7 Troubleshooting

In this Chapter are described contents of error displayed and its

troubleshooting when abnormality occurred in integrated weld control
bus.

Contents

7.1 Troubleshooting ･･････････････････････････････････････････････････････

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7.1 Troubleshooting

Troubles concerning integrated weld control bus connection may occur when power is turned on and
when weld is going on, and are related to to DPR communication and welder system software.

[1] [Error display] screen

[Error display] screen opens when an error occurred during operation.
This is indicated always on [Monitor 2].

[2] Error when power is turned on

(1) In case that the welder timer board is not installed in the rack or not connected
correctly, "E0762 Welder board not installed." is displayed. Confirm the welder timer
board if this error occurred.

(2) In case that welder version differs from that used previously, data between weld
sequences and linear auto stepper and welder parameters may be different. If it is
different, a warning message "W1141 Welder version is unmatched." is issued.
Initialize welder data. (Ref: Chapter 3, 3.12)

[3] Error when weld is in progress

(1) If welder’s isolation does not open, An error message " E0759 Isolation contact failed
to pull in. " is displayed. Confirm the welder’s isolation contact.

(2) If welder’s isolation contact is closed and does not open, an error message "E0760
Isolation contact stuck close." is displayed. Confirm the welder’s isolation contact.

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 7.1 Troubleshooting

(3) If welder’s SCR1 has an abnormal temperature, an error message "E0749 Spot
Welder SCR1 thermal switch actuated." is displayed. Please refer to the welder’s
manual.

(4) If SCR2 of ext. input signals has an abnormal temperature, an error message "E0750
Spot Welder SCR2 thermal switch actuated." is displayed. Please refer to the welder’s
manual.

(5) If error occurred in welder when welding was executed, an warning message "W1142
Welder error occurred." is displayed. This abnormality is displayed as FAULT or
ALERT error according to the setting described in Chapter 3, 3.9 [Welder parameter].
Please refer to Chapter 6, 6.1 [3] [Weld result monitor] or 6.1 [4] [Welder I/F monitor]
for its detail and remove the abnormality.

[4] Trouble of DPR communication

If trouble occurred in the reply from the welder against the command from the robot side
during DPR communication with the welder timer board, an error is displayed and the
robot stops if it is running.

(1) If not connected to welder timer, an error message "E0674 Welder communication
fault (No reply)." is displayed. Upload the weld data. Replace the welder timer if the
error is repeated. (Ref: Chapter 3, 3.13)

(2) If communication data received from welder timer is abnormal, error message "E0675
Welder communication fault (Check sum)." or "E0676 Welder communication fault
(Message wrong)." is displayed. Turn on power again. Replace the welder timer if the
error is repeated.

(3) If there exists checksum error of welder timer, the following error messages are
displayed:
"E0694 Executive EPROM checksum error."
"E0695 LCA EPROM checksum error."
"E0696 Application EPROM checksum error."
"E0697 DPR error."
Install system software again when these errors occurred.

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(4) If software version of welder timer is old, error message "E0757 Weld control is not
supported by weld control network command." is displayed. When this error occurred,
install the system software again.

[5] Welder’s system software

(1) If welder’s mode was tried to change with the welder’s isolation contact ON, error
message "E0761 Isolation contact turned ON." is displayed. When this error occurred,
try the above with the isolation contact OFF.

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7 Troubleshooting