DCE Customer TS Guide

DCE WELDER CONTROL
Troubleshooting Guide
Issued: June, 2003

Revised:
COPYRIGHT  EMHART TEKNOLOGIES, INC., 2003

TABLE OF CONTENTS
NO APPARENT POWER TO SYSTEM ...................................................................................................................................... 2
ASSIST MODULE IS NOT POWERED UP ............................................................................................................................... 3
ERROR 1: WELD TOOL REMAINS IN R POSITIO N ......................................................................................................... 4
ERROR 2: NO SOW.......................................................................................................................................................................... 5
ERROR 3: WELD TOOL NOT IN R POSITION .................................................................................................................... 6
ERROR 4: SOW NOT RESET ....................................................................................................................................................... 7
ERROR 5: WELD PROCEDURE SEQUENCE FAULT ....................................................................................................... 8
ERROR 6: PROGRAM NOT SELECTED ................................................................................................................................. 9

PROGRAM NOT SELECTED (CONT.)....................................................................................................................................10
ERROR 7: PROGRAM NOT ACTIVE .....................................................................................................................................11
PROGRAM NOT ACTIVE (CONT.)..........................................................................................................................................12
ERROR 13: LIFT FAULT .............................................................................................................................................................13
ERROR 14: SHORT CIR CUIT WELD .....................................................................................................................................14
ERROR 15: DROP DOWN TIMEOUT .....................................................................................................................................15
ERROR 16: NO ARC, OPEN CIRCUIT ...................................................................................................................................16
ERROR 17: MEASUREMENT LINE BROKEN ....................................................................................................................17
ERROR 18: USER COUNTER MAINTENANCE REQUIRED ........................................................................................19
ERROR 19: COLLET MAINTENANCE REQUIRED .........................................................................................................20
ERROR 20: WELDTOOL MAINTENANCE REQUIRED .................................................................................................21
ERROR 22: FEEDTUBE MAINTENANCE REQUIRED ...................................................................................................22
ERROR 23: HANDGUN S EQUENCE NOT FOLLOWED .................................................................................................23
ERROR 25: WRONG STUD LOADED .....................................................................................................................................25
ERROR 26: FEEDER OR STUD DIVIDER FUNCTION FAULT ...................................................................................26
ERROR 30: WELD OUT OF TOLERANCE...........................................................................................................................27

I. WELD CURRENT...........................................................................................................................................................28
II. WELD TIME ..................................................................................................................................................................29
III. PENTRATION DEPTH................................................................................................................................................30
IV. ARC VOLTAGE.............................................................................................................................................................31
V. WELD ENERGY............................................................................................................................................................33
VI. PEAK ARC VOLTAGE ................................................................................................................................................35
VII. DROP ARC VOLTAGE................................................................................................................................................37
ERROR 31: WELD ABORTED DUE TO PILOT ARC VOLTAGE................................................................................38
ERROR 32: POWER SUPPLY REGULATION OUT OF RANGE..................................................................................40

ERROR 33: COMMON MEASUREMENT LINE BROKEN .............................................................................................42
ERROR 34: SAFETY CIRCUIT FAULT..................................................................................................................................43
ERROR 35: SYSTEM CONFIGURATION FAULT .............................................................................................................44
ERROR 38: FIBER OPTIC TO FEEDER ................................................................................................................................45
ERROR 39: FIBER OPTIC TO CUSTOMER INTERFACE .............................................................................................46
ERROR 40: FIBER OPTIC TO POWER SUPPLY...............................................................................................................47
ERROR 41: SMPS- PROGRAM NOT LOADED ...................................................................................................................48
ERROR 42: FEEDER- RELAYS STILL ENERGIZED .......................................................................................................49
ERROR 44: TEACH MODE CONDITIONS NOT MET .....................................................................................................50
ERROR 45: START WELD NOT RESET ................................................................................................................................51
ERROR 46: NO STUD LOADED ................................................................................................................................................52
ERROR 47: TEST CONDITIONS NOT MET .........................................................................................................................53
ERROR 49: FEEDER NOT IN AUTOMATIC........................................................................................................................54
ERROR 61: ZCPU- RAM CARD MEMORY CONFIGURATION ..................................................................................55
ERROR 62: ZCPU-RAM MODULE IS MISSING OR DEFECTIVE..............................................................................56
ERROR 97: FEEDER- DRUM DOOR OPEN ........................................................................................................................57
ERROR 98: FEEDER- STUD LEVEL LOW ..........................................................................................................................58
ERROR 100: FEEDER- NO POWER TO AUX. SUPPLY .................................................................................................59
ERROR 102: FEEDER- FEED RAIL NOT FILLED IN TIME ........................................................................................60
ERROR 103: FEEDER- AIR PRESSURE LOW ...................................................................................................................61
ERROR 104: FEEDER- KNIFE NOT IN FRONT POSITION .........................................................................................62
ERROR 106: FEEDER- FEED TUBE LOCKING SWITCH OPEN ...............................................................................63
ERROR 107: FEEDER- SD-2 POSITION TIMEO UT .........................................................................................................64
ERROR 109: FEED CYCLE TIMEOUT ..................................................................................................................................65
ERROR 117: FEEDER- DSP COMMUNICATION .............................................................................................................66
ERROR 118: FEEDER- +5V KEYPAD NOT DETECTED................................................................................................67
ERROR 119: FEEDER- LM/SOLENOID UNDER VOLTAGE........................................................................................68
ERROR 120: WRONG CORRESPONDING STUD ..............................................................................................................69
ERROR 121: FEEDER- LM/SOLENOID OVER VOLTAGE...........................................................................................70
ERROR 122: FEEDER- LM/SOLENOID NOT DETECTED............................................................................................71

ERROR 123: FEEDER- SHORT CIRCUIT, LM/SOL. OUTPUT ...................................................................................72
ERROR 124: FEEDER- AMPLIFIER GROUND FAULT .................................................................................................73
ERROR 125: FEEDER- ENCODER NOT DETECTED .....................................................................................................74
ERROR 126: FEEDER- INSUFFICIENT ROOM FOR LIFT ..........................................................................................75
ERROR 127: LIFT HEIGHT TIMEOUT .................................................................................................................................76
ERROR 128: FEEDER- POWER SUPPLY OVER TEMP. ...............................................................................................77
ERROR 45: FEEDER- LM NOT READY. ..............................................................................................................................78
ERROR 146: FEEDER- SOLENOID CARD MISSING......................................................................................................79
ERROR 147: FEEDER- AMPLIFIER CARD MISSING....................................................................................................80
ERROR 149: FEEDER- 140 VOLTAGE MISSING .............................................................................................................81
ERROR 151: FEEDER- 24V INTERNAL MISSIN G ...........................................................................................................82
ERROR 152: FEEDER- 24V EXTERNAL MISSING..........................................................................................................83
ERROR 153: FEEDER- 24V INTERNAL RELAYS MISSING........................................................................................84
ERROR 154: FEEDER- 24V EXTERNAL RELAYS MISSING.......................................................................................85
ERROR 155: FEEDER- 15V KEYPAD MISSING................................................................................................................86
ERROR 156: FEEDER- +15V AMPLIFIER MISSING.......................................................................................................87
ERROR 157: FEEDER- -15V AMPLIFIER VOLTAGE MISSING................................................................................88
ERROR 159: FEEDER- LM STUD STICKOUT NOT ENOUGH ...................................................................................89
ERROR 160: FEEDER- COLOR MARKING IMPOSSIBLE ...........................................................................................91
ERROR 161: WELDING PART NOT SUPPLIED ................................................................................................................92
ERROR 162: WELDING PART NOT REMOVED ...............................................................................................................93
ERROR 164: FEEDER- LIFT NOT DETECTED B Y ENCODER ..................................................................................94
ERROR 180: ATTEMPT TO WELD WITH DEFAULT SCHEDULE............................................................................95
ERROR 202: POWER SUPPLY- TEMPERATURE TOO HIGH....................................................................................96
ERROR 266: WRONG LOAD- OR FEEDTIME (SF52) ......................................................................................................97
ERROR 268: PROGRAMMING IS NOT ALLOWED .........................................................................................................98
GLOSSARY.........................................................................................................................................................................................99
NO APPARENT POWER TO SYSTEM
DEFINITION: DCE system appears un-powered.
POSSIBLE CAUSES
1) Power switch on the DCE control is off.
2) Power input to DCE control from the plant is not correct (should be 480VAC +/- 10%, 60 cycle, 3-phase).
Or (should be 277VAC +/- 10% in reference to ground).
3) Verify that all power is available to, and inside, the controller. See “Procedure for Power
Verification” in Appendix A.
2
ASSIST MODULE IS NOT POWERED UP
DEFINITION: The ASSIST module (touch-screen module) appears un-powered.
Note: Before proceeding to troubleshooting steps below, verify that all power is available to, and
inside, the controller. See “Procedure for Power Verification” in Appendix A.
POSSIBLE CAUSES
1) Fuses F7, F8, F9, or F10 along the upper back wall of the DCE cabinet are bad. See Appendix B Fig. 7. Check all
of these fuses.
NOTE: If fuses F7, F8, or F9 are bad, you will also see that, along with no power to ASSIST
Module, the Feeders are not powered up. Also, be sure you have performed the Note above
concerning the “Procedure for Power Verification” in Appendix A.
2) Bad ASSIST power supply.

a. Open door to ASSIST module; the power supply is mounted on the back wall.
b. Check for 24vdc on V+ (red wire) and V- (brown wire).
1. If you measured 24vdc at the V+ and V-, then you have a bad ASSIST module and the entire
module must be replaced.
2.. If you did not measure 24vdc on V+ and V-, go to step 3.
3) Check for 120vac on the ASSIST power supply at pins L (black wire) and N (white wire).
a. If you measure 120vac at L and N, the power supply is bad and must be replaced.
b. If 120vac is not measured, check for 120vac at X9 (pins 1 and 2) inside DCE control. Unplug the cable
from X9 inside the DCE control and check pins 1 and 2 on the DCE connector X9 itself.
1. If you measure 120vac at X9 pins 1 and 2, there is a bad 120vac cable between X9 and the
ASSIST module.
2. If you do not read 120vac at X9 pins 1 and 2, see the schematic below to troubleshoot.
DCE main 480vac

power switch DCE CABINET
120vac to
ASSIST module
480vac to 120vac
step-down
transformer
3
ERROR 1: WELD TOOL REMAINS IN R POSITION
DEFINITION: Weld tool remains in rear position longer than pre-set time after “Start” signal received from
robot/PLC.
POSSIBLE CAUSES
1) Low air pressure at feeder. Should be at least 80psi.
2) Defective or improperly adjusted flow controls inside feeder.
3) Sluggish weld tool forward motion

a. Faulty weld tool (bad head-back proximity switch or may need rebuilding).
b. Pinched air lines in Multi-cable assembly (cable assembly that runs from Feeder to Weld Tool).
c. Faulty wiring inside Multi-cable assembly
1. Check Pin P for continuity end to end.
2. Check Pin C for continuity end to end.
3. Check Pin J for continuity end to end.
d. Multi-cable assembly dressing/routing inhibiting head forward motion.
1. Remove air supply from feeder and manually slide head forward and back checking for
restrictions in movement. Movement should be free and smooth.
Reminder: This fault will occur if the head hesitates upon extending, so be sure that action is smooth.
4) Bad head forward/back valve or solenoid on feeder. If valve is equipped with manual actuator, test for functioning
of the valve spool by manually operating the valve.
5) Bad or disconnected valve solenoid cable running from feeder ETF Feeder CPU Board connector X16, through
cable assembly (#55110) to valve pack assembly.
6) Bad ETF Feeder CPU Board. See Appendix B Fig. 3.
4
ERROR 2: NO SOW
DEFINITION: Stud On Work (SOW) not detected 1200ms after weld tool moves forward to the work piece.
POSSIBLE CAUSES
IMPORTANT: REFER TO APPENDIX B FIG. 5 TO DETERMINE WHAT STYLE OF FEEDER YOU

HAVE.
1) No stud in collet
a. Check stud level in feeder bowl/rail.
b. Check for broken or worn collet.
c. Check for jam at feeder bowl/escapement.
d. Check for kinked or worn feed tube.
e. Check air supply to system. Should be 80psi.
f. Check “feed time” is programmed correctly in “Weld Parameters”.
g. Piston assembly inside Weld Tool in need of lubrication.
h. Bad Weld Tool Receiver.
2) Depending on the Feeder style, refer to the following: (See Appendix B Fig. 5 to identify your feeder)
a. For ETF12, ETF13, style feeders:
1. Bad fuse F1 on ETF Motor Driver Board. See Appendix B Fig. 3 and 4.
2. Bad ETF Motor Driver Board. See Appendix B Fig. 3 and 4.
3. Bad or misadjusted motors on feeders. See Appendix 4 for motor adjustment locations.
b. For ETF52 style feeders:
1. Bad fuse F1 on ETF Motor Driver Board. See Appendix B Fig. 3 and 4.
2. Bad ETF Motor Driver Board. See Appendix B Fig. 3 and 4.
c. For ETF90 style feeders:
1. Bad Rail Kicker Assembly. See Appendix B Fig. 8.
2. Bad Rail Kicker Assembly air valve/solenoid. See Appendix B Fig. 8.
3. Bad Knife Assembly air cylinder. See Appendix B Fig. 8.
4. Bad Knife Assembly air valve/solenoid. See Appendix B Fig. 8.
3) Weld tool/Gun cannot reach the work piece. Check cable dressing/fixturing.
4) Worn or dirty or disconnected weld common power cable (ground).
5) Bad Weld Tool.
6) Defective PWM Board on SMPS (Switching Mode Power Supply).

a. Replace PWM Board. Be sure that jumpers X22 and X23 are in the proper position. Refer to Appendix B
Fig.1 “Stud Polarity Set-up Procedure”.
7) Defective SMPS (Switching Mode Power Supply).

a. Replace power supply using the “Changing the DCE Power Supply” procedure in Appendix A.
5
ERROR 3: WELD TOOL NOT IN R POSITION
DEFINITION: Welder Control does not detect that the weld tool is in the rear position.
POSSIBLE CAUSES
1) Low air pressure at feeder. Should be at least 80psi.
2) Defective or improperly adjusted flow controls inside feeder.
3) Sluggish weld tool forward motion

a. Faulty weld tool (bad head-back proximity switch or may need rebuilding).
b. Pinched air lines in Multi-cable assembly.
c. Faulty wiring inside Multi-cable assembly
1. Check Pin P for continuity end to end.
2. Check Pin C for continuity end to end.
3. Check Pin J for continuity end to end.
d. Multi-cable assembly dressing/routing inhibiting head forward motion.
1. Remove air supply from feeder and manually slide weld head forward and back checking for
restrictions in movement. Movement should be free and smooth.
Reminder: This fault will occur if the weld head hesitates upon retracting so be sure that action is
smooth.
4) Bad head forward/back valve or solenoid on feeder. If valve is equipped with manual actuator, test for functioning
of the valve spool by manually operating the valve.
5) Bad or disconnected valve solenoid cable running from feeder ETF Feeder CPU connector X16, through cable
assembly (#55110) to valve pack assembly.
6
ERROR 4: SOW NOT RESET
DEFINITION: Stud On Work signal is still detected 1200ms after head-back.
POSSIBLE CAUSES
1) Collet is welded to the work piece.
2) Low air pressure. Should be between 80-100psi.
3) Weld tool/gun too close to work surface after weld. Collet or newly fed stud is touching the previously welded
stud.
a. With weld tool in the rear position, re-teach robot so that there is approx. 1.5” between stud and work
surface to allow for proper weld tool travel.
4) Short between weld tool weld-cable and work surface ground.

Perform the following test:
a. Power down the DCE controller and open the controller door.
b. Disconnect the weld power cable of the affected weld tool from the SMPS (Switching Mode Power
Supply).
c. Disconnect the weld common cable from the SMPS.
d. Lay the two disconnected cables aside and check for continuity between the weld tool weld-power
connection of the SMPS and the weld common connection of the SMPS.
• If you read continuity across the power supply connections, then the SMPS in the DCE
control is defective.
1. Change the SMPS using the “Changing the DCE Power Supply” procedure in
Appendix A.
e. If you did not read continuity in step (d) above, read for continuity between the disconnected cables.
Ensure that the stud in the weld tool is not touching the work piece.
• If you read continuity between the weld power cables, then there is a short outside the DCE
controller that must be tracked down.
7
ERROR 5: WELD PROCEDURE SEQUENCE FAULT
DEFINITION: During the weld sequence, an error was detected.
POSSIBLE CAUSES
1) Faulty ETF Feeder CPU Board. See Appendix B Fig. 3.
2) Defective PWM Board on SMPS power supply.

Fig. 1 “Stud Polarity Set-up Procedure”.

4) Faulty Shield Gas valve/solenoid on feeder (if used).
5) Faulty Valve Cable assembly (#55110) that runs from ETF Feeder CPU connection X16 to Valve Pack
assembly.
6) Possible faulty DCE ZCPU Board in DCE cabinet. See Appendix B Fig. 3.
7) Possible faulty Aux. Power Supply Board on inside door of DCE control.
8
ERROR 6: PROGRAM NOT SELECTED
DEFINITION: Welder Control does not detect program bit selection from Robot/PLC.
POSSIBLE CAUSES
NOTE: “For HANDGUN operation proceed to step 5.”
1) The program number selected by the Robot / PLC is 0.
2) The welder control has more than one program active AND the Robot / PLC I/O is not wired up to select program
bits.
a. In this case, check to make sure that only program 1 is active . If you want to weld with more than one
program, you must wire your Robot/PLC I/O for program bit selection.
3) Robot / PLC interface is incorrectly wired.

• To verify, at the Keypad “Main Menu” scroll down to “Status”; press “Enter”. Scroll down to
“Customer Interface”; press “Enter”. At this point, you can verify the program being selected at the
bottom of the screen. A “0” indicates that the PLC is not selecting any program bits.
Status Customer Interface Inputs

----------------------------------------
1 2 3 4 5
Operation mode auto - - - -
Start weld * - - - -
Start feed - - - - -
Without weld - - - - -
Reset fault - - - - -
Restart - - - - -
Force WC - - - - -
Start SKK extend - - - - -
Start SKK retract - - - - -
Program number 1
----------------------------------------
<Options “Crawl”>
If using a Robot / PLC and selecting program bits, you can check the data for the external program setting in the
following manner.
a. Enter a program (bit) 1 via the Robot / PLC interface. The “Program Number” line should now say “1”.
Turn off bit 1 input.
b. Enter the program (bit) 2 via the Robot / PLC interface. The “Program Number” line should now say “2”.
c. Enter the program (bit) 4 via the Robot / PLC interface. The “Program Number” line should now say “4”.
d. Enter the program (bit) 8 via the Robot / PLC interface. The “Program Number” line should now say “8”.
“8”. Turn off bit 8 input.
Continued next page
9
PROGRAM NOT SELECTED (CONT.)
e. Enter the program (bit) 16 via the Robot / PLC interface. The “Program Number” line should now say
f. Enter the program (bit) 32 via the Robot / PLC interface. The “Program Number” line should now say
g. Enter the program (bit) 64 via the Robot / PLC interface. The “Program Number” line should now say
If this does not work correctly, the Robot / PLC interface is incorrectly wired or the I/O cable is defective.
h. Defective Customer Interface Board A5.
(HAND-GUN OPERATION)
a. More than one program is activated.
b. For handgun operation, activate Program Number One and ONLY Program Number One of each
Outlet (Weld Tool). Deactivate all other programs using the following procedure
From the “Main Menu”, select “Programming” and press the “Enter” key. Scroll down to the “De/activate
programs” option and press the “Enter” key. Enter the outlet number of the affected outlet and press “Enter” key.
All of the active programs will be highlighted. Using the arrow keys position the arrow cursor in front of program
“2”. Press and hold the “-“ key until the only program highlighted for this outlet is program “1”.
Overview Active Programs Outlet:1

→1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
51 52 53 54 55 56 57 58 59 60
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
81 82 83 84 85 86 87 88 89 90
91 92 93 94 95 96 97 98 99 100
100 101 102 etc. to 127
----------------------------------------
Options “Crawl”
10
ERROR 7: PROGRAM NOT ACTIVE
DEFINITION: The program selected by robot/PLC has not been activated in the Welder Control software.
NOTE: FOR HANDGUN OPERATION GO TO STEP 4
POSSIBLE CAUSES
1) From the “Main Menu”, select “Programming” and press the “Enter” key. Select the “Weld Parameter”; press
“Enter”. The “Weld Parameter” sub-menu is used to activate programs , enter weld currents, weld times, arc
voltages, tolerances, and other options for up to 127 programs per outlet. At this point, you are on line 1 and need to
specify which outlet (SKK/PK) you want. In this example we will use outlet 1; press “1” and “Enter”. Now select
the program that you want activated; in this example press “1” then “Enter”. Use the up/down arrow keys to select
“Program active” line. Use the “+” key until the “Program active” line says “yes”. Do this for all program
numbers to be used by the Robot/PLC.
Press ENTER to save changes.
WELD PROGRAMMING
----------------------------------------
Outlet: 1 Weld Program: 1
Stud ID……………………….._____________
Program Active………………yes
Start Delay…………………….. 200 ms
Weld Current………………….1300 A
Weld Time………………………..28 ms
Lift / Penetration………………1.20 mm -0.10mm
Optimization…………………….no
_______________Monitored Parameters <_>___

2) The Robot / PLC is selecting a program that is not active.
• To verify, from the “Main Menu” scroll down to “Status”; press “Enter”. Select “Customer
Interface” line; press “Enter”.
Status Customer Interface Inputs

----------------------------------------
1 2 3 4 5
Operation mode auto - - - -
Start weld * - - - -
Start feed - - - - -
Without weld - - - - -
Reset fault - - - - -
Restart - - - - -
Force WC - - - - -
Start SKK extend - - - - -
Start SKK retract - - - - -
Program number 1
----------------------------------------
Continued next page
11
PROGRAM NOT ACTIVE (CONT.)
If using a Robot / PLC and selecting program bits, you can check the data for the external program setting in the
following manner:
AT ROBOT/PLC, FORCE OFF ALL PROGRAM SELECTION BITS TO DCE
a. Enter a program (bit) 1 via the Robot / PLC interface. The “Program Number” line should now say “1”.
b. Enter the program (bit) 2 via the Robot / PLC interface. The “Program Number” line should now say “2”.
c. Enter the program (bit) 4 via the Robot / PLC interface. The “Program Number” line should now say “4”.
d. Enter the program (bit) 8 via the Robot / PLC interface. The “Program Number” line should now say “8”.
e. Enter the program (bit) 16 via the Robot / PLC interface. The “Program Number” line should now say
f. Enter the program (bit) 32 via the Robot / PLC interface. The “Program Number” line should now say
g. Enter the program (bit) 64 via the Robot / PLC interface. The “Program Number” line should now say
If this does not work correctly, the Robot / PLC interface is incorrectly wired or the I/O cable is defective.
3) Defective Customer Interface Board A5.
(HAND-GUN OPERATION)
1. For handgun operation, activate Program Number One and ONLY Program Number One. Deactivate all other
programs using the following procedure
From the “Main Menu”, select “Programming” and press the “Enter” key. Scroll down to the “De/activate
programs” option and press the “Enter” key. Enter the outlet number of the affected outlet and press “Enter” key.
All of the active programs will be highlighted. Using the arrow keys position the arrow cursor in front of program
“2”. Press and hold the “-“ key until the only program highlighted for this outlet is program “1”.
Overview Active Programs Outlet:1

→1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
51 52 53 54 55 56 57 58 59 60
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
81 82 83 84 85 86 87 88 89 90
91 92 93 94 95 96 97 98 99 100
100 101 102 etc. to 127
----------------------------------------
12
ERROR 13: LIFT FAULT
DEFINITION:
1. Flag from ETF that there is an error in the position of the LM as detected by the ETF A1 CPU.
2. ETF did not acknowledge the “lift on” command from the SMPS.
3. SMPS did not measure pilot voltage.
4. ETF did not acknowledge the “lift off” command from the SMPS.
POSSIBLE CAUSES
1) Ensure that the PWM Board polarity jumpers X22 and X23 are in the correct position. Refer to Appendix B,
“Stud Polarity Set-up Procedure”.
2) Faulty weld tool. Replace or repair (refer to weld tool tear-down procedure).
a. Faulty LM motor inside weld tool.
b. Faulty Encoder Board inside weld tool.
c. Faulty wiring inside weld tool.
3) Faulty Multi-cable assembly that runs from feeder to weld tool.

a. Check Pin A for continuity from end to end.
b. Check Pin B for continuity from end to end.
4) Faulty ETF Feeder LM Amplifier Board. See Appendix B Fig. 3.
6) Faulty ETF Feeder Filter Board. See Appendix B Fig. 3.
7) Faulty PWM on SMPS (Switching Mode Power Supply).

13
ERROR 14: SHORT CIRCUIT WELD
DEFINITION: Welder Control has not detected that the stud has lifted off of the work piece during the weld.
POSSIBLE CAUSES
a. Faulty LM motor inside weld tool.
2) Faulty Multi-cable assembly (cable that runs from feeder to the weld tool).
4) Faulty ETF Feeder LM Filter Board. See Appendix B Fig. 3.
6) Programmed lift height incorrect.

a. Studs (non-aluminum) – should be 1.2mm.
b. Nuts – should be .8mm.
c. Aluminum studs- contact Emhart Fastening Teknologies.
7) Weld heat schedule too hot.
14
ERROR 15: DROP DOWN TIMEOUT
DEFINITION: The drop down time of the weld tool/gun exceeded 20ms.
POSSIBLE CAUSES
1) Faulty weld tool. Replace or repair.
5) Low ETF Feeder input air pressure. Should be 80-100psi.
6) Weld head forward movement restricted by Multi-cable dressing/routing.
7) Weld schedule too hot.
8) Defective PWM Board on SMPS (Switching Mode Power Supply).

a. Replace PWM Board; refer to Appendix B Fig. 1 “Stud Polarity Set-up Procedure” to make certain you
use proper polarity.

15
ERROR 16: NO ARC, OPEN CIRCUIT
DEFINITION: Arc is extinguished during weld process (either during Pilot Arc or Main Arc phases).
POSSIBLE CAUSES
1) Movement of work piece during weld process. Check “Start delay” of all active programs; ensure at least 200ms
of “Start Delay” time. Take steps to arrest work piece motion during weld process.
2) Weld tool was removed from the work at the beginning of the weld. Monitor weld tool for movement during weld
process.
3) Lift setting is too high for hand held gun or the weld tool/gun-to-work angle is not at 90 degrees.
4) Extremely impure work surface.
5) Frayed or open Weld Common weld power cable.
6) Defective PWM in SMPS (Switching Mode Power Supply).

a. Replace PWM Board. Be sure that jumpers X22 and X23 are in the proper positions. Refer to Appendix
B Fig. 1 “Stud Polarity Set-up Procedure”.
7) Defective SMPS.
16
ERROR 17: MEASUREMENT LINE BROKEN
DEFINITION: Measurement Line circuit interrupted.
POSSIBLE CAUSES
1) Check PWM Polarity jumpers X22 and X23 for correct setting. Refer to Appendix B Fig. 1 “Stud Polarity Set-
up Procedure”.
2) Bad ETF Feeder CPU Fuse F1. See Appendix B Fig. 3.

a. Take side cover off of Feeder JIC Box. Check fuse F1 on CPU.
3) Cables are not hooked up.

a. Be sure all cables are hooked up properly.
b. If system is using more than one outlet, be sure that the cables are all routed to the proper feeders and
weld tools.
4) Measurement line interrupted.

a. Open the door to the DCE cabinet and check the measurement line circuit for the faulted weld tool (See
top of Fig. 9 or 10 in Appendix B):
1. Feeder Application- inside the DCE control cabinet, disconnect weld power cable and
“measurement line” connection of the affected weld tool. SEE APPENDIX B, FIG. 9 and 10.
a. On the cables use Ohmmeter to verify continuity (0Ω) between the weld power
cable and “Measurement Line” wire.
NOTE: Push Measurement Line connector side-button and draw back

protective sleeve to expose metal connection when performing this test.
1. Continuity No?
a. Bad Weld tool. Unplug cables from weld tool and check for
continuity between the Control Cable Connector pin “K” and the Weld
Power Cable Connector on weld tool itself. Should read continuity.
b. Bad Multi-cable package assembly (cable between Feeder and Weld
tool). Replace.
c. Bad “Measurement Line” wire, (wire between DCE cabinet and
Feeder).
d. Bad Weld Power cable (cable between DCE cabinet and Feeder).
e. Bad CPU Board inside Feeder JIC box.
1. Continuity Yes?
a. Faulty PWM in SMPS (Switching Mode Power Supply).
b. Faulty SMPS. Replace power supply using Appendix A “Changing
the DCE Power Supply”.
1. SMB Box (Protective Gas Application ONLY)- inside the DCE control cabinet, disconnect
weld power cable and control cable of the affected weld tool.
(CONTINUED NEXT PAGE)
17
MEASUREMENT LINE BROKEN (CONTINUED)
a. On the cables use Ohmmeter to verify continuity (0Ω) between the weld power-
cable and pin “K” of the control cable.
1. Continuity No?
a. Bad Control Cable (DCE cabinet to SMB Box)
b. Break in SMB Box. Check X2 pin “K” to Multi-cable connection pin
“K”. Should read continuity.
c. Bad Weld tool. Unplug cables from weld tool and check for
continuity between the Control Cable Connector pin “K” and the Weld
Power Cable Connector on weld tool itself. Should read continuity.
d. Bad Multi-cable package assembly (cable between SMB Box and
Weld tool). Replace.
e. Bad Weld Power cable (DCE cabinet to SMB Box).
2. Continuity Yes?
a. Faulty PWM in SMPS (Switching Mode Power Supply).
b. Faulty SMPS. Replace power supply using the “Changing the DCE
Power Supply” procedure in Appendix A.
18
ERROR 18: USER COUNTER MAINTENANCE REQUIRED
DEFINITION: The “User Counter” fault limit for the amount of weld cycles has been reached. This is a user-
defined limit and the user-defined action should be taken. The limit of this counter is customer-
defined and tailored by the customer to the application.
POSSIBLE CAUSES
1) Plug Keypad into the DCE control. From the “Main Menu”, highlight “Maintenance Functions” and press “Enter”.
Highlight the line “Maintenance Statistics” and press “Enter”. At upper right hand corner of “Maintenance
Counters”, enter the number of the affected weld tool and press “Enter”. You will see the following screen:
______ _Maintenance Counters Outlet: 1__
Number of Welds
Collet Feedtube Weldtool User

Act.
Warn.
Fault.
Reset! | Reset! | Reset! | Reset!
___________________________________________________
a. Highlight “Reset!” under the “User” column and press the “Enter” key. A banner reading
“Press <ENT> to confirm!”
will be displayed. Press the “Enter” key to confirm and, after a second or two, the line “Act.” under the
column “User” will be reset to a count of “0”.
b. Be sure to take the appropriate user-defined actions that determined the reason for using this counter for
this weld tool.
c. Reset any remaining faults and continue with normal welding operations.
19
ERROR 19: COLLET MAINTENANCE REQUIRED
DEFINITION: The “Collet Maintenance Counter” fault limit for the amount of weld cycles has been reached.
This counter is used to alert the customer that the collet needs to be changed on this weld tool.
The limit of this counter is customer-defined and tailored by the customer to the appl ication.
POSSIBLE CAUSES
Number of Welds

Act.
Warn.
Fault.
___________________________________________________
a. Highlight “Reset!” under the “Collet” column and press the “Enter” key. A banner reading
column “Collet” will be reset to a count of “0”.
b. Be sure that the collet has been replaced.
20
ERROR 20: WELDTOOL MAINTENANCE REQUIRED
DEFINITION: The “Weldtool Maintenance Counter” fault limit for the amount of weld cycles has been
reached. This counter is used to alert the customer that the weld tool needs rebuilding/cleaning.
The limit of this counter is customer-defined and tailored by the customer to the application.
POSSIBLE CAUSES
Number of Welds

Act.
Warn.
Fault.
___________________________________________________
a. Highlight “Reset!” under the “Weldtool” column and press the “Enter” key. A banner reading
column “Weldtool” will be reset to a count of “0”.
b. Be sure that the weldtool had been rebuilt/cleaned.
21
ERROR 22: FEEDTUBE MAINTENANCE REQUIRED
DEFINITION: The “Feedtube Maintenance Counter” fault limit for the amount of weld cycles has been
reached. This counter is used to alert the customer that the feed tube needs inspection/replacement. The
limit of this counter is customer-defined and tailored by the customer to the application.
POSSIBLE CAUSES
Number of Welds

Act.
Warn.
Fault.
___________________________________________________
a. Highlight “Reset!” under the “Feedtube” column and press the “Enter” key. A banner reading
column “Feedtube” will be reset to a count of “0”.
b. Be sure that the feed tube had been inspected/replaced.
22
ERROR 23: HANDGUN SEQUENCE NOT FOLLOWED
DEFINITION: The correct sequence of operation while welding with a handgun was not observed.
inside, the controller. Se e “Procedure for Power Verification” in Appendix A.
TO WELD WITH REGARD TO ANGULARITY:
The weld sequence should follow this order:

1) SOW = Stud On Work
2) Angularity (see NOTE below)
3) Start = Pulling the trigger
POSSIBLE CAUSES
1) Operator is not following the correct sequence.
2) Angularity is misadjusted. Adjust angularity. See Appendix A “PK560 HANDGUN SET-UP (3 STEPS)”.
3) Bad handgun. Repair or replace.
4) A problem with the Stud on Work detection circuitry, (system not detecting SOW). See “NO SOW” fault Error 2.
NOTE: If desired, you can program the system to weld without regard to Angularity. See the following procedures:
TO WELD WITHOUT REGARD TO ANGULARITY:
the weld sequence is as follows:

1) SOW = Stud On Work
2) Start = Pulling the trigger
For PKLM (Feeder fed hand guns):
a) Plug Keypad into DCE control. From “Main Menu”, select “Programming” and press “Enter”. Select “Outlet
Programming” and press “Enter”. Select the appropriate Outlet number and press “Enter”.
Outlet Programming
Outlet 1 Active.. yes

Outlet ID.........--------------------
Application Type..Standard
Start Feed........Intern after SOW
Permitted WOPs…...1
Pre Gas...........2000 ms
Post Gas..........1000 ms
Color Marking.....no
Air Blow..........yes
Check Stud Length. no Teach!
Feeder Programming.<↓>
Help Message Area
Highlight the line “Check Stud Length. and use the “plus” and “minus” key to set this line to “no”. Try
welding. If you cannot yet weld, go back up to Step 3.
PK560 manually fed hand guns: next page
23
HAND GUN SEQUENCE NOT FOLLOWED (CONTINUED)
For PK560 (manually-fed handgun):
To weld without regard to angularity on this type of gun:
a) Plug Keypad into DCE control. From “Main Menu”, select “Programming”, press “Enter”. Select “Outlet
Programming”, press “Enter”. Select the Outlet number of the PK560 hand gun that you wish to modify,
press “Enter”. You should see the following screen:
Outlet Programming
Outlet: 1 Active .........yes

Outlet ID .........--------
Application type ..Standard
Start Feed ......Intern after SOW
Slide Rail Valves.............Intern
Permitted WOPs .........3
Angularity.....................no
Maintenance counter.<↓>
Help Message Area
b) Highlight the line “Angularity” and use your “plus” and “minus” keys to change this value to “no”. Try
welding.
c) Use Appendix A “PK560 HANDGUN SET-UP (3 STEPS)”.

1. When you get to Step 2, set the angularity for a very “course” sensitivity. Angularity light on the
PKE Box should go on as soon as the smallest pressure is put on the stud when seating the flash
shield of the PK560 on the work piece.
Try to weld. If you cannot yet weld, go back to Step 3.
24
ERROR 25: WRONG STUD LOADED
DEFINITION: The DCE control has identified an incorrect stud loaded into the weld tool. This identification
was made via the lift measuring circuit in the weld tool by checking “pre-load” of stud after
weld tool achieved Stud-On-Work.
POSSIBLE CAUSES
1) Ensure that the correct length stud is loaded in the weld tool and feeder.
2) DCE control is programmed wrong. See Appendix A “Programming Stud Length Detection Weld Head”.
3) Bad or incorrect piston/piston spacer in weld tool.

a. Verify the piston number and piston spacer (if applicable).
b. If piston tip is worn or pitted, replace.
4) Bad Weld Tool. Repair or replace.
5) Bad Multi-Cable assembly that runs from the Weld Tool to the Feeder.
6) Bad ETF Feeder CPU Board. See Appendix B Fig. 3 and 15.
25
ERROR 26: FEEDER OR STUD DIVIDER FUNCTION FAULT
DEFINITION:
*** ONLY USED WITH STUD-DIVIDER SYSTEMS ***
Failure of Stud-Divider systems with the following exceptions:

a. “feeder not in automatic”; fault “49”.
b. “feeder voltage”; fault “100”.
c. “feed tube locking switch”; fault “106”.
d. “rail not filled in time”; fault “102”.
e. “feed cycle time-out”; fault “109”.
POSSIBLE CAUSES
26
ERROR 30: WELD OUT OF TOLERANCE
DEFINITION: One or more of the measured weld parameters was outside the pre-programmed tolerance
range:
POSSIBLE CAUSES
At keypad, hit “ESC” key until “Main Menu” is displayed at the top of the screen. Hit the “F4” key to access the “Weld
Parameter Monitor” screen. Punch in the number of the faulted weld head. The screen now displays the results of the
last weld on the faulted head.
Any highlighted lines on this screen represent an out of tolerance measurement. Refer to the following chart to
troubleshoot the appropriate “Weld Out of Tolerance” value.
I. WELD CURRENT (see page 28)
II. WELD TIME (see page 29)
III. PENETRATION DEPTH (see page 30)
IV. ARC VOLTAGE (see page 31)
V. WELD ENERGY (see page 33)
VI. PEAK ARC VOLTAGE (see page 35) NOTE: Aluminum Welding ONLY
VII. DROP ARC VOLTAGE (see page 37) NOTE: Aluminum Welding ONLY
27
I. WELD CURRENT
-The actual weld current measured during the weld was found to be outside of the +30 amp or –30 amp fixed tolerance
values.
1) Weld circuit resistance is too high.

a. Check weld power cables for fraying and connections
b. Check for proper grounding and weld conditions (coating on work surface).


28
II. WELD TIME
1) Tolerances for “Weld Time” are programmed too tight. From the “Main Menu”, highlight the line “Programming”
and press “Enter”. Highlight “Weld Programming” and press “Enter”. The “Weld Programming” sub-menu is
used to program weld currents, weld times, arc voltages, tolerances, and other options for up to 127 programs per
outlet. At this point, you are on line 1 and need to specify which outlet you want. In this example we will use outlet
1; press “1” and “Enter”. Then select the program you want, in this example we will use program 1; press “1” then
“Enter”. You will see the following screen :
Note: Some line items Weld Programming standard

may or may not be
present depending on Stud ID.............. ---------------
the actual hardware Program Active....... .yes
that is hooked up to Start Delay........... 0 ms
Weld Current.......... 750 A
the system (i.e. type Weld Time............. 21 ms
of feeder, weld tool, Lift/Penetration .....1.50 mm -1.00mm
etc.). Optimization.......... no
Airblow ... ... ... .. no
Check Stud Length. no
SDX Feeder . . . .. ..none
Monitored Parameters.<↓>
Help Message Area
Use the <↓> key to go to page 2 of Programming
Monitored Parameters standard

---------------------
Varc Pilot Limits... 16.0 to 34.0 V
Varc Weld Limits.... 16.0 to 34.0 V
Penetration......... 0.60 to 1.10 mm
Weld Time.......... + 6.0 to -3.0 ms
Weld Energy.......... 550 to 750 J
Lift Height... . .. . 0.5 to 1.5 mm
Weld Parameters.<↓>
Help Message Area

+
Select the line “Weld Time”. Adjust the tolerance for “Weld Time” as necessary by highlighting a
value on this line and use the “plus” and “minus” keys to change that value. Actual tolerances entered
will depend on the application and should always be set to ranges that are consistent with
maintaining good welds.
2) The “Drop Down Time ” has increased causing the weld time to increase.
a. See Error 15: Drop Down Time Out.
29
III. PENTRATION DEPTH
1) Asked for unattainable “Penetration Depth” or tolerances for “Penetration Depth” are programmed too tight. From
the “Main Menu”, highlight the line “Programming” and press “Enter”. Highlight “Weld Programming” and press
“Enter”. The “Weld Programming” sub-menu is used to program weld currents, weld times, arc voltages,
tolerances, and other options for up to 127 programs per outlet. At this point, you are on line 1 and need to specify
which outlet you want. In this example we will use outlet 1; press “1” and “Enter”. Then select the program you
want, in this example we will use program 1; press “1” then “Enter”. You will see the following screen :

may or may not be
Airblow ... ... ... .. no
Help Message Area

---------------------
Weld Time.......... + 6.0 to -3.0 ms
Weld Energy.......... 550 to 750 J
Help Message Area

+
Modify the target Penetration on the “Lift/Penetration” line on page 1; or modify the “Penetration”
tolerances on page 2. Adjust the tolerance for “Penetration” as necessary by highlighting a value on
this line and use the “plus” and “minus” keys to change that value. Actual tolerances entered will
depend on the application and should always be set to ranges that are consistent with maintaining
good welds.
2) Faulty weld tool. Repair or replace.
30
IV. ARC VOLTAGE
1) Tolerances for “Pilot Arc” or “Main Arc” are programmed too tight. From the “Main Menu”, highlight the line
“Programming” and press “Enter”. Highlight “Weld Programming” and press “Enter”. The “Weld Programming”
sub-menu is used to program weld currents, weld times, arc voltages, tolerances, and other options for up to 127
programs per outlet. At this point, you are on line 1 and need to specify which outlet you want. In this example we
will use outlet 1; press “1” and “Enter”. Then select the program you want, in this example we will use program 1;
press “1” then “Enter”. You will see the following screen :

may or may not be Outlet: 1 Weld Program: 1
Airblow ... ... ... .. no
Monitored Parameters.< ↓>
Help Message Area

---------------------
Weld Time.......... + 6.0 to -3.0 ms
Weld Energy.......... 550 to 750 J
Help Message Area

+
Select the line “Varc Pilot Limits” and/or “Varc Weld Limits” depending on which is causing the
WOP conditions. Adjust the tolerance for “Varc” as necessary by highlighting a value on these line
and use the “plus” and “minus” keys to change that value. Actual tolerances entered will depend on
the application and should always be set to ranges that are consistent with maintaining good welds.
2) Excessive oil on work piece.

a. Using the procedure in step 1, change Varc pilot and Varc weld tolerances to ± 0.
After changing tolerances, verify that the qualities of the welds are good.
***IMPORTANT: VERIFY PRESENCE OF OIL BEFORE USING THE FOLLOWING

PROCEDURE. ***
b. If you have poor weld quality you may use the “Optimization”. See “keypad screen” page 1 above:
1. Current – adjusts weld current to compensate for oil.
2. Time – adjusts weld time to compensate for oil.
3. Vdce – adjusts lift height to maintain specific voltage; compensates for oil
31
(ARC VOLTAGE - CONTINUED)
3) PWM Board is defective.

a. Replace PWM Board using Appendix B Fig. 1 “Stud Polarity Setup Procedure” to make certain you use
proper polarity.
2) Defective power supply.

32
V. WELD ENERGY
1) Tolerances for “Weld Energy” is programmed too tight. From the “Main Menu”, highlight the line “Programming”
and press “Enter”. Highlight “Weld Programming” and press “Enter”. The “Weld Programming” sub-menu is
used to program weld currents, weld times, arc voltages, tolerances, and other options for up to 127 programs per
outlet. At this point, you are on line 1 and need to specify which outlet you want. In this example we will use outlet
1; press “1” and “Enter”. Then select the program you want, in this example we will use program 1; press “1” then
“Enter”. You will see the following screen :

may or may not be Outlet: 1 Weld Program: 1
Airblow ... ... ... .. no
Help Message Area

---------------------
Weld Time.......... + 6.0 to -3.0 ms
Weld Energy.......... 550 to 750 J
Help Message Area

+
Select the line “Weld Energy”. Adjust the tolerance for “Weld Energy” as necessary by highlighting a
value on this line and use the “plus” and “minus” keys to change that value. Actual tolerances entered
will depend on the application and should always be set to ranges that are consistent with
maintaining good welds.
(CONTINUED ON NEXT PAGE)
33
(WELD ENERGY - CONTINUED)
NOTE: The calculation for the measured value is: “Energy (J) = Current x Time x Voltage (Vw)”.
Deviations in any of the 3 factors, either singly or in combination, can cause the Energy, measured in Jules (J), to
be out of tolerance.
8) Review the weld to see which of the 3 factors (Current, Time, Voltage) may be contributing to higher or lower than
normal “Weld Energy” readings:
From the “Main Menu”, select “Maintenance Functions” and press “Enter”. Select the “WOP
Memory” and press “Enter”. Punch in the number of the affected Outlet, press “Enter”. The
following screen will be displayed (this is an example page):
WOP page number: page 7

WOP Memory Page: 7 of a possible 256 “pages”,
i.e. stored WOPS.
Outlet: 2 Prog #: 32 11:17:03
Stud ID: ---------------- 02/11/02
Final Lift: 1.50 mm Opt: none
Ref Min Max Act
Vp 18.0 28.0 24.2 V

Vw 18.0 26.0 22.7 V Both “Iw” and “tw” are
Iw 1000 970 1030 1028 A
tw 48 42 52 51.0 ms
higher than normal, though
“Enj” is highlighted Pen 0.20 0.80 0.55 mm both are in tolerance.
indicating this line item is Enj 950 1050 1190 J
outside tolerance. Message: none
Help Message Area
Use the <↑> and <↓> arrow keys to “page” through the recorded WOPs until you see the WOP
caused by Energy. You will know this by the highlighted line “Enj”. Examine the column “Act” for
lines, “Vw”, “Iw”, and “tw” to see what may be contributing to the high or low “Enj” reading.
In the example above, both Iw and tw are higher than normal though both are in tolerance. However,
when plugged into the equation:
Energy = Current x Time x Vw

1190J = 1028A x .051s x 22.7V
1190 Jules is out of tolerance in the above example.
a. Review the values that apply and in the relevant cases do the following:
a. For higher or lower “Vw” (Main Arc Voltages): See “Arc Voltage” Step 2.
b. For higher or lower “Iw” (Main Arc Current): See “Weld Current” Step 1.
c. For higher or lower “tw” (Weld Time): See “Drop Down Timeout”.
34
VI. PEAK ARC VOLTAGE
1) Tolerance for “Peak Arc Voltage” is programmed too tight. From the “Main Menu”, highlight the line
will use outlet 1; press “1” then “Enter”. Then select the program you want, in this example we will use program 1;
Note: Some line items Weld Program Aluminum

may or may not be
present depending on Outlet: 1 Weld Program: 1
the actual hardware Stud ID...............----------------
Program Active........yes
the system (i.e. type Welding Step 1........ 250 A 6 ms
of feeder, weld tool, Welding Step 2........ 220 A 14 ms
Lift Height...........1.50 mm
etc.). Turn Off Time......... 0 ms
Optimization..........no
Check Stud Length.....no Teach!
Help Message Area
Monitored Parameters Aluminum
Outlet: 1 Weld Program: 1.

----------------
Weld Time...........+ 6.0 to - 3.0 ms
Weld Energy......... 550 to 750 J
Varc Peak Detect....+ 10 V

Varc Drop Detect....- 8 V
Help Message Area
Select the line “Varc Peak Detect”. Adjust the tolerance for “Varc Peak Detect” as necessary by
highlighting the value on this line and use the “plus” and “minus” keys to change the value. The
actual tolerance entered will depend on the application and should always be set to a range that is
consistent with maintaining good welds.

After changing tolerances, verify that the qualities of the welds are good.
***IMPORTANT: VERIFY PRESENCE OF OIL BEFORE USING THE FOLLOWING

PROCEDURE. ***
b. If you have poor weld quality you may use the “Optimization”. See “keypad screen” page 1 above:
1. Current – adjusts weld current to compensate for oil.
2. Time – adjusts weld time to compensate for oil.
3. Vdce – adjusts lift height to maintain specific voltage; compensates for oil.
35
(PEAK ARC VOLTAGE - CONTINUED)
proper polarity.

36
VII. DROP ARC VOLTAGE
1) Tolerance for “Drop Arc Voltage” is programmed too tight. From the “Main Menu”, highlight the line

may or may not be
Help Message Area


----------------
Weld Time...........+ 6.0 to - 3.0 ms
Weld Energy......... 550 to 750 J

Help Message Area
Select the line “Varc Drop Detect”. Adjust the tolerance for “Varc Drop Detect” as necessary by
highlighting the value on this line and use the “plus” and “minus” keys to change the value. The

proper polarity.

37
ERROR 31: WELD ABORTED DUE TO PILOT ARC VOLTAGE
DEFINITION: Pilot Arc voltage out of toleranceàABORT WELD. *** ALUMINUM WELDING ONLY ***
POSSIBLE CAUSES
1) Tolerance for “Pilot Arc Voltage” is programmed too tight. From the “Main Menu”, highlight the line

may or may not be
Help Message Area


----------------
Weld Time...........+ 6.0 to - 3.0 ms
Weld Energy......... 550 to 750 J

Help Message Area
Select the line “Varc Pilot Limits”. Adjust the tolerances for “Varc Pilot Limits” as necessary by
highlighting the values on this line and use the “plus” and “minus” keys to change these values. The
38
(WELD ABORTED DUE TO PILOT ARC VOLTAGE - CONTINUED)

After changing tolerances, verify that the quality of the welds are good.
3) PWM Board on SMPS (Switching Mode Power Supply) is defective.

a. Replace PWM Board using Appendix B Fig. 1 “Stud Polarity Setup Procedure” to make certain you

39
ERROR 32: POWER SUPPLY REGULATION OUT OF RANGE
DEFINITION: Occurs while welding. The PWM detects, for a 5ms duration, that the SMPS was unable to
deliver the requested current.
POSSIBLE CAUSES
1) High resistance in the weld loop.

a. Weld “loop” is too long.
1. Determine what Program (1-127) is being used at the problem spot or spots. Examine
the “Weld Current” or “Iw” value programmed for these programs .
2. Using the Programmed “Iw”, use the graph below to determine the maximum weld
“loop” or cable length (Lc).
Iw (Vs) Lc
2000
1800
1600
1400
Iw (Amps)
1200
1000
800
600
400
200
0
0 50 100 150 200 250
Lc (Feet)
40
(POWER SUPPLY REGULATION OUT OF RANGE - CONTINUED)
3. Subtract L2 from Lc, the remainder is the length that L1+ L3 should NOT exceed.
Equipment Requirements
Cable Length Design Procedure
L1 L2
L3
Figure 10 L1 ≤ 40 ft. (12 m)

Cable Length L2 ≤ 30 ft. (9 m)
Design Procedure L1+L2+L3 ≤ 65ft. (20 m)
L1 = Length of the cable connecting the welder controller and the feeder
L2 = Length of the cable connecting the feeder and the weld head
L3 = Length of the weld common cable
4. Choose lengths for L1 and L3, which are within this range from the standard length table
given below:
L1 L2 L3
8 ft. (2.5 m) 8 ft. (2.5 m) 26 ft. (8.0 m)
13 ft. (4.0 m) 20 ft. (6.0 m) 32 ft. (10 m)
26 ft. (8.0 m) 26 ft. (8.0 m) 40 ft. (12 m)
32 ft. (10 m) 30 ft. (9.0 m) 46 ft. (14 m)
40 ft. (12 m)
2) Weld ground connection loose or dirty:
3) Copper grounding block not to specification: ¼” square contact surface at 30lbs of pressure on work.
4) PWM Board on SMPS (Switching Mode Power Supply) is defective.

a. Replace PWM Board and use Appendix B Fig. 1 “Stud Polarity Setup Procedure” to make certain you

41
ERROR 33: COMMON MEASUREMENT LINE BROKEN
DEFINITION: Common Measurement Line circuit interrupted.
POSSIBLE CAUSES
1) Check PWM Polarity jumpers X22 and X23 for correct setting. See Appendix B Fig. 1 “Stud Polarity Setup
Procedure”.
2) Cables are not hooked up.

a. Be sure all cables are hooked up properly.
3) Common Measurement Line interrupted.

a. Open the door to the DCE cabinet and check the Common Measurement line circuit (See Fig. 9 or 10 in
Appendix B).
NOTE: The Common Measurement Line is a wire that runs in parallel with the Weld Common
Power cable to the work-piece grounding block. Both the Weld Common cable and the
Common Measurement Line are tied to the grounding block.
3. At the DCE cabinet, with all cables hooked up, use an ohm-meter to check for continuity
(0Ω) between the nut on the back of the Common Measurement Line banana plug
connector and the Weld Common cable connector. See Fig. 9 or 10 in Appendix B.
a. If an “open” is read at this check, either a break exists in the Weld Common cable
or the Common Measurement Line wire, or one of these wires is not attached at the
work-piece grounding block.
b. If continuity (0Ω) is read at this check:

1. Replace PWM Board on the SMPS (Switching Mode Power Supply)
a. Replace PWM Board. Be sure that jumpers X22 and X23 are in
the proper position. Refer to Appendix B Fig. 1 “Stud Polarity
Set-up Procedure”.
2. Replace SMPS (Switching Mode Power Supply). Replace power supply
using the “Changing the DCE Power Supply” procedure in Appendix A.
42
ERROR 34: SAFETY CIRCUIT FAULT
DEFINITION: Output voltage of SMPS (Switching Mode Power Supply) is continuously checked for limit
voltage of 48V. When exceeded, the power supply stops operating (this may happen when arc
voltage is interrupted).
POSSIBLE CAUSES
1) Bad plant power input to DCE cabinet. Power should be reliable 480VAC +/- 10%, 3-phase, 50-60hz.
2) Bad weld head Multi-Cable Package.
3) Check for loose, frayed or wearing Weld Loop connections.
4) Faulty PWM Board on SMPS (Switching Mode Power Supply).

a. Replace PWM Board. Be sure that jumper X22 and X23 are in the proper position. Refer to Appendix B
5) Faulty SMPS (Switching Mode Power Supply).

43
ERROR 35: SYSTEM CONFIGURATION FAULT
DEFINITION: Improper cable configurations between DCE cabinet and supporting equipment (PKE Box,
SD2, or SDX modules).
1. PKE Box (if used) is plugged into an Outlet other than Outlet 1.
2. If using SD2 (2 feeders feeding 1 head) or SDX (multiple feeders feeding 1 head) system; feeders not hooked
up in a consecutive order (Outlets 1, 2, 3, etc.).
3. SD2 (2 feeders feeding 1 head) or SDX (multiple feeders feeding 1 head) system; Master Feeder cannot be
hooked up on outlet 5.
POSSIBLE CAUSES
1) Ensure that the system is cabled properly:

a. PKE system (manual load guns)- Ensure that PKE hybrid communication cable is hooked up to Outlet 1 in
the DCE control.
b. SD2 (2 feeders feeding 1 head) or SDX (multiple feeders feeding 1 head) system- Ensure that the Feeder
hybrid communication cables are hooked up in consecutive order in the DCE control (Outlet 1, 2, 3,etc. or
Outlet 2, 3, 4, etc.).
c. SD2 (2 feeders feeding 1 head) or SDX (multiple feeders feeding 1 head) system- Ensure that the Master
Feeder hybrid communication cable is not hooked up to Outlet 5 in the DCE control. The Master Feeder
is the feeder to which the weld head is actually hooked up.
44
ERROR 38: FIBER OPTIC TO FEEDER
DEFINITION: Welder Control DCE ZCPU Board has lost fiber-optic communication with the feeder.
POSSIBLE CAUSES
1) Bad fuse F2 on ETF Feeder CPU Board E510A. See Appendix B Fig. 3.
2) Bad fuse F7, F8, or F9 along upper back wall of DCE Welder Control. See Appendix B Fig. 7.
3) Bad ETF fiber optic cable.
4) Bad Hybrid Cable (DCE Welder Control to ETF Feeder).
5) Bad DCE ZCPU Board. See Appendix B Fig. 7.
6) Bad ETF Feeder CPU Board E510A. See Appendix B Fig. 3.
7) Bad Relay K2 (power to feeders) inside the DCE Welder Control. See Appendix B Fig. 7.
8) Bad Safety Board (inside DCE control). See Appendix B Fig. 11.
45
ERROR 39: FIBER OPTIC TO CUSTOMER INTERFACE
DEFINITION: Welder Control DCE ZCPU Board has lost fiber-optic communication with the Customer
Interface Board.
POSSIBLE CAUSES
1) Bad Fiber Optic cable that runs between DCE ZCPU and Customer Interface Board.
2) Robot/PLC is not sending the necessary 24vdc power to the Customer Interface Board.
3) Bad DCE Customer Interface Board. See Appendix B Fig. 6.
46
ERROR 40: FIBER OPTIC TO POWER SUPPLY
DEFINITION: Welder Control DCE ZCPU Board has lost fiber-optic communication with the PWM Board on
the SMPS Power Supply.
POSSIBLE CAUSES
1) Bad Fiber Optic Cable that runs between DCE ZCPU and PWM (on the Power Supply).
2) Bad Relay K1 (power to Power Supply). See Appendix B Fig. 7.

a. Replace PWM Board. Be sure that jumpers X22 and X23 are in the proper position. Refer to Appendix A
“Stud Polarity Set-up Procedure”.
4) Bad Safety Board. SEE APPENDIX A “DCE SAFETY BOARD TRUTH TABLE”; ALSO SEE
APPENDIX B Fig. 11 FOR LOCATION OF SAFETY BOARD.

47
ERROR 41: SMPS- PROGRAM NOT LOADED
DEFINITION: Fault occurs when DCE ZCPU sends program to PWM on the Power Supply, but PWM does
not acknowledge receipt of the program.
POSSIBLE CAUSES

a. Replace PWM Board. Be sure that jumpers X22 and X23 are in the proper position. See Appendix B
Fig. 1 “Stud Polarity Setup Procedure”.
2) Bad RAM module on the DCE ZCPU Board. See Appendix B Fig. 7.

48
ERROR 42: FEEDER- RELAYS STILL ENERGIZED
DEFINITION: DCE ZCPU orders the ETF CPU Board Relay K1 to switch off; Relay di d not turn off. DCE
ZCPU will order this relay turned off prior to DCE Relay K2 switching off all power to the
feeder. The DCE ZCPU should get a report from the feeder that ETF CPU Board K1 was
turned off prior to feeder power-down.
This is a safety feature that turns off 24vEXT/INT power in the feeder in case Relay K2 in the
DCE fails to open its contacts during “E-Stop” or “Op-Stop”.
POSSIBLE CAUSES
2) Bad Safety Board in DCE. SEE APPENDIX A “DCE SAFETY BOARD TRUTH TABLE”; ALSO SEE
49
ERROR 44: TEACH MODE CONDITIONS NOT MET
DEFINITION: The “Operation-Stop Bypass” mode was entered within 3 seconds of entering the “Operation
Stop” mode.
POSSIBLE CAUSES
NOTE: “Operation-Stop Bypass Mode” is correctly configured when:

a. “Operation-stop” mode has been selected by the customer for at least 3 seconds.
b. “Bypass” key-switch on the front of the DCE cabinet door is turned to the “Bypass”
position.
c. Customer “Live-Man” switch at customer control is engaged.
1) Entered “Operation-Stop Bypass” mode too quickly after entering “Operation Stop” mode. You must wait at least
3 seconds after entering “Operation Stop” mode before you enter “Operation-Stop Bypass” mode.
2) Bad Safety Board. SEE APPENDIX A “DCE SAFETY BOARD TRUTH TABLE”; ALSO SEE
50
ERROR 45: START WELD NOT RESET
DEFINITION: The “Start” signal from Robot/PLC was active at the time the Customer Interface Board was
powered up.
POSSIBLE CAUSES
1) The Robot/PLC has activated the “Start” signal before powering up the Customer Interface Board. Force the
“Start” signal off at the Robot/PLC and reset the fault, if necessary, at the DCE.
2) Bad Customer Interface Board. See Appendix B Fig. 6.
3) Bad DCE ZCPU. See Appendix B Fig. 7.
51
ERROR 46: NO STUD LOADED
DEFINITION: When using Stud Divider, SD2, and SDX, the selected feeder did not perform a feed cycle by the
time of welding.
POSSIBLE CAUSES
1) In “Outlet Programming”à “Auto Repeat Feed” was set to “No” and tried to feed.
2) “Corresponding Stud” is set to “None” and try to feed.
3) Feeder not in “Auto” mode and try to feed.
52
ERROR 47: TEST CONDITIONS NOT MET
DEFINITION: While in “Status Test Process ” screen on Keypad, “Start” sent by Robot/PLC without the
Robot/PLC placing the DCE in a “test” mode.
POSSIBLE CAUSES
1) Robot/PLC should place the DCE in an appropriate test mode before sending “Start” signal to the DCE while
keypad is in the “Status Test Process” screen of the Keypad.
a. Robot/PLC should use the Mode Select 1 and Mode Select 2 bits to set the proper test mode:
1. Mode Select 1 high; Mode Select 2 low --- Dry Cycle with part
2. Mode Select 1 low; Mode Select 2 high --- Dry Cycle without part.
NOTE: The Test Modes are used for test purposes only. The system will NOT weld while in these modes.
2) Bad Customer Interface Board. See Appendix B Fig. 6.
53
ERROR 49: FEEDER NOT IN AUTOMATIC
DEFINITION: A Keypad is connected to feeder and the “Manual” screen is displayed while the customer sends
the “Start” signal to the DCE.
POSSIBLE CAUSES
1) Ensure that, if the Keypad is connected to the DCE, that the display is NOT in the “Manual” screen while trying to
weld in normal operations. If it is press the “ESC” key several times until you are in the “Main Menu” screen.
54
ERROR 61: ZCPU- RAM CARD MEMORY CONFIGURATION
DEFINITION: DCE ZCPU RAM configuration is corrupt or not recognized.
POSSIBLE CAUS ES
1) Clear RAM (See “Clear RAM Procedure” in Appendix A) and reprogram the DCE.
2) Bad RAM; replace and reprogram DCE. See Appendix B Fig. 7.
3) Bad DCE ZCPU Board; replace and reprogram DCE. See Appendix B Fig. 7.
55
ERROR 62: ZCPU-RAM MODULE IS MISSING OR DEFECTIVE
DEFINITION:
POSSIBLE CAUSES
1) Clear RAM (See “Clear RAM Procedure” in Appendix A) and reprogram the DCE.
2) Bad RAM module in DCE ZCPU Board. Replace and reprogram DCE. See Appendix B Fig. 7.
3) Bad DCE ZCPU Board. Replace and reprogram DCE. See Appendix B Fig. 7.
56
ERROR 97: FEEDER- DRUM DOOR OPEN
DEFINITION: Missing jumper or signal that connects X11 pins 4 and 6 of the ETF CPU Board (E510A).
inside, the controller. See “Procedure for Powe r Verification” in Appendix A.
POSSIBLE CAUSES
1) Jumper between pins 4 and 6 of X11 on the ETF Feeder CPU Board. See Appendix B Fig. 15.
57
ERROR 98: FEEDER- STUD LEVEL LOW
DEFINITION: A low stud level is detected in the feeder as measured by the stud level proximity switch.
POSSIBLE CAUSES
1) Low stud level exists in 1 or more feeders. Check stud level and refill if necessary.
2) Bad “stud level” detection proximity switch on feeder.
58
ERROR 100: FEEDER- NO POWER TO AUX. SUPPLY
DEFINITION: One or more ETF CPU Board power supplies have failed.
POSSIBLE CAUSES
10) Bad fuse F1 on ETF Feeder LM Amplifier Board E512A. See Appendix B Fig. 3..
11) Bad ETF Feeder CPU Board E510A. See Appendix B Fig. 3 and 15.
12) Bad ETF Feeder LM Amplifier Board E512A. See Appendix B Fig. 3.
13) Bad ETF Feeder transformer F1T1. See Appendix B Fig. 3.
59
ERROR 102: FEEDER- FEED RAIL NOT FILLED IN TIME
DEFINITION: Feed Rail Min. proximity switch did not detect full Feed Rail within 60 seconds of activation of
rail filling device.
POSSIBLE CAUSES
1) Low stud level in feeder.
2) Jam in feeder preventing the Feed Rail from filling.
3) Bad fuse F1 on ETF Motor Driver Board 55052. See Appendix B Fig. 2, 3, and 4.
4) Bad ETF Motor Driver Board 55052. See Appendix B Fig. 2, 3, and 4.
5) Bad Feed Rail proximity switch. See Appendix B Fig. 15.
6) Bad ETF Feeder CPU Board E510A. See Appendix B Fig. 3 and 15.
60
ERROR 103: FEEDER- AIR PRESSURE LOW
DEFINITION: Input air pressure to the feeder has dropped to 60psi.
POSSIBLE CAUSES
1) Check input air pressure to feeder. Input air pressure should be 80-100psi.
2) Bad Air Pressure Monitor switch. Remove side cover of ETF Control Box. See Appendix B Fig.16.
61
ERROR 104: FEEDER- KNIFE NOT IN FRONT POSITION
DEFINITION: Only used in feeders that have escapement slide block/knife blade proximity switch. No
software yet written for this option.
POSSIBLE CAUSES
62
ERROR 106: FEEDER- FEED TUBE LOCKING SWITCH OPEN
DEFINITION: The Feed Tube Locking switch circuit is not complete. This is a switch used on handgun
systems to detect if the feed tube is attached or not. This switch is not used on weld heads BUT
IS jumpered inside the weld head. The connection made on the handgun or weld head is Pin C
to Pin H on the control cable.
POSSIBLE CAUSES
1) Feed tube not properly mounted on handgun (if this is a handgun system). Ensure that feed tube, once mounted,
engages the Feed Tube Locking Switch.
2) Bad Feed Tube Locking Switch (handgun only).
3) Bad Multi-Cable assembly that runs from the feeder to the weld tool.
63
ERROR 107: FEEDER- SD-2 POSITION TIMEOUT
DEFINITION:
POSSIBLE CAUSES
64
ERROR 109: FEED CYCLE TIMEOUT
DEFINITION:
1. DCE ZCPU did not get “Commence Feed Cycle” bit from feeder within 6 seconds of “Feed Initiate” from
DCE ZCPU.
2. DCE ZCPU did not get “Piston Back” bit from feeder in 6 seconds after “Feed Initiate” from DCE ZCPU.
3. DCE ZCPU did not get “Piston Fwd” bit from feeder 6 seconds after receiving “Piston Back” from feeder.
4. DCE ZCPU did not get “Feed Cycle Stop Acknowledge” from feeder.
5. If “Stud Arrival Sensor” is “On”, stud doesn’t arrive before feed cycle ends.
POSSIBLE CAUSES
1) “Operation Stop” mode was entered during a feed cycle.
2) On “T-Stud” feeders, incorrect “Load Time” or “Feed Time” programmed at “Outlet Programming”.
3) Ensure “Stud Arrival Sensor” option is set to “no”.

a. With Keypad plugged into DCE control, press “ESC” until you see “Main Menu” displayed.
b. Use the arrow keys to select the line “System Configuration”, press “Enter” key.
c. Use the arrow keys to select the line “System Parameters”, press “Enter” key.
d. Use the arrow keys to select the “Outlet” line of the feeder that is faulted, press “Enter”.
e. Use the arrow keys to select the line “Stud Arrival Sensor”, use the “+/-“ keys to ensure that this line reads
“no”, press “Enter”.
65
ERROR 117: FEEDER- DSP COMMUNICATION
DEFINITION: ETF Feeder reports to the DCE ZCPU inside the DCE that the Main Processor on the ETF
Feeder CPU Board is not talking to the DSP (slave processor) on the ETF Feeder CPU Board.
Note: Before proceeding to troubleshooting s teps below, verify that all power is available to, and
POSSIBLE CAUSES
2) Software problem. May need to reload software on the ETF CPU Board. Make sure that the correct software
version is loaded. Contact Emhart Teknologies for assistance.
66
ERROR 118: FEEDER- +5V KEYPAD NOT DETECTED
DEFINITION: See Fault 100.
POSSIBLE CAUSES
1) See Fault 100 steps 1-7.
67
ERROR 119: FEEDER- LM/SOLENOID UNDER VOLTAGE
DEFINITION: See Fault 100.
POSSIBLE CAUSES
1) See Fault 100 steps 1-7.
68
ERROR 120: WRONG CORRESPONDING STUD
DEFINITION: After the “Start” signal is give to the DCE by the Robot/PLC, the weld head moves forward to
the work. At this time the ETF Feeder CPU Board is informed of the value of pre-load as
measured by the Weld Tool Encoder Board, compares that value to the value it was taught to
recognize, and has calculated that the length of the stud did not give the correct pre-load
measurement; therefore the wrong stud is in the weld tool or stud is missing.
POSSIBLE CAUSES
1) Missing or wrong stud loaded in the weld head.
2) Weld tool probe/flash shield “stick-out” misadjusted. Perform the following 2 procedures:
a. Adjust “stick-out” of weld tool See Appendix B Fig. 14.
. b. Use the appropriate procedure depending on whether you are using a Weld Head or Hand gun.
1. See Appendix A “Programming Stud Length Detection (Angularity) Hand Gun”.
2. See Appendix A “Programming Stud Length Detection Weld Head”.
3) Teaching of robot positioning is incorrect. If possible, at head forward, the stud and the probe should be in as close
to the same plane of the work piece as possible.
a. Readjust probe orientation at problem points on work piece.
b. Re-teach the robot positioning at the problem points on work piece.
4) Bad weld tool (head or gun). Replace or repair weld tool.
5) Bad Multi-cable assembly running from the feeder to the weld tool (head or gun). Replace or repair cable
assembly.
6) Bad ETF Feeder CPU Board. Replace Board. See Appendix B Fig. 3.
69
ERROR 121: FEEDER- LM/SOLENOID OVER VOLTAGE
DEFINITION: A voltage measurement discrepancy on the LM Amplifier Board has been detected.
POSSIBLE CAUSES
1. Bad fuse F1 on ETF Feeder LM Amplifier Board E512A. Do not confuse F1 on the ETF CPU board with F1 on
the LM Amplifier Board. Be sure to identify the LM Amplifier Board. See Appendix B Fig. 3.
2. Bad ETF Feeder LM Amplifier Board E512A. See Appendix B Fig. 3.
3. Bad ETF Feeder CPU Board E510A. See Appendix B Fig. 3.
70
ERROR 122: FEEDER- LM/SOLENOID NOT DETECTED
DEFINITION: ETF does not detect the wires connected to either the LM motor or Solenoid inside the Weld
Tool (depending on which configuration, LM or Solenoid, that the feeder is set up for).
POSSIBLE CAUSES
1) Bad Weld Head or Hand Gun.
2) Bad Multi-cable Assembly (cable that runs from the ETF Feeder to the Weld Head or Hand Gun).
3) Bad ETF Feeder Filter Assembly E518A. See Appendix B Fig. 3.
4) Bad ETF Feeder LM Amplifier Board E512A or Solenoid Board (depending on which configuration, LM or
Solenoid, that the feeder is set up for). See Appendix B Fig. 3.
71
ERROR 123: FEEDER- SHORT CIRCUIT, LM/SOL. OUTPUT
DEFINITION: The ETF LM Amplifier Board detects a short circuit across the output pins to the LM motor
inside the LM Weld Tool.
POSSIBLE CAUSES
1) Bad fuse F1 on ETF Feeder LM Amplifier Board E512A. Do not confuse F1 on the ETF CPU board with F1 on
the LM Amplifier Board. Be sure to identify the LM Amplifier Board. See Appendix B Fig. 3.
2) Bad LM Weld Head or LM Hand Gun.
72
ERROR 124: FEEDER- AMPLIFIER GROUND FAULT
DEFINITION: The ETF LM Amplifier Board detects a short to ground in the LM circuit.
POSSIBLE CAUSES
1) Bad LM Weld Head or LM Hand Gun.
5) Bad ETF Feeder CPU Board E510A. See Appendix B Fig. 3..
73
ERROR 125: FEEDER- ENCODER NOT DETECTED
DEFINITION: ETF Feeder CPU Board does not detect the handshaking signals from the Weld Tool Encoder
Board. The Encoder Board is the board inside the Weld Tool that measures stud motion and
velocity.
POSSIBLE CAUSES
1) Bad Weld Tool. Replace or repair.
2) Bad Multi-cable Assembly (Cable package that runs from the Feeder to the Weld Tool).
74
ERROR 126: FEEDER- INSUFFICIENT ROOM FOR LIFT
DEFINITION: After the “Start” signal is give to the DCE by the Robot/PLC, the head moves forward to the
work. At this time the “Lift On” command is give to the LM Control. The LM Control
determines the “absolute position” (or pre-load distance) of stud as measured by the encoder
and has calculated that, given the total travel available, the programmed “Lift” trajectory
cannot be achieved.
POSSIBLE CAUSES
1) Weld tool probe/flash shield “stick-out” misadjusted. Perform the following 2 procedures:
a. Adjust “stick-out” of weld tool using Appendix B Fig. 14.
. b. Use the appropriate procedure depending on whether you are using a Weld Head or Hand gun.
1. See Appendix A “Programming Stud Length Detection (Angularity) Hand Gun”.
2. See Appendix A “Programming Stud Length Detection Weld Head”.
assembly.
75
ERROR 127: LIFT HEIGHT TIMEOUT
DEFINITION: If “Lift Off” command is not issued within 400ms of “Lift On”, the LM motor is switched off
and this fault is displayed.
POSSIBLE CAUSES
1) Faulty PWM Board on SMPS (Switching Mode Power Supply). See Appendix B Fig. 9.
2) Faulty ETF Feeder CPU Board inside Feeder. See Appendix B Fig. 3.
3) Faulty DCE ZCPU Board. See Appendix B Fig. 7.
76
ERROR 128: FEEDER- POWER SUPPLY OVER TEMP.
DEFINITION: Ambient temperature of the Servo Amplifier Board E512A has exceeded 85°C (or 185°F).
POSSIBLE CAUSES
1) Duty-cycle of LM Motor in weld head is too high. This can occur for the following reasons:
a. Stud lifted too long for the cycle time between welds.
b. Stud lifted too high for the cycle time between welds.
c. Ambient air temperature of plant environment too high for cycle time between welds.
2) Bad ETF Feeder LM Amplifier Board. See Appendix B Fig. 3.
77
ERROR 45: FEEDER- LM NOT READY.
DEFINITION: During attempt to weld, at least one fault was detected with the Linear Motor (LM) circuit.
POSSIBLE CAUSES
1) Bad ETF Feeder LM Amplifier Board fuse F1 or F2. See Appendix B Fig. 3.
3) Bad ETF Feeder input power transformer F1T1. See Appendix B Fig. 3.
78
ERROR 146: FEEDER- SOLENOID CARD MISSING
DEFINITION: ETF CPU Board does not detect the presence of the Solenoid Board inside the Feeder.
POSSIBLE CAUSES
1) ETF Feeder LM Amplifier Board is not seated properly into the ETF CPU Board. See Appendix B Fig. 3.
a. Power down the DCE Control.
b. Remove and reseat the Solenoid Board.
c. Power up the DCE Control. If fault is still present, proceed to step 2.
79
ERROR 147: FEEDER- AMPLIFIER CARD MISSING
DEFINITION: ETF CPU Board does not detect that the Amplifier Board E512A is plugged into the ETF CPU
Board.
POSSIBLE CAUSES
1) ETF Feeder LM Amplifier Board is not seated properly into the ETF CPU Board. See Appendix B Fig. 3.
a. Power down the DCE Control.
b. Remove and reseat the Amplifier Board E512A.
c. Power up the DCE Control. If fault is still present, proceed to step 2.
80
ERROR 149: FEEDER- 140 VOLTAGE MISSING
DEFINITION: ETF Feeder CPU Board E510A does not detect 140 volts available at the ETF Feeder LM
Amplifier Board E512A.
POSSIBLE CAUSES
3) Bad ETF Feeder Transformer F1T1. See Appendix B Fig. 3.
81
ERROR 151: FEEDER- 24V INTERNAL MISSING
DEFINITION: 24vdc Internal Power is not detected.
POSSIBLE CAUSE:
1) ETF Feeder CPU Board fuse F4 is bad. See Appendix B Fig. 3.
2) See fault 100, steps 1-7.
82
ERROR 152: FEEDER- 24V EXTERNAL MISSING
DEFINITION: 24vdc External Power is not detected.
POSSIBLE CAUSES
1) ETF Feeder CPU Board fuse F5 is bad. See Appendix B Fig. 3.
83
ERROR 153: FEEDER- 24V INTERNAL RELAYS MISSING
DEFINITION: ETF Feeder does not detect 24vdc internal power.
POSSIBLE CAUSES
84
ERROR 154: FEEDER- 24V EXTERNAL RELAYS MISSING
DEFINITION: ETF Feeder does not detect 24vdc external power.
POSSIBLE CAUSES
85
ERROR 155: FEEDER- 15V KEYPAD MISSING
DEFINITION: See fault 100, steps 1-7
POSSIBLE CAUSES
86
ERROR 156: FEEDER- +15V AMPLIFIER MISSING
POSSIBLE CAUSES
87
ERROR 157: FEEDER- -15V AMPLIFIER VOLTAGE MISSING
POSSIBLE CAUSES
88
ERROR 159: FEEDER- LM STUD STICKOUT NOT ENOUGH
DEFINITION: After the “Start” signal is give to the DCE by the Robot/PLC, the head moves forward to the
work. At this time the ETF Feeder CPU Board analyzes the position of the stud as measured by
the Weld Tool Encoder Board. The LM Control determines the “absolute position” (or pre-
load distance) of stud as measured by the encoder and has calculated that the programmed
“Penetration” depth cannot be achieved.
POSSIBLE CAUSES
1) Weld tool probe/flash shield “stick-out” misadjusted.

a. Adjust “stick-out” of weld tool using APPENDIX B FIG. 14.
2) Wrong or unachievable “Penetration” depth programmed into “Weld Programming”.

NOTE: Programmed “Penetration” cannot exceed “Stick-Out” (see step 1), and , as a practical
matter, should be less than the “Stick-Out” value.
a. From the “Main Menu”, select “Programming” and press the “Enter” key. Select the “Weld Parameter”;
press “Enter”. The “Weld Parameter” sub-menu is used to activate programs , enter weld currents, weld
times, arc voltages, tolerances, and other options for up to 127 programs per outlet. At this point, you are
on line 1 and need to specify which outlet (SKK/PK) you want. In this example we will use outlet 1; press
“1” and “Enter”. Now select the program you want to modify; in this example press “1” then “Enter”. Use
the up/down arrow keys to select “Lift/Penetration” line. Select the 2nd value (Penetration) on this line.
Use the “+” key to modify “Lift/Penetration”. Do this for all program numbers to be used by the
Robot/PLC.
Press ENTER to save changes.
WELD PROGRAMMING
----------------------------------------
Stud ID……………………….._____________
Program Active…………………yes
Start Delay…………………….. 200 ms
Weld Current………………….1300 A
Weld Time………………………..28 ms
Lift / Penetration………………1.20 mm -0.10mm
Optimization…………………….no
_______________Monitored Parameters <_>___

(Continued on next page)
89
ERROR 159: FEEDER- LM STUD STICKOUT NOT ENOUGH (Continued)
assembly.
90
ERROR 160: FEEDER- COLOR MARKING IMPOSSIBLE
DEFINITION:
POSSIBLE CAUSES
91
ERROR 161: WELDING PART NOT SUPPLIED
DEFINITION: Used only on ETF45 (Pick and Place Feeder.
POSSIBLE CAUSES
92
ERROR 162: WELDING PART NOT REMOVED
DEFINITION: Used only on ETF45 (Pick and Place Feeder).
POSSIBLE CAUSES
93
ERROR 164: FEEDER- LIFT NOT DETECTED BY ENCODER
DEFINITION: Encoder Board inside the weld head that is used to measure stud movement (lift, plunge, etc.)
did not measure the stud motion during the attempt to weld.
POSSIBLE CAUSES
a. Dirty or damaged Encoder Strip inside the weld tool.
2) Faulty Multi-cable assembly (cable that runs from feeder to the weld tool).
4) Faulty ETF Feeder LM Filter Board. See Appendix B Fig. 3.
94
ERROR 180: ATTEMPT TO WELD WITH DEFAULT SCHEDULE
DEFINITION: Tried to weld with a program that has not been modified from the default settings.
POSSIBLE CAUSES
1) You must change at least one value in “Weld Parameters” screen of “Programming”.
a. From the “Main Menu”, highlight the line “Programming” and press “Enter”. Highlight “Weld
Programming” and press “Enter”. The “Weld Programming” sub-menu is used to program weld currents,
weld times, arc voltages, tolerances, and other options for up to 127 programs per outlet. At this point, you
are on line 1 and need to specify which outlet you want. In this example we will use outlet 1; press “1” and
“Enter”. Then select the program you want, in this example we will use program 1; press “1” then “Enter”.
You will see the following screen :

may or may not be
Airblow ... ... ... .. no
Help Message Area

---------------------
Weld Time.......... + 6.0 to -3.0 ms
Weld Energy.......... 550 to 750 J
Help Message Area

+
NOTE: Ensure that you have entered ALL of the proper settings to achieve a proper weld
95
ERROR 202: POWER SUPPLY- TEMPERATURE TOO HIGH
DEFINITION: Power supply reached temperature of 70° C or 157° F.
POSSIBLE CAUSES
1) Defective PWM on SMPS (Switching Mode Power Supply).


96
ERROR 266: WRONG LOAD- OR FEEDTIME (SF52)
DEFINITION:
POSSIBLE CAUSES
97
ERROR 268: PROGRAMMING IS NOT ALLOWED
DEFINITION: Programming of “Outlet Parameters” and “Weld Parameters” has been prohibited by dip-
switch 8 on the DCE ZCPU Board.
POSSIBLE CAUSES
1) Perform the following procedure:

a. Power down the DCE control; wait 30 seconds. Open front door of DCE and remove top cover.
b. Locate DCE ZCPU Board. It is the Board on the right wall, top left. See Appendix B Fig. 7.
c. Locate the dip-switches along the right edge of the DCE ZCPU Board.
d. Ensure that dip-switch 8 is in the OFF position.
e. Power up the DCE control and continue programming.
2) Faulty DCE ZCPU Board. See Appendix B Fig. 7.
98
GLOSSARY
(NOTE: All terms in bold text can be cross-referenced in the Glossary.)
Angularity – A condition that must be achieved where the weld tool-to-work piece angle must be 90° plus or
minus a programmable tolerance. Angularity is measured by an Encoder Board in LM Weld Tools or by a
proximity switch in PK560 Handguns .
Arc Voltage – Voltage measured between the stud and the work piece once the stud has “lifted” off of the
work piece. The arc voltage is measured by the PWM Board in conjunction with the Measurement Line
and the Common Measurement Line . See Pilot Arc and Main Arc.
Auxiliary Power Supply Board – Power supply Board mounted on the inside door of the DCE cabinet.
Collet – The fingered chuck on the Weld Tool that holds the stud during the weld cycle.
Common Measurement Line – One of the wires used by the PWM Board as a voltmeter lead to measure
Arc Voltage. This line runs in parallel with the common weld power cable out to the grounding block for
the work piece, at which point the Common Measurement Line is attached to the common weld power cable.
COW – “Collet On Work”. This is an undesirable condition. Created when an empty collet (due, for
example, to a miss-fed stud or nut) in the weld tool is able to touch the grounded work piece. The DCE
“sees” Stud On Work (see SOW) and attempts to weld the collet to the work piece.
Customer Interface Board – The Board located inside the DCE that communicates with the Robot/PLC.
DCE – The Welder Control cabinet.
Drop Down Time – The time is takes the stud to travel from the lifted position back to the work piece during
the Plunge phase of the weld cycle.
Drop Time – See Drop Down Time .
Encoder Board – The circuit Board inside the Weld Tool (usually of the Linear Motor type) that measures
the actual lift distance achieved by the Weld Tool. It also measures the velocity of the Plunge action of the
stud.
ETF – Generic term for a Feeder used in DCE stud welding systems. Normally specified with numerical
suffix (for example: ETF12, ETF90, etc.)
ETF CPU Board – The central processing unit inside the Feeder.
ETF Filter Board – A circuit board inside the Feeder that routes the Lift signal to the Weld Tool.
Feeder – The device in welding system that automatically feeds the stud (or nut) to the Weld Tool.
Flash Shield – The round metal sleeve on the front end of Handguns that surrounds the Collet and stud.
Adjusted on PK560 guns to set Lift dimension (.045”). Adjusted on PLM guns to adjust Stick-Out. This
sleeve helps contain the arc “flash” during the weld process. It is also used to contain the Shield Gas in
operations where protective gas is required.
Note: Can be installed on Weld Heads where protective gas is required during the weld.
Handgun – One of the Weld Tools. A hand held device with trigger used by operator to weld the stud to the
99
work piece. See Weld Tool.
JIC Box – The control box on ETF Feeders that contains circuit boards necessary for Feeder operation.
Lift – The act of pulling (lifting) the stud off of the work during the weld cycle. Controlled by a Linear
Motor or by a Lift Coil inside the Weld Tool.
Lift Coil – An electro-magnet inside PK560 Weld Tools that causes the stud to lift off of the work piece.
Lift Height – The dimension to which the stud has been lifted off of the work piece after commencement of
the weld cycle. This height is programmable with Linear Motor Weld Tools and should be manually set to
.045” on PK560 Handguns .
Linear Motor – Device used in LM Weld Tools that causes the stud to lift off of the work piece.
LM Amplifier Board – A Board inside the Feeder that converts 5v lift signal generated by the ETF CPU
Board into 140v and sends it to the Linear Motor inside the Weld Tool via the ETF Filter Board.
Main Arc – Arc Voltage measured between the stud and the work piece during Weld Time phase of the
weld cycle. See Weld Time .
Measurement Line – One of the wires used by the PWM Board as a voltmeter lead to measure Arc
Voltage. This line runs in parallel with the Weld Tool weld power cable and is attached to the weld power
cable inside the Weld Tool.
Multi-cable Assembly – A cable assembly that runs from the Feeder to the Weld Tool. The assembly
contains a control cable, a weld power cable, and air lines (head forward, head back, piston forward, and
piston back). The assembly may also contain a Shield Gas line if needed.
Outlet – A term roughly interchangeable with Weld Tool (i.e. Head 1 = Outlet 1; Gun 1 = Outlet 1). This
term is used extensively on the keypad of the DCE control in place of Weld Tool, Weld Head, or Handgun.
See Weld Tool.
Pilot Arc – Arc Voltage measured between the stud and the work piece during the pilot phase of the weld
cycle.
PKE Box – The device that takes the place of a Feeder when using manually loaded PK560 Handguns .
The PK560 Handguns are plugged into this unit.
PK560 – A specific type of Handgun where the stud or nut is manually loaded by the operator into the front
of the gun each time a welding operation is to be performed. Usually followed by a letter designator (i.e.
PK560R, PK560B, etc.) to indicate the type of stud or nut for which this gun is set up.
PLM – A specific type of Handgun that uses a Linear Motor.
Plunge – The process of driving the stud from the lifted position back to the work piece; accomplished by
using either a Linear Motor in an LM Weld Tool or a plunge spring in a PK560.
Plunge Time – See Drop Down Time .
100
Preload – A measurement of the distance (upon seating the Probe or Flash Shield on the work piece) that
the stud has traveled in relation to the Probe or Flash Shield. This measurement is directly affected by the
adjustment of the Probe or Flash Shield.
Probe – Angled rod mounted next to the Collet on the front of Weld Heads . Used as a physical stop to halt
the pneumatic head forward motion. This probe has NO electrical properties whatsoever (i.e. it is not the
“ground” for weld current). See “Probe Set-up Procedure” in Appendix B Fig. 14.
Program – One of the 127 programmable heat schedules available to each of the 5 Outlets on a DCE welder
control. These programs are selectable by the Robot/PLC for the purpose of using different programs at
different weld positions on the work piece.
PWM Board – The circuit Board located on the front of the SMPS that controls output weld current,
measures output weld current, and measures the Arc Voltage.
Shield Gas – An inert protective gas (usually Argon) laid down around the weld zone to displace oxygen
during the weld. An SMB Box must be used to dispense the gas.
SOW – “Stud On Work”. This is a signal generated by touching the stud (held by Collet in weld tool) to the
grounded work-piece. Necessary for the weld process to continue.
Slide Rail – Refers to the pneumatically operated head forward and head back action of Weld Heads .
SMB Box – A module used to dispense Shield Gas from a remote source (such as an Argon bottle), through
the Multi-cable Assembly, through the Weld Tool, and out to the weld zone.
SMPS – “Switching Mode Power Supply”. The large square power supply located in the lower portion of
the DCE. This power supply produces the weld current.
Stick-Out – The distance that the stud extends out in front of the edge of the Probe or Flash Shield. This is
adjustable and should be set in accordance with the procedures in Appendix B Fig. 14.
Weld Energy – A measure of the energy applied to the weld. It is measured on every weld and displayed (in
Jules) on the keypad. The formula applied:
Energy (J) = Main Arc Voltage x Main Current x Weld Time
Weld Head – One of the Weld Tools; used typically on robot arms, pedestal stations, or inside a fixed tool.
Requires no human intervention. Under Robot/PLC control the weld head slides pneumatically forward to
the work piece, welds, and slides pneumatically to the rear position. See Weld Tool.
Weld Schedule – See Program.
Weld Time – The duration of the weld phase (Main Current) of the weld cycle. Programmable by the user.
Weld Tool – The device that physically touches the stud or nut to the work piece for welding. This may take
the form of a Weld Head or Handgun.
101

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DCE Customer TS Guide

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DCE WELDER CONTROL

Issued: June, 2003

COPYRIGHT  EMHART TEKNOLOGIES, INC., 2003

ASSIST MODULE IS NOT POWERED UP ............................................................................................................................... 3

ERROR 1: WELD TOOL REMAINS IN R POSITIO N ......................................................................................................... 4

ERROR 3: WELD TOOL NOT IN R POSITION .................................................................................................................... 6

ERROR 4: SOW NOT RESET ....................................................................................................................................................... 7

ERROR 5: WELD PROCEDURE SEQUENCE FAULT ....................................................................................................... 8

ERROR 6: PROGRAM NOT SELECTED ................................................................................................................................. 9

ERROR 14: SHORT CIR CUIT WELD .....................................................................................................................................14

ERROR 15: DROP DOWN TIMEOUT .....................................................................................................................................15

ERROR 16: NO ARC, OPEN CIRCUIT ...................................................................................................................................16

ERROR 17: MEASUREMENT LINE BROKEN ....................................................................................................................17

ERROR 18: USER COUNTER MAINTENANCE REQUIRED ........................................................................................19

ERROR 19: COLLET MAINTENANCE REQUIRED .........................................................................................................20

ERROR 20: WELDTOOL MAINTENANCE REQUIRED .................................................................................................21

ERROR 22: FEEDTUBE MAINTENANCE REQUIRED ...................................................................................................22

ERROR 23: HANDGUN S EQUENCE NOT FOLLOWED .................................................................................................23

ERROR 25: WRONG STUD LOADED .....................................................................................................................................25

ERROR 26: FEEDER OR STUD DIVIDER FUNCTION FAULT ...................................................................................26

ERROR 30: WELD OUT OF TOLERANCE...........................................................................................................................27

ERROR 32: POWER SUPPLY REGULATION OUT OF RANGE..................................................................................40

ERROR 34: SAFETY CIRCUIT FAULT..................................................................................................................................43

ERROR 35: SYSTEM CONFIGURATION FAULT .............................................................................................................44

ERROR 38: FIBER OPTIC TO FEEDER ................................................................................................................................45

ERROR 39: FIBER OPTIC TO CUSTOMER INTERFACE .............................................................................................46

ERROR 40: FIBER OPTIC TO POWER SUPPLY...............................................................................................................47

ERROR 41: SMPS- PROGRAM NOT LOADED ...................................................................................................................48

ERROR 42: FEEDER- RELAYS STILL ENERGIZED .......................................................................................................49

ERROR 44: TEACH MODE CONDITIONS NOT MET .....................................................................................................50

ERROR 45: START WELD NOT RESET ................................................................................................................................51

ERROR 46: NO STUD LOADED ................................................................................................................................................52

ERROR 47: TEST CONDITIONS NOT MET .........................................................................................................................53

ERROR 49: FEEDER NOT IN AUTOMATIC........................................................................................................................54

ERROR 61: ZCPU- RAM CARD MEMORY CONFIGURATION ..................................................................................55

ERROR 62: ZCPU-RAM MODULE IS MISSING OR DEFECTIVE..............................................................................56

ERROR 97: FEEDER- DRUM DOOR OPEN ........................................................................................................................57

ERROR 98: FEEDER- STUD LEVEL LOW ..........................................................................................................................58

ERROR 100: FEEDER- NO POWER TO AUX. SUPPLY .................................................................................................59

ERROR 102: FEEDER- FEED RAIL NOT FILLED IN TIME ........................................................................................60

ERROR 103: FEEDER- AIR PRESSURE LOW ...................................................................................................................61

ERROR 104: FEEDER- KNIFE NOT IN FRONT POSITION .........................................................................................62

ERROR 106: FEEDER- FEED TUBE LOCKING SWITCH OPEN ...............................................................................63

ERROR 107: FEEDER- SD-2 POSITION TIMEO UT .........................................................................................................64

ERROR 109: FEED CYCLE TIMEOUT ..................................................................................................................................65

ERROR 117: FEEDER- DSP COMMUNICATION .............................................................................................................66

ERROR 118: FEEDER- +5V KEYPAD NOT DETECTED................................................................................................67

ERROR 119: FEEDER- LM/SOLENOID UNDER VOLTAGE........................................................................................68

ERROR 120: WRONG CORRESPONDING STUD ..............................................................................................................69

ERROR 121: FEEDER- LM/SOLENOID OVER VOLTAGE...........................................................................................70

ERROR 122: FEEDER- LM/SOLENOID NOT DETECTED............................................................................................71

ERROR 124: FEEDER- AMPLIFIER GROUND FAULT .................................................................................................73

ERROR 125: FEEDER- ENCODER NOT DETECTED .....................................................................................................74

ERROR 126: FEEDER- INSUFFICIENT ROOM FOR LIFT ..........................................................................................75

ERROR 127: LIFT HEIGHT TIMEOUT .................................................................................................................................76

ERROR 128: FEEDER- POWER SUPPLY OVER TEMP. ...............................................................................................77

ERROR 45: FEEDER- LM NOT READY. ..............................................................................................................................78

ERROR 146: FEEDER- SOLENOID CARD MISSING......................................................................................................79

ERROR 147: FEEDER- AMPLIFIER CARD MISSING....................................................................................................80

ERROR 149: FEEDER- 140 VOLTAGE MISSING .............................................................................................................81

ERROR 151: FEEDER- 24V INTERNAL MISSIN G ...........................................................................................................82

ERROR 152: FEEDER- 24V EXTERNAL MISSING..........................................................................................................83

ERROR 153: FEEDER- 24V INTERNAL RELAYS MISSING........................................................................................84

ERROR 154: FEEDER- 24V EXTERNAL RELAYS MISSING.......................................................................................85