS

-- index of the $DIN port for insufficient current alarm from timer
VAR sbwi_word_alrm_1: ARRAY[1] OF INTEGER
-- index of the $WORD port to inform the field of faulty welding alarm from timer
VAR sbwi_bit_alrm_1: ARRAY[1] OF INTEGER
-- index of the bit of the $WORD port to inform the field of faulty welding alarm from timer
VAR sbwi_word_alrm_2: ARRAY[1] OF INTEGER
-- index of the $WORD port to inform the field of hardware alarm from timer
VAR sbwi_bit_alrm_2: ARRAY[1] OF INTEGER
-- index of the bit of the $WORD port to inform the field of hardware alarm from timer
VAR sbwi_word_high_cur: ARRAY[1] OF INTEGER
-- index of the $WORD port to inform the field of excess current alarm from timer
VAR sbwi_bit_high_cur: ARRAY[1] OF INTEGER
-- index of the bit of the $WORD port to inform the field of excess current alarm from timer
VAR sbwi_word_low_cur: ARRAY[1] OF INTEGER
-- index of the $WORD port to inform the field of insufficient current alarm from timer
VAR sbwi_bit_low_cur: ARRAY[1] OF INTEGER
-- index of the bit of the $WORD port to inform the field of insufficient current alarm from timer

For gun change:

VAR sbwi_din_gun_on_flange: ARRAY[2] OF INTEGER
-- index of the $DIN port to indicate gun on flange

The following variables have been introduced for the SWIM integrated welding timer:
VAR sbwi_sp_word_swim: ARRAY[2] OF INTEGER
st
-- index of 1 word exchanged with SWIM
VAR sbwi_len_word_swim: ARRAY[2] OF INTEGER
-- number of I/O words with SWIM
VAR sbwb_swim: ARRAY[2] OF BOOLEAN EXPORTED FROM sb_hw
-- flag to indicate management of SWIM cards by application
VAR sbwb_wpar_from_swim: BOOLEAN EXPORTED FROM sb_hw
-- flag to indicate reading of technological parameters from SWIM
VAR sbwi_w_thickness: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD sheet thickness from SWIM to C3G Plus
VAR sbwi_w_weld_force: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD welding pressure from SWIM to C3G Plus
VAR sbwi_w_trafo_temp: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD input of transformer on gun thermostat
VAR sbwi_b_trafo_temp: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT input of transformer on gun thermostat
VAR sbwi_w_ev_ok: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD input of digital feedback of digital solenoid valve
VAR sbwi_b_ev_ok: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT input of digital feedback of digital solenoid valve
VAR sbwi_w_air_press: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD for air pressure switch on media panel
VAR sbwi_b_air_press: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT for air pressure switch on media panel
VAR sbwi_w_water_flow: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD input of water flow switch on media panel
VAR sbwi_b_water_flow: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT input of water flow switch on media panel

A_SW SPOT WELDING APPLICATIONS 4-11

02/1000
CONFIGURATIONS C3G Plus

VAR sbwi_w_water_press: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw

-- index $WORD input of water pressure switch on media panel
VAR sbwi_b_water_press: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT input of water pressure switch on media panel
VAR sbwi_w_prot_scr: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD input main circuit breaker on Application Box released
VAR sbwi_b_prot_scr: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT input main circuit breaker on Application Box released
VAR sbwi_w_inp_tele: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD input of welding power contactor closed feedback
VAR sbwi_b_inp_tele: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT input of welding power contactor closed feedback
VAR sbwi_w_out_water_flow: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD for control of water shut-off solenoid valve on media panel
VAR sbwi_b_out_water_flow: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT for control of water shut-off solenoid valve on media panel
VAR sbwi_w_out_tele: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD for control of welding power contactor
VAR sbwi_b_out_tele: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT for control of welding power contactor
VAR sbwi_w_fk: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD for end of sequence from welding timer
VAR sbwi_b_fk: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT for end of sequence from welding timer
VAR sbwi_w_inp_weld_yn: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD for input WELD YES from welding timer
VAR sbwi_b_inp_weld_yn: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT for input WELD YES from welding timer
VAR sbwi_w_swim_ready: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD timer READY input
VAR sbwi_b_swim_ready: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT timer READY input
VAR sbwi_w_pre_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal tip change pre-alarm from timer
VAR sbwi_b_pre_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- indix BIT to signal tip change pre-alarm from timer
VAR sbwi_w_alrm_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal request tip change from timer
VAR sbwi_b_alrm_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to signal request tip change from timer
VAR sbwi_w_req_tip_dress: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal request tip dressing from timer
VAR sbwi_b_req_tip_dress: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to signal request tip dressing from timer
VAR sbwi_w_weld_fault: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal welding fault from timer
VAR sbwi_b_weld_fault: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to signal welding fault from timer
VAR sbwi_w_swim_fault: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD fault code from SWIM to C3G Plus

4-12 A_SW SPOT WELDING APPLICATIONS

02/1000
C3G Plus CONFIGURATIONS

VAR sbwi_w_start: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw

-- index $WORD start welding to timer
VAR sbwi_b_start: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT start welding to timer
VAR sbwi_w_weld_yn: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD WELD YES/NO command to timer
VAR sbwi_b_weld_yn: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT WELD YES/NO command to timer
VAR sbwi_w_reset: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal reset fault to timer
VAR sbwi_b_reset: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to signal reset fault to timer
VAR sbwi_w_reset_fk: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal reset and end of sequence to timer
VAR sbwi_b_reset_fk: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to signal reset and end of sequence to timer
VAR sbwi_w_reset_repeat: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to signal reset and repeat spot to timer
VAR sbwi_b_reset_repeat: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to signal reset and repeat spot to timer
VAR sbwi_w_idx_wp: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD welding program selection to timer
VAR sbwi_sp_wp: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
st
-- index 1 BIT welding program selection to timer
VAR sbwi_len_wp: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- number of BIT welding program selection to timer
VAR sbwi_dout_pre_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $OUT to indicate tip change pre-alarm to the field from timer
VAR sbwi_dout_alrm_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $OUT to indicate request tip change to the field from timer
VAR sbwi_dout_req_tip_dress: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $OUT to indicate request tip change to the field from timer
VAR sbwi_word_pre_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to indicate tip change pre-alarm to the field from timer
VAR sbwi_bit_pre_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to indicate tip change pre-alarm to the field from timer
VAR sbwi_word_alrm_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to indicate request tip change to the field from timer
VAR sbwi_bit_alrm_tip_change: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to indicate request tip change to the field from timer
VAR sbwi_word_req_tip_dress: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to indicate request tip dressing to the field from timer
VAR sbwi_bit_req_tip_dress: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to indicate request tip dressing to the field from timer
VAR sbwi_word_ready: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to indicate timer status to PLC
VAR sbwi_bit_ready: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to indicate timer status to PLC
VAR sbwi_word_weld_fault: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to indicate welding fault to PLC from timer
VAR sbwi_bit_weld_fault: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index BIT to indicate welding fault to PLC from timer

A_SW SPOT WELDING APPLICATIONS 4-13

02/1000
CONFIGURATIONS C3G Plus

VAR sbwi_word_tmr_alrm: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw

-- index $WORD transmit timer alarm code to PLC
VAR sbwi_w_prog_echo: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD to write echo of program code from SWIM
VAR sbwi_w_out_balance: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- index $WORD for electric gun balancing solenoid valve
VAR sbwi_b_out_balance: ARRAY[2] OF INTEGER EXPORTED FROM sb_hw
-- Index BITfor electric gun balancing solenoid valve

I/O CONNECTIONS
The I/O required by the application and how they are mapped vary depending on the hardware configuration
selected:

1) SB200_00.CNF C3G_Plus BOSCH_5000 MFDC

(Standard configuration: SBHW.COD)
Single welding timer: BOSCH series PSS 5000 Medium Frequency
Single arm, number: 1
Cards required: slot4 slot5 slot6
IOM IOM IOM

Inputs
$DIN[35]: Circuit breaker fault (sbwi_din_prot_scr[1])
$DIN[36]: Air present pressure switch (sbwi_din_air_press[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])
$DIN[65]: End of welding timer sequence (sbwi_din_fk[1])
$DIN[66]: Timer Weld Yes/No status (sbwi_din_weld_ynn[1])
$DIN[67]: Timer ready (sbwi_din_ready[1])
$DIN[68]: Failed welding from timer (sbwi_din_weld_fault[1])
$DIN[69]: Minor welding fault (sbwi_din_warning[1])
$DIN[71]: Tip change pre-alarm (sbwi_din_pre_tip_change[1])
$DIN[72]: Tip change alarm (sbwi_din_alrm_tip_change[1])
$GIN[14]:
$DIN[33]: Position welding power contactor contacts
(sbwi_gin_tele[1]
sbwi_sp_gin_tele[1]
sbwi_len_gin_tele[1])
$GIN[15]:
$DIN[45..48]: Inverter alarm code (sbwi_gin_mfpsu_alrm[1]
sbwi_sp_mfpsu_alrm[1]
sbwi_len_mfpsu_alrm[1])

4-14 A_SW SPOT WELDING APPLICATIONS

03/0301
C3G Plus CONFIGURATIONS

Outputs
$DOUT[51]: Reset inverter fault (sbwi_dout_mfpsu_reset[1])
$DOUT[52]: Stop inverter current (sbwi_dout_mfpsu_stop[1])
$DOUT[81]: Start welding (sbwi_dout_start[1])
$DOUT[91]: Weld Yes/No command (sbwi_dout_weld_yn[1])
$DOUT[92]: Timer alarm reset (sbwi_dout_reset[1])
$DOUT[93]: Timer alarm reset and End of Welding (sbwi_dout_reset_fk[1])
$DOUT[94]: Timer alarm reset and Repeat Welding (sbwi_dout_reset_repeat[1])
$GOUT[1]:
$DOUT[82..90]: Welding program code (sbwi_gout_idx_wp[1])
(sbwi_sp_wp[1])
(sbwi_len_wp[1])
$GOUT[14]:
$DOUT[57]: Welding power contactor command (sbwi_gout_tele[1])
(sbwi_sp_gout_tele[1])
(sbwi_len_gout_tele[1])

2) SB200_00.C01 COMAU standard

(User configuration: SBHWUSER.COD)
Configuration based on: SB200_00.CNF C3G_Plus BOSCH_5000 MFDC

Inputs
$DIN[2]: Welding gun fully open prx (sbwi_din_tot_open[1])
$DIN[5]: Weld transformer thermostat (sbwi_din_trafo_temp[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])

2a) SB200_00.C02 VOLVO Belgium

(Standard configuration: SBHWUSER.COD)
Configuration based on: SB200_00.CNF C3G_Plus BOSCH_5000 MFDC

Inputs
$DIN[2]: Welding gun fully open prx (sbwi_din_tot_open[1])
$DIN[3]: Welding gun open prx (sbwi_din_gun_open[1])
$DIN[5]: Weld transformer thermostat (sbwi_din_trafo_temp[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])
$DIN[41]: Request gun close from Maintenance Box
(sbwi_din_close_gun[1])
Outputs
$DOUT[53]: Cooling water circuit solenoid valve
(sbwi_dout_water_flow[1])
$DOUT[59]: Request tip change (Pre-alarm OR Alarm)
(sbwi_dout_pre_tip_change[1])
(sbwi_dout_alrm_tip_change[1])

A_SW SPOT WELDING APPLICATIONS 4-15

02/1000
CONFIGURATIONS C3G Plus

3) SB201_00.CNF C3G_Plus FASE_332_D AC

(Standard configuration: SBHW.COD)
Single welding timer: FASE 332 D
Single arm, number: 1
Cards required: slot4 slot5 slot6
IOM IOM IOM

Inputs
$DIN[1]: Proportional sv digital response (sbwi_din_ev_ok[1])
$DIN[5]: Weld transformer thermostat (sbwi_din_trafo_temp[1])
$DIN[35]: Circuit breaker fault (sbwi_din_prot_scr[1])
$DIN[36]: Air present pressure switch (sbwi_din_air_press[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])
$DIN[65]: End of welding timer sequence (sbwi_din_fk[1])
$DIN[66]: Timer Weld Yes/No status (sbwi_din_weld_yn[1])
$DIN[67]: Timer ready (sbwi_din_ready[1])
$DIN[68]: Failed welding from timer (sbwi_din_alrm1[1])
$DIN[69]: Hardware alarm (sbwi_din_alrm2[1])
$DIN[71]: Tip change pre-alarm (sbwi_din_pre_tip_change[1])
$DIN[72]: Tip change alarm (sbwi_din_alrm_tip_change[1])
$DIN[74]: Excess current (sbwi_din_high_cur[1])
$DIN[75]: Insufficient current (sbwi_din_low_cur[1])
$GIN[14]:
$DIN[33]: Position welding power contactor contacts
(sbwi_gin_tele[1]
sbwi_sp_gin_tele[1]
sbwi_len_gin_tele[1])

Outputs
$DOUT[29]: Proportional sv electronics powered (sbwi_dout_alim_ev_prop[1])
$DOUT[81]: Start welding (sbwi_dout_start[1])
$DOUT[91]: Weld Yes/No command (sbwi_dout_weld_yn[1])
$DOUT[92]: Timer alarm reset (sbwi_dout_gen_reset[1])
$GOUT[1]:
$DOUT[82..88]: Welding program code (sbwi_gout_idx_wp[1])
(sbwi_sp_wp[1])
(sbwi_len_wp[1])
$GOUT[14]:
$DOUT[57]: Welding power contactor command (sbwi_gout_tele[1])
(sbwi_sp_gout_tele[1])
(sbwi_len_gout_tele[1])

4-16 A_SW SPOT WELDING APPLICATIONS

02/1000
C3G Plus CONFIGURATIONS

3a) SB201_00.C01 with floor-mounted gun (MFG)

(Standard configuration: SBHW.COD)
This configuration is suitable when an electric servo gun is used with I/O towards the control unit hard-wired
on IOM5.
Standard configuration: SB201_00.CNF C3G Plus Fase_332_AC

Inputs
$DIN[43]: Welding transformer thermostatic switch (sbwi_din_trafo_temp[1])

Outputs
$DOUT[61]: Gun balancing solenoid valve (sbwi_dout_balance[1])
ON: Status of balancing solenoid valve
during welding (sbwb_dout_balance_in_weld[1])
In case of electric gun, the following I/Os are then eliminated:
Proportional sv digital response (sbwi_din_ev_ok[1])
Proportional sv electronic supply (sbwi_dout_alim_ev_prop[1])

3b) SB201_00.C02 FASE_332 su SMART H4

(Standard configuration: SBHW.COD)
This configuration has been created to manage welding gun I/Os on SMART H4 robots.
Configuration based on: SB201_00.CNF C3G Plus Fase_332_AC

Inputs
$DIN[2]: Gun open prx (sbwi_din_gun_open)
$DIN[3]: Welding gun fully open prx (sbwi_din_tot_open)

A new type of proportional solenoid valve has been introduced and the following I/Os have been eliminated:
Proportional sv digital response (sbwi_din_ev_ok[1])

A_SW SPOT WELDING APPLICATIONS 4-17

02/1000
CONFIGURATIONS C3G Plus

4) SB202_00.CNF C3G_Plus BOSCH_5000 AC

(Standard configuration: SBHW.COD)
Single welding timer: BOSCH series PSS 5000 (20 [ms])
Single arm, number: 1
Cards required: slot4slot5 slot6
IOM IOM IOM

Inputs
$DIN[1]: Proportional sv digital response (sbwi_din_ev_ok[1])
$DIN[35]: Weld transformer thermostat (sbwi_din_prot_scr[1])
$DIN[36]: Air present pressure switch (sbwi_din_air_press[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])
$DIN[65]: End of welding timer sequence (sbwi_din_fk[1])
$DIN[66]: Timer Weld Yes/No status (sbwi_din_weld_yn[1])
$DIN[67]: Timer ready (sbwi_din_ready[1])
$DIN[68]: Failed welding from timer (sbwi_din_weld_fault[1])
$DIN[69]: Minor welding fault (sbwi_din_warning[1])
$DIN[71]: Tip change pre-alarm (sbwi_din_pre_tip_change[1])
$DIN[72]: Tip change alarm (sbwi_din_alrm_tip_change[1])
$GIN[14]:
$DIN[33]: Position welding power contactor contacts
(sbwi_gin_tele[1]
sbwi_sp_gin_tele[1]
sbwi_len_gin_tele[1])

Outputs
$DOUT[29]: Proportional sv electronics powered (sbwi_dout_alim_ev_prop[1])
$DOUT[81]: Start welding (sbwi_dout_start[1])
$DOUT[91]: Weld Yes/No command (sbwi_dout_weld_yn[1])
$DOUT[92]: Timer alarm reset (sbwi_dout_reset[1])
$DOUT[93]: Reset timer fault & End of welding (sbwi_dout_reset_fk[1])
$DOUT[94]: Reset timer fault & Repeat welding (sbwi_dout_reset_repeat[1])$GOUT[1]:
$DOUT[82..90]: Welding program code (sbwi_gout_idx_wp[1])
(sbwi_sp_wp[1])
(sbwi_len_wp[1])
$GOUT[14]:
$DOUT[57]: Welding power contactor command (sbwi_gout_tele[1])
(sbwi_sp_gout_tele[1])
(sbwi_len_gout_tele[1])

4a) SB202_00.C01 COMAU standard

(Standard configuration: SBHWUSER.COD)
Configuration based on: SB202_00.CNF C3G_Plus BOSCH_5000 AC
Input
$DIN[2]: Welding gun fully open prx (sbwi_din_tot_open[1])
$DIN[5]: Welding transformer thermostat (sbwi_din_trafo_temp[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])

4-18 A_SW SPOT WELDING APPLICATIONS

02/1000
C3G Plus CONFIGURATIONS

5) SB206_00.CNF C3G_Plus FASE_334_AC

Single welding timer: FASE series WELD 334
Single arm, number: 1
Cards required: slot4 slot5 slot6
IOM IOM IOM

Inputs
$DIN[1]: Proportional sv digital response (sbwi_din_ev_ok[1])
$DIN[5]: Weld transformer thermostat (sbwi_din_trafo_temp[1])
$DIN[35]: Circuit breaker fault (sbwi_din_prot_scr[1])
$DIN[36]: Air present pressure switch (sbwi_din_air_press[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])
$DIN[65]: End of welding timer sequence (sbwi_din_fk[1])
$DIN[66]: Timer Weld Yes/No status (sbwi_din_weld_yn[1])
$DIN[67]: Timer ready (sbwi_din_ready[1])
$DIN[68]: Welding fault (sbwi_din_alrm1[1])
$DIN[69]: Hardware alarm (sbwi_din_alrm2[1])
$DIN[71]: Tip change pre-alarm (sbwi_din_pre_tip_change[1])
$DIN[72]: Tip change alarm (sbwi_din_alrm_tip_change[1])
$DIN[74]: Excess current (sbwi_din_high_cur[1])
$DIN[75]: Insufficient current (sbwi_din_low_cur[1])
$GIN[14]:
$DIN[33]: Position welding power contactor contacts
(sbwi_gin_tele[1]
sbwi_sp_gin_tele[1]
sbwi_len_gin_tele[1])

Outputs
$DOUT[29]: Proportional sv electronics powered (sbwi_dout_alim_ev_prop[1])
$DOUT[81]: Start welding (sbwi_dout_start[1])
$DOUT[91]: Weld Yes/No command (sbwi_dout_weld_yn[1])
$DOUT[92]: Timer alarm reset (sbwi_dout_gen_reset[1])
$GOUT[1]:
$DOUT[82..88]:Welding program code (sbwi_gout_idx_wp[1])
(sbwi_sp_wp[1])
(sbwi_len_wp[1])
$GOUT[14]:
$DOUT[57]: Welding power contactor command (sbwi_gout_tele[1])
(sbwi_sp_gout_tele[1])
(sbwi_len_gout_tele[1])

A_SW SPOT WELDING APPLICATIONS 4-19

02/1000
CONFIGURATIONS C3G Plus

5a) SB206_00.C01 FASE_334_AC FIAT program 937 (H4)

(Standard configuration: SBHW.COD)

Inputs
$DIN[2]: Gun open prx (sbwi_din_gun_open)
$DIN[3]: Gun fully open prx (sbwi_din_tot_open)

Outputs
$DOUT[20]: Gun balancing solenoid valve (sbwi_dout_balance)
ON: Status of gun balancing sv during welding (sbwi_dout_balance_in_weld)
A new type of proportional solenoid valve has been introduced and the following I/Os have been eliminated:
Proportional sv digital response (sbwi_din_ev_ok[1]:=0)
Proportional sv electric supply (sbwi_dout_alim_ev_prop[1]:=0)

6) SB210_00.CNF C3G_Plus BOSCH PSS 2081 D

Single welding timer: BOSCH series PSS 2081 D
Single arm, number: 1
Cards required: slot4 slot5 slot6
IOM IOM IOM

Inputs
$DIN[1]: Proportional sv digital response (sbwi_din_ev_ok[1])
$DIN[35]: Circuit breaker fault (sbwi_din_prot_scr[1])
$DIN[36]: Air present pressure switch (sbwi_din_air_press[1])
$DIN[37]: Cooling water flow switch (sbwi_din_water_flow[1])
$DIN[65]: End of welding timer sequence (sbwi_din_fk[1])
$DIN[66]: Timer Weld Yes/No status (sbwi_din_weld_yn[1])
$DIN[67]: Timer ready (sbwi_din_ready[1])
$DIN[70]: Request tip dressing
$DIN[71]: Tip change pre-alarm (sbwi_din_pre_tip_change[1])
$DIN[72]: Tip change alarm (sbwi_din_alrm_tip_change[1])
$GIN[14]:
$DIN[33]: Position welding power contactor contacts
(sbwi_gin_tele[1]
(sbwi_sp_gin_tele[1]
(sbwi_len_gin_tele[1])
$GIN[16]:
$DIN[75..80]: Timer alarms code (sbwi_gin_tmr_alrm[1]
(sbwi_sp_tmr_alrm[1]
(sbwi_len_tmr_alrm[1])

4-20 A_SW SPOT WELDING APPLICATIONS

02/1000
C3G Plus CONFIGURATIONS

Outputs
$DOUT[29]: Proportional sv electronic supply (sbwi_dout_alim_ev_prop[1])
$DOUT[81]: Start welding (sbwi_dout_start[1])
$DOUT[91]: Weld Yes/No command (sbwi_dout_weld_yn[1])
$DOUT[92]: Timer alarm reset (sbwi_dout_gen_reset[1])
$DOUT[93]: Welding current alarm reset (sbwi_dout_ksr_reset[1])
$DOUT[95]: Tip dressing
$DOUT[96]: Tip change carried out
$GOUT[1]:
$DOUT[82..87]: Welding program code (sbwi_gout_idx_wp[1])
(sbwi_sp_wp[1])
(sbwi_len_wp[1])
$GOUT[14]:
$DOUT[57]: Welding power contactor command (sbwi_gout_tele[1])
(sbwi_sp_gout_tele[1])
(sbwi_len_gout_tele[1])

7) SB230_00.CNF C3G_Plus SWIM FASE_334 weld module

Single welding timer: FASE series SWIM 334 integrated on bus-VME
Single arm, number: 1
Cards required: slot4 slot5
IOM IOM

Configuration
11 (SWIM-FASE): Integrated timer code (sbvi_intwt_code)
2 (bus-VME): Type of interface to timer (sbvi_timer_interface)
ON: SWIM management enabled (sbwb_swim[1])
st
100: Address 1 $WORD dialogue with SWIM (sbwi_len_word_swim)
8: Number of $WORD exchanged with SWIM (sbwi_len_word_swim)
OFF: Read technological parameters from SWIM (sbvb_wpar_from_swim)

Inputs
$DIN[2]: Gun open prx (sbwi_din_gun_open)
$DIN[5]: Transformer on gun thermostats (sbwi_din_trafo_temp)

Signals via bus-VME

Media Panel/Application Box

Inputs
$WORD[110], BIT 10: Main Ap Box circuit breaker released (sbwi_w_prot_scr)
(sbwi_b_prot_scr)
$WORD[110], BIT 1: Air pressure switch (sbwi_w_air_press)
(sbwi_b_air_press)
$WORD[110], BIT 2: Water pressure switch (sbwi_w_water_flow)
(sbwi_b_water_flow)
$WORD[110], BIT 3: Welding power contactor closed (sbwi_w_inp_tele)
(sbwi_b_inp_tele)
Outputs
$WORD[110], BIT 8: Close welding power contactor command (sbwi_w_out_tele)
(sbwi_b_out_tele)

A_SW SPOT WELDING APPLICATIONS 4-21

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CONFIGURATIONS C3G Plus

SWIM

Input
$WORD[109], BIT 1: End of welding sequence (sbwi_w_fk)
(sbwi_b_fk)
$WORD[109], BIT 2: Weld Yes/No status (sbwi_w_weld_yn)
(sbwi_b_weld_yn)
$WORD[109], BIT 3: Timer ready (sbwi_w_ready)
(sbwi_b_ready)
$WORD[109], BIT 4: General welding fault (sbwi_w_weld_fault)
(sbwi_b_weld_fault)
$WORD[109], BIT 5: Request tip dressing (sbwi_w_req_tip_dress)
(sbwi_b_req_tip_dress)
$WORD[109], BIT 6: Tip change pre-alarm (sbwi_w_pre_tip_change)
(sbwi_b_pre_tip_change)
$WORD[109], BIT 7: Tip change alarm (sbwi_w_tip_change)
(sbwi_b_tip_change)
$WORD[112]: SWIM alarm code (sbwi_w_swim_fault)
$WORD[113]: Index $WORD to echo SWIM program code (sbwi_w_prog_echo[1])
Outputs
$WORD[101], BIT 1: Start welding (sbwi_w_start)
(sbwi_b_start)
$WORD[101], BIT 2: Weld YES/NO command (sbwi_w_weld_yn)
(sbwi_b_weld_yn)
$WORD[101], BIT 3: Reset general alarm (sbwi_w_reset)
(sbwi_b_reset)
$WORD[101], BIT 4: Reset faults and end of sequence (sbwi_w_reset_fk)
(sbwi_b_reset_fk)
$WORD[101], BIT 5: Reset faults and repeat spot (sbwi_w_reset_repeat)
(sbwi_b_reset_repeat)
Output groups
$WORD[101]: Select welding program (sbwi_w_idx_wp)
8: First bit of program selection group (sbwi_sp_wp)
9: Number of bit of program selection group (sbwi_len_wp)

4-22 A_SW SPOT WELDING APPLICATIONS

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C3G Plus CONFIGURATIONS

7a) SB230_00.C01 FIAT prg 192 Cassino

(User configuration: SBHWUSER.COD)
Configuration based on: SB230_00.CNF C3G Plus + SWIM FASE 334
applicable on robots H1, H2, H4 with electric/air gun
for project FIAT 192 (Cassino plant).

Configuration
FALSE: Reading of technological parameters from SWIM (sbvb_wpar_from_swim)

Signals from/to PLC

Inputs
$WORD[26], BIT 8: Input cycle without workpiece (sbwi_inp_word_no_piece)
(sbwi_inp_bit_no_piece)

Outputs
$WORD[18], BIT 1: Tip change pre-alarm from timer (sbwi_word_pre_tip_change)
(sbwi_bit_pre_tip_change)
18, 2: Request tip change from timer (sbwi_word_tip_change)
(sbwi_bit_tip_change)
18, 16: Cycle without workpiece active (sbwi_out_word_no_piece)
(sbwi_out_bit_no_piece)
18, 8: Welding fault from timer (sbwi_word_weld_fault)
(sbwi_bit_weld_fault)

7b) SB230_00.C02 FIAT prg 192

(User configuration: SBHWUSER.COD)
Configuration based on: SB230_00.CNF
applicable for H1, H2, H4 robots with floor-mounted electric gun for the FIAT 192
project.

Signals from/to gun

Input
$WORD[109], BIT 12: Weld transformer thermostat input (sbwi_w_trafo_temp[1])
(sbwi_b_trafo_temp[1])

Output
$WORD[102], BIT 2: Pneumatic gun balancing SV output (sbwi_w_out_balance[1])
(sbwi_b_out_balance[1])
OFF: Status of balancing SV during welding (sbwb_dout_balance_in_weld[1])

A_SW SPOT WELDING APPLICATIONS 4-23

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CONFIGURATIONS C3G Plus

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4-24 A_SW SPOT WELDING APPLICATIONS

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 A_SW Spot Welding
C3G Plus Applications

DIALOGUE WITH WELDING TIMER

FEATURES 1-1
USER INTERFACE 2-1
INSTRUCTIONS 3-1
CONFIGURATIONS 4-1
DIALOGUE WITH WELDING TIMER 5-1
APPENDIX A A-1

SUMMARY

Paragraph
Page
Management 5-1
A_SW Spot Welding
Applications C3G Plus

This page has been left intentionally blank

C3G Plus DIALOGUE WITH WELDING TIMER

MANAGEMENT
The ? in SX_arm? indicates the arm to which the program refers. SX_arm1 is therefore the program
that manages arm 1.

SX_arm? is a NOHOLD program referring to arm 1 activated when the WELD_INIT call is made. It provides
management of the welding gun. The program starts up when the welding spot is reached, or n milliseconds
before, and acts as follows:
1) Stores robot current position:
if a cycle is interrupted, on return to the cycle a check is made that the robot is still in the position
stored with a tolerance defined by the application parameter configuration variables: SXvr_lin_delta
and SXvr_jnt_delta (depending on the type of robot axes). If the robot is no longer in the point stored,
the following warning is given: "Robot not in welding position" and the controller returns to the
movement program.
2) Before proceeding to give the welding start, it checks the following in order:
2.a) the timer is included;
2.b) the timer is ready (if the function is provided);
2.c) the welding program is included in the preset range;
2.d) the solenoid valve OK Input is ON;
2.e) the gun is retracted (if furnished with the specific micro);
2.f) the end of welding sequence Input is not ON;
2.g) there has not been a cycle stop.
The following tests are carried out in the INTEGRATED SPOT (according to the hardware configuration file):
air present for proportional solenoid valve;
overtemperature of welding transformers;
gun cooling water present;
welding circuit breaker closed.
3) One of the following events can occur after the welding start has been given:
3.a) the end of sequence is received;
3.b) the cycle is interrupted (HOLD);
3.c) after n milliseconds, neither 3.a and nor 3.b has occurred
(n milliseconds is the "SXwi_tmr_fk" variable of the application parameters configuration file).

The INTEGRATED SPOT can receive the serious welding timer alarm.

4) Depending on which of the events occurs:

3.a end of sequence, "SX_arm?" removes the start signal and ends its work, control is returned
to the motion program;
3.b interrupt cycle, "SX_arm?" removes the start signal and (for the COMAU/BOSCH timer)
checks whether the end of sequence is received within the time "SXwi_tmr_fk". If this is the
case, control is returned to the motion program, otherwise it waits for the cycle to be restored
and then starts again from point (2);
3.c timeout, "SX_arm?" indicates the "end of welding sequence failure" alarm; when the alarm is
restored it starts again from point (2).
Before control is returned to the motion program, any gun open and gun closed micros are tested to check
whether the gun is open and not closed.
These tests can be enabled/disabled by setting the sbvb_gun_open_check and sbvb_gun_close_check
variables (EXPORTED FROM sb_hw) to TRUE/FALSE. These tests are only available in A_SW1B.

In case of a minor alarm (current alarm) in the INTEGRATED SPOT, "START WELDING" is
maintained and a "RESET CURRENT ALARM" is given simultaneously to generate an "END OF
WELDING SEQUENCE".

A_SW SPOT WELDING APPLICATIONS 5-1

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DIALOGUE WITH WELDING TIMER C3G Plus

5) No welding occurs if:

2.g cycle on hold, "SX_arm?" waits for the cycle to be restored and starts again from point (2);
2.f end of sequence ON, "SX_arm?" gives the "end of welding sequence = ON before start" alarm;
after the alarm is reset it starts again from point (2);
2.e welding gun not closed, "SX_arm?" gives the "welding gun tot. open prx = ON"; after the alarm is
reset, it starts up again from point (2);
2.d solenoid valve not OK, if the solenoid valve OK signal is sent within "SXwi_time_pr" milliseconds
"SX_arm?" returns to point (2), otherwise it generates the "prop. sv = OFF, gun pressure not OK"
alarm; after the alarm is restored it starts again from point (2);
2.c program outside range, the signal was already sent at the start of the movement toward the
welding spot; control is returned to the motion program;
2.b timer not ready (for timers that provide this information), "SX_arm?" gives the "timer ready = OFF,
timer not ready" alarm; after the alarm is reset it starts again from point (2);
2.a timer excluded, a check is made that the welding spot name is included in the preset range
(otherwise control is returned to the movement spot name);
if in AUTO-LOCAL or REMOTE, "SX_arm?", after checks are made on:
welding position;
welding gun closed;
cycle not on hold;
commands the welding gun to be closed for a time "SXwi_delay_hand" and, after it is opened, waits
for another "SXwi_delay_open" milliseconds before returning control to the movement program (for the
variable, see the application parameters configuration file);
if in PROGRAMMING, "SX_arm?" does not do anything since in this mode it is the programmer who
will have total control of the welding gun; control is therefore returned to the movement program.
Welding may not have occurred if the following tests have failed:
- air present for proportional solenoid valve;
- overtemperature of welding transformers;
- gun cooling water present;
- welding circuit breaker closed;
there is a restart from point 2 in on reset of the alarms.

5-2 A_SW SPOT WELDING APPLICATIONS

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 A_SW Spot Welding
C3G Plus Applications

APPENDIX A
FEATURES 1-1
USER INTERFACE 2-1
INSTRUCTIONS 3-1
CONFIGURATIONS 4-1
DIALOGUE WITH WELDING TIMER 5-1
APPENDIX A A-1

SUMMARY

Paragraph Page

A_SW1B application program A-1

Specific items in the status window for A_SW1B A-1
Specific instructions for A_SW1B A-1
List of predefined alarms and messages in A_SW1B A-8
Application A_SW1B alarm codes A-8
A_SW2 application program A-9
Specific items in the status window for A_SW2 A-9
Specific instructions for A_SW2 A-9
A_SW2 parameters configuration file A-11
A_SW2 hardware configuration file A-11
List of predefined alarms and messages in A_SW2 A-12
I/O connections A-12
Application A_SW2 alarm codes A-16
Error messages A-16
Installation A-16
Communication Boards A-17
Boards A-17
General A-18
Technological A-19
Information messages A-20
Examples of tip change management in different cases of "Integrated spot" A-21
A_SW Spot Welding
Applications C3G Plus

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C3G Plus APPENDIX A

A_SW1B APPLICATION PROGRAM

This chapter describes the parts of the A_SW1B application program that are not common to the other Spot
Welding application programs.

SPECIFIC ITEMS IN THE STATUS WINDOW FOR A_SW1B

Explanation of the specific A_SW1B "fields":
Weld: - welding timer program selected
*: - Y/N WELD YES/NO, this symbol represents a welding spot
W: - Y if the timer is included
- N if the timer is excluded
- * if the INCL_APPL (OFF) routine has been used

SPECIFIC INSTRUCTIONS FOR A_SW1B

PRESS(x)
Example of call:
PROGRAM prog_1
ROUTINE press(ai_prog : INTEGER) EXPORTED FROM sb_appl
BEGIN
...
press(3)
...
END prog_1

Parameters:
x -- > INTEGER: welding program
What it does:
Selects a welding channel; the timer adapts to the new selection and sets the relative pressure.
When to use it:
To set the pressure values that correspond to the welding program; to advance selection of the welding
program (see example of gun retraction).
Operation in detail:
When PRESS is called it checks that:
the program that called it belongs to an arm enabled for welding;
the previous welding channel is within the predefined range. If it is outside the range the: "PRESS
value outside x..y limits" alarm is sent.
After selecting the welding channel it waits for a time, "sbwi_delay_pr" (default 50 [ms], see
configuration of A_SW1B parameters) and then tests the solenoid valve Input OK. If within the time
"sbwi_time_pr" (see configuration of A_SW1B parameters) the Input is not = ON, the "prop. sv = OFF,
gun pressure not OK" alarm is sent. After resetting the alarm it repeats the test.

A_SW SPOT WELDING APPLICATIONS A-1

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APPENDIX A C3G Plus

WELD_NOW(ai_wprog)
Example of call:
PROGRAM prog_1
ROUTINE weld_now(ai_wprog : INTEGER) EXPORTED FROM sb_appl
BEGIN
...
MOVE TO pnt0001p
weld_now(3) -- Selects program 3 and welds.
MOVE TO pnt0002p
weld_now(-1) -- Welds with program 3.
...
END prog_1

Parameters:
ai_wprog : INTEGER welding program
What it does:
Selects the welding program and sends the start welding command.
When to call it:
To start welding at any point of the work program or in the user routine.
Operation in detail:
It selects the welding program (indicated in its parameter) by calling the routine of the PRESS application,
so that the pressure associated with the previous welding program is set and reached. If the value of the
parameter received is -1, PRESS is not called; welding is started using the last program that was
selected.
DEC_GLOBAL(ab_b : BOOLEAN)
Example of call:
PROGRAM prog_1
ROUTINE dec_global(ab_b : BOOLEAN) EXPORTED FROM sb_appl
BEGIN
...
dec_global(ON) -- Enable sticking electrode control function.
...
dec_global(OFF) -- Disable sticking electrode control function.
...
END prog_1
Parameters:
ab_b : BOOLEAN
What it does:
Enables/disables the sticking electrode control function.
When to use it:
It is generally used to enable/disable the sticking electrode control function for all welding spots of the
work program or part thereof.
Operation in detail:
It sets the application program so that the sticking electrode control is executed or not at each welding
spot. At the end of welding, before starting to move away from the welding spot, a digital input to enable
continuation is tested; if the input is OFF, the gun close and re-open command is sent to try to «unstick»
the tip. If it stays OFF the sticking electrode alarm is sent. If it moves to ON, a tips no longer «stuck»
message is sent.

A-2 A_SW SPOT WELDING APPLICATIONS

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C3G Plus APPENDIX A

NO_DEC
Example of call:
PROGRAM prog_1
ROUTINE no_dec : INTEGER EXPORTED FROM sb_appl
BEGIN
...
MOVE TO pnt0001p,
WITH CONDITION[weld(1, FALSE)],
WITH CONDITION[no_dec]
ENDMOVE
...
END prog_1

Parameters:
none.
What it does:
Locally disables the sticking electrode control on one welding spot.
When to use it:
When, with the sticking electrode control enabled for all welding spots, a few odd points on which the
control function is to be disabled must be distinguished in the program.
Operation in detail:
It sets the application program so that the sticking electrode control is not executed on the corresponding
welding spot. At the end of welding, the digital input to enable continuation is not tested.
SWING(ab_sts)
Example of call:
PROGRAM prog_1
ROUTINE swing(ab_sts : BOOLEAN) EXPORTED FROM sb_appl
BEGIN
...
swing(ON)
...
END prog_1

Parameters:
ab_sts : BOOLEAN
What it does:
swing(ON) --> activates extra movement of the welding gun
swing(OFF) --> deactivates extra movement of the welding gun
When to use it:
To activate/deactivate an extra welding gun movement in addition to the retract and close movements
invoked by the CLOSE HAND x instructions. The extra movement may be, for instance, the swinging of a
gun arm.
Operation in detail:
Having ensured that the gun is fully open, it invokes the extra movement of the welding gun. If the
movement is not executed within 2 seconds (position proximity switch reading), an alarm is sent.

A_SW SPOT WELDING APPLICATIONS A-3

01/0598
APPENDIX A C3G Plus

WELD(x,y)
Example of call:
PROGRAM prog_1
ROUTINE weld(ai_prog : INTEGER; ab_before: BOOLEAN) EXPORTED FROM sb_appl
BEGIN
...
MOVE JOINT TO pnt0001p,
WITH CONDITION[weld(2, FALSE)],
ENDMOVE
...
END prog_1

Parameters:
x --> INTEGER: welding program
y --> BOOLEAN: FALSE -> does not advance, TRUE -> advances start time
What it does:
Before starting the movement, it sets the welding program to the timer and defines the condition to be
used to advance or otherwise the start time of welding when point pnt0001p is reached.
When to use it:
On MOVEs to welding points.

If the advance welding start time is used, the $TERM_TYPE of the movement must only be
NOSETTLE. The use of FINE or COARSE would be a contradiction, requiring precise positioning
on the point before welding while advancing the start of welding.
If the advance welding start time is not used, any $TERM_TYPE can be used because in this case
the start is sent at the theoretical end of the NOSETTLE movement, or at the real end in case of
COARSE or FINE.
Operation in detail:
When WELD is called it checks that:
the previous welding channel is within the predefined range. If it is outside the range, a “WELD value
outside x..y value" is sent; when the robot reaches the welding point, it does not weld.
Depending on the FALSE or TRUE parameter, it returns the type of condition to be used. In case of
FALSE the condition will be WHEN AT END DO, i.e. it welds at the end of the movement, whether this
is the theoretical end ($TERM_TYPE:=NOSETTLE) or real end ($TERM_TYPE:=COARSE or FINE
according to the tolerance required). In case of TRUE, it advances or delays, in relation to the
theoretical end of the movement, the time defined in the last BEFORE_HAND routine that was called.

A-4 A_SW SPOT WELDING APPLICATIONS

01/0598
C3G Plus APPENDIX A

INCL_APPL(ab_sts: BOOLEAN)
Only available with the "integrated spot" configurations.
Example of call:
PROGRAM prog_1
ROUTINE incl_appl(ab_sts : BOOLEAN) EXPORTED FROM sb_appl
BEGIN
.....
incl_appl(OFF)
..
..
..
incl_appl(ON)
END progr_1
Parameters:
ab_sts -----> BOOLEAN: status of application program
What it does:
Includes/excludes the application program hardware (welding switch, water closing solenoid valve) and all
the relative controls.
When to use it:
During automatic tool change to disconnect the current to the tool change plates.
During maintenance to prevent cooling water from flowing on tips.
Operation in detail:
When INCL_APPL is called:
if ab_sts is ON:
- enables the application program in the «included» status by activating the power contactor and
the water if allowed by the current condition.
if ab_sts is OFF:
- enables the application program in the «excluded» status by opening the power contactor and
excluding the flow of cooling water by means of the closing solenoid valve. During exclusion, all
controls of hardware devices, such as the timer, power contactor and flow switch are disabled.

LARGE_OPEN
Example of call:
PROGRAM prog_1
ROUTINE large_open: INTEGER EXPORTED FROM sb_appl
BEGIN
...
MOVE TO pnt0001p,
WITH CONDITION[weld(1, FALSE)],
WITH CONDITION[large_open],
ENDMOVE
...
END prog_1

Parameters:
none
What it does:
Opens the welding gun fully at the end of welding.

A_SW SPOT WELDING APPLICATIONS A-5

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APPENDIX A C3G Plus

When to use it:

When for mechanical/time reasons gun pre-stroke opening must be executed before moving to the next
point.
It can only be used on welding moves associated with the WELD routine
Operation in detail:
After receiving the end of sequence signal from the welding timer, the closing solenoid valve is released
and the pre-stroke solenoid valve is opened.
Thanks to the pneumatic circuit, this type of movement reduces overall gun closed to gun fully open time.

REOPEN
Example of call:
PROGRAM prog_1
ROUTINE reopen (ar_reopen_quote:REAL): INTEGER EXPORTED FROM sb_appl
BEGIN
...
MOVE LINEAR TO xtn0001x,
WITH CONDITION[weld(1, OFF)],
WITH CONDITION[reopen(50)],
ENDMOVE
...
END prog_1

Parameters:
ar_reopen_quote (REAL) : required opening quote [mm].
What it does:
This function is used to bring the tips of the electric gun to a different quote compared to the initial one at
the end of a welding point.
When to use it:
It can only be used on welding moves associated with the WELD routine

A-6 A_SW SPOT WELDING APPLICATIONS

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C3G Plus APPENDIX A

Example of calling the A_SW1B technological routines

Note the use of PRESS to advance selection of the welding program of the weld:
PROGRAM prog_1
BEGIN
weld_init -- Def. condition initialization
before_hand(50) -- Def. condition for advance
...
MOVEFLY TO pnt0002p ADVANCE
press(2) -- Pre-selects the program
MOVE TO pnt0001p -- Moves to the first point
CLOSE HAND 2 -- Retracts the gun
DELAY 300 -- Waits for retraction
MOVE JOINT TO pnt0001p, -- Repeats the MOVE to the
WITH CONDITION[weld(2, FALSE)], -- same point
ENDMOVE -- to call the weld...
...
MOVE JOINT TO pnt0003p, -- Selects the welding
WITH CONDITION[weld(5, TRUE)], -- program,
ENDMOVE -- in advance.
...
MOVE JOINT TO pnt0004p, -- Selects the welding
WITH CONDITION[weld(1, FALSE)], -- program,
ENDMOVE -- moves to the point and welds
-- (without advance).
...
OPEN HAND 2 -- Fully opens the gun
...
END prog_1
From this version the pre-stroke can be executed directly by the application program; the instructions defined
above can be replaced by:
MOVE JOINT TO pnt0001p,
WITH CONDITION[weld(2,FALSE)],
END CONDITION

A_SW SPOT WELDING APPLICATIONS A-7

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APPENDIX A C3G Plus

LIST OF PREDEFINED ALARMS AND MESSAGES IN A_SW1B

The A_SW1B application includes a number of predefined alarms and messages for use with statements
A_ALARM('x') and A_MESSAGE('x') where x is a number between 1 and 10.

Alarms
A_ALARM('1') - Parity bit incongruity
A_ALARM('2') - Wrong program coding
A_ALARM('3') - Robot not in rest position
A_ALARM('4') - Welding gun tot. open prx out of order

Messages
A_MESSAGE('1') - Wait for "robot program start" = ON from PLC
A_MESSAGE('2') - Received "robot program start" = ON from PLC

APPLICATION A_SW1B ALARM CODES

43261:A_SW1B ..(see technological error a) "Error messages")
43262:A_SW1B ..(see technological error b) "Error messages")
43263:A_SW1B ..(see technological error c) "Error messages")
43264:A_SW1B ..(see technological error d) "Error messages")
43265:A_SW1B ..(see technological error e) "Error messages")
43266:A_SW1B ..(see technological error f) "Error messages")
43267:A_SW1B ..(see technological error g) "Error messages")
43268:A_SW1B ..(see technological error h) "Error messages")
43269:A_SW1B ..(see technological error i) "Error messages")
43270:A_SW1B ..(see technological error l) "Error messages")
For the INTEGRATED SPOT the following alarms also exist:
43271:A_SW1B ..(see error (si1) "Error messages")
43272:A_SW1B ..(see error (si2) "Error messages")
43273:A_SW1B ..(see error (si3) "Error messages")
43274:A_SW1B ..(see error (si4) "Error messages")
43275:A_SW1B ..(see error (si5) "Error messages")
43276:A_SW1B ..(see error (si6) "Error messages")
43277:A_SW1B ..(see error (si7) "Error messages")
43278:A_SW1B ..(see error (si8) “Error messages”)
43279:A_SW1B ..(see error (si9) “Error messages”)
43280:A_SW1B ..(see error (si10) “Error messages”)
43281:A_SW1B ..(see error (si11) “Error messages”)

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C3G Plus APPENDIX A

A_SW2 APPLICATION PROGRAM

This chapter describes the parts of the A_SW2 application program that are not common to the other Spot
Welding packages.

SPECIFIC ITEMS IN THE STATUS WINDOW FOR A_SW2

Explanation of the specific A_SW2 "fields":
W1: - first welding timer program selected.
W2: - second welding timer program selected.
C1: - first welding timer status (included/excluded).
C2: - second welding timer status (included/excluded).

SPECIFIC INSTRUCTIONS FOR A_SW2

PRESS(x,y)
Example of call:
PROGRAM prog_1
ROUTINE press (ai_wprog1,ai_wprog2: INTEGER) EXPORTED FROM s2_appl
BEGIN
...
press (3, 6)
...
END prog_1

Parameters:
x --> INTEGER: first gun welding program
Y --> INTEGER: second gun welding program
What it does:
Selects a welding channel for each gun; the timers adapt to the new selection and set the corresponding
pressure values. To modify the program of only one gun, set the other to –1.
When to use it:
To set the pressure values that correspond to the welding program; to advance selection of the welding
program (see example for gun retraction).
Operation in detail:
When PRESS is called it checks that:
the program that called it belongs to an arm enabled for welding;
the previous welding channels are within the predefined range. If they are outside the range the: "PRESS
value outside x..y limits" alarm is sent.
One welding channel at a time waits for a time "s2wi_delay_pr" (default 50 [ms], see configuration of
A_SW2 parameters) and then tests the solenoid valve Input OK. If within the time "s2wi_time_pr" (see
configuration of A_SW2 parameters) the Input is not = ON, the "prop. sv = OFF, gun pressure not OK"
alarm is sent. After resetting the alarm it repeats the test.

A_SW SPOT WELDING APPLICATIONS A-9

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APPENDIX A C3G Plus

WELD(x,y,z)
Example of call:
PROGRAM prog_1
ROUTINE weld(ai_wprog1, ai_wprog2:INTEGER; ab_before:BOOLEAN)
EXPORTED FROM s2_appl
BEGIN
...
MOVE JOINT TO pnt0001p,
WITH CONDITION[weld(2, 1, FALSE)],
ENDMOVE
...
END prog_1

Parameters:
x --> INTEGER: first gun welding program
y --> INTEGER: second gun welding program
z --> BOOLEAN: FALSE -> does not advance, TRUE -> advances start time
What it does:
Before starting the movement it sets the welding programs to the timer and defines which condition must
be used to advance or otherwise the start time of welding when reaching point pnt0001p. If welding is to be
executed with just one gun, set the other to –1.
When to use it:
On MOVEs to welding spots.
If the advance welding start time is used, the $TERM_TYPE of the movement must only be
NOSETTLE. The use of FINE or COARSE would be a contradiction, requiring precise positioning on
the point before welding while advancing the start of welding.
If the advance welding start time is not used, any $TERM_TYPE can be used because in this case
the start is sent at the theoretical end of the NOSETTLE movement, or at the real end in case of
COARSE or FINE.

Operation in detail:
When WELD is called it checks that:
the previous welding channel is within the predefined range. If it is outside the range, a “WELD value
outside x..y value" is sent; when the robot reaches the welding point, it does not weld.
Depending on the FALSE or TRUE parameter, it returns the type of condition to be used. In case of FALSE
the condition will be WHEN AT END DO, otherwise: WHEN TIME x BEFORE END DO, where x is the time
defined in BEFORE_HAND. When one of these conditions occurs (at the end of the MOVE or x milliseconds
before), the motion program enables programs "s2_arm1" and "s2_arm2" and waits for these to manage the
guns according to the system status and then enable program execution to restart.

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Example of calling the A_SW2 technological routines

Note the use of PRESS to advance selection of the welding program of the weld and the possibility of
changing just one program:
PROGRAM prog_1
BEGIN
weld_init -- Def. condition initialization
before_hand(50) -- Def. condition for advance
...
MOVEFLY TO pnt0002p ADVANCE
press(2, 11) -- Pre-selects the programs
MOVE TO pnt0001p -- Moves to the first point
CLOSE HAND 2 -- Retracts the gun
DELAY 300 -- Waits for retraction
MOVE JOINT TO pnt0001p -- Repeats the MOVE to the
WITH CONDITION[weld(2, 1, FALSE)], -- same point
ENDMOVE -- to call the weld
...
MOVE JOINT TO pnt0003p, -- Selects the welding
WITH CONDITION[weld(5, 3, TRUE)],
ENDMOVE -- programs moving to the
-- weld spot in advance.
...
MOVE JOINT TO pnt0004p, -- Selects the welding
WITH CONDITION[weld(7, -1, FALSE)],
ENDMOVE -- programs, moves to the point
-- and welds with the
-- first gun only (no advance).
...
OPEN HAND 2 -- Fully re-opens the gun
...
press(-1, 3) -- Pre-selects the program
-- of the second gun and
-- leaves that of the first
-- unchanged.
...
END prog_1

A_SW2 PARAMETERS CONFIGURATION FILE

For configuration of A_SW2 parameters in the S2_CONF.COD file refer to the "A_SW1B PARAMETER
CONFIGURATION FILE" chapter, replacing the prefix "sb" with "s2".

A_SW2 HARDWARE CONFIGURATION FILE

This application program is able to manage one arm only with theCOMAU/BOSCH or FASE WELD 320+ welding
timers (two per arm); it recognizes the additional IOM and RIO cards. For hardware configuration, refer to the
"A_SW1B HARDWARE CONFIGURATION FILE" chapter, replacing the prefix "sb" with "s2".

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LIST OF PREDEFINED ALARMS AND MESSAGES IN A_SW2

The A_SW2 application includes a number of predefined alarms and messages for use with statements
A_ALARM('x') and A_MESSAGE('x') instructions where x is a number between 1 and 10.
Alarms
A_ALARM('1') - Parity bit incongruity
A_ALARM('2') - Wrong program coding
A_ALARM('3') - Robot not in rest position
A_ALARM('4') - Welding gun tot. open prx out of order

Messages
A_MESSAGE('1') - Wait for "start robot program" = ON from PLC
A_MESSAGE('2') - Received "start robot program" = ON from PLC

I/O CONNECTIONS
The I/O required by the application and how they are mapped vary depending on the hardware configuration
file selected:

1) S20001_00.CNF 2 COMAU/BOSCH IOM arm 1

Dual welding timer: COMAU/BOSCH
Single arm, number: 1
Welding gun: on board robot
Cards required: slot4 slot5
IOM IOM

Input
$DIN[1]: Proportional sv digital response 1
$DIN[2]: Gun 1 prx fully open
$DIN[5]: Proportional sv digital response 2
$DIN[6]: Gun 2 prx fully open
$DIN[7]: End of welding sequence timer 1
$DIN[8]: Timer ready 1
$DIN[33]: Select robot program 1
$DIN[34]: Select robot program 2
$DIN[35]: Select robot program 4
$DIN[36]: Select robot program 8
$DIN[37]: Select robot program 16
$DIN[38]: Robot program odd parity
$DIN[39]: Robot program start
$DIN[40]: Exclude timer 1
$DIN[41]: Exclude timer 2
$DIN[42]: End of welding sequence timer 2
$DIN[43]: Timer ready 2
$SDIN[15]: Reset application alarm (remote U3)

Output
$DOUT[17]: Gun closing sv 1
$DOUT[21]: End robot program ***
$DOUT[22]: Gun closing sv 2
$DOUT[24]: Start welding timer 1
$DOUT[25]: Select program timer 1 weight 0

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C3G Plus APPENDIX A

$DOUT[26]: Select program timer 1 weight 1

$DOUT[27]: Select program timer 1 weight 2
$DOUT[28]: Select program timer 1 weight 3
$DOUT[29]: Select program timer 1 weight 4
$DOUT[30]: Even parity timer 1
$DOUT[52]: Timer 1 not excluded
$DOUT[53]: Timer 2 not excluded
$DOUT[54]: Start welding timer 2
$DOUT[59]: Select program timer 2 weight 0
$DOUT[60]: Select program timer 2 weight 1
$DOUT[61]: Select program timer 2 weight 2
$DOUT[62]: Select program timer 2 weight 3
$DOUT[63]: Select program timer 2 weight 4
$DOUT[64]: Even parity timer 2
$SDOUT[15]: Not robot application alarm (remote U3)

*** this Output signal is not invoked by the application program; it must be managed by the work
program in this position as the application must be able to read it.

2) S20002_00.CNF 2 FASE WELD 320+ IOM arm 1

Dual welding timer: FASE WELD 320+
Single arm, number: 1
Welding gun: on board robot
Cards required: slot4 slot5
IOM IOM

Input
$DIN[1]: Proportional sv digital response 1
$DIN[2]: Gun 1 prx fully open
$DIN[5]: Proportional sv digital response 2
$DIN[6]: Gun 2 prx fully open
$DIN[7]: End of welding sequence timer 1
$DIN[33]: Select robot program 1
$DIN[34]: Select robot program 2
$DIN[35]: Select robot program 4
$DIN[36]: Select robot program 8
$DIN[37]: Select robot program 16
$DIN[38]: Odd parity
$DIN[39]: Robot program start
$DIN[40]: Exclude timer 1
$DIN[41]: Exclude timer 2
$DIN[42]: End of welding sequence timer 2
$SDIN[15]: Reset application alarm (remote U3)

Output
$DOUT[17]: Gun closing sv 1
$DOUT[21]: End of robot program***
$DOUT[22]: Gun closing sv 2
$DOUT[24]: Start welding timer 1
$DOUT[25]: Select program timer 1 weight 0
$DOUT[26]: Select program timer 1 weight 1
$DOUT[27]: Select program timer 1 weight 2

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APPENDIX A C3G Plus

$DOUT[28]: Select program timer 1 weight 3

$DOUT[52]: Timer 1 not excluded
$DOUT[53]: Timer 2 not excluded
$DOUT[54]: Start welding timer 2
$DOUT[59]: Select program timer 2 weight 0
$DOUT[60]: Select program timer 2 weight 1
$DOUT[61]: Select program timer 2 weight 2
$DOUT[62]: Select program timer 2 weight 3
$SDOUT[15]: Not robot application alarm (remote U3)

*** this Output signal is not invoked by the application program; it must be managed by the work
program in this position as the application must be able to read it.

3) S20004_00.CNF 2 FASE WELD 320+ arm 1

Dual welding timer: FASE WELD 320+
Single arm, number: 1
Welding gun: on board robot
Cards required: slot4
IOM

Input
$DIN[1]: Proportional sv digital response 1
$DIN[2]: Gun 1 prx fully open
$DIN[5]: Proportional sv digital response 2
$DIN[6]: Gun 2 prx fully open
$DIN[7]: End of welding sequence timer 1
$DIN[8]: End of welding sequence timer 2
$DIN[13]: Exclude timer 1
$DIN[14]: Exclude timer 2
$SDIN[15]: Reset application alarm (remote U3)

Output
$DOUT[17]: Closing sv gun 1
$DOUT[19]: Select program timer 2 weight 0
$DOUT[20]: Select program timer 2 weight 1
$DOUT[21]: Select program timer 2 weight 2
$DOUT[22]: Select program timer 2 weight 3
$DOUT[24]: Start welding timer 1
$DOUT[25]: Select program timer 1 weight 0
$DOUT[26]: Select program timer 1 weight 1
$DOUT[27]: Select program timer 1 weight 2
$DOUT[28]: Select program timer 1 weight 3
$DOUT[29]: Closing sv gun 2
$DOUT[30]: Start welding timer 2
$SDOUT[15]: Not robot application alarm (remote U3)

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C3G Plus APPENDIX A

4) S20007_00.CNF 2 COMAU/BOSCH IOM arm 1 R.P.

Dual welding timer: COMAU/BOSCH
Single arm, number: 1
Welding gun: stationary. The robot brings the part to be welded to the gun
Cards required: slot4 slot5
IOM IOM

Input
$DIN[7]: End of welding sequence timer 1
$DIN[8]: Timer 1 ready
$DIN[9]: Exclude timer 1
$DIN[10]: Exclude timer 2
$DIN[33]: Select program robot 1
$DIN[34]: Select program robot 2
$DIN[35]: Select program robot 4
$DIN[36]: Select program robot 8
$DIN[37]: Select program robot 16
$DIN[38]: Odd parity
$DIN[39]: Robot program start
$DIN[43]: End of welding sequence timer 2
$DIN[44]: Timer 2 ready
$SDIN[15]: Reset application alarm controller 1 (remote U3)
$SDIN[16]: Reset application alarm controller 2 (remote U3)

Output
$DOUT[3]: Timer 1 not excluded
$DOUT[5]: Timer 2 not excluded
$DOUT[17]: Closing sv gun 1
$DOUT[18]: Closing sv gun 2
$DOUT[20]: End of robot program ***
$DOUT[24]: Start welding timer 1
$DOUT[25]: Select program timer 1 weight 0
$DOUT[26]: Select program timer 1 weight 1
$DOUT[27]: Select program timer 1 weight 2
$DOUT[28]: Select program timer 1 weight 3
$DOUT[29]: Select program timer 1 weight 4
$DOUT[30]: Even parity
$DOUT[49]: Select program timer 2 weight 0
$DOUT[50]: Select program timer 2 weight 1
$DOUT[51]: Select program timer 2 weight 2
$DOUT[52]: Select program timer 2 weight 3
$DOUT[53]: Select program timer 2 weight 4
$DOUT[54]: Even parity
$DOUT[55]: Start welding timer 2
$DOUT[15]: Not application alarm robot controller 1 (remote U3)
$SDOUT[16]: Not application alarm robot controller 2 (remote U4)

*** this Output signal is not invoked by the application program; it must be managed by the work
program in this position as the application must be able to read it.

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APPENDIX A C3G Plus

APPLICATION A_SW2 ALARM CODES

For A_SW2 alarm codes see paragraph "A_SW1B ALARM CODES", replacing each A_SW1B code with
A_SW2.

ERROR MESSAGES
Whenever the application detects a status preventing it from operating correctly, an error situation is
generated and the application waits for the alarm to be reset.
The error situation results in:
- immediate interruption of the procedure currently in progress;
- switching-off of green light U3 or U4 on the C3G Plus and on the TP (if 16-line type);
- a signal to the outside world of the error condition: the not alarm output is set to OFF;
- the PC video status screen becomes red and the error message appears;
- the error message is recorded in the C3G Plus ERROR.LOG file.
The alarm number and message vary according to the application that is being used.
The alarm number is the same for all installation and RIO alarms. Depending on the application being used it
is:

INSTALLATION
43299 A_SW1B
43299 A_SW2

File: x not found

The diskette is not inserted, cannot be read, or does not include the application file x.
Check whether file x is on the diskette and reset the alarm using the "SHIFT + SCRN" keys on the keyboard.
The procedure will start again from where it was interrupted.

RAMDISK full
Indicates that there is not enough space on the RAM DISK to copy the application programs from the
diskette to the ram disk (min. space required: 130 kbytes).
Check the ram disk and delete any files that are no longer needed. Press keys "SHIFT + SCRN" on the
keyboard and the procedure will start again from where it was interrupted.

Device error
The diskette is missing or cannot be read.
Check the diskette and press keys "SHIFT + SCRN" to continue the procedure.

Application incompatible with EZ

The EZ on the ram disk is not compatible with the application being loaded.
Check that the EZ loaded and the application program being loaded are suitable for the application.
In special cases, an application other than EZ can be loaded setting bit 12 of $CNTRL_CNFG to 1.
Restart the procedure from the beginning.

C3G Plus not allowed

The status of the C3G Plus is no longer that required for the initial installation procedure, i.e. it is not
DRIVES OFF + PROGRAM.
Restore the status required to continue the procedure.

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COMMUNICATION BOARDS

RIO board not configured

The RIO card has not been configured. Run the RIO configuration TOOL PDL2 and reset the alarm with
the "SHIFT + SCRN" keys on the keyboard to continue.

RIO board configuration parameter incorrect

The RIO configuration parameters are not included in the range available. Execute the PDL2 TOOL for RIO
configuration and reset the alarm with the "SHIFT + SCRN" keys on the keyboard to continue.

PFDP board not configured

The DP profibus card has not been configured. Run the network card configuration TOOL PDL2 and reset
the alarm with the "SHIFT + SCRN" keys on the keyboard to continue.

IBSL board not configured

The Interbus slave card has not been configured. Run the network card configuration TOOL PDL2 and
reset the alarm with the "SHIFT + SCRN" keys on the keyboard to continue.

IBSL board not configured with COMAU protocol

The Interbus slave card has not been configured as the primary interface but according to standard
Interbus protocol instead of COMAU. Run the network card configuration TOOL PDL2 and reset the alarm
with the "SHIFT + SCRN" keys on the keyboard to continue.

DNT board not configured

The DeviceNet slave card has not been configured. Run the network card configuration TOOL PDL2 and
reset the alarm with the "SHIFT + SCRN" keys on the keyboard to continue.

BOARDS
Board not configured in slot
Configuration of the logical table does not match that of the physical table. Execute the PDL2 TOOL for I/O
configuration and reset the alarm with the "SHIFT + SCRN" keys on the keyboard to continue.
Board not present in slot
The card in the slot indicated is not the right one. Insert the cards required according to the hardware
configuration file chosen during the initial installation procedure and reset the alarm by pressing the "SHIFT
+ SCRN " keys on the keyboard to continue.
I/O configuration not allowed
The cards required by the application are not present or are faulty.
Check that the cards required are present and function correctly according to the selected configuration file.
Logical table and physical table configuration must match.
Restart the procedure from the beginning.

Only the text, causes and remedies are given in the description of the general alarms, technological
☞ alarms and information messages that follows. The alarm number will differ according to the spot
welding application and is given in the APPENDIX chapter, remembering that the reference between
text and alarm number is the letter preceding each of the alarms.

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GENERAL
There are two categories of general alarms:
1) SYS_CALL failed alarms with the following structure:
- alarm number (same for all alarms)
- application name (e.g.: A_SW1B)
- SYS_CALL operation (e.g.: 'ML')
- SYS_CALL arguments (e.g.: 'sb_menu')
- error comment (e.g.: 'Insufficient memory')
Example:
43299 : A_SW1B ('ML', 'sb_menu'). Insufficient memory.
2) WIN_LOAD failed alarms with the following structure:
- alarm number (same for all alarms)
- application name (e.g.: A_SW1B)
- window file name (e.g.: 'sb_rack.scr')
- load line and column (e.g.: 5,0)
- window in which to load (e.g.:'cb21:')
- error comment (e.g.: 'File does not exist')
Example:
A_SW1B WIN_LOAD('sb_rack.scr' , 5, 0, 'cb21:'). File does not exist.
a) File: x not found
Application file x is not on the ramdisk.
Load file x from the application diskette to the ramdisk and reset the alarm by pressing the "SHIFT +
SCRN" keys. The application will start again from where it was interrupted.
b) Not enough space on ramdisk for file: x
There is not enough space on the ramdisk.
Delete any files that are no longer needed and reset the alarm by pressing keys "SHIFT + SCRN" on
the keyboard. The application will start up again from where it was interrupted.
c) Not enough space in memory or file: x not found
There is not enough memory to load file x or file x is not on the ramdisk.
Check whether file x is actually on the ramdisk (if not, copy it from the application diskette) and if there
is enough space to load it into memory (if not, delete files that are no longer needed). Reset the alarm
by pressing keys "SHIFT + SCRN" on the keyboard and the application will start again from where it
was interrupted.
d) Not enough space memory for loading: x
There is not enough memory to copy file x.
Delete any files no longer needed from the memory and press "SHIFT + SCRN" to reset the alarm -
the application will start up again from where it was interrupted.
e) Failed activation of: x
It is not possible to activate file x.
Find out why it does not activate by trying to activate the file x using the C3G Plus command:
(Program Go <x>).
f) $NUM_TIMER < 34 MUST BE >= 34
This alarm indicates that the value of system variable $NUM_TIMER is < 34.
Set $NUM_TIMER to a value ≥ 34, save the configuration and restart the system.
g) $NUM_LUNS < 20 MUST BE >= 20
This alarm indicates that the value of system variable $NUM_LUNS is < 20.
Set the $NUM_LUNS variable to a value ≥ 20, save the configuration and restart the system.
h) $NUM_DEVICES < 20 MUST BE >= 20
This alarm indicates that the value of system variable $NUM_DEVICES is < 20.
Set the $NUM_DEVICES variable to a value ≥ 20, save the configuration and restart the system.
Reset the alarm and restart the application program by pressing keys "SHIFT + SCRN" on the keyboard.

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C3G Plus APPENDIX A

TECHNOLOGICAL
a) fk missing from timer
The time for the end of sequence from the welding timer has expired.
Check:
- the hardware connection between C3G Plus and welding timer;
- welding timer faults.
b) WELD parameter out of range
A call to the WELD statement has been made with a non-existent welding channel.
Modify the program, make the call correctly and reset the alarm (U3 or U4).
c) fk = ON before welding start
The end of welding sequence is ON before the application has given the welding start.
Check:
- the hardware connection between C3G Plus and welding timer;
- welding timer faults.
d) BEFORE_HAND parameter out of range
A call has been made to the BEFORE_HAND statement with a welding start advance time that is out
of range.
Modify the program, make the call correctly and reset the alarm (U3 or U4).
e) Solenoid valve = OFF, welding gun pressure not OK
The solenoid valve OK input is not ON and the welding gun pressure therefore may not be OK.
Check:
- the hardware connection between C3G Plus and welding gun;
- operation of the proportional solenoid valve.
f) PRESS parameter out of range
A call has been made to the PRESS statement with a parameter out of the accepted limits.
Modify the program, make the call correctly and reset the alarm (U3 or U4).
g) Welding gun tot. open prx = ON
The welding gun fully open input is ON and the gun therefore has not been closed.
Modify the program, making the call to the WELD statement after closing the welding gun and reset
the alarm (U3 or U4).
h) Wrong parameter: $WORD 17-32, bit 1-16
A call has been made to the $WORD control statements of the RIO with wrong parameters.
Modify the program, make the call correctly and reset the alarm (U3 or U4).
i) Timer ready = OFF, timer not ready
The timer ready input is OFF and a welding sequence cannot therefore be started.
Check:
- the hardware connection between C3G Plus and welding timer;
- welding timer faults.
l) Wrong parameter or out of range 1-10
Indicates that a call has been made to the
A_ALARM and A_MESSAGE statements with an index > 10.
Modify the program, make the call correctly and reset the alarm (U3 or U4).
si1) $DIN[...]=ON, weld transformer over temperature
Indicates an overtemperature of the weld transformer on gun board.

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si2) $DIN[...]=OFF, no gun cooling water flow

Indicates that no cooling water flow is supplied to the welding gun/inverter electrodes.
si3) $DIN[...]=ON, SCR protection alarm
Indicates that the welding disconnect in the C3G Plus cabinet is open: the entire welding part is not
powered.
si4) $DIN[...]=OFF, no proportional sv air
Indicates that no air is supplied to the proportional solenoid valve for adjustment of gun closing
pressure.
si5) $DIN[...]=ON, micro indicates "gun closed"
Indicates thet, after the gun opening command, the gun closed micro has remained ON.
Check whether the gun has in fact not open and, if so, check efficiency of the micro and of the Input.
si6) $DIN[...]=OFF, micro does not indicate "gun open"
Indicates that, after the gun opening command, the gun open micro has remained OFF.
Check whether the gun has in fact not opened and, if so, check efficiency of the micro and of the
Input.
si7) Timer alarm <alarm number>: <timer messages>
Indicates that there is a welding timer alarm; relative code and message are displayed. For the
messages from timer, see the documentation about the timer.
si8) $DIN[...] = ..., $DIN[...] = ..., swinging not closed
The swinging closed and not open micros indicate that the gun arm swinging closing command has
not been performed.
si9) $DIN[...] = ..., $DIN[...] = ..., swinging not open
The swinging open and not closed micros indicate that the gun arm swinging opening command has
not been performed.
si10) $DIN[...] = OFF, swinging not allowed
Indicates that swinging of the gun arm has been requested with the gun not fully open.
si11) $DIN[...] = OFF, electrodes stuck
Indicates that the electrodes are stuck to the metal after the gun opening command.
si12) $DIN[...] = OFF, gun not on flange
Indicates that an attempt has been made to include the timer using the incl_appl routine without the
gun connected on the flange (applications with gun change).

INFORMATION MESSAGES
The information messages appear only on the screen of the C3G Plus system. They do not generate an
alarm and merely indicate a number of situations specific to the application.
a) Application ready
Indicates that the application is ready for use.
b) Alarm reset on armx
Indicates that an alarm has been reset from a remote position or by U3 (in PROG or LOCAL) on armx.

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C3G Plus APPENDIX A

EXAMPLES OF TIP CHANGE MANAGEMENT IN DIFFERENT CASES OF

"INTEGRATED SPOT"
MANAGEMENT OF TIP CHANGE
Communication on digital I/O to Timer and Fieldbus to PLC:
IF word_bit(26,1) = ON THEN
-- Accept request tip change from PLC
-- call_prog_34
ENDIF
-- call_prog_34:
set_word(18,3,ON) -- Tip change setting in progress
MOVE TO change_pos -- Robot moves to change position
set_word(18,4,ON) -- Set robot to change position
wait_word(26,2,ON) -- Wait for change executed (from PLC)
$DOUT[51] := ON -- Set change executed (to timer)
set_word(18,4,OFF) -- Reset robot to change position
MOVE TO home -- Robot moves away from change position
wait_word(26,1,OFF) -- Wait for reset request change (from PLC)
$DOUT[51] := OFF -- Reset change executed to timer
set_word(18,3,OFF) -- Tip change resetting in progress

Communication on digital I/O to Timer and digital I/O to PLC:

IF word_bit(26,1) = ON THEN
-- Accept request tip change from PLC
-- call_prog_34
ENDIF
-- call_prog_34:
$DOUT[83] := ON -- Tip change setting in progress
MOVE TO change_pos -- Robot moves to change position
$DOUT[84] := ON -- Set robot to change position
WAIT FOR $DIN[66] -- Wait for change executed
$DOUT[51] := ON -- Set change executed to timer
$DOUT[84] := OFF -- Reset robot to change position
MOVE TO home -- Robot moves away from change position
WAIT FOR $DIN[65] := OFF -- Wait for reset request change
$DOUT[51] := OFF -- Reset change executed to timer
$DOUT[83] := OFF -- Tip change resetting in progress

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Communication on Fieldbus/VME to Timer and Fieldbus to PLC:

IF word_bit(26,1) = ON THEN
-- Accept request tip change from PLC
-- call_prog_34
ENDIF
-- call_prog_34:
BEGIN
set_word (18,3,ON) -- Tip change setting in progress
MOVE TO change_pos -- Robot moves to tip change position
set_word (18,3,ON) -- Set robot to change position
wait_word (26,2,ON) -- Wait for change executed from PLC
set_word (109,8,ON) -- Set tip change executed to timer
set_word (18,4,OFF) -- Reset robot to change position
MOVE TO home -- Robot moves to rest position
wait_word (26,1,OFF) -- Wait for reset request change from PLC
wait_word (101,4,OFF) -- Wait for reset request change from timer
set_word (18,3,OFF) -- Tip change resetting in progress

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