1. LINE MOTION POSITION TRAVEL TERMINATION # TYPE DATA SPEED WORLD 50% 1: L P [1] 2000 IPM FINE 2: L P [2] 2000 IPM FINE 3: L P [3] 2000 IPM FINE 4: L P [4] 100 IPM FINE 5: L P [5] 2000 IPM FINE 6: L P [1] 2000 IPM FINE

3. FINE VS. CNT TERMINATION MOVE CURSOR TO TERMINATION COLUMN, ONTO FINE, PRESS F4 CHOICE KEY, ENTER ON CNT LINE MOTION POSITION TRAVEL TERMINATION # TYPE DATA SPEED WORLD 50% 1: L P [1] 2000 IPM CNT 100 2: L P [2] 2000 IPM CNT100 3: L P [3] 2000 IPM FINE 4: L P [4] 100 IPM FINE 5: L P [5] 2000 IPM CNT 100 6: L P [1] 2000 IPM CNT 100

5. L - LINEAR VS. J - JOINT MOTION MOVE CURSOR TO MOTION TYPE COLUMN, ONTO L, PRESS F4- CHOICE, ENTER ON JOINT LINE MOTION POSITION TRAVEL TERMINATION # TYPE DATA SPEED WORLD 50% 1: J P [1] 100 % CNT 100 2: J P [2] 100 % CNT100 3: J P [3] 100 % FINE 4: L P [4] 100 IPM FINE 5: J P [5] 100 % CNT 100 6 J P [1] 100 % CNT 100

11. TO ACHIEVE THE BEST CYCLE TIME POSSIBLE, PROGRAM ACCORDING TO THIS CHART, AS MUCH AS SAFE TESTING WILL ALLOW: AIR MOVE ARC START MIDDLE- OF -WELD ARC END POINT POINT POINT POINT J - 100% J - 100% L ( C ) - W.T.S. L ( C ) - W.T.S. CNT 100 FINE CNT 100 FINE

12. 1: J P [1] 100% CNT 100 2: J P [2] 100% CNT 100 3: J P [3] 100% FINE ARC START [1] 4: L P [4] 100 IPM CNT 100 5: L P [5] 100 IPM CNT 100 6: L P [6] 100 IPM CNT 100 7: L P [7] 100 IPM CNT 100 8: L P [8] 100 IPM CNT 100 9: L P [9] 100 IPM CNT 100 10: L P [10] 100 IPM FINE ARC END [1] 11: J P [11] 100% CNT 100 12: J P [1] 100% CNT 100 END USE F2-ARC START & F4-ARC END KEYS USE F3-WELD POINT KEY FOR MIDDLE OF WELD POINTS KEEP WIRE TIP 1/2 INCH FROM EDGE OF BOX MIDDLE-OF-WELD POINTS MUST BE 1/8 INCH FROM CORNER OF BOX JGFRM 50%

13. 5 4 3 1 2 6 1: J P [ 1 ] 100% CNT100 2: J P [ 2 ] 100% CNT100 3: J P [ 3 ] 100% FINE ARC START [ 1 ] 4: L P [ 4 ] 40 IPM CNT100 5: L P [ 5 ] 40 IPM FINE ARC END [ 1 ] 6: J P [ 6 ] 100% CNT100 7: J P [ 1 ] 100% CNT100 END DON’T FORGET: USE F1-POINT FOR AIR MOVES USE F2-ARC START FOR ARC START USE F3-WELD POINT FOR MIDDLE OF WELD POINT USE F4-ARC END FOR ARC END JGFRM 50%

14. R + X + Y USING THE RIGHT-HAND-RULE FOR PROGRAMMING WORLD COORDINATE SYSTEM - A FIXED, NONADJUSTABLE, SYSTEM BASED ON THE ROBOT’S FRONT AND CENTER MOUNTED POSITION + Z IS UP OK TO USE IF FACING THE ROBOT FRONT AND CENTER AS SHOWN ABOVE, PROGRAMMING AT THE CENTER TABLE

15. R + X + Y USING THE RIGHT-HAND-RULE FOR PROGRAMMING JOG FRAME COORDINATE SYSTEM - JGFRM AN ADJUSTABLE, SYSTEM BASED ON WHERE ONE IS STANDING, FACING THE ROBOT. CAN HAVE UP TO 5 JOG FRAMES SETUP + Z REMAINS UP OK TO USE IF FACING THE ROBOT FROM A DIFFERENT ANGLE AS SHOWN ABOVE + X + Y

16. 1 2 5 6 7-AE 8 3-AS 4 C T F1-POINT DEFAULT LINES 1: L P[ ] 100 IPM FINE 2: J P [ ] 100 % CNT 100 3: J P [ ] 50 % FINE 4: C P [ ] P [ ] 100 IPM CNT 100 ED_DEF POINT F1 JGFRM 50% 1: J P [1] 100 % CNT 100 2: J P [2] 100 % CNT 100 3: J P [3] 100% FINE ARC START [1] 4: L P [4] 100 IPM CNT 100 END JGFRM 50% 1: J P [1] 100 % CNT 100 2: J P [2] 100 % CNT 100 3: J P [3] 100% FINE ARC START [1] 4: L P [4] 100 IPM CNT 100 5: C P [5] P [ ] 100 IPM CNT 100 END TOUCHUP F3 PRESS SHIFT + F3 TOUCHUP TO RECORD P [6] AFTER RECORDING THE TOUCHUP POINT, YOU MUST CURSOR DOWN TO END STATEMENT

17. JGFRM 50% 1: J P [1] 100 % CNT 100 2: J P [2] 100 % CNT 100 3: J P [3] 100% FINE ARC START [1] 4: L P [4] 100 IPM CNT 100 5: C P [5] P [6] 100 IPM CNT 100 6: L P [7] 100 IPM FINE ARC END [1] 7: J P [8] 100 % CNT 100 8: J P [1] 100 % CNT 100 END 1 2 5 6 7-AE 8 3-AS 4 F1-POINT DEFAULT LINES 1: L P[ ] 100 IPM FINE 2: J P [ ] 100 % CNT 100 3: J P [ ] 50 % FINE 4: C P [ ] P [ ] 100 IPM CNT 100 ED_DEF POINT F1

18. C C C C C C C C C C C C T T T T T T T T T T T T J J J J J J J J J L L ARC END IN A STEP: PRESS NEXT, F1-INST, ENTER ON ARC. AT SUBMENU, ENTER ON ARC END, KEY IN A 1, ENTER.

19. 1 2 5 6 7-AE 8 3-AS 4 C T F1-POINT DEFAULT LINES 1: L P[ ] 100 IPM FINE 2: J P [ ] 100 % CNT 100 3: J P [ ] 50 % FINE 4: C P [ ] P [ ] 100 IPM CNT 100 ED_DEF POINT F1 JGFRM 50% 1: J P [1] 100 % CNT 100 2: J P [2] 100 % CNT 100 3: J P [3] 100% FINE ARC START [1] 4: L P [4] 100 IPM CNT 100 END JGFRM 50% 1: J P [1] 100 % CNT 100 2: J P [2] 100 % CNT 100 3: J P [3] 100% FINE ARC START [1] 4: L P [4] 100 IPM CNT 100 5: C P [5] P [ ] 100 IPM CNT 100 END TOUCHUP F3 PRESS SHIFT + F3 TOUCHUP TO RECORD P [6] AFTER RECORDING THE TOUCHUP POINT, YOU MUST CURSOR DOWN TO END STATEMENT

20. P3 – PRESS SHIFT & F2 ARC START P6 – PRESS SHIFT & F3 TOUCH UP, THEN CURSOR DOWN TO END P7 – PRESS SHIFT & F4 ARC END P4 – PRESS SHIFT & F3 WELD POINT P1 – PRESS F1 POINT BY ITSELF, CURSOR DOWN TO J MOTION DEFAULT LINE, ENTER P5 – PRESS F1 POINT KEY BY ITSELF, CURSOR TO CIRCULAR DEFAULT LINE, ENTER P2 – PRESS SHIFT AND F1 POINT P8 – PRESS F1 POINT BY ITSELF, CURSOR TO J MOTION DEFAULT LINE, ENTER.THEN PRESS SHIFT AND F1 POINT FOR P1 HOME POINT P3-PRESS SHIFT & F2 ARC START P7- PRESS SHIFT & F4 ARC END P4-PRESS SHIFT & F3 WELD POINT P5- PRESS F1 POINT KEY BY ITSELF, CURSOR TO CIRCULAR DEFAULT LINE, ENTER P6- PRESS SHIFT & F3 TOUCHUP, THEN CURSOR DOWN TO END P2- PRESS SHIFT AND F1 POINT P8-PRESS F1 POINT KEY BY ITSELF, CURSOR TO J MOTION LINE, ENTER. THEN RECORD 1 MORE POINT, SHIFT & F1 POINT, PUT A 1 IN THE BRACKETS FOR HOME POINT P1- PRESS FI POINT KEY BY ITSELF, CURSOR TO J MOTION LINE, ENTER.

21. JGFRM 50% 1: J P [1] 100 % CNT100 2: J P [2] 100 % CNT100 3: J P [3] 100 % FINE ARC START [1] 4: WEAVE SINE [1] 5: L P [4] 10 IPM FINE ARC END [1] 6: WEAVE END 7: J P [5] 100 % CNT 100 8: J P [1] 100% CNT 100 END AS WS AE WE 11 22 3 4 55 1: WEAVE SINE 2: WEAVE FIG 8 3: WEAVE CIRC 4: WEAVE END TO TEACH WEAVE INSTRUCTIONS: 1. PRESS NEXT KEY 2. PRESS F1-INST KEY 3. CURSOR TO WEAVE SELECTION (PRESS #8-NEXT PAGE IF NECESSARY) 4. PRESS ENTER 5. WEAVE SUB-MENU NOW APPEARS

22. FREQ. 1 HZ. AMP. P/P 8 MM 4 MM WEAVE SCHEDULE PRESS DATA KEY, THEN F1-TYPE, ENTER ON WEAVE JGFRM 50 % FREQ AMP L-DWELL R-DWELL Hz. mm sec sec 1: 1.0 4.0.1 SEC.1 SEC 2: 1.0 4.0.1 SEC.1 SEC 3: 1.0 4.0.1 SEC.1 SEC FREQ 1 Hz AMP 4 mm FREQ 4 Hz AMP 30 mm 1.0 sec DWELL L & R

23. SINE WEAVE FIGURE 8 WEAVE CIRCULAR WEAVE

24. JGFRM 50% 1: J P [1] 100 % CNT100 2: J P [2] 100 % CNT100 3: J P [3] 100 % FINE ARC START [1] 4: WEAVE SINE [1] 5: L P [4] 10 IPM FINE ARC END [1] 6: WEAVE END 7: J P [5] 100 % CNT 100 8: J P [1] 100% CNT 100 END AS WS AE WE 11 22 3 4 55 1: WEAVE SINE 2: WEAVE FIG 8 3: WEAVE CIRC 4: WEAVE END TO TEACH WEAVE INSTRUCTIONS: 1. PRESS NEXT KEY 2. PRESS F1-TYPE KEY 3. CURSOR TO WEAVE SELECTION (PRESS #8-NEXT PAGE IF NECESSARY) 4. PRESS ENTER 5. WEAVE SUB-MENU NOW APPEARS

25. Press MENUS. Select SETUP. Press F1, [TYPE]. Select Weave. You will see a screen similar to the one at the right: SETUP\Weave\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ 1/11 NAME VALUE 1 Weave Enable Group Mask [1,*,*,*,*] 2 Dwell delay type: Move 3 Frame type: Tool&Path 4 Elevation: 0 deg 5 Azimuth: 0 deg 6 Center rise: 0.0 mm 7 Radius: 0.0 mm 8 Blend weave end: YES [ TYPE ] 1 * ADDITIONAL WEAVE SETTINGS IF A SIDE-TO-SIDE WEAVE, IN THE FLAT POSITION IS NOT DESIREABLE, THE WEAVE ANGLE CAN BE CHANGED BY MAKING CHANGES TO WEAVE AZIMUTH AND ELEVATION.

26. AZIMUTH SIDE-TO-SIDE WEAVE, WITH AZIMUTH SET TO 0 DEGREES FRONT-TO-BACK WEAVE, WITH AZIMUTH SET TO 90 DEGREES

27. ELEVATION ELEVATION SET TO 0 DEGREES, WEAVE IS FLAT, PERPENDICULAR TO TORCH TIP ELEVATION SET TO +45 DEGREES, WEAVE NOW AT AN ANGLE TO TORCH TIP

28. R RIGHT PRO. XYZ LEFT PRO. ABC ROBOT CONTROL LERRe RSR 1 RSR 2 RSR0001 1: CALL ABC END RSR0002 1: CALL XYZ END TO CHANGE OVER : 1. BRING UP RSR PROGRAM ON TEACH PENDANT 2. CURSOR ONTO OLD PROGRAM NAME 3. PRESS F4-CHOICE 4. CURSOR TO DESIRED PROGRAM NAME, PRESS ENTER 5. CAREFULLY TEST K OPTIONAL ON/OFF KEY SWITCH FOR CELLS WITH DOORS

29. R ZONE 2 ZONE 1 LERRe RSR 1 RSR 2 PRO. RSR0001 1: CALL HOME 2: CALL HOME1 3: CALL ZONE1 4: CALL HOME1 5: CALL HOME END PRO. RSR0002 1: CALL HOME 2: CALL HOME2 3: CALL ZONE2 4: CALL HOME2 5: CALL HOME END PRO. HOME ARM AGAINST J2 SWITCH, 1: J P [ 1 ] 100% CNT100 CENTERED ON J1 SWITCH END PRO. HOME1 1: J P [ 1 ] 100% CNT100 END ARM STILL ON J2 SWITCH BUT AXIS J1 TURNED INTO ZONE 1 PRO. HOME2 1: J P [ 1 ] 100% CNT100 END ARM STILL ON J2 SWITCH BUT AXIS J1 TURNED INTO ZONE 2 PRO. ZONE1 1: CALL HOME1 2: CALL “YOUR PRO. NAME” 3: CALL HOME1 END PRO. ZONE2 1: CALL HOME2 2: CALL “YOUR PRO. NAME” 3: CALL HOME2 END K OPTIONAL ON/OFF KEY SWITCH FOR CELLS WITH DOORS AUX AXIS POSITIONER CELLS WITH LOCAL STOP

30. R ROBOT CONTROL ECSAM RSR0001 1: CALL SIDE A END RSR0002 1: CALL SIDE B END TO CHANGE OVER : 1. BRING UP SIDE A OR B PROGRAM ON TEACH PENDANT 2. CURSOR ONTO OLD PROGRAM NAME 3. PRESS F4-CHOICE 4. CURSOR TO DESIRED PROGRAM NAME, PRESS ENTER 5. CAREFULLY TEST Re SIDE A PRO. WELD 1 SIDE B PRO. WELD 2 SIDE A 1: CALL WELD 1 END SIDE B 1: CALL WELD 2 END

44. Collision Guard Setup Screen To access the Collision Guard setup screen, press the Menus key, cursor to line Setup, Enter. Press the F1-Type key, cursor to line Collision Guard, Enter. The following screen now appears: COL\GUARD\SETUP\\\\\\\\\\\\\\\\\\\\\\\\\ 1/3 1 Collision Guard status: ENABLED\ 2 Sensitivity: 100% 3 Sensitivity Macro Reg.: R[ 7] [ TYPE ] HELP ENABLED DISABLED

45. TEST\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ 1/17 \\\1:J P[1] 100% CNT100 2:J P[2] 100% CNT100 3:J P[3] 40% FINE : Arc Start[1] 4:L P[4] 20.0inch/min FINE : Arc End[1] 5:J P[5] 100% CNT100 6: R[7]=120 7: COL GUARD ADJUST 8:J P[6] 100% CNT100 9:J P[7] 100% CNT100 10:J P[8] 100% CNT100 11: R[7]=140 12: COL GUARD ADJUST 13:J P[9] 40% FINE : Arc Start[1] 14:L P[10] 20.0inch/min FINE : Arc End[1] 15:J P[11] 100% CNT100 16:J P[1] 100% CNT100 [End] POINT ARCSTRT WELD_PT ARCEND TOUCHUP> Press F1-INST, cursor to Registers, Enter. Cursor to line …=…, Enter. Cursor to line R [ ], Enter. Key in desired Register number, 7 for this example, Enter. Cursor to line Constant, Enter. Key in desired sensitivity setting, 120 for this example, Enter. Press F1-INST, cursor to line Macro, Enter. Cursor to line CG_ADJST, Enter. Smooth Motion Jerky Motion Smooth Motion

46. TEST\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ 1/15 \\\1:J P[1] 100% CNT100 2:J P[2] 100% CNT100 3:J P[3] 40% FINE : Arc Start[1] 4:L P[4] 20.0inch/min FINE : Arc End[1] 5:J P[5] 100% CNT100 6: COL DETECT OFF 7:J P[6] 100% CNT100 8:J P[7] 100% CNT100 9:J P[8] 100% CNT100 10: COL DETECT ON 11:J P[9] 40% FINE : Arc Start[1] 12:L P[10] 20.0inch/min FINE : Arc End[1] 13:J P[11] 100% CNT100 14:J P[1] 100% CNT100 [End] [ INST ] [EDCMD]> Press F1-INST, cursor to line Collision Detect, Enter. Cursor to either line Col Detect On Or Col Detect Off, Enter. Smooth Motion Jerky Motion Smooth Motion

47. COL\GUARD\SETUP\\\\\\\\\\\\\\\\\\\\\\\\\ 1/3 1 Collision Guard status: ENABLED\ 2 Sensitivity: 100% 3 Sensitivity Macro Reg.: R[ 7] 4 Collision Guard Error DO [ * ] 5 Collision Guard Enabled DO [ * ] [ TYPE ] HELP ENABLED DISABLED Collision Guard Setup Screen (Ver. 6.41 and above)

48. TEST\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ 1/15 \\\1:J P[1] 100% CNT100 2:J P[2] 100% CNT100 3:J P[3] 40% FINE : Arc Start[1] 4:L P[4] 20.0inch/min FINE : Arc End[1] 5:J P[5] 100% CNT100 6: COL GUARD ADJUST 120 7:J P[6] 100% CNT100 8:J P[7] 100% CNT100 9:J P[8] 100% CNT100 10: COL GUARD ADJUST 140 11:J P[9] 40% FINE : Arc Start[1] 12:L P[10] 20.0inch/min FINE : Arc End[1] 13:J P[11] 100% CNT100 14:J P[1] 100% CNT100 [End] [ INST ] [EDCMD]> Press F1-INST, cursor to line Collision Detect, Enter. Cursor to line Col Detect Adjust, Enter. Press F-key for Direct, key in desired sensitivity value, Enter. Smooth Motion Jerky Motion Smooth Motion Collision Guard Adjust With VER. 6.41 and above

49. THRU – ARC – SEAM - TRACKING WORKS BY UTILIZING WELD CURRENT FEEDBACK SIGNAL STICKOUT LENGTH HAS A DIRECT EFFECT ON WELDING CURRENT. AS STICKOUT LENGTH INCREASES, WELD CURRENT DECREASES. AS STICKOUT LENGTH DECREASES, WELD CURRENT INCREASES.

50. THRU – ARC – SEAM - TRACKING TORCH IS CENTERED IN THE WELD JOINT WHILE WEAVING STICKOUT LENGTH IS THE SAME ON BOTH SIDES OF THE WEAVE. THEREFORE, WELDING CURRENT IS THE SAME ON BOTH SIDES OF THE WEAVE

51. STICKOUT LENGTH IS NOW MUCH SHORTER ON THIS SIDE OF THE WEAVE STICKOUT LENGTH IS NOW MUCH LONGER ON THIS SIDE OF THE WEAVE WELD JOINT HAS SHIFTED IN THIS DIRECTON WELDING CURENT IS NOW HIGHER ON THIS SIDE OF THE WEAVE WELDING CURENT IS NOW LOWER ON THIS SIDE OF THE WEAVE THRU – ARC – SEAM - TRACKING

52. THREE METHODS TO DETERMINE WELD CURRENT: 1.WELD STATUS SCREEN 2.WELD SCHEDULE SCREEN – F2 DETAIL 3.FRONT PANEL METER ON WELDING POWER SOURCE

53. THRU – ARC – SEAM - TRACKING TOO LARGE OF AN ANGLE MINIMUM 2 MILLIMETER WALL LIMITATIONS

54. How Changes to the Position Register Affect the Weld PR Element Effects on the Weld X The position register X element elongates or shortens the weld. A positive X value adds to the weld length on both ends of the weld. A negative X value shortens both ends of the weld. Y The position register Y element offsets the weld laterally. When facing the end of the weld, positive Y is to the right side of the weld. The lateral movement will be perpendicular to the tool. Z The position register Z element elevates the weld. Movement of the torch will be perpendicular to the weld path and aligned with the tool/path plane. W The position register W element changes the tool orientation by rotating about X. X is the weld path. This changes the torches work angle. P The position register P element changes the tool orientation by rotating about Y. Y is perpendicular to the torch. This changes the torches lead/lag angle relative to the weld path. RThe position register R element has no effect on the weld. How Changes to the Position Register Affect the Weld PR[13] UF:F UT:F CONF:NDB 000 X \\\\\0.000 mm W 0.000 deg Y ‑ 5.000 mm P 0.000 deg Z 5.000 mm R 0.000 deg DATA\Position\Reg\\\\\\\\\\\\\\\\\\\\\\\ 13/100 PR[ 10: ]=R PR[ 11: ]=R PR[ 12: ]=* PR[ 13:\\\\\\\\\\\\\\\\]=* PR[12] UF:F UT:F CONF:NDB 000 X \\\\\0.000 mm W 0.000 deg Y 5.000 mm P 0.000 deg Z 5.000 mm R 0.000 deg DATA\Position\Reg\\\\\\\\\\\\\\\\\\\\\\\ 12/100 PR[ 10: ]=R PR[ 11: ]=R PR[ 12:\\\\\\\\\\\\\\\\]=* PR[ 13: ]=*